Service Manual (ID180,ID290)
Contents
1. Fuel is of incorrect type dirty Empty the tank and refill with polluted or contains water clean fuel of correct type 15 THE HEATER SUDDENLY STOPS Servicing Manual Overheat thermostat incorrectly activated Excessive overheating of combustion chamber overheat thermostat correctly activated 16 Wrong location of overheat thermostat after incorrect servicing repairs etc Wrong thermostat setting use of an incorrect type Wrong too large nozzle size see specification chart Wrong too high fuel pressure see specification chart Insufficient ventilation due to motor fault Insufficient ventilation due to fan failure Blockage of airways due to dirt or foreign objects Exhaust pipe partially obstructed Combustion chamber clogged by soot see chapter 3 10 THE MAINTENANCE OPERATIONS DESCRIBED IN THIS MANUAL MUST BE CARRIED OUT BY QUALIFIED PERSONNEL ONLY IN COMPLIANCE WITH THE ELECTRICAL SAFETY STANDARDS IN FORCE ONLY USE ORIGINAL OR RECOMMENDED SPARE PARTS 3 1 CHECKING THE SUPPLY VOLTAGE The supply voltage must match with the rated voltage indicated on the data plate The actual input voltage must be within 15 and 10 of the rated voltage for good and safe operation e Measure the mains voltage inserting the multimeter tips into the electrical socket and compare it with the rated voltage written on the data plate If no voltage is found e Check the electrical syste2. Shell Bacharach reference scale Pressure gauge for oil pressure measurement Electrical multimeter ASAD Ill 55 Ill 56 41
3. kerosene gross heating value Kcal kg 11 025 08 according to standard prEN 13842 2002 Electrical Specifications 0869 44 Package Specifications TECHNICAL DATA SHEET FOR INDIRECT FIRED OIL HEATERS 55 kW MODEL Thermal Specifications Efficiency Power lp kel 4200 Power Output Fuel Pressure mm S Air Lock Adjustment Airflow Specifications Air Flow Rating mh 2500 myn 1475 ft min 3 sickle shaped Electrical Specifications Rated Voltage V Hz Weight Tank Capacity 6kg ei It liters 14 U S gal Lenght Outlet Diameter 1405 mm 55in 308 mm 12 in Width Flue Diameter 20 mm 150 6 in DN 869 44 Package Specifications o1l gross heating value Kcal kg 10869 kerosene gross heating vakfr Kcal kg 11 025 08 according to standard prEN 13842 2002 830 mm TECHNICAL DATA SHEET FOR INDIRECT FIRED OIL HEATERS 85 kW MODEL Thermal Specifications Airflow Specifications Electrical Specifications Maximum Thermal Power Diesel Oil mh MS00 A 2650 femin US alar o Power Input 7217 12 0 mm B W TU hr e ON ER WN FT oo oo n e lajs BTU hr Lige Pitch Power Output 742 25549 ee E z t2 d Oo OO O2 OO La Z e o az o lt er Efficiency Power Input Kcal 5 1680 mm 66 in 443 mm A Width Flue Diameter 150 A 37 in Fuel Pressure oil gross heating value Kcal kg 10869 44 Package Specifications kero
4. made of galvanized steel which also acts as a support for the whole machine a support fixed on the tank to which the lower half shell of the heater is connected This support also contains the electrical board a lower half shell which together with the upper half shell forms the air duct where heat is transferred to the flowing air All main components are directly fixed onto the lower shell an upper half shell that completes the air duct and can be disassembled by unscrewing 6 screws for servicing and maintenance On the indirect fired heaters with flue the upper shell includes a circular hole for the flue collar on the upper shell you can also find an inspection door that allows operators to reach the components inside the heater and to carry out most of the repair and maintenance operations on the rear a protection guard is fitted on the air inlet to prevent any contact with the rotating parts of fan motor on the front a half cylindrical protection shield if fitted between the combustion chamber and the lower shell to limit the temperature of such part that 1s directly accessible and can be touched by the operators Y Servicing Manual gt On the front a diffuser outlet cone allows the warm air on indirect fired heaters or the mixture of warm air and exhaust gases on direct fired heaters to be released into the heated room The axle with wheels and the support foot are connected below the tank 2 2 FAN MOTOR AS
5. NITION Servicing Manual Check that the oil tank is full Check for air bubbles in the oil filter Check that the nozzle is clean Check that the whirl disc is clean Ckeck that the flame sensor is not damaged clean and properly fixed in its seat Check the adjustment of air lock Check for presence of external spurious lights sunlight lamps 14 Tighten the oil line fittings Check for damages cracks in the oil hoses See chapter Cleaning the combustion head See chapter Cleaning the combustion head Clean the flame sensor with a soft cloth and ethylic alcohol Replace the flame sensor 1f damaged or burnt See technical data sheets section Look for and eliminate light reflections due to sunrays lamps etc that could reach and disturb the flame sensor Look for fires inside the machine Servicing Manual Look for the correct nozzle size on the setting chart Check the nozzle size R eplace if necessary Check the air lock adjustment See setting chart Check that the nozzle is clean See chapter 3 8 Replace the nozzle THE HEATER STARTS FLAME IGNITES BUT COMBUSTION IS NOT GOOD Check that the fuel filter is See chapter 3 7 clean See chapter 3 12 Check that the pump filter is clean Check that there are no air Tighten fittings bubbles in the fuel line Replace faulty pipes hoses Measure and adjust the pressure Incorrect fuel pressure Replace the pump see chapter 3 12
6. SEMBLY Description An electrical motor drives both the fan and the oil pump A helicoidal fan provides a constant air flow in the axial direction a part of which is used for the combustion the remaining part flows along the surfaces of the combustion chamber and of the heat exchanger and it is consequently heated The fan is connected to the motor shaft by means of a threaded pin The oil pump has the function to suck fuel from the tank and to drive it to the nozzle at the rated pressure the pump is connected to the motor shaft by a resin joint and fixed to the motor casing by means of 3 threaded pins Single phase 2 or 4 poles motors with rotational speeds of 2800 rpm or 1400 rpm are used according to the heater model See technical data sheet for detailed motor specifications ILL 1 particolare gruppo motore MIRAGE 85H TORNADO 115 Servicing Manual 2 3 FUEL CIRCUIT Description The fuel circuit 1s basically composed of tank suction and return hoses fuel filter fuel pump fuel solenoid valve high pressure microhose combustion head nozzle VV VN VN VV The gear pump driven by the motor sucks fuel from the tank and increases its pressure to the rated value At the pump outlet a fuel cut out solenoid valve SV is fitted The pump is controlled by the flame control unit During normal operation the valve is open and the pressurized fuel flows to the nozzle where it is atomized mixed with primary combustion ai
7. Servicing Manual 09 06 2004 00 a A MOBILE OIL OR KEROSENE FIRED EMERGENCY AIR HEATERS MIRAGE TORNADO SIAL S p A C so Inghilterra 15 12084 MONDOVT CN Tel 0174 560611 fax 0174 481086 Website www sialspa it e mail tec com C sialspa it Copyright No section of this document can be reproduced in any form or processed by means of electronic systems copied or distributed without written permission by SIAL S p A The translation into other languages is also allowed only under written permission by SIAL S p A The use of this document is restricted to SIAL servicing centers and to distributors of SIAL products This manual is not intended for end users Technical changes SIAL S p A has the right to modify any instruction description and specification contained in this document without prior notice FOREWORD Thank you for choosing the SIAL MIRAGE TORNADO heaters We would like to remind you that as for any machine you can get good operation and performance only if the heaters are correctly used and always kept in perfect efficiency If required the SIAL Technical Service can give you suggestions and assistance The SIAL MIRAGE TORNADO heaters are especially intended for the professional heating of civil industrial and agricultural premises Read and follow carefully the instructions contained in this manual before starting any servicing or maintenance operation SIAL S p A will not acce
8. T THERMOSTAT 170 red markings 170 red markings 170 red markings Servicing Manual SETTING CHART DIRECT FIRED HEATERS WITHOUT FLUE CHAMBER INLET it 8 holes dia 6 mm it 8 holes dia 10 mm dia 350mm 3 blades 18 dia 500mm 4 blades 33 WHIRL BAFFLE DISC out dia 76mm in dia 2 mm 10 blades out dia 76mm in dia 2 mm 10 blades FUEL FUEL BURNER PUMP PRESSURE NOZZLE DANFOSS 12 bar DANFOSS R3 1 25 60 H DANFOSS 12 bar R5 33 DELAVAN 2 20 80 W OVERHEAT THERMOSTAT AIR LOCK OPENING 4mm 100 lock position black markings 1 5 13 mm 100 black markings lock position um TECHNICAL DATA SHEET FOR INDIRECT FIRED OIL HEATERS 37 kW MODEL Thermal Specifications Maximum Thermal Power Diesel Oil US o Power Inpu 3130 E BTUhr 1 ower Out kW BTU hr t Fuel Pressure DR OO 00 ka IF c gt D ES O gt N IN Un NIN QN QN ON Maximum Thermal Power Kerosene Consumption Kg kcal hr KW k W Efficiency TU Power Output Kalle KW BTU uel Pressure Power Output F p Air Lock Adjustment mm Airflow Specifications Air Flow Rating mh 2000mm 1180 ft min 3 sickle shaped Temperature Rise Delta keen re 97 F Noise Level at 1m at2 m dB A average with original hood Il SS Y ol gross heating value amp gal kg i
9. a pressure gauge with a suitable measuring range Ill 39 2 e Clean the filter with compressed ar or wash 1t with clean Diesel oil e Reassemble To replace the pump e Loosen the pump fixing screws e Make sure that the motor pump resin joint 1s correctly fitted e Replace the pump and reassemble the whole unit 3 13 CHECKING AND REPLACING THE FUEL SOLENOID VALVE e Unscrew the solenoid valve fixing nut Ill 40 e Extract the valve casing e Unscrew the fixing nut of the inner cylinder 26 Ill 41 e Extract the inner cylinder and clean it with Diesel oil Ill 42 Check that the inner cylinder can slide freely If required clean the piston To replace the solenoid valve e Open the electrical board e Check voltage at the solenoid valve terminals Ill 43 If a voltage can be measured on the terminals shown in the picture but the solenoid valve does not work e Disconnect the valve leads from the burner control unit e Replace the solenoid valve e Reconnect and check operation 3 14 CHECKING CLEANING ADJUSTING REPLACING ELECTRODES e Extract the burner head Ill 44 e Check that the electrode tips are clean e f not clean them with a soft brush and then with compressed air e Check the clearances between electrode tips and between electrode tips and nozzle e Adjust the clearances according to the diagram below To check that ignition spark 1s regul
10. als Check for proper operation Reassemble the electrical panel 33 CHECKING AND REPLACING THE MOTOR e Extract the electrical board see picture e Check voltage at the motor terminals using a multimeter Ill 11 e Disassemble the fan see chapter 3 4 e Loosen the fuel pump fixing screws and disconnect the pump see chapter 3 12 e Unscrew the fixing screws of the motor bracket on the lower support 18 lil 12 e Unscrew the fixing screws of the motor on the bracket 13 111 e Replace motor and fix it on the bracket Connect bracket to lower support Connect motor leads on the terminal board following the wiring diagram e Check operation e Reassemble fan fuel pump rear guard upper shell and electrical board To replace the capacitor e Remove the inspection cover e Extract the capacitor from its support e Disconnect leads on the capacitor 19 Ill 14 e Replace the capacitor with one with same capacity UF rating e Connect check operation and reassemble 34 CHECKING AND REPLACING THE FAN WARNING MAKE SURE THAT THE HEATER IS NOT POWERED BEFORE OPERATING ON MOVING PARTS WITHOUT GUARDS IN PLACE BODY INJURY DANGER e Remove the rear guard and look for possible damages or obstructions not allowing the fan to rotate To replace a damaged fan e Unscrew the fixing screw on the fan hub Ill e Extract the damaged fan and replace it e Check by hand that the
11. ar e nsert the nozzle holder into the burner head and fix it wih a proper screw e Completely open the air lock e Disconnect the solenoid fuel valve from mains e Give power to the heater and allow a start cycle to take place turning the ON OFF switch to I ON e Visually check that the ignition electrodes produce a regular spark Warning At ignition an 11 kW high voltage is produced between the electrode tips Carefully follow the electrical safety regulations during all servicing and maintenance operations e Reconnect the solenoid valve leads after checking spark To replace the electrodes e Disconnect the high voltage leads from electrodes e Unscrew the electrode fixing screws e Replace the electrodes and reconnect the high voltage leads e Reassemble the burner head 3 15 CHECKING AND REPLACING HIGH VOLTAGE CABLES e Check that the high voltage cables are properly connected e Check the conditions of high voltage cables and look for possible damages Disconnect the high voltage cables from electrodes and from the ignition transformer in the electrical board 3 17 REPLACING THE FUSE e Open the electrical board e Extract the fuse from the fuse holder in the electrical board Ill 46 e Connect the new cables and check operation 3 16 CHECKING REPLACING THE IGNITION TRANSFORMER Ill 46 To replace the transformer e Unscrew the transformer fixing screw and nut e Check the
12. ase it from the fixing hooks e Open the filter and extract the filter cartridge Ill 25 22 e Remove the inspection cover e Loosen do not unscrew completely the fixing screws of the end disc on the combustion head e Unscrew the nozzle taking care not to touch the electrode as impacts could damage the electrode ceramic insulators and impair good Ill 30 ignition e Slightly rotate the combustion head clockwise so that the screw heads match with the big holes on end disc This will be helpful when reassembling as the screws will act as supporting and centering means for the combustion head Ill 29 e Clean the nozzle blowing compressed air inside it e If cleaning is not sufficient replace the nozzle Only use the nozzle sizes and types recommended by the manufacturer see setting Ill 51 chart e Reassemble the nozzle e Extract the combustion head e Reassemble the burner head and the inspection COVer 39 CHECKING CLEANING REPLACING THE BURNER HEAD AND THE WHIRL DISC 23 Ill 32 e Clean the whirl disc using a brush and then blow compressed air on it To get good combustion the air flow openings in the whirl disc should be perfectly clean and free og Sa AAT 9 Il 33 3 10 CLEANING THE COMBUSTION CHAMBER e Remove the upper shell e Disassemble the burner head see chapter 3 8 e Disassemble the combustion head see chapter 39 e Unscrew the fixing screw
13. ck see chapter 3 9 Ill 20 Lack of combustion air due to installation too close to a wall or in a small room without openings towards outside AIR LOCK ADJUSTMENT e Remove the inspection cover e Unscrew the fin screw on the combustion head e Move the air lock in the axial direction to reach the position shown on the setting chart supplied by the manufacturer see setting chart at the end of this manual 21 III 21 3 6 CLEANING THE FUEL TANK To clean the fuel tank e Lift the heater at about 1 m height using a fork truck or other suitable means e Place a proper container under the heater tank e Unscrew the drainage cap on the tank bottom to discharge the fuel completely Ill 22 To clean the fuel filler filter extract the filter from the tank filler cap clean it and reassemble Servicing Manual e Clean the filter cartridge using a soft brush and then blow compressed air To replace the complete filter e Loosen the filter fittings and unscrew the filter bracket fixing nut e Reassemble and connect fuel hoses 3 8 CHECKING CLEANING REPLACING THE OIL FILTER Ill 23 e Remove the inspection panel e Remove the fixing screw on the burner head 3 7 CHECKING CLEANING REPLACING nozzle holder THE OIL FILTER Ill 26 Ill 24 e Unscrew the lower filter body glass e Extract the nozzle holder by rotatng it e Pour out the fuel contained in the filter clockwise to rele
14. conditions of fuse on the electrical board e Replace the faulty fuse with one with identical e Disconnect the high voltage cables from the current ratings See technical specifications transformer e Disconnect the high voltage cables from the burner control unit 3 18 CHECKING CLEANING AND REPLACING THE FLAME SENSOR HLtransformer HT transforme 1 EN line K m e Extract the flame sensor from its seat in the L Ye burner head disc by turning it about 4 turn to es gic y p loosen the fixing feet of flame sensor support Ill 47 e Replace the transformer reconnect cables to transformer and burner control unit following the wiring diagram shown on the label placed on the electrical board cover 28 Servicing Manual e Gently push the sensor leads to extract the flame sensor Clean the sensor glass with a cloth soaked with ethylic alcohol to eliminate any soot or dust residuals Ill 50 It 1s possible to check the proper operation of the flame sensor simply using a multimeter Connect the multimeter terminals to the sensor leads and proceed as follows e Setthe multimeter to measure resistance e Expose the flame sensor to light e Under normal conditions the tester should show ohmic resistance quickly decreasing as illumination increases To replace the flame sensor e Disconnect the flame sensor leads from the burner control unit see wiring diagram e Replace the faulty sensor e Reconnec
15. during future ignition sequences is therefore prevented The aftercooling time is factory set and independent of the action of a limit control or similar devices on the combustion chamber The aftercooling time lasts about 1 minute and 45 seconds Lock out sequence In the event of flame shut down due to lack of fuel or to another reason see also the par SAFETY OPTIONS IN CASE OF ABNORMAL OPERATION the flame control unit will put the heater in a safety condition starting the lock out sequence During this sequence the fuel solenoid valve SV is immediately closed within the safety time T4 lt 1s and then an aftercooling cycle will start to cool the surfaces of the combustion chamber The ignition transformer is powered and therefore a spark is produced by the electrodes during the aftercooling cycle as described above Reset sequence The unit can be reset by pushing the red reset pushbutton with integral warning lamp on the control panel For safety reasons reset will only be possible after about 30 s from lock out Also in the event of electrical supply failure restoration reset will only be possible after 30 s approximately Servicing Manual 1 4 SAFETY OPTIONS IN CASE OF ABNORMAL OPERATION e Spurious external light or anticipated ignition During the prepurge time no flame signal must come to the flame control unit A flame signal with no flame could be due to external lights short circuit in the flame sensor or in the fla
16. el Protecting cover against water dust Power cable with strain relief and plug ON OFF switch Remote room thermostat socket with plastic cover and inner electrical bridge closing circuit for operation without thermostat Reset pushbutton with built in warning lamp high voltage ignition transformer fuse with fuseholder electronic burner flame control unit YYYY Y Y Y Y WV 3 TROUBLESHOOTING 12 Servicing Manual SWITCH ON THE HEATER STARTS yes Check for correct voltage rating see data plate Check that the green warning lamp on the control panel is alight Check fuse burn outs damages etc Check the burner control unit Check that the red lock out warning light is not alight Check that the overheat thermostat has not been activated Check that the remote thermostat is properly connected and adjusted For operation without remote thermostat check that the thermostat socket cover is correctly inserted in the socket 13 Check all electrical connections Check the warning lamp Replace with a new one with identical ratings See Chapter o Replace the burner control unit Wait 30 seconds and push to reset Open the inspection cover and push to reset Check connections Set a temperature value higher than room temperature Check the metal bridge inside the cover Reinsert and lock THE HEATER STARTS THE PREPURGE SEQUENCE STARTS BUT THEN THE HEATER STOPS WITHOUT IG
17. fan can rotate freely without interference e Check operation after reassembling guards 3 5 EXHAUST GAS ANALYSIS for heater with flue only COMBUSTION AIR ADJUSTMENT Perform an exhaust gas analysis with the Shell Bacharach method to check the quality of combustion e Use a standard smokemeter Shell Bacharach pump Ill 16 e Insert a test strip into the pump slot 111 17 e Connect an extension for exhaust gas analysis to the flue adapter 20 D Ill 18 e With the heater operating in normal conditions draw in the exhaust gases for 10 times IMPORTANT 10 TIMES EXACTLY taking care to carry out all movements slowly and using the complete piston stroke e Extract the paper strip check the colour and compare it with the reference scale to assign a smoke number the Oil fired heaters manufacturer to give a smoke number equal to 0 zero of the Shell Bacharach scale A smoke number greater than 1 indicates bad combustion Should this occur the causes of the problem should be detected and eliminated are factory set by The most important factors that can cause high smoke numbers are Clogged combustion chamber due to incorrect installation exhaust flue obstructed or badly designed see chapter 3 10 and user instruction manual Operation without flue adapter Dirty combustion head fuel lines and or nozzle see chapter 3 9 gt Too closed adjustment of air lo
18. ga 308 mm 2 in Width Flue Diameter Height 898mm Don 10869 44 Package Specifications 11 025 08 Lenght 1760 mm Height 965 mm Width 650 mm Weight 116 Kg AA Maximum Hose Lenght o id o1l gross heating value Kcal kg kerosene gross heating value Re JO according to standard prEN 13842 2002 4 2 WIRING DIAGRAM Basic version EV TR M Ordianal FR T E TS N Y E I FS C 5 FC MIX 17 up ge HE HTReens g ie AL e IN EV TR N o FR cd R vd Hl TH TL L H u FR black Gah m FC PL FL TH IN PL B J D L i us i o Ne 15 EN S alk Ce IN E RA white H E PL oc E pus ETA CP N n pr i Optional Fuel solenoid valve High voltage transformer Motor Warning lamp Overheat thermostat Fuse Flame sensor Reset pushbutton Switch Remote room thermostat Heated filter optional Optional FR blua CC d MI 3 17 Hd w Reont Ve wal NT rn D dli blue ILS Ev TR M y p uL T gei SI Eat Fe brown black put GIL Fe PL TH IN PL 188 FS 1 Dn Lr j dx H1 Mi 13 EE pa to Mi UR white rt Opliannl 40 SL TS FS FC PL IN TH FR Fuel solenoid valve High voltage transformer Motor Warning lamp Overheat thermostat Fuse Flame sensor Reset pushbutton Switch Remote room thermostat Heated filter optional 4 3 SPECIAL SERVICING TOOLS Smokemeter Strips for smokemeter
19. ional circumferential openings on the burner head allow another amount of air called secondary air to flow into the chamber That 1s an additional air delivery that completes combustion During the whole ignition sequence the electrodes are powered by the high voltage transformer and produce a spark that ignites the fuel air mixture The function of the whirl disc is to induce a rotational component in the primary air flow and therefore to decelerate it this way the mixing of fuel and air 1s increased and the combustion improved The combustion chamber is made of stainless steel It includes a rear end on which the combustion head is fitted a front end with hole on direct heaters without hole on indirect heaters a front flame shield on direct heaters the heat exchanger with gas passageways the exhaust gas flue collar the protection shield around the chamber a manually resettable overheat thermostat VN WV VV NN 2 5 ELECTRICAL BOARD 11 Servicing Manual Description ILL 5 particolare cruscotto The electrical board has the function to broadcast the electrical supply coming from the electrical system through the power cord to all components by means of a control command electronic device called burner flame control unit This part has also the task to monitor flame and to ensure safe operation of the heater during all 1ts operational sequences The electrical board consists of the following parts Control pan
20. m fuse s and the main distribution board e Check the electrical socket Note Only carry out maintenance repairs on the heater and not on the electrical system for which servicing by authorized personnel is required 32 CHECKING AND REPLACING THE POWER CORD e Check that the green warning lamp lights up If 1t does not this means the heater 1s not powered e Check the conditions of cable and plug and look for damages and failures e Unscrew the fixing screws of the control panel and extract the electrical board e Unscrew the fixing screw of the resin board cover and remove the cover e Check voltage between mains terminals live and neutral on the cable strain relief If no voltage is found check the fuse If it is damaged or burnt replace it with one with same current ratings slow blow type To replace the power cord e Only use HO7RN F power cords Europe or SJT power cords USA with watersplash proof plug e Disconnect the line leads and earth leads from terminals e Check the capacitor e To replace the motor e Unpower the machine by unplugging it e Disconnect the motor leads on the burner Ill 9 control unit see picture 10 e Remove the upper shell by unscrewing its 6 e Remove the defective cable fixing screws Insert the replacement cable into the strain relief inner lenght about 5 cm Fix the strain relief into its seat Connect the line and earth leads to termin
21. me sensor leads fault in the flame signal amplifier fire on board of the unit or should the solenoid valve SV not properly interrupt the fuel flow to the nozzle to anticipated 1gnition of the fuel air mist during the prepurge time In this case after the prepurge time and the safety time the unit goes to lock out Special attention 1s required in the event that the heater 1s directly exposed to sunlight e g when used outdoors It may happen that sunrays come into the combustion chamber and give a false flame signal especially when the heater 1s new and the inner surfaces are bright and reflect light e Flame failure at ignition If there 1s no flame signal at the end of the safety time T4 the flame control unit goes to lock out condition e Flame failure during operation If the flame signal fails during operation the flame control unit closes the fuel solenoid valve the fuel flow to the nozzle is interrupted and a new prepurge ignition cycle is started In case of lock out the unit can be manually reset after 30 s approx e Overheat thermostat activation In the event of combustion chamber overheating the overhat thermostat interrupts the electrical supply to the flame control unit and to all components The heater is immediately stopped The possible causes of overheating are described in par 3 TROUBLESHOOTING GUIDE 2 FUNCTIONAL DESCRIPTION OF COMPONENTS 2 1 CASING FRAME Description The heater casing consists of atank
22. ng operation of flame control unit Setting chart Indirect fired heaters with flue Setting chart Direct fired heaters without flue Technical data sheets for indirect fired heaters with flue Technical data sheets for direct fired heaters without flue Wiring diagrams Basic version and versions with filter and nozzle fuel pre heater Special tools for servicing 1 OPERATIONAL DIAGRAMS AND SEQUENCES 1 1 INDIRECT FIRED HEATERS WITH FLUE Burner head Fuel pump Flue Combustion chamber closed Motor Fuel tank Pan 1 2 DIRECT FIRED HEATERS WITHOUT FLUE Burner head Fuel pump Combustion chamber open Motor Fuel tank Fan 1 3 HEATERS WITH AND WITHOUT FLUE OPERATIONAL SEQUENCE T1 TZ L T4 To Ed Prepurge time T2 Ignition time T3 Operation time T4 Safety time at flame failure T5 Aftercooling time SW Switch M Motor T Ignition transformer SV Fuel solenoid valve PH Flame sensor F Flame Prepurge sequence During the prepurge time about 10 s the fan blows air into the combustion chamber to expell any residual exhaust gases The ignition transformer T produces a spark so that any small fuel residuals coming from the solenoid valve through the nozzle are completely burnt At the same time the flame control unit checks for presence of flame or spurious light inside the combustion chamber should this occur the ignition sequence is interrupted and the heater locks out that is all the electrical comp
23. onents are immediately unpowered Ignition sequence During the ignition time after the prepurge time the fuel solenoid valve EV opens and the spark produced by the electrode ignites the fuel mist sprayed by the nozzle The flame sensor photoresistor PH must feel the presence of flame within 1 s safety time otherwise the flame control unit locks out and the motor is stopped If the flame sensor only feels a small flash and not a continuous flame the whole prepurge and ignition sequence is repeated and then if ignition is still unsuccessful the unit goes to lock out and stops Servicing Manual Operational sequence 15 s after a regular flame ignition the flame control unit de energizes the 1gnition transformer and the electrodes stop sparking The heater goes on operating with self sustained combustion The flame control unit monitors the regular presence of flame by means of the flame sensor Any abnormal condition such as lack of fuel blockage of air inlet outlet dirty or clogged nozzle that impairs regular combustion has the effect to close the fuel solenoid valve SV and to interrupt the fuel flow to the burner within the safety time The flame control unit will then start a new complete prepurge ignition sequence and should the problem repeat the unit will lock out and the aftercooling sequence will start Restart sequence If the flame shuts down for any reason the flame control unit repeats the whole start sequence consi
24. pt any responsibility for damages to persons goods properties or to the machine itself that may result from non compliance with the instructions contained in this manual and with the Laws and safety rules in force in the Country of destination 1 1 1 2 1 3 1 4 4 2 4 3 Servicing Manual INDEX OF CONTENTS Operational diagrams and sequences Indirect fired heaters with flue Direct fired heaters without flue Heaters with and without flue operational sequence Safety options in case of abnormal operation Functional description of components Casing Frame Motor fan assembly Fuel circuit Burner head Combustion chamber Electrical board Troubleshooting guide Operating flow chart Checking the supply voltage Checking replacing the power cord Checking replacing the motor Checking replacing the fan Exhaust gas analysis Combustion air adjustment Cleaning the fuel tank Checking cleaning replacing the fuel filter Checking cleaning replacing the fuel nozzle Checking cleaning replacing the burner head and the whirl disc Cleaning the combustion chamber Replacing the motor pump joint Checking adjusting replacing the fuel pump Checking and replacing the fuel solenoid valve Checking cleaning replacing the ignition electrodes Checking replacing the high voltage cables Checking replacing the ignition transformer Replacing the fuse Checking cleaning replacing the flame sensor Checking replacing the overheat thermostat Checki
25. r and ignited by the electrode spark The flow of primary air to the burner is adjusted by an air lock on the combustion head Under abnormal operating conditions see also flow chart the flame control unit closes the solenoid valve SV fuel does not come to the nozzle but goes back to the tank through the return hose An adjustment screw is fitted on the front of the pump it allows to adjust the pressure and consequently the fuel flow I8ZONIZO EN SULZ 19449 d L gt l MOYANO MI SOWA ILL 2 particolare gruppo filtro gasolio ILL 3 particolare pompa gasolio 2 4 BURNER HEAD COMBUSTION CHAMBER 10 Description ILL 4 particolare testa di combustione A certain amount of air coming from the fan flows around the combustion head and depending on the air lock setting a part of it the so called primary air flows inside the burner head The primary air is distributed and mixed with the atomized fuel jet exiting the nozzle by means of a baffle disc To get good combustion and therefore high efficiency the adjustment of the primary air fuel ratio must be very accurate For this purpose please carefully follow the setting specifications and instructions contained in this manual The burner head includes nozzle holder air lock baffle disc whirl disc fuel nozzle ignition electrode flame sensor photoresistor VV Y Y Y Y The fuel coming out of the nozzle is atomized and mixed with primary air Addit
26. s on the combustion head 24 Ill 34 e Extract the combustion chamber and if required clean using Diesel oil e Fliminate any Diesel residuals carefully dry and reassemble the combustion head the burner head and the upper shell 3 11 REPLACING THE MOTOR PUMP JOINT e Loosen do not unscrew completely the 3 fixing screws on the fuel pump Ill 55 e Extract the pump sliding it in the axial direction e Close the inspection panel and start a short ignition cycle 10 s prepurge followed by 3 s first ignition e Shut down the heater turning the ON OFF switch to 0 so that the aftercooling cycle starts and the motor continues to rotate e Open the inspection cover and turn the screw on the pump head clock ot anticlockwise reading at the same time the pressure gauge until the correct pressure setting 1s reached Ill 36 e Check the conditions of the coupling and replace it if required e Make sure that the motor shaft can rotate freely move the fan by hand to check e Reassemble 3 12 CHECKING CLEANING ADJUSTING REPLACING THE FUEL PUMP Ill 38 e Remove the inspection cover To measure the delivery pressure To measure the suction vacuum e Unscrew the screw on the upper part of the e Unscrew the screw marked with V pump e Connect a vacuum meter to the port V To clean the pump filter e Unscrew the filter fixing screw on the pump carter and extract the filter Ill 37 e Connect
27. sene gross heating ve Kcal kg 11 025 08 Lenght 1760 mm Height 965 mm according to standard prEN 13842 2002 Width 650 mm Weight 124 Kg mm S Air Lock Adjustment TECHNICAL DATA SHEET FOR DIRECT FIRED OIL HEATERS 67 kW MODEL Airflow Specifications Air Flow Rating Daten 1650 ft min Thermal Specifications Temperature Rise Delta keen o Consumption Kg hr Efficiency Power Input kcal mm Fuel Pressure S Air Lock Adjustment according to standard prEN 13842 2002 Electrical Specifications Rated Voltage V Hz Rated Current 110 6 143 Ib 5 liters 405mm 55in DOS mm 20 mm Height 50 mm ol gross heating value Kcal kg 10869 44 Package Specifications kerosene gross heating value Kcal kg 11 025 08 14 U S gal Lenght Outlet Diameter 2 1n 830 mm TECHNICAL DATA SHEET FOR INDIRECT FIRED OIL HEATERS 115 kW MODEL Thermal Specifications Maximum Thermal Power Diesel Oil Consumption Kat Efficiency uel Pressure NO at 3 C 37F N OO LA IN cal hr NO NO NO TU hr cal h Lu N de E ES m c Or E l a TU hr 0 00 Hose Diameter MEE NENNEN ower Output AO A BT Ur 000 uel Pressure ENS pat A Air Lock Adjustment Electrical Specifications Rated Voltage 110 60 Airflow Specifications Air Flow Rating mh V 2850 ft min i Noise Level dB A average 14 U S
28. sting of the prepurge and the ignition sequences If there is no flame signal within the safety time T4 the control unit goes to lock out and the red lamp on the control panel lights up If on the contrary a small flame signal is detected within the safety time the control unit repeats the start sequence The whole sequence will be repeated 3 times maximum and then the unit will definitely lock out A maximum number of 3 ignition tries has been fixed to avoid that excessive smoke is produced during the repeated starting sequences This effect could occur when the fuel tank is almost empty and the suction hose contains fuel and air mixed or when the nozzle is partially blocked or damaged and therefore the pressurized fuel 1s incorrectly sprayed Aftercooling sequence During this time the heater 1s subjected to a cooling cycle to avoid excessive overheating of materials and components that could occur if the motor fan suddenly stopped This sequence is also very important from the point of view of efficiency as all the residual heat that accumulates in the combustion chamber can be recovered and sent in the space to be heated For safety reasons it has been established that the high voltage 1gnition transformer must be energized during the aftercooling time By doing this any small fuel residuals coming from the solenoid valve SV will burn completely and will not accumulate inside the combustion chamber Any explosion risk or abnormal heat release
29. t reassmble and check operation 3 19 CHECKING REPLACING THE OVERHEAT THERMOSTAT e Remove the inspection cover and or the upper shell e Check that the thermostat 1s properly fixed and connected To replace the thermostat e Disconnect the thermostat cables e Replace the thermostat e Reconnect and reassemble To reset the overheat thermostat e Unplug the heater e Remove the inspection door e Push the reset button i 22 3 20 CHECKING OPERATION OF BURNER FLAME CONTROL UNIT Perform the following tests to check operation of the burner control unit Check reset pushbutton lock out warning lamp Ensure that the lock out warning lamp is correctly connected see diagram MI M19 gt Check that there is electrical continuity between the terminals and 3 of the reset pushbutton gt Check that there is a 18 20V voltage between the terminals M2 and M19 of the burner control unit when the unit is in lock out condition the lamp is alight Electrical continuity check Unplug the heater gt Turn switch to I ON gt Set the room thermostat in a operating closed position gt Check that the overheat thermostat is closed gt Check electrical continuity between terminals M3 and M4 of the electronic control unit with all wires connected Power supply to loads Plug the heater gt Turn switch to I ON gt Set the room thermostat in a operating closed position gt Using a multime
30. ter check that the burner control unit is powered 30 gt Check voltage on the transformer motor and solenoid valve terminals and that they are correctly energized according to the operational cycle The voltage supply to components must match with the mains voltage Should this not occur or should the components not be correctly energized according to the operational cycle replace the flame control unit with a new one Lock out test Start the heater and wait that the ignition cycle is completed wait until the ignition spark stops Disconnect the flame sensor fast on from terminal M5 on the burner control unit The heater must immediately lock out gt The red warning lamp must light up Reset must be possible only after at least 30 seconds 31 Servicing Manual 4 1 SETTING CHART INDIRECT FIRED HEATERS WITH FLUE CHAMBER WHIRL FUEL FUEL BURNER AIR LOCK INLET BAFFLE PUMP PRESSURE NOZZLE OPENING DISC MIRAGE it 8 holes dia 350mm out dia 76mm 1 DANFOSS 12 bar DANFOSS 3mm 37H 6 mm dia 3 blades in dia 27mm R3 0 65 60 H USA 18 10 blades lock position 1 it 8 holes dia 350mm out dia 76mm DANFOSS 12 bar DANFOSS 7 mm 6 mm dia 3 blades IN dia 27mm H3 1 00 60 H 18 10 blades lock position 2 MIRAGE it 8 holes dia 500mm out dia 76mm DANFOSS 12 bar DELAVAN 14 mm 85 H 10 mm dia 4 blades in dia 22mm R5 1 50 80 W USA 33 10 blades lock position 3 5 4 22 OVERHEA
Download Pdf Manuals
Related Search