OPERATING- INSTRUCTIONMANUAL ZANTINGH FORCEDGASBURNER

Transcription

1 OPERATING- INSTRUCTIONMANUAL ZANTINGH FORCEDGASBURNER \

2 IMPORTANT read this first! This manual is an integral part of the product; it includes instructions for installation, commissioning and operation. Read instructions attentively! Manufacturers responsibility and warranty shall not apply if installation, commissioning, operation or maintenance is not in accordance to the regulations of this manual. Store this manual carefully! Contents: Page 1. Introduction 3 2. Regulation 4 3. Important notes Maintenance Explanation instruction manual 5 4. Installation compilation Burnerpart Airfan part Pilot gasline Controlpanel Control switches and reset buttons controlpanel Frequency control 9 5. Start sequence Failure report burner What to do when a failure appears 16 MM MK7 16 Lockout messages electronic MM controller type MK7 17 LMV 5xx 216 Lockout messages electronic controler type LMV 21 8 Operation manual Autoflame MK7 Evo 25 9 Operation manual Siemens LMV5xx Operation manual load controller Zantingh-Dtron Change over from gas to oil and visa versa Switch witch over from heat to steam production Warranty Conditions Enclosures 34 Burner type code 35 Burner P G/O 35 Burner M G/O 36 Gastrain P 37 Gastrain MK7 39 Page. 2

3 1. Introduction Dear Customer, We would like to thank you for your confidence in our organisation and product. We provide this manual to ensure distribution of all the important information for your safety, optimal profit and product lifetime. We recommend you read this manual and instructions carefully before installing the Forced gas burner. In order to meet these objectives, installation, commissioning, operation and maintenance shall be carried-out in accordance to the instructions of this manual and local regulations. The safety and operating instructions must be followed. Our technical department can provide additional information and support. If you have any questions, please contact us. Phone general +31(0) Phone service +31(0) or Page. 3

4 2. Regulation BELANGRIJK: IMPORTANT: Use a notified installer for mounting the burner installation. The instructions meet the applicable (local) standards and regulations. 3. Important notes - Commisioning a Zantingh burner, with or without electronic fuel-air ratio controller, ought to be done with the utmost precision and by Zantingh authorized persons. - Every commisioning or change of settings of the burner installation by somebody other then mentioned above, can lead to dangerous situation and have consequences on the product liability and warranty. - Changes of the burner installation may only be done in conformity and after a confirmation in writing by Zantingh. - A burner installation is a combination of: - Electrical engineering - Gas engineering - Central Heating engineering - Measuring and control engineering - Therefore tread your burner installation as the hart of your company and restricted the operation authorization only for trained persons. Before any activities always switch off the main switch and take care that during activities the main switch can t be switched on! Fire or other emergency situations: When accessible; Close the gas valve (A1) of the gasstrain and switch off the main switch of the burnerpanel. When there s fire in the boilerroom you need to switch off the electrical power with the therefore on the outside wall mounted fire switch Page. 4

5 3.1 Maintenance To assure safe and proper functioning of the burner, it is recommended that the burner be checked out and serviced at least 1x per year and to be done by a qualified service technician. Don t ever do any maintenance or any other activity on the burner without adequate knowledge and understanding of the system. Remarks: - De burner installation is supplied conform the relevant safety regulations, but it s your responsibility to ensure the safety by yearly, according the regulations, maintenance the installation. - To ensure good functioning of the heating installation the boilerroom needs to be kept clean. It may not be used for storage. Parts which need maintenance needs to be an accessible. - Keep the air supply grille and air extraction openings free and clean. Inadequate air ventilation can lead to a risk of life. - The boiler room needs to be lighted with mounted electrical lights, so during absence of day light activities on all parts of the installation can be done. - Any water leakage needs to be repaired immediately. - When you re not certain about anything of control or use, please contact your burner engineer or supplier. 3.2 Explanation instruction manual To make this manual more understandable and better readable you need to find out which type of burner you have. (TR or RKB) and which kind of burner control you have. This information you can find on the nameplate on the right side of the burner. The translation key of the type code you can find in the enclosure. The air-fuel ratio controller can be pneumatic or electronic. Electronic burners are made with an Autoflame MM, type MK7. This air-fuel ratio controller and load controller in one package. The pneumatic air-fuel ratio controlled burners are made with air-fuel ratio controller Siemens SKP 75 in the gasstrain. A Zantingh Dtron 308H controls the burnerload. Page. 5

6 4. INSTALLATION COMPILATION 4.1 Burnerpart The burnerpart is a welded plate steal house. Under the burnerhouse there s an air valve section, this controls the air supply in to the burner. A servomotor drives the valves. Load controller or burner controller controls the servomotor. A possible lack of air will be measured and guarded by 1,2 or 3 air-pressure switches (LD2). When you have a burnertype TR the pressure switches are in the topside of the burner. When you have a burnertype RKB the switches are mounted under the burnerhouse. The primary- and secundar- burner combustion devices are situated in the cylindric part of the burner. On the side of the cylindric part the flame guard is mounted. The pilot burner is positioned central in the burnerhead. The pilot burner is made with an electrical ignition. For the electrical ignition there s a high voltage transformer in the burnerhouse. Under the cylindric part of the burners there s the gassupply connection. When it s an electronic controlled burner the gas quantity control valve is positioned here and a servomotor drives it. 4.2 Airfan part The airfan is positioned under the burner. The airfan supplies the needed combustion air. This airfan has a direct coupled and balanced fan wheel. The fan wheel is driven by an electromotor. TR burners have the airfan directly connected to the air-valves section. RKB burners have there airfan lose and standing on the floor. The connection is made with a flexible sleeve. The airfan has to be mounted on the floor using vibration isolators. Through an electrical circuit in the burner control panel and the frequency controller a variable speed of the electromotor is realized, because of this the airfan can give a load depending air quantity. The airfan is standard made with a grid on the inlet to prevent contact danger. For noise reduction there's plate silincer on the inlet of the airfan. Optional there are cylindric noise silencer available. 4.3 Gastrain The gastrain ensures that the gas, supplied by the distribution net, to the burner is controlled. For controlled supply of gas to the burner there are a several guard and control units mounted on the gasstrain. Shutt-off valve (pos.a1) De shutt-off valve (A1) has the function to shutt-off the gas supply to the burner installation. This is can be when: Fire and other emergency situations. Maintenance on the gasstrain equipment. Leakage on or between [arts after the valve. Shutt-off of burner installation for a long time. Filter (pos.f1) The filter (F1) prevents, that dirt and welding grain from the gas supply line will not get into the equipment of the gasstrain. This to protect the equipment for damage against dirt. Page. 6

7 Safety valves (pos.va1-va2) These safety valves are there to automatic open or close the gas supply to the burner. For safety reasons there are used 2 gas safety valves (VA1 + VA2). In the second safety valve (VA2) is also a pneumatic controlled gas pressure regulator. This gas pressure regulator controls the outlet pressure at any rotational speed of the airfan. Valve proving system (pos. VPS / VDK / TC) With burners controlled pneumatic there is a valve proving system unit parallel on the first safety valve. Burners with MM MK7 are made with a pressure sensor between the two safety valves. Then the valve proving system is in the MM MK7. The valve proving will check before en during the burnerstart the safety valves. When a leakage is detected the burner will shutt-off and lockout electrical. The lockout will appear on control panel with a signal light. Minimum gas pressure safety device (pos. LD1) The pressure switch (LD1) is activated as soon as the gas pressure before the gas valves reach under the minimum limit value, as a result of which the burner no longer burns stable. The setting value is determined during the commissioning of the burner. Maximum gas pressure safety device (pos. HD en HD1) - The pressure switch (HD), mounted on the burnerhead guards on full load, by pressure control, the maximum burner/boiler capacity. - The pressure switch (HD1), mounted on the burnerhead guards, by pressure control, start load of the burner. The settings of the pressure switches will be done at commisioning of the burner installation. Manometer (pos. M) en press-button valve (pos. K2) By pushing on the press-button valve the supplied inlet pressure can be read off the manometer. Manual shutt-off valve (pos. A2) (optional) The manual shutt-off valve (A2) is made to when needed use for: Use with commisioning Emergency purpose 4.4 Pilot gasline Shutt-off valve (pos. K1) The ball-valve (K1) is used to bleed the gassupply line. The bleed line has to be made with a separate pipe trough the roof in the outside air. (the opening has to be protected against dirt en rain) When no bleeding line is made the ball valve has to be plugged off. Pilot gas solenoid valves (pos. MK1/MK2) Thee pilot gas solenoid valves are there to automatic open or close the gas supply to the pilot burner. (pos. AB). Page. 7

8 4.5 Controlpanel In the controlpanel all the used electrical controlled operation-, guard- en control units of the burner, airfan, gastrain, boiler and other secundar connected devices together. Through the in the controlpanel made electrical circuits are all the devices in such a way connected together, that the total installation can function safe. These circuits can be classified in the next main groups: Boiler/safety circuit; Thermostat (start) circuit; Burner controlbox (label L&S, type LFL); Load controller; External control (Fiduface); Failure signal lights; Motorgroups /Fuses; Control switches and reset buttons. Optional CO 2 -circuits + CO-detector Build in controllers: Electronic: Air-Fuel ratio controller and load controller and burner controller (Autoflame MM MK7). Pneumatic: Load controller (Zantingh Dtron 308H). 4.6 Control switches and reset buttons controlpanel On the controlpanel are a few switches and press-button valves; Fire switch on/off; Selector switch load control with the next 4 choices: 1 = automatic, modulated by load controller 2 = low flame. 3 = manual; burner load can only be changed with press buttons higher/lower (Only with MK7). 4 = external; burner load and on/off status is controlled by climate- or Procces computer Reset MM: only used to reset a failure of a Autoflame MM MK7; Reset; Reset all occur failures; Reset alarm; Resets the external alarm signal; The next switches can optional be on the controlpanel: Selector switch gas/oil; Selector switch heat/steam; CO 2 dosing on/off Page. 8

9 4.7 Frequency control A circuit in the controlpanel controls the electromotor of the airfan. With a frequency control, positioned outside the controlpanel, the rotation speed of airfan is controlled depending on burnerload. The speed variation at an electronic burner is realised directly from the control unit (MK7). With a pneumatic controlled burner the potentiometer is in the servomotor. Both ways realise a signal of 0-10V to the frequency control. Common setting: Frequency on low flame approx. 25 Hz (= ± 1400 cycles). Frequency on high flame circa 50 Hz (= ± 2800 cycles). Advantage frequency control In the lowest rotation speed the electromotor has approximately 1/5 of the maximum power consumption. When you compare this with a one speed motor this gives a substantial energy saving. The fact that the burner can give a continuously variable load makes it very appropriate for a proces burner (steam), but also for dosing CO 2. When the installation has a good setup there will be no fluctuation in the heat or CO 2 - production. Page. 9

10 5. Start sequence When the nominal gas pressure is present, the right power supply is on the panel, de safety valves are closed, the on/off thermostat gives an on signal and all other boiler limits are there, the burner will start when the burner on/off switch is set on 1. The next start sequence will appear: A. After switching-on first the airfan start on low speed, immediate or after a short delay. B. When the airfan is on nominal speed, the servomotor of the air quantity control valve (pos. HR2) open to maximum opening. When the servomotor, which the air quantity control valve controls, doesn t make a complete preset stroke, de air quantity control valve will not be open enough. The burner will be shutt-off and lock-out (When Autoflame is used there will be appear a MM error). The airfan will go to maximum speed (50Hz) approx. linear to the air valves. C. If the air quantity control valve is opened the pre-purge time starts. During the 30 seconds pre purge time the boiler furnace will be ventilated, to clear all possible left flue-gasses out the furnace. During to total pre purge time the open position of the air quantity control valve and the minimum air pressure will be checked. D. On the end of the pre purge time the airfan goes to the low speed (+/- 25Hz) and the air quantity control valve will be positioned in the start/low flame position. If it s an electronic controlled burner also the gas quantity control valve (pos. HR1) controlled by a servomotor will be positioned in the start/low flame position. The minimum air pressure is checked during operation checked by a second air pressure switch (pos. LD2 low). E. All the air and gas control are in start position now. The next step is ignition of the pilot burner. A few second after reaching all the start positions the ignition transformer will be switched on. It will make an electrical spark between to ignition electrodes. F. After 3 seconds the pilot gasvalves (pos. MK1 en MK2) will be opened and the spark will light the gas. After the safety time of 5 sec. the flame guard will check if the pilot flame is formed and seen by the UV scanner. The time of 5 seconds in were the pilot flame needs to be formed is called the first safety time. If the flame is not formed in this time the flame control will lockout. The signal light flame failure will light up. At the end of the first safety time the spark will switch off. The pilot flame has to burn stabile now without the spark. The flame guard will check the flame from now till end of operation time. Page. 10

11 G. When the pilot flame is there and checked by the flame guard, the main burner will be igniting after a short time. To start the main flame the main valves (pos. VA1 en VA2) have to open. The pneumatic gas pressure regulator, which is mounted on the second safety valve (pos. VA1 en VA2), shall set the output pressure, which is necessary with the set burnerload. 5 seconds after opening the safety valves the pilot valves will be shutt-off. The mainflame has to be stabilized and checked by the flame guard. When flames guard doesn t there or not detects the main flame there will be an immediate lockout and the signal light flame failure we light up. The time of 5 seconds were the pilot- (pos. MK1 en MK2) and main valves are all opened together is called the second safety time. To secure an easy steady start of the main flame there is a maximum gas pressure switch (pos. HD1). It s only active during the start. The minimum gas pressure switch (pos. LD1) guards the supplied gas pressure continuous on it s lowest applicable level. H. After the main flame is formed and the start sequence of the burner controlbox is successful rounded, the burner is in operation on low flame. With a pneumatic controlled burner the drum switch in the controlbox has stopped en the load controller starts. With an electronic controlled burner approx. 35 seconds after opening main valves the load controllers starts. I. If the loadcontrol switch on the controlpanel is set on 1 Auto the burnerload and on/off switching will be controlled by the loadcontroller. The maximum gas pressure switch (pos. HD) guards the maximum burnerload by measuring gas pressure. Page. 11

12 6. FAILURE REPORT BURNER Gasvalves/leaktest Before and during every burnerstart de safety valves (pos. VA1 en VA2) and pillot valves (pos. MK1 en MK2) will be checked on leakage. Possible causes: Failure leaktest (by pneumatic) or Valve Proving System (VPS in MK7) can point that on of the safety- pilot valves were not closed during standstill/start period. Check: If bleed valve K1 is closed/gastight External gasleakage visible (smell/ leak finder /soap off) Note the position of the burner controlbox (if applicable) were the failure occur. Gaspressure to low With a minimum gaspressure switch (pos. LD1) mounted before the safety valves, the supplied minimum gaspressure is continuous checked. If the gas supply pressure dropped lower then 20% of the normal pressure (or other setpoint which is safe according authorized burner engineer), the safety device locks out. Check: If manual gasvalve (A1) is opened total; The gas supply pressure before gastrain, by pressing the press-button valve (pos. K2) under the manometer de current pressure can be read of the manometer (pos. M). Or check the manometer on the gastrain of the gas supplier. This pressure has to be approx. the same as in the contract. When the gaspressure supply is ok, de gas filter (pos. F1) on possible dirt. (First close manual gasvalve A1.) Maximum gaspressure With a maximum gaspressure switch (pos. HD1) mounted on the gas inlet of the burner, a nice and smooth start of the mainburner is secured. Measuring of the startpressure does this. When there s a higher pressure then setpoint a lockout occurs. With a maximum gaspressure switch (pos. HD) also mounted on the gas inlet of the burner, the boiler is protected against overload. Measuring of the gaspressure on the burnerhead does this. When there s a higher pressure then setpoint a lockout occur. Possible causes: Check: Abnormal outlet pressure of pressure regulator. Dirty condenser. Very abnormal gassupply pressure. The position of the burner controlbox (if applicable) were the failure occur The condensate drain of the condenser. Page. 12

13 Motors Overload In the controlpanel are a few overload relays to protect the electro motors, when a failure occurs the overload relays needs to be reset manual. The types, which are in our panels, are combined thermal and maximum current protectors. Check: If all tree phases (L1, L2 en L3) still have to normal charge If all the fuses are not broken. Replace them when necessary. (We advice to change all tree of them) And note which the overload relay gives a lockout, if after reset the motor makes a growl and doesn t run smooth it s possible that one phase still isn t ok. Air pressure to low Guarding the airpressure with the airpressure switches (pos. LD2 low en LD2 high) mounted on the burner. The pressure is checked after 30 seconds after the airfan is started. Signal light Airpressure low (with pneumatic and electronic). Signal light MM failure and text in MK7 display T52 (see failure sheet MK7) Possible causes: The airinlet of the airfan is blocked (plastic bag). The airfan is very dirty. Air valves are very dirty. The flexible measuring hose to pressure switch broken or blocked. The overload relay is locked out (see previous item). check: The inlet of the airfan. Maximum temperature and or pressure The boiler is protected against to high temperature and or pressure. The protection is done with a maximum thermostat or maximum pressostat. If the de maximum temperature or pressure is exceed the burner locks out. The supplied maximal thermostat by Zantingh is locked mechanical and has to be reset on the thermostat self and on the burnerpanel. Possible causes: Required setpoint, maybe to high. To less water and/or air bubbles in the boiler, fill up and bleed. Lowwater The waterlevel in the boiler is guarded to protect the boiler against serious damage by overheating, when there s not enough water in the boiler. This safety device can be in 2 ways: One or two electrodes mounted in the boiler. Mechanical float switch. Possible causes: To low waterlevel for example by leakages in system. Non-working feedwaterpump or expansionsystem. With high pressure steamboiler, consult the relevant documentation of the boiler supplier. Page. 13

14 Max. temp. Condenser ECO (when applicable) This failure appears if the water temperature in the fluegas condenser is too high. Check: If there s enough flow over the condenser. (Circulationpump doesn t work or manual shutt-off valves are closed.) If there s no air in the condenser or in the connected system. WARNING!! When bleeding watch out for hot parts and spraying hot water! Max. Pressure condenser ECO (when applicable) Pollution of the condenser, is checked with a pressure switch which measures the backpressure of the condenser. When the backpressure gets to high the switch the burner gets a lockout. The pressure switch is mounted on the fluegas duct between boiler and condenser. Possible causes: Condenser is dirty. Fluegasvalve(s) not in the right position. Condensate drain blocked. Check: Possible dirt, by opening the inspection cover. The position of the fluegas valves. The condensate drain and syphon under the condenser. MM error... When on display of the Autoflame MM MK7 electronic loadcontroller the Lock out screen appears, then the MM has found an internal error in the system. Before pressing the reset button note the Error code. After reset MM and repeated error contact our service department. Frequency control code F When an internal or external error appears on the frequency control then the frequency control stops and an error code with a symbol F with a number of the failure appears with a short description in the screen. Warning! If you contact our service department because of a failure, please note the error code and description. After the cause of the failure is cleared the error can be reset with the button reset / enter Under normal conditions the frequency control needs no maintenance. The frequency control has a cooling fan were the surrounding air is blown over the cooling body. Take care that the openings aren t blocked. When the cooling body gets to hot the control will go in error F14. Page. 14

15 Flame failure Flame failure is the most difficult error to trace, which you can have on a burner installation. If the flame guard locates the flame or not, depending on the stage of the start sequence a flame failure can occur. A flame failure can occur because the gas flame doesn t ignite. The problem can be the electric spark doesn t ignite the pilot flame or the pilot flame doesn t ignite the main flame. An other cause can be that the combustion is so bad that the flame during the operation goes out. Because of the many possible causes it s very hard to find out why the flame failure occur. That s why we asked to try to find out on which stage of the start sequence the failure is there. When applicable note the position of the burnercontrolbox. Possible causes: No ignition spark because of: Defect ignition transformer; Defect or wrong adjusted ignition electrodes; Lose ignition cables; Spark not on right position (jump over to earth/mass). No pilot flame: Defect gas solenoid(s) (pos. MK1 en MK2) No combustible gas mixture, doesn t ignite Pilot valve isn t detected by flame guard or flame signal to low No mainflame: Defect safety valve(s) (pos. VA1 en VA2) The manual shutt-off valve (pos. A2) at the burner is not open. The air-gas ratio is not good, that s why the air-gas mixture doesn t ignite, or even goes out during operation. Mainflame is not detected by the flame guard because the flame signal is to low. Flame failure before gasvalves has opened by: Defect UV-scanner Strange light for example through sight-glass. IMPORT: After a failure the reset button has to be pressed to reset a failure. Before reset, note the position or symbol in the screen of the burnercontrolbox or the number and or text in the display of the MM-unit MK7. Attention!! It s possible that maximum thermostat and lowwater float device are mechanical locked. The reset button is on the safety device itself and should be reset first. If the burner doesn t start it s possible that there s a failure on the CO 2 -dosingunit and/or CO-detector. Page. 15

16 7. WHAT TO DO WHEN A FAILURE APPEARS IMPORTANT: Before any maintenance first switch off the main switch on the burnerpanel. Lock the switch so nobody can switch on the mainswitch during maintenance. Don t work with live voltage in panel. With switching of the main switch off the burnerpanel also the power of a connected CO 2 -panel can be switched off. All safety devices, which are part of the burner installation, are visualized with a signal light on the controlpanel. This happens after every lockout of a safety device. To reset the failure use the reset button. After this the burner will try to restart. During this restart keep close eye on parts which maybe not function ok. WHAT TO DO WHEN A FLAME FAILURE APPEARS? Pneumatic controlled burners have a burner controlbox LFL1.. mounted in the controlpanel. 1. The start sequence of the burner is controlled by the Burner control box LFL1, Simultaneous on the start sequence a mechanical clock with symbols on it is running which will stop on a position when there s a lockout. Please note this position so searching for the problems can be easier. 2. Also note the burnertype and manufacturing year. Contact our service department. They will first try to solve the problem by phone. MM MK7 When the burner is made with electronic control MK7, burner control is built in the unit. 1. Note when there s a failure, and before reset the text, which appears in the display of the MK7 unit. 2. Also note the burnertype and Manufacturing year. Contact our service department. They will first try to solve the problem by phone. Page. 16

17 System Configuration In the system configuration screen you can choose the visual mode of the mm unit. You can choose to set it in MK6 or MK7 mode. The mode that is selected will ligt in the left corner of the mode button. In this screen you can also see serial number mm unit and software versions of div part of the unit. (See {1 right upper corner) You can set the clock date and time or set and start/stop timer in the clock section You can put the screen on hold to clean. In the help section. On the left side you can view the settings in options and parameters LOCKOUT MESSAGES ELECTRONIC MM CONTROLLER TYPE MK7 In the Autoflame MK7 there s the burnercontrol, with gas- and airsensors there s also several safety devices which will give a lock-out message in display and the light MM- Error. If a failure occurs the MK7 will also give in which phase the failure appeared. This information is very important. Error The mm error screen will appear when an error occurs other than the Safety loop errors. The Lamp mm error will light up and an alarm signal will be given. In the mm error screen an lockout message will be given with a phase indication when in the burner cycle a lockout is appeared inclusive the time and date of the fault. If after reset there s still a failure, please contact our service department. Please note the following information: Lockout, phase, Occurred. (See lock out screen ) Installation number/serial number burner (See sticker on the burner panel) Mm serial nr, Burner control software, MM control software, Display Software ({1 See System configuration screen Right upper corner) Page. 17

18 Lockout Message Code nr: Action: Simulated flame The flame is present when it should not be. Check if there a flame in the furnace: When a flame is the furnace, immediately close the manual shutt-off valve. (A1) When no flame in the furnace. Check if the flame scanner can see sun light trough sightglass No flame signal Switch off burner. Check position of flame scanner and clean if necessary the class of the flame scanner. Switch on burner and check step by step the start sequence. If possible through the sight glass in the boiler. Sequence: Pre-purge, ignition, pilot flame, ignition off, mainflame, pilotgas off. Now burner is in operation. Contact our service department and tell them the text in display and the observations. Air Pressure Outside Air pressure during operation to low. Limits Or No air proving - Check fuses, overload relay. Reset overload relay and frequency control - Check airinlet opening of airfan. Air Sensor Recommission Error Airsensor + (number) AIR RE- COMM Sensor /MK7 internal fault. Contact our service department and tell them the A/D Converter Error 47 Check 12 V on terminals #40 en 41. Check/replace fuse (back site MM-unit). Contact our service department and tell them the text in display. 12V/5V Supply Error 44 Check 12 V on terminals #40 en 41. Check/replace fuse (back site MM-unit). Contact our service department and tell them the text in display. CH1 Positioning Error CH2 Positioning Error CH3 Positioning Error CH4 Positioning Error One or more channels (servomotors) are not in their programmed position. Page. 18

19 Error melding: Code nr: Action: CH1 Gain Error CH2 Gain Error CH3 Gain Error CH4 Gain Error Excessive VPS Operations Gas pressure low Gas pressure low limit Gas pressure high limit Gas sensor + number Check wiring and screens of the channel/servomotor, which causes the error. VPS has operated 3 times without burner firing. Switch off main switch and after 30 seconds on. Reset failure. Low gas pressure before burnerstart. Check supply pressure. Gas pressure to low, out of range of sensor. Check supply pressure. Gas pressure to high, out of range of sensor. Sensor MK7 internal Error failure. Contact our service department and tell them the Load Detector Error 03 Circuit of temperature sensor broken. Check the wires on lose or bad contact. Prolonged lockout reset Prolonged voltage present on terminal #56/lockout reset button permanently pressed. Prove cct fail T52 Loss of input on terminal #52. Terminal #52 must see an input at all times from the position to purge to the end of the post purge (cct = closed circuit). Purge air pressure low Safety fail T54 Sensor supply voltage 12V Shutter fault Terminal 86 inverse Insufficient air pressure during purge. Check airinlet of airfan. Check/ replace fuses and/or overload relay. Reset frequency control and reset panel. Insufficient air pressure during start/operation Check airinlet of airfan. Check/ replace fuses and/or overload relay. Reset frequency control and reset panel. 12V power supply to sensors out of range (11,75 12,25 Volt). UV signal detected during shutter operation on UV self check. Check wiring on terminals #21/22. Terminal #85 and 86 have input or don t have input when otherwise was expected. Terminal fault Electronic fault on terminal #85 of #86. UV short circuit Connections to UV tube shorted, check wiring Page. 19

20 Error melding: Code nr: Action: VSD Feedback Error 83 Check screen and wiring to frequency controller. VPS gas pressure low VPS air proving fail VPS air zeroing fail VPS gas proving fail FSR fault Vent valve O/P Main fuel 1 O/P Main fuel 2 O/P Start fuel O/P Motor O/P Ignition O/P Watchdog fault 1a Watchdog fault 1b Watchdog fault 1c Watchdog fault 1d Watchdog fault 2a Watchdog fault 2b Watchdog fault 2c Watchdog fault 2d Ram test failed Prom test failed CPU test failed Input fault BC input short Lockout 198,199,200,201,202 Zero low gas sensor Zero high gas sensor Signal dev Counts low Counts high Check supply pressure. Contact our service department and tell them the Check 1st main valve. Contact our service department and tell them the Check wiring of pilot gas valve. Contact our service department and tell them the Check 2nd main valve and pilot valve. The difference between the signals of the sensors is too big. Page. 20

21 Error melding: Code nr: Action: Signal high Sensor supply voltage Signal dev Counts low Counts high Signal high Page. 21

22 LMV5XX When the burner is made with electronic control LMV5x, burner control is built in the unit. 1. Note when there s a failure, and before reset the text, which appears in the display of the MK7 unit. 2. Also note the burnertype and Manufacturing year. Contact our service department. They will first try to solve the problem by phone. LOCKOUT MESSAGES ELECTRONIC CONTROLLER TYPE LMV In the LMV there s the burnercontrol, with gas- and airsensors there s also several safety devices which will give a lock-out message in AZL display and the message Error. If a failure occurs there is also information given in which phase the failure appeared. This information is very important. Error Page. 22

23 The mm error screen will appear when an error occurs other than the Safety loop errors. The Lamp Burner control failure will light up and an alarm signal will be given. In the LMV screen an lockout message will be given with a phase indication when in the burner cycle a lockout is appeared inclusive the time and date of the fault. If after reset there s still a failure, please contact our service department. Please note the following information: Lockout, phase, Occurred. (See LMV display) Installation number/serial number burner (See sticker on the burner panel) Page. 23

24 For the complete parameter list, refer to Set t ing List I7550 Page. 24

25 8 Operation manual Autoflame MK7 Evo Normal operation In the MK6 mode there are at the Autoflame MM unit a great amount of buttons and leds. The end user does not use, most of the buttons and leds. The display gives the next values as information: Button: STATUS: Required setpoint Actual value Autoflame MM unit MK7 Evo Setpoint change With steam boilers: When the boiler is used for steam production the operation of the Autoflame is the same as for a heat production. The required set point (steam pressure) is in Bar. Heat production boilers: To read out these values you have to push the button STATUS. With the arrow buttons and the set point can be changed (required temperature in ºC) Button MM: - Channel 1: De position of the gas servomotor in degrees - Channel 2: De position of the air servomotor in degrees - Channel 3: Control of the frequency control servomotor position in degrees During normal operation RUN led constant lighted. Page. 25

26 Heat / Steam electronic controlled burners If boiler is used for heating/steam with an electronic burner, the Autoflame controls the burnerload when producing heat. During producing steam the burnerload is controlled by the Zantingh Dtron. For operation instructions of the Autoflame MM see instruction Autoflame on page 22. For operation instructions of the Zantingh Dtron see instruction on page 26. (For changing over from Heat to Steam see page 28.) TEMPERATURE SETTINGS AUTOFLAME MM Before any changes are made, be convinced what the maximum work temperature/pressure is of the installation. May by any reason the boiler temperature of pressure get to high, the maximum thermostat of pressostat will lockout. (See chapter failures) Standard Settings Autoflame MM: Setpoint plus 6 degrees ºC; burner stops. Setpoint min 2 degrees ºC; burner starts. Actual value 10 degrees ºC under setpoint; burner on high flame Between 10 an 0 degrees ºC under setpoint; burner will modulate The burner engineer can only change these settings. * When it s a steam installation Temperature = steampressure Degrees ºC = bar x 0.1 Thermostat = Pressostat Page. 26

27 Language selection: The language screen allows you to for selection of on screen language. This language will be applied throughout the MK7 screens. The MK7 can accommodate any language. If you are interested in translating the onscreen text to a language that does not appear on this menu, please contact Zantingh directly on info@zantingh.com. Setting the time: The set clock screen is used to set the time used for all functions within the MK7. It is particularly important for logging functions such as Lockouts. 1. Press the Set clock button to access the Set Clock screen. 2. Enter the Set Clock password (10 10) using the keypad and press continue. 3. Use the up down arrow buttons to change the date and time. 4. Once complete press the set button to save any changes or the exit button to leave the Set Clock screen without making any changes. Setting runtimes: The Run Times screen allows the user to set the times at which the boiler will initiate, be off, on or at a reduced set point. The reduced set point is set on the status screen. 1. Press the Run Times button to access the Run Times screen. 2. Using the keypad enter the Run Times password (11 11) and press Continue 3. Directly beneath the Run Times heading is the current boiler status and if Run Times is enabled or disabled. By default this facility is disabled. To enable/disable press on the text to change. 4. If the Run Times facility is enabled, editing of Run Times is also enabled. In order to change the Run Times for each day press on the text of the day that needs editing. This will give you the next screen. 5. Use the up down arrow buttons, select the time at which the burner starts (start:) and the time the burner stops (Stop:). The mode of operation can also be selected by pressing the text applicable. Once the desired settings have been for the current day have been setup press the Exit button to return to the main Run Times screen. Note: The time range between the start and stop time refers to the ON times. All times outside of this range will be either off or in a reduced setpoint, depending upon which option is selected. For modes always off and always on the times section is disabled as this is no longer applicable. Repeat steps 4 and 5 until each day has been set up as desired. Once complete, press the Enter button to record the changes or the exit button to discard any changes made. Page. 27

28 9 Operation manual Siemens LMV5xx Normal operation The end user is allowed to make several setting changes in the LMV display. Here we give some information about them. Status: Required Actual value Setpoint change With steam boilers: When the boiler is used for steam production the operation of the LMV is the same as for a heat production. The required setpoint (steam pressure) is in Bar. Heat production boilers: To read out these values you have to push the buttons < SELECT >. With the arrow buttons < and > the setpoint can be changed (required temperature in ºC). Main menu level < Display of operation < Operation Boiler setpoint Setpoint W1 Setpoint W1 Act : 80 Nw: 80 Set your new value with < and >. Afther changing the value confirm with Heat / Steam electronic controlled burners If boiler is used for heating/steam with an electronic burner, the Autoflame controls the burnerload when producing heat. During producing steam the burnerload is controlled by the Zantingh Dtron. For operation instructions of the Autoflame MM see instruction Autoflame on page 22. For operation instructions of the Zantingh Dtron see instruction on page 26. (For changing over from Heat to Steam see page 28.) When your settings are finisched, return to main menu by pressing: 3x ESC Display of operation Normal operation Setpoint xxxxºc actual.value xxxxºc Fuel Gas Standby 12 Page. 28

29 TEMPERATURE SETTINGS OF THE INSTALLTION Before any changes are made, be convinced what the maximum work temperature/pressure is of the installation. May by any reason the boiler temperature of pressure get to high, the maximum thermostat of pressostat will lockout. (See chapter failures) Standard Settings LMV: Setpoint plus 6 degrees ºC; burner stops. Setpoint min 2 degrees ºC; burner starts. Actual value 10 degrees ºC under setpoint; burner on high flame Between 10 an 0 degrees ºC under setpoint; burner will modulate The burner engineer can only change these settings. * When it s a steam installation Temperature = steampressure Degrees ºC = bar x 0.1 Thermostat = Pressostat Language selection: The AZL5 can output the display texts in different languages. Changeover to another language takes place via menu: Params & Display AZL5 Language. In addition to English as the basic language, the AZL5 provides another 5 languages. This means that a language group can comprise a maximum of 6 languages. Using the program update function of the PC tool, additional language groups can be loaded to the AZL5 together with the relevant program version. Hence, direct exchange of the language without loading a new program version is not possible. Setting the time: Setting the time and date can be done via menu: Operation Date, time of day. Change the date or time by selecting with enter and higher and lower with < and >. Confirm with enter. Page. 29

30 10 Operation manual load controller Zantingh-Dtron Normal operation The loadcontroller Zantingh Dtron is a 3-position output step less loadcontroller. At the front of the controller the required setpoint can be set. The on and off function is also integrated in the loadcontroller. The display also gives the next values for info: Green display: ZANTINGH Required boiler setpoint. Red display: Actual boiler temperature/ pressure. Change setpoint Warm water boilers: With pushing the arrow buttons and the setpoint can be changed. Standard Settings Zantingh Dtron: Setpoint plus 6 degrees ºC; burner stops. Setpoint min 2 degrees ºC; burner starts. Actual value 10 degrees ºC under setpoint; burner on high flame. Between 10 an 0 degrees ºC under setpoint; burner will modulates. The burner engineer can only change these settings. * When it s a steam installation Temperature = steampressure Degrees ºC = bar x 0.1 Thermostat = Pressostat Page. 30

31 11 Change over from gas to oil and visa versa. (If applicable) From gas and oil; Before change over the burner from gas to oil set burnerload switch on low and wait until the burner is on low flame. Now set the burner switch burner on/off on off. Set the selector switch from gas to oil. Check if every oil shutt-off valves to the oilpump or opened and if the oilpump is filled with oil. The total installation has to fill with oil and no air. When this isn t the case major defect can occur. The oilpump is a non self-suction pump. Set the fluegas inlet valve of the condenser on bypass. Close the Shutt-off valve A1. Set the burnerload switch on Auto and switch on the burner. Important! When not specifically noticed the burner is made for oil as emergency fuel. After running longer then 24 hours on oil the burnersystem can get dirty. A reliable and clean can t be guarantied. If a flame failure accurse more then 3 times during start-up, check the furnace if there s no oil inside. When the boiler temperature is higher the 65 ºC the oil in the furnace can gasify. At the next attempt to start, the ignition can ignite the gasified oil and can cause a explosion. During yearly necessarily maintenance there must be a possibility to run on oil! Arrange enough oil on stock. Note. Installing, check and filling the oiltank and oilpiping from the oiltank to the oilpump is not in the scope of our service engineer. This is the responsibility of the client. From oil to gas; Switch off the burner. Close all oil valves in the oilline. Set the selector switch from oil to gas. Switch the load control switch to the wanted setting. Open shutt-off valve A1. Switch on the burner. Important Before start, check the furnace if there s no oil insite. When the boiler temperature is higher the 65 ºC the oil in the furnace can gasify. At the next attempt to start, the ignition can ignite the gasified oil and can cause a explosion. Ask the burner engineer to demonstrate the change over from gas to oil and back. Page. 31

32 12. Switch witch over from heat to steam production. (When applicable) From heat to steam production; Before change over the burner from gas to oil set burnerload switch on low and wait until the burner is on low flame. Now set the burner switch burner on/off on off. Switch the selector switch from steam to heat Check if the boiler installation is according the operation manual of the boiler supplier. Set the burnerload switch on Auto and switch on the burner. From steam to heat production; Before change over the burner from gas to oil set burnerload switch on low and wait until the burner is on low flame. Now set the burner switch burner on/off on off. Switch the selector switch from heat to steam Check if the boiler installation is according the operation manual of the boiler supplier. Set the burnerload switch on Auto and switch on the burner. Ask the burner engineer to demonstrate the change over from heat to steam production and back. Page. 32

33 13. WARRANTY CONDITIONS Zantingh B.V. guarantees this Zantingh product for the installer under the following conditions. The installer guarantees this product to the user under the same conditions provided below. 1. The period of guarantee is valid as from the day of delivery on location. The guarantee has a fixed period of 12 months, based on the agreed sales price. 2. A recognized installer according to the applicable general and local standards should install the device and regulations and the assembly and operation instructions provided by Zantingh. 3. The system may not be moved from the original location. 4. The guarantee becomes null and void if and when: Defects of the system are not reported in writing to the installer and/or Zantingh B.V. immediately after having been discovered or these could have been discovered. Defects are caused by errors, improper use or neglect by the user and/or installer who has given the order or his/her legal successor or caused by external causes. During the period of guarantee a third party is requested to or make provisions to the system or when the user has done so without prior written consent by the installer and/or Zantingh B.V. During the period of guarantee no expert inspections and/or maintenance work are periodically performed to equipment requiring the same. Corrosion has been caused by polluted flue gas, to be determined by Zantingh B.V. If after research is carried out, one or more of the above conditions have not been taken into account and are the reason for any guarantee claim, the costs for the required research by Zantingh B.V. or third parties will be charged to the user. 5. The initial request based on the guarantee obligations described in this article should be submitted in writing to the installer within five working days after the error or defect has been observed or could reasonably have been observed. 6. The stipulations included in our general guarantee, sales and payment conditions, issued by the ORGALIME S 2000 General conditions for the supply of mechanical, electrical and electronic products are also applicable. Zantingh B.V. will not be liable for any consequential damage to the Zantingh system other than a defect covered by the guarantee as described above. Moreover, Zantingh B.V. will not be liable for any damage to income and/or loss of profit to the user of any nature what so ever. 7. Any costs incurred by assembly or disassembly, travelling or accommodation expenses, constructional costs and such required to execute the terms of the guarantee are excluded. Any dispute between Zantingh B.V. and the buyer regarding a claim based on the guarantee, will be resolved by an expert and independent authority if so desired. The parties agree to abide by the binding decision of said authority. Page. 33

34 14. Enclosures Burner type code RKB 10 ND HO M G/O Burner type Options: TR RKB Capacity Options: Combustion type Options: ND (Nox Down) Combustion head Option: DKR ( Ultra low Nox) HO ( Low Nox) Gas-Air ratio control Options: P (Pneumatic controlled) M (Electronic controlled) Fuel G (only gas) G/O (Gas/oil) Page. 34

35 Burner P G/O Page. 35

36 Burner M G/O Page. 36

37 Gastrain P Page. 37

38 Gastrain MK7/LMV5xx Page. 38

39 Imprint All rights reserved, including the rights to the translations. Nothing from this issue may be copied, stored in an automatic data file or made public in any way or by any means, be it electronically, mechanically, photocopy or otherwise, without prior written consent from Zantingh B.V. Reprinting, including excerpts, is forbidden. Changes, errors and misprints reserved. These assembly and operation instructions comply with the technical requirements at the time of printing. We reserve the right to make technical and design changes. Page. 39

40 Brander Bedieningsvoorschrift ENG 2015v1 Page. 40