Home

Service Manual

1. Bypass Fuel Nozzle Assembly Delivers atomized fuel to Burn in Furnace Bypass fuel pressure is regulated through the Return Fuel System to increase the Nozzle pressure on High Fire and decrease the Nozzle pressure on Low Fire 70 Ig L it L Syste m Pilot Ignition Transformer Ge nera Produces high energy electrical current for Spark ignition of the Pilot Propane Pilot Propane Tube Delivers Propane for Propane Pilot Ignition Pilot Ignition Electrode Delivers high energy Spark for ignition of the Pilot Propane Pilot Propane Regulator Controls Propane pressure for Pilot Propane Ignition Pilot Propane Valve Opens to control Propane flow for Pilot Propane Ignition 71 Ignition System Ignition Electrode Pilot Ignition Electrode Delivers high energy Spark for ignition of the Pilot Propane Tip of Electrode must be centered in the small hole and flush with the outside of the Pilot Propane Tube Pilot Propane Tube Delivers Propane for Propane Pilot Ignition 72 Ignition System Pilot Ignition Transformer Component Location nio electrical current for Spark ignition of the Pilot Propane Pilot Propane Regulator Controls Propane pressure for Pilot Propane Ignition Pilot Propane Valve Opens to control Propane flow for Pilot Propane Ignition 73 Air Fuel Adjustment PREREQUISITE The Burner Fan and Burner Gun Assembly M
2. power in the safety circuit See Safety Circuit Diagram 2 rere COLLE aa e I od Eeo Le Loco Le C 19 Burner Relay Certain conditions must be met before the PLC will turn on the Burner Relay si Low Water Cut 1 and Low Water Cut 2 must be engaged See Low Water Cut Off High Pressure Limit Switch must be engaged See High Pressure Limit Switch HPLS Operating Pressure Limit Switch must be engaged See Operating Pressure Limit Switch OPLS Water level in the boiler must reach the Boiler Water Level Target See Water Level Control Steam pressure must be below operating set point See Steam Pressure Control 20 Burner Relay Once all the conditions for start up are met the PLC sends a 24 VDC signal here to close the relay When the coil receives 24 VDC from the PLC If water level and steam pressure are within normal Contacts close supplying this wire with 120 VAC limits for operation this terminal will be supplied with See Safety Circuit Diagram 1 120 VAC See Safety Circuit Diagram 1 21 High Pressure Limit Switch HPLS The HPLS is a safety device which shuts off the fire if the steam pressure in the boiler gets too high HPLS is normally closed as long as the steam pressure is below the set point If the steam pressure exceeds the set point the switch trips and breaks the safety circuit which shuts down the fi
3. Gun Assembly Bypass Fuel Nozzle Assembly Pilot Propane Tube Delivers Propane during Pilot Ignition Flame Sensor ess Pilot Ignition Electrode Nozzle Fuel Press Gauge Active spark during Pilot Ignition Nozzle Fuel Press Sensor sends signal to PLC Air Louver Run Actuator drives Air Louver open and closed for High Low firing rates Fuel Pump Press Regulator also controls High Fire Pressure Set to 280 300psi typical 3 Way Fuel Valve directs fuel to Air Louver Run Actuator on High Fire Main Oil Valve Fuel Pump Press Gauge Safety Shutoff Oil Valve Opens when Burner fires Bypass Fuel Valve Fuel Pump Opens on Low Press Sensor Low Fire Press Regulator Fire Sends signal to PLC Set to 160 180psi typical Closes High when in Low Fire Fire Opens when Burner fires Fuel System Color Right Front View Red Oil Pressure from Fuel Pump to Bypass Nozzle Blue Return Oil from Bypass Nozzle Yellow Final Return Oil on Low Fire when Bypass Valve is open and 3way valve is closed Green Final Return Oil on High Fire when 3way Valve is open and Bypass Valve is closed 68 Fuel System Color Right Front View Red Oil Pressure from Fuel Pump to Bypass Nozzle Blue Return Oil from Bypass Nozzle Yellow Final Return Oil on Low Fire when Bypass Valve is open and
4. LWCO 1 LWCO 2 burner relay recieves the 24 VDC contacts close between the two yellow wires at the bottom closing the circuit and sending power to the burner relay in the safety chain 12 VDC to 24VDC Power Converter 24 VDC to all 24 VDC Coi Air Flow Switch 12 DC Supply to Relay When 12 VDC power is applied to 86 The contacts close between 30 and 87 to provide 12 VDC power to the system LWCO Diagram The red wire below provides the safety relays with the The yellow wires below are the 24 VDC 24 VDC power for the signal to the PLC It is jumpered PLC to the Low Water 1 Test and Low Water 1 Reset from Air Flow Switch through Control Power 24 VDC to Low Water 2 Reset 4 VDC to Low Water 1 Test 24 to Safety Relays 1 5 5 safety relays are used to tell the PLC the state of each safety Low Water 1 Test is 6 device Each device recieves its normally open when it power at A1 on the relay before receives 24 VDC from it When the switch inside a safety i the PLC on A1 device closes it provides contacts close between 120 VAC to the safety relay which 9 and 5 to simulate closes the relay sending a 24 VDC 3 to the PLC to indicate the safety Low Water 1 fault 2 1 Test Li to Safety Relays Low Water Low Li 1 When the Burner On Off switch on the c
5. 12 VDC from Battery 24 VDC Power Converter un W 4 20 mA common 12 VDC Power 24 From Low Fire Switch when louvei d 13 Pump Wiring Yellow Black Brown White Yellow Ground Safety Circuit The safety circuit is a chain of switches that determine whether the burner may be operated safely The circuit is designed so that each switch when closed provides the power for the next switch in the chain In order for the fire to run power must reach the end ofthe chain Bumer On Off RED RED BLK LWC ALWC HLC Gb Te hH High Pressure Operating Pressure Burner Relay Low Water Cut Off 1 Low Water Cut Off 2 Limit Switch Limit Switch On Off m wy 120 VAC power is introduced into the chain when the Burner On Off switch on the control panel door is turned on Power flows down the chain as each switch closes Each component in the system will be discussed in more detail later 15 Safety Relays In order for the PLC to know the state of the safety circuit 24 VDC signal must be sent from each component in the circuit to the PLC To accomplish this we use a series of relays that is supplied with 24 VDC power and is switched by the 120 VAC as it flows through the safety device circuit The safety relays are normally open A2 is acommon neutral 120 VAC for all relays 9 is always supplied with 24 VDC power When a safet
6. 3way valve is closed Green Final Return Oil on High Fire when 3way Valve is open and Bypass Valve is closed 3 Way Fuel Valve Opens to direct fuel to Air Louver Run Actuator on High Fire Closes on Low Fire Air Louver Run Actuator Drives Air Louver open and closed for High Low firing rates on 1 Bypass Fuel Valve Opens on Low Fire to bypass fuel to Low Fire Press Regulator This decreases fuel pressure at the Nozzle Low Fire Press Regulator Closes on High Fire to Controls Bypass Fuel increase fuel pressure at Pressure to lower Nozzle the Nozzle pressure for Low Fire Operation 69 Fuel System Color Right Front View Red Oil Pressure from Fuel Pump to Bypass Nozzle Blue Return Oil from Bypass Nozzle Yellow Final Return Oil on Low Fire when Bypass Valve is open and 3way valve is closed Green Final Return Oil on High Fire when 3way Valve is open and Bypass Valve is closed Low Fire Press Regulator Controls Bypass Fuel Pressure to lower Nozzle pressure for Low Fire Operation 3 Way Fuel Valve Opens to direct fuel to Air Louver Run Actuator on High Fire Closes on Low Fire Bypass Fuel Valve Opens on Low Fire to bypass fuel to Low Fire Press Regulator This decreases fuel pressure at the Nozzle Closes on High Fire to increase fuel pressure at the Nozzle
7. Flame Sensor 8 N N Syste M Detects Flame presence in all stages of boiler operation General Pilot Ignition Electrode Delivers high energy Spark for ignition of the Pilot Propane A Pilot Propane Tube Delivers Propane for Propane Pilot Ignition Pilot Ignition Transformer Produces high energy electrical current for Spark ignition of the Pilot Propane Pilot Propane Valve Opens to control Propane flow for Pilot Propane Ignition NS gt Pilot Hose Delivers Propane for Propane Pilot Ignition Propane Pressure Sensor Monitors Propane Pressure E 4 EI from Propane Supply Tank Pilot Propane Recut Sends signal to PLC Controls Propane pressure 87 for Pilot Propane Ignition Ignition System Ignition Electrode Pilot Ignition Electrode Delivers high energy Spark for ignition of the Pilot Propane Pilot Propane Tube Delivers Propane for Propane Pilot Ignition Pilot Ignition Electrode Adjustment Set gap to 1 8 between tip of Electrode and edge of Pilot Propane Tube 88 Ignition System Component Location Pilot Ignition Transformer Flame Sensor Produces high energy Detects Flame presence in all electrical current for Spark stages of boiler operation ignition of the Pilot Propane Pilot Propane Valve Opens to control Propane flow for Pilot Propane Ignition Pilot Propane Tube Delivers Pr
8. through the Blue wire to 9 1 When CR 1 receives a 120 signal from the Honeywell Burner Controller on 14 Contacts close between 12 8 and 9 5 12 8 sends a 12 VDC signal to 2 on the VFD to start the fan 9 5 sends 120 VAC to the Air Flow Switch and to the VFD relay in the safety chain to tell the PLC that the VFD has been started 12 VDC power from Battery 12 VDC from Battery through the Control Power Relay 00000 60 SOU Bee 5 olololololololo LOEn ERLEBTEN The safety relays are used to tell the PLC the state of each safety device Each device recieves its power at 1 on the relay before it When the switch inside a safety device closes it provides 120 VAC to the safety relay which closes the relay sending a 24 VDC to the PLC to indicate the safety switch is closed It also provides the Power supply to the next safety device hiss oh E Honeywell Burner Control Once power has progressed to the OPLS the PLC turns on the burner relay which sends a 120 VAC signal to 6 on the Honeywell that it is safe to start the burner The Honeywell sends a 120 VAC signal out to the CR1 to start the fan on 5 Once the fan Starts and the Air Flow Switch closes the Honeywell receives a 120 VAC signal on 7 that it is safe to procede
9. 23 4 5 6 7 8 9 10 11 12 4 DAA ZT Z Dd E 9 DAA CT 1 s146 lal hase Z os Fureur _ 04405 __ eM 249 2 Relay Block DY 1eu19u13 T 3ndino Dojeuy pee Ex d c T nduj Bojeuy OPENJIY ASANO la Jayempacy 3 Le i P 6 Discrete Outputs Discrete Outputs 2 Terminal Strip 1 Discrete Inputs RAM e e 23 485 06 7 1 je F1 2 Fuse Block sem Labels Joyenyoy J Ano J93eM S pjojruew eBung wears F F8 F4 F5 F6 WLAS S 16 S uleajs wears S 2 F3 Fir 4 29 d 5514 oe 5 5 V 930N Note All fuses are Buss Rating R U9919S uono 9J0 J 2 UO u93IMS 440 NO 01 OQA ZT S U33IMS UOINSOG Joyenyoy J9AnO 0 JGA pZ U99J9S YINO 210U 0 DCA VC YIM 19UJ9u34 03 OCA vC SpJe INdINO pue 214 11 03 v sAejoy s1osues bojeuy le 511010 93eJ45siq 03 JAN HZ 04 JOMOd DAA vC 9 95nJ 03 DCA VC J9119AU0j JoMOd DOA vc 01 DAN CT do1S HEeIS 036 0 DAA ZI J9 9AUOT ZT 01 2QA ZI 53467 440M pue 03 JA CT S T 670 6 1 F
10. Boiler Water Temp Sensor LS Circulation Pump Feed Water Pump Water System a PS Feed Water Valve Feed Water Temp Sensor A Supply Water Shut Off Valve 28 Water System Circulation Hot water is pulled out of the boiler It passes through the Y strainer to the circulation pump It is then pumped to the feed water pipe where it mixes with the cold supply water as it enters the boiler Feed Water The warm mixed water from the supply water and circulation water enters the boiler Supply Water Cold water is pulled in through the bulk head fittings in the water tanks It passes through the supply water shut off valve and T strainer to the feed water pump It is then pumped through the feed water valve and mixed with the hot circulation water as it enters the boiler 22 Water Level Control There are 2 main factors that will affect the water level in the boiler the supply water system and the feed water control system In order for the water level in the boiler to be controlled properly both of these systems must be functioning correctly Feed Water Control System Supply Water System 30 Supply Water System The supply water system contains the water tanks the supply water shut off valve the T strainer and the feed water pump Water tanks are the source of water to fillthe boiler They must have water inthem The supply water shut off valve stops the flow of w
11. Gauge 0 30psi III L f High Pressure Limit Switch setatiSOpsi _________ ______ 4 Operating Pressure Limit Switch set at 14 5 psi 7 _ 14 5 psi auto rese 4 4 8 4 4 4 Boiler Water Level 0 12in 4 8in Below 4 in Above 10 in Steam PSI 1 Transducer 30 psi 6 13 psi More than 2 psi differential Selectable and Differential Limit adjustable in Steam PSI 2 Transducer 30 psi 6 13 psi More than 2 psi differential Selectable and Differential Limit adjustable in Feed Water Temperature 0 300 F 100 240 F Above 150 F differential Disable in Settings Alarm Status Screen Adjust in Boiler Water Temperature 0 300 F 100 240 F Above 150 F differential Disable in Settings Alarm Status Screen Adjust in Settings Alarm Settings Rear Door Temperature 0 300 F 100 150 F Above 250 F Disable in Settings Alarm Status Screen Adjust in Settings Alarm Settings Propane Pilot Pressure 0 100 psi 10 12 psi Below 5 psi Disable in Settings Pilot Propane Fuel Pump Pressure Gauge 0 300 psi 145 155 psi Fuel Pump Pressure Transducer 500 psi 145 155 psi Nozzle 1 pressure 0 500 psi 145 155 psi if 20 psi less than Fuel Pump High Fire if Disable in Settings Alarm Status Screen 30 psi less than Fuel Pump High Fire Nozzle 2 pressure 0 500 psi 145 155 psi if 20 psi less than Fuel Pump High Fire if Disable in Settings Alarm Status Screen 30 psi less t
12. OFF WHEN gt 1 PSI ABOVE STEAM PSI TARGET PSIN A HERE CONSTANT PSI READING ALWAYS COMPARES TO STEAM PSI 1 SENSOR FOR SAFETY REDUNDANCY AVERAGE OF STEAM PSI 1 amp 2 SENSORS PSI HERE MUST BE AT LEAST 0 5 PSIBELOW STEAM PSI TARGET TO START BURNER AND OPERATE THROUGH WARM UP PERIOD STEAM PSI 2 SENSOR HIGH FIRE RELAY COMBUSTION AIR LOUVER ON OFF ON BY STEAM PSI CLOSED 1 5 sec TO OPEN OPEN 1 5 sec TOCLOSE CLOSED OPEN TO LOW TO LOW HI LOW HI BY STEAM PSI 1 5 sec TO CLOSE CLOSED 61 DewPoint 6110 Trainin g Complete Burner Overview Right Side View 63 Complete Burner Overview Left Side View 64 Air System Right Rear View Air Louver Purge Actuator opens louver during purge cycles Airflow Switch Burner Fan Motor Air Louver Upper Fan Cleaner Tube Burner Fan Air Louver Run Actuator drives louver open and closed for High Low firing rates Air Louver Lower 65 Air System Top Front Left View Air Louver Purge Actuator opens louver during Air Louver purge cycles Run Actuator drives louver open and closed for High Low firing rates Air Louver Upper Fan Cleaner Tube Burner Fan Air Louver Lower Airflow Switch Z Burner Fan Motor Airflow Switch Airflow Switch High Pressure Line Airflow Switch Low Pressure Line 66 Fuel System General View Burner
13. POST PURGE 80 Air System Right Front View pl High Pressure Connection Airflow Switch Burner Fan Burner Fan Motor A a Air Louver Actuator Airflow Switch Drives louver open and closed during Air Louver Airflow Switch the following stages Low Pressure Hose PRE PURGE RUN for High Low firing rates 8 POST PURGE Fuel System T Press Gauge A Press Sensor General View Sends signal to PLC 278 Stage Fuel Line Fuel Pump Fuel Inlet Port from Fuel Tank 278 stage Fuel Press Sensor not shown here but this is the location when equipped Sends signal to PLC Reads 2nd Nozzle Pressure on High Fire 151 stage Fuel Press ae not shown here but this is the location when equipped Sends signal to PLC Reads 1st Nozzle Pressure on Low Fire and High Fire Fuel Pump Press Regulator Set to 145 150psi typical u Combustion Air Diffuser Cone Fuel Return Port to Fuel Tank 1 Stage Fuel Line 274 Stage Oil Valve Opens when Burner is in High Fire Safety Shutoff Oil Valve Opens when Burner fires on Low Fire and High Fire This is a redundant Safety Shut off Valve if the 1 Stage High Pressure Fuel Oil Valve fails to close on Burner shut down 1 Stage Oil Valve Line to Valves Opens when Burner fires on Low Fire and High Fire 1st and 274 Stage Fuel Nozzles 82 Fuel System Fuel Lines 274 St
14. TO PLC SR 1 BURNER SWITCH MANUAL ON ANUNCIATION SR 2 LOW WATER CUT OFF 1 ON ANUNCIATION SR 3 LOW WATER CUT OFF 2 ON ANUNCIATION SR 4 HIGH PRESS LIMIT CONTROL ON ANUNCIATION SR 7 CR 1 CONTROL RELAY VFD ON ANUNCIATION SR 7 CR 2 CONTROL RELAY VFD ON ANUNCIATION SR 8 BLOWER AIR PRESS SWITCH ON ANUNCIATION STEAM PSI amp FLAME MANAGEMENT BOILER WATER TEMP SENSOR CONSTANT TEMP READING BUT N A HERE LOW HOLD BELOW 180F PSI CONTROL ABOVE 180F CONSTANT TEMP READING BUT N A HERE i s YYETWZT s AVERAGE OF STEAM PSI 1 amp 2 SENSORS PSI N A HERE PSI HERE MUST BE AT LEAST 0 5 PSI BELOW STEAM PSI TARGET TO START BURNER AND OPERATE THROUGH WARM UP PERIOD WHEN gt 0 5 PSI BELOW TARGET OFF WHEN gt 4 PSI ABOVE STEAM PSI TARGET LO WHEN gt 0 5 PSI ABOVE TARGET STEAM PSI 2 SENSOR CONSTANT PSI READING ALWAYS COMPARES TO STEAM PSI 1 SENSOR FOR SAFETY REDUNDANCY 60 ON OFF ON BY STEAM PSI DewPoint 6210 Burner Sequence Table BURNER STATE HONEYWELL LED DISPLAY BURNER SYSTEM VFD VARIABLE FREQUENCY DRIVE BURNER COMBUSTION FAN MOTOR COMBUSTION AIR LOUVER HI FIRE LOUVER OPEN SWITCH PILOT GAS VALVE OIL SHUTOFF VALVE 1st STAGE OIL VALVE 2nd STAGE OIL VALVE FLAME SIGNAL DETECTOR PRIMARY SAFETY SYSTEM BURNER SWITCH MANUAL LOW WATER CUT OFF 1 LOW WATER CUT OFF 2 HIGH PRESS LIMIT CONTROL CR 1 CONTROL RELAY VFD CR 2 CONTROL RELAY VFD BLOWER AIR PRESS SWITCH PLC CONTROLS B
15. a Low Water 1 fault 7 and 8 on LWCO 2 are connected to Low Water 2 Reset relay which is a normally closed relay If there is a Low Water 2 fault the circuit between 7 and 8 must be broken to reset the relay Water must be detected when the is reset otherwise the Low Water 2 fault will return immediately See relays above for more details w 24 VDC Power X12 VDC from Battery i E When 12 VDC power is applied to 86 The contacts close between 30 and 87 to provide 12 VDC power to the system 12 Louver Actuator Diagram and low fire Normal Operation 120 VAC from low fire switch rela The Louver Actuator controls how far the air louver will open which controls the amount of air flow through the burner The Louver Actuator works in connection with two separate control systems in the burner the PLC and the Honyewell Burner Controller The PLC controls the action of the Louver Actuator The Honeywell Burner Controller is a safety device which confirms that all functions are being carried out safely and correctly There are two separate systems inside the Louver Actuator which interact with these two control systems The 4 20 mA signal and the 12 VDC power work together with the PLC to open and close the louver to the correct position The 24 VDC power runs through position switches which communicate with the Honeywell Burner Controller to verify t
16. alternates between Low Fire High Fire and Off depending on the steam pressure demand The PLC receives the signal from the Steam Pressure Transducers and switches the burner between Low Fire High Fire and Off to maintain the correct steam pressure 49 Burner Blow Down Simple Screen Supply Boile Steam Fuel Pilot Water Water Press Level Propane Top Top Front Rear Bottom Bottom Front Rear Feed Pump Boiler w Water Purge Steam Purge Ambient Feed Burner State Fuel 188 88 68 48 28 Steam Pressure Control Logic Because steam pressure is such a critical measurement the two Steam Pressure Transducers both measure the steam pressure inside the boiler The PLC compares the readings from each sensor and calculates the average for the actual steam pressure reading The steam pressure reading from the pressure transducers is displayed here on the field work screen 70 Steam Purge 50 Compare the Boiler Steam Pressure readings to the Pressure Gauge reading on the top front end of the Boiler Select the Sensor that watches The DewPoint may be operated on one sensor for a short period of time until the bad sensor can be replaced All pressure safety devices will still function normally However to ensure accurate steam pressure control the DewPoint should never be operated for an extended time with one Steam Pressure Transducer Steam Pressure Control Log
17. indicate the safety switch is closed It also provides the Control Power When the Burner On Off switch on the control panel door Above is turned on it introduces 120 VAC power into the safety circuit OPLS and HPLS are normall closed they Power cascades down the chain through each safety open when steam pressure reaches their device through the Black Grey Blue and Orange circuits set point OPLS 14 PSI HPLS 15 PSI to the right LWCO 1 LWCO 2 See lolololololololo LWCO 1 and LWCO 2 are normally open They close when probes contact water in the boiler See Low Water Cut Off diagram for more detail mu axe mm se u did DO p When 12 VDC power is applied to 86 The contacts close between 30 and 87 to provide 12 VDC power to the system 24 to all 24 VDC Cor 12 VDC power from Battery 12 VDC from Battery 12 VDC trom Battery um Safety Circuit Diagram 2 This 24 VDC provides the safety relays with the 24 VDC power for the signal to the PLC It is jumpered from Air Flow Switch Relay Whenever the VFD is supplied with 240 VAC current which is any time the generator is running the Blu Blk wire from 14 on the VFD should be supplied with 12 VDC power this closes the contacts between 9 and 5 on CR 2 wich provides 120 VAC
18. AT LEAST 0 5 PSI BELOW STEAM PSI TARGET TO START BURNER AND OPERATE THROUGH WARM UP PERIOD LO WHEN gt 0 5 PSI ABOVE TARGET STEAM PSI 2 SENSOR CONSTANT PSI READING ALWAYS COMPARES TO STEAM PSI 1 SENSOR FOR SAFETY REDUNDANCY HIGH FIRE RELAY ON OFF ON BY STEAM PSI OFF WHEN gt 1 PSI ABOVE STEAM PSI TARGET eg ge yaw IE EE COMBUSTION AIR LOUVER CLOSED 1 5 sec TO OPEN OPEN 1 5 sec TOCLOSE CLOSED OPEN TOLOW OPENTOLOW HI LOW BY STEAM PSI 1 5 sec TO CLOSE CLOSED 90 Air Fuel Adjustment PREREQUISITE The Burner Fan and Burner Gun Assembly SHOULDBE CLEAN before adjusting the Air Fuel Ratio to tune the Burner If Flue Temperatures are running high above 600 degrees your Boiler Fire Tubes are likely sooted up and will also require cleaning before tuning the Burner 2 Always watch for Smoke DO NOT RUN A SMOKEY BURNER Unless you really enjoy cleaning soot from your Boiler Fire Tubes Adjust Air Louver Position from Touch Screen from the Tune Burner Menu Follow instructions on the Touch Screen to tune the Burner for both Low Fire and High Fire Adjustments Remember to re tune the Burner when elevation or seasonal temperatures change Adjust Fuel Pump Pressure 1 Set Fuel Pump Pressure to 145 150psi with Burner running 91 Cleaning Page 1 Clean Burner Internally every 50 Hours e Remove this cover and use compressed air to clean the e Bu
19. Manifold Drain Valve The Manifold Drain Valve opens to drain any waterthat has accumulated in the bottom of the steam manifold It normally opens for 30 seconds and closes for 30 seconds The open time can be changed in settings The valve is a 0 5 in standard port brass ball valve It is driven by an EH3 On Off actuator The Manifold Drain Valve is located on the bottom of the steam manifold here 55 Steam Purge Valve The Purpose of the steam purge valve is to keep the steam pressure low enough that the burner will not shut off when turning around or using low steam rates This prevents big drops in steam pressure because of the burner shutting off during operation The steam purge valve uses a 1 in full port valve with an EH2 On Off actuator The steam purge valve is located in the middle of the steam manifold 56 Steam Valve The steam valves control the steam rate to the corresponding steam manifold in the baler They are a 1 5 in standard port brass ball valve with an EH2 4 20 mA actuator The steam purge valve is located in the middle of the steam manifold 27 Valve Repair Before you begin turn the valve to the fully closed position careful not to damage the surfaces on the valve where the seats will need to seal 1 Remove the retainer nut from the end of the valve and remove the outer seat and the ball the ball must be in the closed position before it can be removed 2 Remov
20. PLC X7 24 VDC Sign Mo PLC XS 17 Generator Power Water System Burner Burner Status Tune Burner 1000 800 600 400 200 0 150 75 0 0 Supply Boiler Steam Fuel Pilot Water Water Press Level Propane Flue Boiler Ambient Feed Burner State Feed Pump Circ Pump Water Purge Steam Purge Fuel Sequence Control Switch Low Water 1 Low Water 2 High Pressure Limit Operating Pressure Ctri Burner Relay Fan VFD Air Flow Switch Tune Burner 22 elevation and temperature conditions change Burner will not smoke when tuned As each safety device engages and the signal is sent to the PLC indicators on the Systems Start screen will turn green to indicate that the device is engaged Remember The Safety Relays send this signal to the PLC Ifthe device is engaged but the PLC is not receiving the signal that it is engaged check the relay 18 Burner Relay The Burner Relay is the switch the PLC uses to turn the burner on and off It is located in the safety chain after the safeties for water level and pressure Therefore if for any reason a safety trips for water level or pressure it will cut off the power to the relay and shut off the burner regardless of what the PLC is telling it to do The Burner Relay is located in the bottom right corner of panel 2 It receives a 24 VDC signal to the coil from the PLC which switches the 120
21. RE LOUVER CLOSED SWITCH PILOT IGNITION TRANSFORMER PILOT GAS VALVE OIL SHUTOFF VALVE ist STAGE OIL VALVE 2nd STAGE OIL VALVE FLAME SIGNAL DETECTOR ON FOR 10 sec THEN 10 sec ON FOR 15 sec ON THROUGHOUT RUN STATE ON FOR 15sec ON THROUGHOUT RUN STATE ON OFF ON BY STEAM PSI SAFE START CHECK TO BE SURE THERE IS NO FLAME CHECK TO PROVE FLAME PRIMARY SAFETY SYSTEM BURNER SWITCH MANUAL MUST BE ON LOW WATER CUT OFF 1 LOW WATER CUT OFF 2 HIGH PRESS LIMIT CONTROL OPERATING PRESS CONTROL BURNER RELAY CR 1 CONTROL RELAY VFD MUST BE ON CR 2 CONTROL RELAY VFD MUST BE ON BLOWER AIR PRESS SWITCH MAY BE ON MAY BE ON MAY BE ON MUST BE ON MUST BE ON MUST BE ON PLC CONTROLS BURNER ON OFF CONTROL DY7 BURNER RELAY SR RELAY ANNINCIATION TO PLC SR 1 BURNER SWITCH MANUAL ANUNCIATION SR 2 LOW WATER CUT OFF 1 ON ANUNCIATION SR 3 LOW WATER CUT OFF 2 ANUNCIATION SR 4 HIGH PRESS LIMIT CONTROL ON ANUNCIATION SR 7 CR 1 CONTROL RELAY VFD ON ANUNCIATION SR 7 CR 2 CONTROL RELAY VFD ON ANUNCIATION SR 8 BLOWER AIR PRESS SWITCH ON ANUNCIATION STEAM PSI amp FLAME MANAGEMENT BOILER WATER TEMP SENSOR CONSTANT TEMP READING BUT N A HERE LOW HOLD BELOW 180F PSI CONTROL ABOVE 180F CONSTANT TEMP READING BUT N A HERE WETTEN Li m HI WHEN gt 0 5 PSI BELOW TARGET AVERAGE OF STEAM PSI 1 amp 2 SENSORS PSI N A HERE PSI HERE MUST BE
22. Steam 000000 DewPoint 6110 Burner Sequence Table BURNER STATE PURGE HOLD PURGE HOLD PROPANE RUN LOW FIRE RUN LOW FIRE HIGH FIRE STANDBY T19 HI FIRE E T18 LOW FIRE PILOT LA HEATING BOILER ON CONTROLLED BY STEAM STANDBY prer SWITCH SWITCH IGNITION LOW 180F PRESSURE DEMAND INITIATE Power HONEYWELL LED Hanc DIS P LAY Main Main BURNER SYSTEM VFD VARIABLE FREQUENCY DRIVE BURNER COMBUSTION FAN MOTOR COMBUSTION AIR LOUVER ELECT ACTUATOR COMBUSTION AIR LOUVER OIL ACTUATOR HI FIRE LOUVER OPEN SWITCH STARTS 6 sec TO HIGH ON 6 sec TOLOW HIGH LOW HIGH BY STEAM PSI LOW ON WHEN HIGH PILOT GAS VALVE ON FOR 10 sec THEN 10 sec OIL SHUTOFF SAFETY VALVE ON FOR 15sec ON THROUGHOUT RUN STATE MAIN OIL VALVE ON FOR 15sec ON THROUGHOUT RUN STATE LOW FIRE BYPASS OIL VALVE oN ON OFF ON OFF BY STEAM PSI HIGH FIRE 3 WAY OIL VALVE ON OFF ON BY STEAM PSI FLAME SIGNAL DETECTOR SAFE START CHECK TO BE SURE THERE IS NO FLAME CHECK TO PROVE FLAME PRIMARY SAFETY SYSTEM BURNER SWITCH MANUAL MUST BE LOW WATER CUT OFF 1 MAY BE ON MUST BE ON SSE SSS LOW WATER CUT OFF 2 MAY MUST BE een HIGH PRESS LIMIT CONTROL MAY BE ON MUST BE ON CR 1 CONTROL RELAY VFD MUST BE ON CR 2 CONTROL RELAY VFD MUST BE ON BLOWER AIR PRESS SWITCH PLC CONTROLS BURNER ON OFF CONTROL DY7 BURNER RELAY SR RELAY ANNINCIATION
23. Sy 3 26 2016 Steam Pressure 15 PSI Low Water Water Level Sensor 1 Pressure Relief Valve Cut Off Sensor Operating Pressure Limit Switch Steam Pressure Gauge High Pressure Limit Switch Steam Pressure Sensor 2 Boiler Water Temp Sensor v Boiler Water Sight Glass Feed Water Temp Sensor Steam Valves Steam Purge Valve Water Purge Valve Flue Temp Sensor Boiler Door Temp Sensor ca Furnace Sight Glass Circulation Water Pump Feed Water Pump Feed Water Valve Boiler Drain Valve Air Flow Switch Gun Assembly Burner Cone Fuel Nozzles Fuel Pump Fuel Pressure Gauge Louver Actuator Fuel Pressure Sensor IR Flame Sensor Ignition Transformer Control Switch Fan Motor Ignition Electrode Propane Regulator Fuel Valves Propane Valve Propane Pressure Sensor 6210 Panel 1 3188 182 Ba 15 PIE C Gla Gale 6210 Panel 2 amp 3 Relay Controls all 3 Control 112 v and 24 v power Boiler Water Level Sensor Transmitter Terminal A pz pue ZT 10 440 NO JJO NO 9 ZT SSYUMIMS uonsog sAejay 5 siosu s Bojeuy y E URS 0 pue 974 1 24 N eB n 20 1 9 5 4 91 JA LEE 15 Fuse Block
24. URNER ON OFF CONTROL DY7 BURNER RELAY SR RELAY ANNINCIATION TO PLC SR 1 BURNER SWITCH MANUAL SR 2 LOW WATER CUT OFF 1 SR 3 LOW WATER CUT OFF 2 SR 4 HIGH PRESS LIMIT CONTROL SR 7 CR 1 CONTROL RELAY VFD SR 7 CR 2 CONTROL RELAY VFD SR 8 BLOWER AIR PRESS SWITCH STEAM PSI amp FLAME MANAGEMENT PURGE HOLD T19 HI FIRE SWITCH SAFETY INITIATE START STANDBY ON 1 5 sec TO OPEN SAFE START CHECK TO BE SURE THERE IS NO FLAME MUST BE ON MAY BE ON MAY BE ON MAY BE ON MUST BE ON MUST BE MUST BE ON MUST BE ON MUST BE ON ANUNCIATION ON ANUNCIATION ANUNCIATION ON ANUNCIATION ON ANUNCIATION ON ANUNCIATION ON ANUNCIATION PURGE HOLD T18 LOW FIRE SWITCH PROPANE PILOT IGNITION MAIN OIL IGNITION 30 SECOND PURGE Alarm 1 5 sec TOCLOSE CLOSED OPEN TO LOW FOR 10 sec 10 sec ON FOR 15 sec m ON FOR 15 sec RUN LOW FIRE HEATING BOILER ON LOW TO 180F RUN LOW FIRE HIGH FIRE CONTROLLED BY STEAM PRESSURE DEMAND OPEN TO LOW HI LOW HI BY STEAM PSI ON THROUGHOUT RUN STATE ON THROUGHOUT RUN STATE ON OFF ON BY STEAM PSI CHECK TO PROVE FLAME 15 SECOND POSTPURGE STANDBY 1 5 sec TO CLOSE BURNER ALARM BOILER WATER TEMP SENSOR CONSTANT TEMP READING BUT N A HERE LOW HOLD BELOW 180F PSI CONTROL ABOVE 180F CONSTANT TEMP READING BUT N A HERE r SS HI WHEN gt 0 5 PSIBELOW TARGET gt LO WHEN gt 0 5 PSIABOVE TARGET
25. UST BE COMPLETELY CLEAN before adjusting the Air Fuel Ratio to tune the Burner If Flue Temperatures are running high above 600 degrees your Boiler Fire Tubes are likely sooted up and will alsorequire cleaning before tuning the Burner 4 Check for Smoke on High Fire With Fuel Pump Pressure set to 280 300psi with Burner running this should produce Nozzle Pressure of 160 180psi on High Fire Air Louvers should be fully open There should be no continuous smoke on High Fire however it is normal to see a short puff of dark smoke when the burner transitions from Low to High Fire If there is smoke lower the Pump Pressure until smoke clears If you must lower the Pump Pressure to less than 250psi you will need to diagnose the problem and correct it before operation DO NOT RUN A SMOKEY BURNER 3 Sorry Low Fire Air Louver Adjustment Screw Adjust Air Louver toward closed until Burner just starts to smoke on Low Fire Then adjust Air Louver toward open until Burner just clears smoke on Low Fire Low Fire Press Regulator While Burner is in Low Fire Air Louvers closed set Nozzle pressure to 70 80psi Fuel Pump Press Regulator Set Fuel Pump Pressure to 280 300psi with Burner running 2 Finally adjust Air Louver toward open 1 additional 1 turn on Low Fire 74 ed N ng 3 Clean Burner Internally every 50 Hours Remove this front cover and use compressed a
26. age Fuel Line Fuel Pump Fuel Inlet Port from Fuel Tank Fuel Return Port to Fuel Tank 1 Stage Fuel Line High Pressure Fuel Line to Valves 83 Fuel System Fuel Valves and Nozzles 155 Stage Oil Valve Opens when Burner fires on Low Fire and High Fire x 274 Stage Oil Valve Opens when Burner is in High Fire Safety Shutoff Oil Valve Opens when Burner fires on Low Fire and High Fire This is a redundant Safety st Shut off Valve if the 1 Stage 1 Stage Oil Valve fails to close on Fuel Nozzle Burner shut down On in both Low Fire and High Fire 2nd Stage Fuel Nozzle On when in High Fire 84 Fuel Pump Fuel System Press Sensor Fuel Pressure Sensors and Controls Fuel Pump Press Regulator Set to 145 150psi typical 274 stage Fuel Press Sensor not shown here but this is the location when equipped Sends signal to PLC Reads 2nd Nozzle Pressure on High Fire 1st stage Fuel Press Sensor not shown here but this is the location when equipped Sends signal to PLC Reads 1st Nozzle Pressure on Low Fire and High Fire 85 Fuel System 1st amp 274 Stage Burner Gun Assembly Exploded View 274 Stage Fuel Line On when in High Fire 1 Stage Fuel Nozzle On in both Low Fire and High Fire 274 Stage Fuel Nozzle On when in High Fire 1 Stage Fuel Line On in both Low Fire and High Fire 86
27. ater to the T strainer so that is can be cleaned without spilling water all over the ground It must be open to allow water supply to the feed water pump The feed water pump pumps the water into the boiler It should be running any time the water system is active The T strainer stops particles in the supply water from being pumped into the boiler It should be cleaned every time the water tanks are filled If it is not cleaned frequently it will plug and stop the water flow into the boiler 31 Water Level Control This consists of three components the boiler water level sensor the PLC and the feed water valve The feed water valve opens to allow water to flow into the boiler to raise the water level When the water has reached the correct level inside the boiler the valve closes to stop the flow of water into the boiler The boiler water level sensor measures the level of the water in the boiler and sends a signal to the PLC to indicate what the water level is The water level in the boiler is measured in inches and should correspond to the level in the sight glass on the upper right side of the The PLC is programmed to maintain the boiler water level at a set point Default 5 in When the boiler water level sensor indicates that the water level has dropped below the set point the PLC tells the feed water valve to open to allow water to flow into the boiler When the water level reaches the set point th
28. ding 24 VDC power to the High Fire Switch Relay which will close the relay sending 120 VAC signal to the Honeywell Burner Controller telling it that the louver has opened The Honeywell Burner Controller will then go to the purge state The burner will purge for 30 seconds After the purge is complete the Honeywell Burner Controller will tell the PLC through the Mod Bus connection that the purge is complete it will go into a Purge Hold state again and wait until it receives a signal that the louver is closed The PLC will tell the Louver Actuator to close Once the actuator has closed beyond the Low Fire Switch the Low Fire Switch will close sending 24 VDC power to the LowFire Switch Relay which will close the relay sending 120 VAC signal to the Honeywell Burner Controller telling it that the louver has closed The Honeywell Burner Controller will then progress to Pilot Ignition AE A samai asi a olololololololo a 1 100 je 120 VAC from Rela When position switches in actuator close 24 DC is applied to A2 contacts close between 9 and 5 sending 120 VAC to the Honeywell Burner Controller which confirms that the louver is in the correct position CJ of e When 12 VDC power is applied to 86 The contacts close between 30 and 87 to provide 12 VDC Ground power to the system 12 VDC power from Battery
29. e retainer nut on the stud at the top of the valve 3 Remove the stud and the inner seal by pressing the stud down into the valve and out the end Remove the outer seal Remove the inner seat re assemble do these steps in reverse with the new parts 58 DewPoint 6210 Start Up Timeline 1 Generator Starts and Runs 2 Feed Water Pump Turns On and Runs i YV C 3 Feed Water Actuator Opens and lets water into the Boiler until Boiler reaches operating level 4 Burner Control Power comes on automatically unless manually shut off 2 YV Y V Y Y Y r r fff fff 5 Low Water Cut Off Probe 2 makes contact with Boiler Water 6 Low Water Cut Off Probe 1 makes contact with Boiler Water and satisfies Both LWCO safeties at this time f f f f f f f f f 7 Circulation Pump Turns On 8 Burner Controller checks for overpressure over 15 existing Boiler PSI in the boiler by Checking the High Pressure Limit sensor 4 44 484 4 f f f f f r f f f f f f f f 9 Burner Controller checks for overpressure over 14 5 existing Boiler PSI in the boiler by Checking the Operating Pressure Control sensor 10 System Waits for the Burner Relay to be initiated done automatically during a Start or done manually if system was started using Start Fill 11 Burner Relay is active After the Target Boiler Wate
30. e The circulation pump will not run until the water system is active and Low Water 1 is closed water is above Low Water 1 35 Feed Water Valve The Feed Water Valve controls the flow of supply water into the boiler to maintain the proper water level 36 Boiler Water Temp and Feed Water Temp Sensors The Boiler Water and Circulation Water Temp sensors are both critical for boiler operation When the boiler is heating up the burner will not go to high fire until the boiler water temp reaches 180 degrees F During operation the PLC is always comparing the readings from both sensors Both sensors are exactly the same and can be interchangeable if needed 37 Sensors The readings from the Boiler Water Temp and Feed Water Temp sensors can be seen on the touch screen controller on the two screens to the right The feed water will normally be cooler than the boiler water when the Feed Water Valve is open When the Feed Water Valve is closed the two sensors will normally read very close to the same Boiler Water Feed Water 220 250 deg 120 250 deg F Default temp differential set point 150 deg F Hold Shut Down Burner Blow Down Simple Screen Boiler Water Temp and Feed Water Temp Field Work Supply Boiler Steam Fuel Pilot Water Water Press Level Propane Front Rear Bottom Bottom Front Rear Feed Pump Circ Pump F 70 Ambie
31. e PLC tells the valve to close which stops the flow of water into the boiler 32 Water System Safeties Low Water Cut Off The Low Water Cut Off LWCO is a safety device designed to ensure that the water level in the boiler never drops below a safe level during operation The LWCO consists of two probes One is slightly longer than the other Each probe is a totally separate sensor from the other The tip of the probes sit at the lowest safe level in the boiler When the water level in the boiler rises enough that it touches the tip of the probe the LWCO knows that the water is high enough to safely operate If the water level in the boiler drops so that the water is no longer touching the probe the LWCO knows that the water is below the safe operating level The only function of the LWCO is to shut off the flame if the boiler water level drops below the safe operating level It does not have any effect on water level control See Safety Circuit for more detail on the Low Water Cut Off 33 Feed Water Pump The Feed Water Pump is used to pump the supply water from the water tanks to the boiler The Feed Water Pump runs anytime the water system is active The flow of water from the Feed Water Pump to the boiler is controlled by the Feed Water Valve See Feed Water Valve 34 Circulation Pump The Circulation Pump is used to pull hot water out of the boiler and circulate it back through the feed water pip
32. empty position h Next slide the float to the full position and verify 20 mA output i Adjust gain pot on signal conditioner if required to get 20 mA when float is at the full point j Finally slowly move the float up and down the full length of the stem watching the meter for abnormal output readings k Now the sensor and signal conditioner test good Any errors in readings when connected in your application may be the result of i How the signal conditioner wires are routed ii Grounding of sensor and tank ii Or other application amp installation issues Staheli West Inc 600 N Airport Road Cedar City Utah 435 586 8002 info staheliwest com 0 19 Signal Conditioners Continuous Output Sensor to 4 20 mA 4 20 mA Output Loop Powered 24 Vdc powered from loop e Adjustable Zero 4 ma output by 25 turn sealed pot e Adjustable Gain 20 ma output by 25 turn sealed pot Two piece terminal blocks plug in for easy wiring Load resistor typically 250 ohms Epoxy sealed electronics for industrial applications Reverse polarity protected Voltage spike and surge protected Ordering Information Part number SCL BMOBB lt 250 OHMS 2 4 20 mA 2 7 SIGNAL 1 42 Staheli West Inc 600 N Airport Road Cedar City Utah 435 586 8002 info staheliwest com Feed Water Valve The Feed Water Valve controls the flow of supply water into the boiler to maintain the prop
33. er water level See Water Level Control for more detail The valve is a 1 in STD port brass ball valve It is driven by an EH2 4 20 mA actuator The Feed Water Valve is located inside the back door here 43 Feed Water Pump The Feed Water Pump is used to pump the supply water from the water tanks to the boiler The Feed Water Pump runs anytime the water system 15 active The flow of water from the Feed Water Pump to the boiler is controlled by the Feed Water Valve See Feed Water Valve This pump requires little or no service other than reasonable care and periodic cleaning Occasionally however a shaft seal may become damaged and must be replaced The procedure as outlined on the next page will enable you to replace the seal 44 Circulation Pump The Circulation Pump is used to pull hot water out of the boiler and circulate it back through the feed water pipe The circulation pump runs any time the water system is active and Low Water 1 is closed water is above Low Water 1 This pump requires little or no service other than reasonable care and periodic cleaning Occasionally however a shaft seal may become damaged and must be replaced The procedure as outlined on the next page will enable you to replace the seal 45 Pump Service NOTICE The highly polished and lapped faces of this seal are easily damaged Read instructions and handle the seal with care Some models are equipped with an impelle
34. han Fuel Pump High Fire Flue Temperature 0 1000 F 300 450 F Above 600 F Disable in Settings Alarm Status Screen Adjust in Air Flow Sensor Communicates with Honeywell Controller to oo Infrared Flame Detector 0 15v Screen Reading 3 15 v Screen Reading Works with Honeywell Controller Flame Amplifier 95
35. hat the purge cycle was completed correctly During normal operation when the burner state is Run the PLC controls the opening and closing of the actuator for low and high fire This is determined by the steam pressure in the boiler which is sensed by the two pressure transducers on the top front of the boiler The 4 20 mA signal from the PLC tells the Louver Actuator how far it should be open The 12 VDC motor inside the Louver Actuator drives the Louver open to the position called for by the 4 20 mA signal The Honeywell Burner Controller does not care what the Louver Actuator is doing when the burner state is Run For the burner to ignite safely an effective purge cycle must be completed For an effective purge cycle to take place the air louver must open completely and the fan must move air through the completely open louver for 30 seconds The Honeywell Burner controller uses the 24 VDC position switches in the Louver Actuator to confirm that an effective purge has taken place When the burner initiates the Honeywell Burner Controller will call for a purge cycle it will start the fan it will send a signal to the PLC through the Mod Bus connection that it wants to purge it will go into a Purge Hold state and wait until it receives a signal that the louver is open The PLC will tell the Louver Actuator to open completely Once the actuator has opened beyond the High Fire Switch the High Fire Switch will close sen
36. he float toward the empty end of the sensor and the resistance will decrease e With an ohmmeter connect between Black amp Yellow wires The closer the float is to full the lower the resistance typically will be less than 100 ohms Move the float toward the empty end of the sensor and the resistance will increase f With an ohmmeter connect between Red amp Yellow wires the resistance will not change with float movement The resistance will be 600 750 ohms g Theresistance tests above must never be above 900 ohms h If the sensor output changes as described above the sensor is good i Reconnect sensor wires to signal conditioner 2 Test Signal Conditioner Turn off power Disconnect any wires from the two position terminal block Measure the incoming power voltage this must be 10 28 VDC With an amp meter set to measure milliamps DC i Connect a 250 ohm resistor to the signal terminal on the signal conditioner ii Connect meter positive lead to loose end of 250 ohm resistor Connect meter negative lead to power supply GROUND iv Connect power to plus terminal on the signal conditioner terminal block e If the float on the sensor cannot be moved i e remote location or installed in tank verify signal conditioner output is between 4 20 mA f If the float on the sensor can be moved slide the float to the empty position and verify 4 mA output g Adjust zero pot on signal conditioner if required to get 4 mA when float is at
37. ic If the readings from the two pressure transducers are ever more than 2 psi different from each other an error message will appear that will require the operator to select which transducer matches the reading on the mechanical gauge The selection can be made by selecting the sensor that matches directly from the error message Load Defaults or by going to Menu Settings Boiler Pressure Pressure Sensor Selection and select the matching sensor Select 51 Steam Pressure Control Logic The PLC automatically adjusts the flame between Low Fire High Fire and Off to keep the steam pressure within 1 psi of the Boiler Steam Pressure Operating Target logic for this is Select High Fire When steam pressure is more than 1 psi below the Operating Target and the boiler water is more than 180 deg the Burner goes to High Fire Low Fire When steam pressure is within 1 psi or and or the boiler wateris below 180 degrees of the Operating Target the Burner goes to Low Fire Off When the steam pressure is more than 1 psi greater than the Operating Target the burner goes to off The Boiler Steam Pressure Operating Target can be found by going to Settings Boiler Pressure 52 EH2 4 20 mA EH2 On Off ZU EH3 4 20 mA with Position Switches EH3 On Off Actuators The EH2 4 20 mA actuator is used in several locations on the machine It receive
38. ing level and shuts off the burner The Low Water Cut Off has only two Functions 1 Shutoff the burner if water level drops below safe level 2 Tells the PLC to start the Circulation Pump when the LWCO is engaged See LWCO Diagram for more detail on the Low Water Cut Off 24 Operating Pressure Limit Switch OPLS The OPLS is a safety device uses to shut off the fire if the steam pressure in the boiler gets too high The OPLS is normally closed as long as the steam pressure is below the set point If the steam pressure exceeds the set point the switch trips and breaks the safety circuit which shuts down the fire When steam pressure drop back below the set point The OPLS will automatically reset see Safety Circuit Diagram 1 and Safety Circuit Daigram 2 23 Operating Pressure Limit Switch OPLS The OPLS set point may be adjusted by turning this nut Clockwise increases set point Counter clockwise decreases set point Operating Range Recommended Set Point 0 15 psi 14 psi 26 Water System The purpose of the water system is to provide the boiler with water and maintain the proper water level during operation It is essential for both function and safety that the water inside the boiler is maintained at an appropriate level The Water System can be broken down into 4 main parts Controls and Safeties Supply Water Blue Feed Water Purple Circulation Red puse 27
39. ir to clean the 1 Clean entire Burner Area at least Daily but preferably each time you load with water Use Compressed Air to remove dust and crop debris from around the Burner and Generator Clean Burner Fan at least Daily but preferably each time you load with water eon 4 Connect your compressed air hose to the small red hose on this valve Open the Valve 4 or 5 times for about 2 seconds each time to blow dust off the fins of the Burner Fan Be sure your compressed air has enough pressure to spin the Fan Burner Fan thoroughly from the top Gun Assembly Flame Sensor Sight Tube Ignition Electrode Propane Pilot Tube 75 Reference Resources For Complete DewPoint 6110 Burner Training Videos Go To www staheliwest com Login Customer Portal Username customer Password dewpoint 6110 Burner Videos Or go to this link https drive google com folderview id OBzP5iQZMFZCafIRXT 3IrUIJoWIN3bVJYcTJvODBIdTVna2FnVnFOWHCc5S3JIUKk9ieHIhZ Uk amp usp drive web DewPoint 6210 Burner Training Complete Burner Overview Right Side View Complete Burner Overview Left Side View 79 Air System Right Rear View Air Flow Switch Checks for Airflow during Buner Start up and Operation Burner Fan Motor Burner Fan Air Louver Air Louver Actuator Drives louver open and closed during the following stages PRE PURGE RUN for High Low firing rates
40. irst until rubber drive ring hits shaft shoulder 5 Screw impeller on shaft until impeller hub hits shaft shoulder This will automatically locate seal in place and move the sealing washer face up against seat facing Reinstall impeller screw if used 46 Pump Service 3 4 socket EN f E fn shoulder di Cardboard ff washer AE 227 supplied w seal Rubber 2 Mechanical seal Surface E Mechanical seal Stationary rotating half put cy me 3 UN Seal Plate A Seal removal rotating half 5838 0109 B Seal removal stationary half C Stationary half installation D Rotating half installation 47 Y Strainer The Y strainer will catch any large particles as the boiler water is pulled out and recirculated The Y strainer should be flushed at the end of each day by opening the hand valve on the front for several seconds If the Y strainer is not flushed often it will cause malfunction of the circulation system If the screen inside the Y strainer becomes damaged or permanently plugged the screen can be easily replaced 48 Steam Pressure Control This system consists of three components the Steam Pressure Transducers the PLC and the Burner The two pressure transducers sense the pressure inside the boiler and send that information to the PLC The Burner provides the fire which increases the pressure inside the boiler The burner
41. l F2 F3 F4 F5 F6 F F8 F9 F10 F11 F12 accessory 4l Am of ob 85 Signal from PLC Relay 30 Bi m ground y Touch Screen Power Diagram 12 VDC power is provided by the generator battery It enters the panel throught the 3B and 3A harnesses From there it feeds the control relay 30 and the 12 fuse in panel 3 from the 12 fuse it feeds the rocker switch on the C more controller When the switch is turned on 12 VDC is applied to control relay 86 which closes the contacts between 30 and 87 This provides 12 VDC to all compenents that require 12 VDC power Fuse 4 in panel 3 supplies 12 VDC to the 24 VDC power converter which more Controller supplies 24 VDC power to fuse 5 Fuse 5 supplies 24 VDC for fuses 6 11 Fuse 10 provides 24 VDC power to the C more LJ 11 Back View When power is applied to 86 the contacts close between 30 and 87 to provide 12 VDC and 24 VDC to the system oe bi Il ARR atety Circuit Diagram 1 This 24 VDC provides the safety relays with the 24 VDC power for the signal to the PLC It is jumpered from Air Flow Switch through Control Power The safety relays are used to tell the PLC the state of each safety device Each device recieves its power at 1 on the relay before it When the switch inside a safety device closes it provides 120 VAC to the safety relay which closes the relay sending a 24 VDC to the PLC to
42. nt Feed Steam Purge Burner State Fuel Steam Purge Menu Diagnostics gt Inputs Outputs gt Analog Inputs Analog Inputs Analog Outputs Discrete Inputs Discrete Outputs 1 2 Supply Water Level Boiler Water Temp Fuel Level Feed Water Temp Fuel Press Pump Ambient Temp Propane Press Furnace Door Temp Steam Psi 1 Steam Psi 2 Boiler Water Level 38 Boiler Water Temp and Feed Water Temp If the feed water is too much cooler than the boiler water 150 deg F it indicates a failure in the circulation system and gives an alarm to the operator Alarm Settings Load Defaults Flue Temp Ambient Temp Alarm Alarm Limit Limit Door Temp WaterTemp Alarm Differential Limit Alarm Limit Max Pressure Differential Setpoint The temperature differential set point can be adjusted by going to Menu Settings 2 Alarm Settings on the touch screen controller and adjusting the set point here Supply Water Alarm Enable Water Temp Water Temp Differential Alarm is Disabled REPAIR AS SOON AS POSSIBSE Differential Alarm The Boiler Water and Feed Water temperature differential will not be monitored automatically Before operating with disabled sensor verify that Disabled Circulation Pump is operating correctly and Stainer is not plugged Ambient r Alarm Enabled Flue Temp Alarm Enabled Furnace Door Temp Alarm Enabled Fo
43. ontrol panel door is turned on it introduces 120 VAC power into the safety circuit Power cascades down the chain through each safety device beginning with Low Water 1 and Low Water 2 12 VDC power from Battery VDC from Battery 4 Black and Grey wires carry 120 VAC to and from LWCO relays switch is closed It also provides thj i Power supply to the next safety 2 device IL ololololo The LWCO sensor relays detect water in the boiler by sensing resistance between the probe which is connected to 6 and ground which is connected at 5 When resistance is detected contacts close between 1 and 10 This closes the circuit for this link in the safety chain and sends 120 VAC power to the safety relay in the safety chain See 1 above See Safety Circuit Diagram 1 amp Safety Circuit Diagram 2 Low Water 2 Reset is normally closed When it receives 24 VDC from the PLC on A1 contacts open between 9 and 1 to reset 16 5 LWCO 2 et 1 11 10 1 2 2 0 LWCO 1 3 LWCO 2 8 4 8 qe cm gt B 7 5 7 6 6 7 and 8 on LWCO 1 are connected to Low Water 1 Test relay which is a normally open relay Since this is a normally open circuit LWCO 1 will automatically reset once water is detected after a Low Water 1 fault If the relay is closed it will cause the contacts between 1 and 10 to open simulating
44. opane for Propane Pilot Ignition Pilot Ignition Electrode Delivers high energy Spark for ignition of the Pilot Propane Pilot Propane Hose Delivers Propane for Propane Pilot Ignition Propane Pressure Sensor Pilot Propane Regulator Monitors Propane Pressure Controls Propane pressure from Propane Supply Tank for Pilot Propane Ignition Sends signal to PLC 89 DewPoint 6210 Burner Sequence Table BURNER STATE PURGE HOLD 30 SECOND PURGE HOLD PROPANE MAIN OIL RUN LOW FIRE RUN LOW FIRE HIGH FIRE 15 SECOND SAFETY START BURNER ALARM INITIATE STANDBY T19 HI FIRE PURGE T18 LOW FIRE PILOT IGNITION HEATING BOILER CONTROLLED BY STEAM SWITCH SWITCH IGNITION ON LOW TO 180F PRESSURE DEMAND STANDBY POSTPURGE au Power Power Power Power Power Power Power Power Power Power Power Power Power HONEYWELL LED 5 9 Pit Pilot piot Bia u Pilot Pilot Pilot NL ONE JW Fiame NEL XM Hae Fame Fame 0 Flame Flame Flame _Flame DISPLAY man Main Main Main EN NE Main Main Main Main Main E aam NECEM CT Alarm Alarm EE gp i nn BURNER SYSTEM VFD VARIABLE FREQUENCY DRIVE STARTS CLOSED 1 5 sec TO OPEN OPEN 1 5 sec TOCLOSE CLOSED OPEN TO LOW OPEN TO LOW HI LOW BY STEAM PSI 1 5 sec TO CLOSE CLOSED ON LO FI
45. r Technical Support please contact your Dealer or call Staheli West 435 586 8002 The temperature differential alarm can be disabled by going to Settings Alarm Status on the touch screen controller and disable alarm here Make sure to read warning to the right when disabling alarm 39 Electrical path of the Boiler Water Level Sensor By steven 0000 NN Troubleshooting Guide Boiler Water Level Sensor DewPoint 6210 40 Staheli West Inc 600 N Airport Road Cedar City Utah 435 586 8002 info staheliwest com Staheli West Inc 600 N Airport Road Cedar City Utah 435 586 8002 info staheliwest com 55 pp mE S ss OL Qo ge CCS Staheli West Inc 600 N Airport Road Cedar City Utah 435 586 8002 info staheliwest com Signal From Conditioner Staheli West Inc 600 N Airport Road 41 Cedar City Utah 435 586 8002 info staheliwest com 4 20 mA VRO Trouble Shooting Test individual components of system to isolate problem 1 Test Sensor Output a Turn off power b Disconnect sensor wires from signal conditioner Sensor is now a potentiometer with the i Black wire being the wiper and Red amp Yellow wires the ends of the potentiometer d With an ohmmeter connect between Red amp Black wires The closer the float is to full the higher the resistance typically 500 to 750 ohms Move t
46. r level is satisfied the program sequence to the next step 12 Burner Initiate Checks that Voltage and Frequency tolerances aremet 13 Burner Standby Checks that all safeties are in their correct state 14 Fan VFD turns On and begins to spin the Fan 15 Pre purge Power is sent to the Fan Motor and the Air Louver opens to 100 16 Air Flow Switch must confirm the Fan started and air is moving through the Burner C f f f f ff f f f ff f f f fff f f f 17 Purge goes for 30 seconds 18 Burner Louver goes completely closed at the end of the 30 second Purge 19 Propane solenoid opens and the Ignition Transformer sparks for 10 seconds 20 Pilot Flame is sensed with the IR Flame Detector 21 Main Fuel Valve 1 and the Safety fuel valve Main Valve 2 open to start Main Oil Ignition 22 Main flame is verified using the IR flame sensor 23 Burner advances to Low Fire 24 Burner heats the Boiler Water on Low Fire until the Boiler Water reaches 180 25 Burner goes to High Fire after the Boiler Water Temp gets above 180 degrees F 26 Burner stays on High Fire until the target pressure is reached Default 128 27 Steam Purge Valve opens for 30 seconds to purge oxygen 28 Screen changes from the Systems Start to liability Release 29 When the Liability is agreed the screen changes to Field Work 30 DewPoint 6210 is ready to
47. r screw which has a left hand thread Before unscrewing the impeller remove the impeller screw REMOVAL OF OLD SEAL 1 After unscrewing impeller carefully remove rotating part of seal by prying up on sealing washer using two screw drivers see Figure 5A Use care not to scratch motor shaft 2 Remove seal plate from motor and place on flat surface face down Use a screwdriver to push ceramic seat out from seal cavity see Figure 5B INSTALLATION OF FLOATING SEAT Figure 5C 1 Clean polished surface of floating seat with clean cloth 2 Turn seal plate over so seal cavity is up clean cavity thoroughly 3 Lubricate outside rubber surface of ceramic seat with soapy water and press firmly into seal cavity with finger pressure If seat will not locate properly in this manner place cardboard washer over polished face of seat and press into seal cavity using a 3 4 socket or 3 4 piece of standard pipe 4 DISPOSE OF CARDBOARD WASHER Be sure polished surface of seat is free of dirt and has not been damaged by insertion Remove excess soapy water INSTALLATION OF ROTATING PART OF SEAL UNIT Figure 5D 1 Reinstall seal plate using extreme caution not to hit ceramic portion of seal on motor shaft 2 Inspect shaft to make sure that it is clean 3 Clean face of sealing washer with clean cloth 4 Lubricate inside diameter and outer face of rubber drive ring with soapy water and slide assembly on motor shaft sealing face f
48. re HPLS should only trip if the OPLS fails to shut off the flame See Operating Pressure Limit Switch When steam pressure drop back below the set point The HPLS requires a manual reset to let the burner restart see Safety Circuit Diagram 1 and Safety Circuit Daigram 2 To reset the HPLS pressure in the boiler must drop below the set point and the switch must be reset manually by pressing firmly on reset button on top of the sensor 22 High Pressure Limit Switch HPLS The HPLS set point may be adjusted by turning this nut Since the HPLS is a backup to the OPLS it is normally set 1 PSI higher than the OPLS Clockwise increases set point Counter clockwise decreases set point Operating Range Recommended Set Point 0 15 PSI 15 PSI 29 Low Water Cut LWCO The Low Water Cut Off is a safety device designed to ensure that the water level in the boiler never drops below a safe level during operation The LWCO consists of two probes One is slightly longer than the other Each probe is a totally separate sensor from the other The tip of the probes sit at the lowest safe level in the boiler When the water level in the boiler rises enough that it touches the tip of the probe the LWCO knows that the water is high enough to safely operate If the water level in the boiler drops so that the water is no longer touching the probe the LWCO knows that the water is below the safe operat
49. rner Fan area Gun Assembly Clean entire Burner Area at 1 least Daily but preferably each time you load with water Use Compressed Air to remove dust and crop debris from around the Burner and Generator 92 3 Clean Burner Flame Sensor and Sight Tube every 50 Hours Remove Sensor from Tube to clean Cleaning Page 2 4 Clean Ignition Electrode and Propane Tube e Assembly every 50 Hours Use Compressed Air to remove dust and crop debris from the Ignition Assembly by attaching your air compressor hose to the short Red Air Hose that is attached to this port Then turn on your air hose 4 5 times for 2 3 seconds each time 93 Reference Resources For Complete DewPoint 6110 Burner Training Videos Go To www staheliwest com Login Customer Portal User name customer Password dewpoint 6210 Burner Videos 94 Sensors Sensor Function Range Normal Range Trip Alarm Options Supply Water Level 0 1000 gallons Below 200 gal Disable in Settings Alarm Status Screen Fuel Supply Level 0 300 gallons Below 30 gal Disable in Settings Alarm Status Screen Ambient Temperature 32 212 F Above 110 F Disable in Settings Alarm Status Screen Adjust in Settings Alarm Settings Low Water Cut Off 1 actuate on contact with water Below about 1 inch in site glass Low Water 04 actuate oncontactwithwater Belowabout 1inch in site glass Manual Steam Pressure
50. s an analog signal from the PLC which can range from Closed to 100 open and anywhere in between It has a four pin plug and a red position indicator It can be interchanged with any actuator that has the same plug The EH2 On Off actuator is used on the steam purge valve It receives a discrete signal from the PLC which tells the actuator to open or close completely It has a three pin plug and a yellow position indicator It can be interchanged with any actuator that has the same plug The EH3 4 20 mA actuator with position switches is a very specialized actuator that is used to control the airflow to the burner It receives an analog signal from the PLC which can range from Closed to 100 open and anywhere in between It has an eight pin plug and a red position indicator For more detail see Louver Actuator The EH3 On Off actuator is used on the manifold drain valve It receives a discrete signal from the PLC which tells the actuator to open or close completely It has a three pin plug and a yellow position indicator It can be interchanged with any actuator that has the same plug 53 Blow Down Valve The Blow Down Valve opens to let concentrated water out of the boiler to maintain good water quality inside the boiler See Automatic Blow Down System for more detail The valve is a 1 in STD port brass ball valve It is driven by an EH2 4 20 mA actuator The Blow Down Valve is located inside the back door here 54
51. y switch in the system closes it allows 120 power to flow to 1 When 1 receives 120 VAC from the switch contacts close between 9 and 5 sending the 24 VDC signal to the PLC that the safety switch is closed The 120 VAC supply for the next safety switch in the chain is also connected to 1 Therefore when A1 receives power it tells the PLC that the switch is closed and it provides power to the next switch in the chain In this way the power cascades down the safety circuit sending information to the PLC along the way See Safety Circuit Diagram 1 amp Safety Circuit Diagram 2 for details 24 VDC to PLC 24 VDC Signal ta PLC 24 VDC Signal to PLC X1 24 VDC Signal to PLC X2 24 VDE Signal ta PLC X3 24 VDC Signal to PLC X4 E 24 VDE Signal to PLC X5 Bumer On Off v n d sd d od ue Burner Rela Low Water Cut Off 1 Low Water Cut Off 2 Ne a 24 VDC input Limit Switch Limit Switch 120 VAC to next Switch in circuit Sequence 24 VDC Signal to PLC 24 VDC Signal ta PLC X 24 VDC Signal to PLC X3 34 VDC Signal ta PLC X4 24 VDC Signal ta PLC X5 24 VDC Signal to PLC X1 Burner On Off High Pressure Operating Pressure Bumer Relay Low Water Cut Off 1 Low Water Cut Off 2 ss iu Limit Switch Limit Switch On Off UNE 32 LINE 45 Air Flow Switch 24 VDC Signal ta

Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents