Installation and Operating Instructions
Contents
1. If it fails to fire up after three or four attempts it s no good just repeatedly pushing the flame failure reset button You have to look for the reason and most importantly you need to take the burner gun off the heater boiler and look to see if its dumped some wet oil in the furnace If it has this needs to be removed by wiping it out with a rag See faults possible causes and remedies If you don t wipe out most of the oil when you eventually find the fault and get the burner fired up very soon afterwards that wet oil will heat up and start vapourising and the gases ignite into a ball of flame and the burner gun starts backfiring It s a bit scary the first time it happens with vibration and smoke coming out around the mounting bracket If it s only fairly sedate let it run for a while on a small flame say 1 on the hand wheel and it will dry out that wet oil and start running smoothly But if it s a bit violent you must switch off the burner gun remove it and dry out the wet oil with a rag before attempting another start up 12 TOPIC 6 Maintenance It s hard to be specific about how often each maintenance procedure needs to be done because it depends on the nature dirtiness of the waste oil you re burning the number of hours you re running and or the number of litres you re using The only safe way is to start out by doing the maintenance more often than necessary and gradually increasing your intervals according2. h The LMO14 LMO24 LMO44 and this Data Sheet are intended for use by OEMs which integrate the burner controls in their products Use features Use The LMO are designed for the startup and supervision of 1 or 2 stage forced draft oil burners in intermittent operation Yellow burning flames are supervised with photoresis tive detectors QRB blue burning flames with blue flame detectors In terms of housing dimensions electrical connections and flame detectors the LMO are identical with the LOA oil burner controls Oil burners with fans to EN 267 Burner controls for use with atomization oil burners of monoblock design to EN 230 LMOAA for use with stationary direct fired air heaters General features Undervoltage detection Electrical remote reset Bridging contact for oil preheater Monitoring of time for oil preheater Accurate and reproducible control sequence thanks to digital signal handling Controlled intermittent operation after 24 hours of continuous operation Limitation of the number of repetitions Multicolor indication of fault status and operational status messages CC1N7130en Siemens Building Technologies 12 12 2005 HVAC Products 24 Function Preconditions for startup Undervoltage Time supervision oil preheater Controlled intermittent operation Control sequence in the event of fault Resetting the burner control Ignition program with LMO14 113B2 and LMO24 113B2
3. to match it When it gets heavy enough the container breaks the electrical connection between the float switch and the pump If your float is set up properly it s very unlikely that it will ever fail But if it does the consequences are severe enough that you simple must have a safety back up With the pump transfer system you can afford to use a smaller diameter pipe but we recommend at least one inch 25 mm Oil Feed from Day Tank to Burner Gun Your day tank must be higher than your burner gun to ensure a good gravity feed Fit the ball valve at the outlet point and then run a 25 mm flexible hose directly to your burner gun connecting at the pre heat tank in place of the plug 31 We recommend you use a generous length of hose that runs down to the floor and up to the burner This will enable you to take the burner on and off the heater or boiler without having to disconnect the oil line We normally use a transparent flexible petrol and oil resistant PVC hose eg Nylex TMP That stands for transparent multi purpose and the hose has a thin red line on it Its important that 90 elbows are used at each end If the hose is fitted in a horizontal position it will eventually sag and kink Filtration You must have some form of filtration in your oil supply system Consult your Kroll agent for advice on the best type and size to suit your needs 100 Micron is a good filter element size De Gassing As the oil heats
4. be reset This state is also maintained in the case of mains failure When lockout occurs the burner control can immediately be reset To do this press the lockout reset button for about 1 second 3 seconds The LMO can only be reset when all contacts in the line are closed and when there is no undervoltage If the flame is lost during TSA the burner will be reignited but only until the end of TSAmax This means that several ignition attempts can be made during TSA re fer to Control sequence If the flame is lost during operation a maximum of 3 repetitions can be made If the flame is lost for the fourth time during operation the burner will initiate lockout The repetition count is restarted each time controlled switching on by R takes place CC1N7130en 12 12 2005 25 Operation display diagnostics Operation E Lockout reset button EK is the key operating element for resetting E the burner control and for activating deactivating the diagnostic func E tions 4k The multicolor signal lamp LED in the lockout reset button is the key i Yellow indicating element for both visual diagnostics and interface diagnostics A Green LED Both EK and LED are located under the transparent cover of the lockout reset but ton There are 2 diagnostic choices 1 Visual diagnostics Operational status indication or diagnostics of the cause of fault 2 Interface diagnostics Wi
5. favour setting a tiny bit on the rich side If it s too lean it will still run okay but may be a reluctant starter Like a car they always start better if they re a bit rich If it s reluctant to start the first thing to do if you re sure you ve got the oil at the nozzle and it s had time to pre heat properly is close the air down a bit and try again Topic 5 Starting and Running the BR 5 Before attempting to fire up the burner gun it is important that you have a reasonable understanding of how it works particularly the sequence of the various functions Operation Overview When the thermostat calls for heat the burner will not fire up straight away First it the motor spins up for a PURGE period of about 10 seconds The purpose of this is to remove un burnt fuel amp vapour in the furnace It does this by blowing air into the furnace from the secondary air fan 5 This dilutes the un burnt fuel and then the electrodes 14 ignite the weakened mixture You ll get a small poof as this happens The purge goes on for about 10 seconds so the fan can push out the gases You ll always get a small amount of smoke out of the flue at this time During the purge period the photo electric PE cell 6 which is located in a small plastic socket on the right hand side of the burner gun barrel is checking to see that there is no light ie no flame present After the initial poof and subsequent purging there should be
6. hand wheel on 1 and set your secondary air regulator at a small opening Increase the boiler thermostat up burner will start to purge After about 10 seconds you ll hear the click of the electrovalve 33 and your burner should fire up within two or three seconds INCREASING THE FLAME SIZE When the burner has been running on a small flame in a stable manner for five minutes or so you can gradually wind it up to your desired power setting 11 AUTOMATIC RESTART If the burner is running and the flame dies for some reason eg lack of oil instead of shutting down on lame failure ten seconds after the flame disappears the burner control box is programmed to attempt one restart ie ten seconds after losing sight of the flame it goes back to the purge period purges for about ten seconds the magnetic valve clicks open again and this time if it doesn t fire up within ten seconds it shuts down on flame failure The red flame failure light comes on and you have to wait about fifty seconds before you can reset the flame failure lock out by pushing on the red illuminated button and trying again NOTE It will not automatically attempt a restart if it fails to fire up on an initial start up It only does that if the PE cell loses sight of light while it s actually running NOTE 2 The latter BR Series burners have been fitted with the LMO24 intelligent controller See the Pgs 25 to 27 at rear of manual FLAME FAILURE
7. it can get a build up of rubbish or carbon in the splines The spiral is symmetrical so it can go back in either way but take care that it is located properly and doesn t flip sideways when you are reassembling the nozzle PHOTO ELECTRIC CELL 6 Over time the PE cell will get a bit of soot on it which affects its ability to see the flame It should be pulled out and wiped every two weeks or so If it shows signs of being heat affected it s probably because the heater boiler is overdue for cleaning and the excess back pressure is pushing heat back into the burner gun Because of the importance of the PE cell it would be wise to keep a spare one on hand HYDRAULIC COUPLING 64 We have fitted this so that when you disconnect the de gassing pipe it doesn t drip oil everywhere However you will need to clean both male and female parts occasionally to ensure that the opening is clear and that the coupling goes together without undue downward pressure If it leaks oil you may need to replace the O ring in the female side ELECTROVALVE 33 These units rarely give trouble but it s wise to clean them at least once each season Take careful note when disassembling of what goes where Unplug the 3 pin plug and take the electrovalve off the burner gun by unscrewing the three small pipes attached to it Undo the top nut and slip the magnetic block ie the energizer off the post Unscrew the four small Phillips head screws to r
8. pipe This enables you to soak it in petrol or caustic soda which helps soften the carbon After scraping you can finish it off on a small wire wheel Like all the maintenance procedures we recommend they should be done before they have to be done Note that the hole in the middle of the diffuser plate is not symmetrical It is cut away more on the top to accommodate the electrodes ELECTRODES A visual inspection will tell you whether the tips of the electrodes 14DX SX need cleaning It s important that neither of these electrodes is touching or too close to the diffuser plate or you ll find the spark will jump to the plate instead of between the electrodes If an electrode ever comes loose inside its ceramic casing you can tighten it up again with the nipple that the high tension lead clips on to That nipple is actually a threaded nut screwed on the end of the electrode wire itself Check the ceramic casings for cracks at least once each season and replace them when necessary 14 If the electrodes and nozzle pipe assembly is covered in wet oil it should be disassembled and cleaned NOZZLE Remove the nozzle assembly 16 with a 14mm spanner Unscrew the front part 17mm spanner from the rear part and in between you ll find a small spiral This doesn t spin itself but it causes the emulsified oil to spin as it leaves the nozzle and this creates better atomization This spiral needs to be checked once a month because
9. reasonable range of settings where it runs smoothly It s hard to describe but when you have established the oil setting where you want it you should adjust the air opening so that the flame is a bright yellow or orange colour but clear around the outside so you can see the back of the furnace To get a feel for oil air ratio do this exercise While looking through the viewing window of your water heater slowly move the secondary air regulator disc 11 through its range At a very small opening you ll see the flame get very sloppy and not clear around the outside If you leave it like that for a few minutes it will start to run very rich and blow black smoke start pulsating and run very roughly When that just starts to happen gradually open up the air and you ll see the flame tighten up and become clear around the edge As you keep opening the air it will start to run to lean The flame gets very crisp and white smoke belches out the flue and starts to leak out around the burner mount If you go too far the flame will die Your best and easiest guide is what you see at the top of the flue at least initially After a while you ll learn to read the flame quite well IF YOU RE GETTING GREY OR BLACK SMOKE IT S TOO RICH AND NEEDS MORE AIR IF YOU RE GETTING WHITE SMOKE IT S TOO LEAN AND YOU NEED TO CLOSE THE AIR DOWN A LITTLE If there s no smoke at all then you re pretty close to the mark If in doubt
10. to what you find Before commencing any maintenance disconnect all power BURNER GUN OIL STRAINER The large oil strainer 29 should be checked about once every 2 weeks WATER AND OIL DRAIN Its normal for a bit of water to accumulate in the bottom of the pre heat tank It should be drained off through the drain cock 32 at least once a week If you want to completely drain the pre heat tank remove the large strainer 29 The drain cock 32 is ineffective for this purpose because of its small aperture and internal galleries in the pre heat tank PRE HEATING ROD Over time a tough coating of carbon or clinker will build up on this rod 60 IT IS ABSOLUTELY IMPERATIVE THAT IT BE REMOVED AND CLEANED AT LEAST TWICE EACH SEASON As the clinker builds up the rod works less efficiently If the coating is too big it is very difficult to remove the rod for cleaning To remove the heating rod firstly disconnect and remove the thermostat 62 from it s pocket Take note of where the wires go so you can refit them correctly Write it down Please do not try to unscrew the heating rod with a shifting spanner It s important that you equip yourself with a 32mm RING spanner A ring spanner is preferable to a socket because you can see that the whole heating rod is turning and not just the hex nut Once the rod is out you can remove the carbon There s no easy way to do this that we re aware of You just have to scr
11. your expected consumption Given time the water and sludge will settle to the bottom It is ABSOLUTELY ESSENTIAL that the oil feed outlet from your tank is well above the lowest point We recommend that at least 10 of the tank s capacity be below the outlet You should have another outlet at the lowest point to drain off accumulated water and sludge once or twice each year If possible locate this drain at the opposite end to the feed outlet and slope the tank that way slightly It is very important to have two storage tanks to allow settling time Most waste oil has moisture and dirt Suspended in it If you can let it settle for 3 or 4 weeks a lot of the rubbish will fall to the bottom Every time you get a new delivery of oil not only does it have its own suspended contaminants but when you pump it into your tank it stirs up some of the sludge that has settled out of previous deliveries With two tanks you can be running one while the other is settling We recommend you fill both tanks during Summer because the longer it sits there the better it gets We recommend the building of a bund wall This can be as simple as an earth dam around your tank or it can be constructed with a concrete slab and blocks painted with a sealant on the inside Degassing Pipe in s EZ J Furnace ri Bulk Tank w Header Tank Bulk Tank E ON OFF Burner Gun LE Day Tank A certain amount of fi
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13. FOR YOUR HEATER OR BOILER The flame should never touch the sides of the furnace If it does it s highly likely that the atomized mixture will condense into wet oil and you ll get incomplete combustion and wet oil in the bottom of your furnace If the flame hits the back of the furnace but not the sides and you don t want to run at a lower setting it may be possible to erect a target of ceramic tiles or fire bricks there This will protect the back of your furnace If your boiler is rated at 50 KW we recommend setting the flame to approximately 1096 less so for the a maximum setting of betwwen 3 amp 4 on the hand wheel SECONDARY AIR Efficient combustion requires the correct ratio between oil and air in your furnace This air oxygen comes into your furnace in two ways The primary air is drawn in through the pipe 66 and mixed emulsified with the oil in the compressor The primary air volume is fixed for each burner Its the secondary air which must be adjusted to suit the oil volume and back pressure We do this by loosening the knurled lock nut on the secondary air regulator 11 and rotating this black disc to increase or decrease the size of the windows 90 if you wind up the oil you need to open up the secondary air also Don t be too concerned about this It s not a temperamental device There is not one sweet spot where it runs perfectly and runs badly on any other setting There s a
14. ION before starting any maintenance work always disable both the main switch and the toggle switch on the burner to prevent damage to the burner amp yourself 1 Clean the oil filter s on the BULK oil supply periodically weekly if using waste oil 2 Clean the oil filters 29 in the burner 2 weekly for 29 3 Open the drain cock 32 once a week fortnight to release possible water 4 Clean the heat rod TWICE PER SEASON 60 Use a scraper and wire wheel Then flush out the pre heater tank 27 to get rid of sludge at the bottom of the tank use petrol and a toothbrush 5 Clean the diffuser 15 monthly or every time the flame is not burning cleanly The diffuser does tend to carbon up so it must be cleaned The nozzle 16 should also be checked by removal amp dis assembly 6 After long operating intervals after the winter heating season for example please carry out the following operations a Put some lubricating oil possibly light oil into the primary air inlet pipe 66 of the compressor Start the burner for a short while a few rotations only to allow the lubricating oil to be well distributed into the rotor and blades of the compressor This will inhibit eventual corrosion and the eventual sticking of the blades in the compressor rotor as water may be always present in waste oil STARTING THE BURNER AFTER 240V power removal If restarting the burner after a long period of burner inactivity turn the
15. Installation and Operating Instructions Kroll WASTE OIL FIRED BURNER GUN MODEL BR 5 Kroll Heaters Australia ABN 67108717451 Fact 2 36 Amberley Crescent Dandenong Vic 3175 Phone 03 9791 3082 Fax 03 9791 3048 E mail sales kroll heaters com au Web www kroll heaters com au FREECALL 1800 805 243 INDEX Introduction Topic 1 Topic 2 Topic 3 Topic 4 Topic 5 Topic 6 Topic 7 Appendix Principle of Waste Oil Burning What is Waste Oil Mounting the Burner Gun Oil Feed Starting and Running the Burner Gun Maintenance Faults Possible Causes and Remedies Short Maintenance Guide Exploded Parts View amp Circuits Pg 10 13 16 18 Introduction Thank you for choosing a Kroll waste oil fired burner This manual will explain how to install operate and maintain your burner Kroll burners can be fitted to air furnaces or heaters which push out warm air or to boilers to produce hot water It s important that you also read the separate manual about that apparatus in conjunction with this burner manual When you burn waste oil in a Kroll burner provided you have it adjusted correctly and attached it toa compatible heater or boiler it will run cleanly and reliably BUT in exchange for being able to run on this free or inexpensive fuel you have to put up with inconvenience of some extra maintenance compared to using gas heating oil or electricity If you are not prepared to carry ou
16. Limitation of repetitions 813 Siemens Building Technologies HVAC Products Burner control is reset All contacts in the line are closed and there is demand for heat undervoltage e Flame detector is darkened and there is no extraneous light e Safety shutdown from the operating position takes place should mains voltage drop below about AC 165 V Um AC 230 V Restart is initiated when mains voltage exceeds about 175 V Uu AC 230 V If the oil preheater s release contact does not close within 10 minutes the burner control will initiate lockout After no more than 24 hours of continuous operation the burner control will initiate automatic controlled shutdown followed by a restart If lockout occurs the outputs for the fuel valves the burner motor and the ignition equipment will immediately be deactivated 1 second Cause Mains failure Voltage has fallen below the undervoltage threshold Extraneous light during t1 Lockout at the end of t1 Extraneous light during tw Prevention of startup lockout after 40 sec onds at the latest Lockout at the end of TSA No flame at the end of TSA Loss of flame during operation Oil preheater s release contact does not close within 10 minutes Max 3 repetitions followed by lockout In the event of lockout the LMO remains locked and the red signal lamp LED will light up The burner control can immediately
17. The primary air is drawn in through the copper pipe 66 When this mixture of warm oil and air bubbles reaches the nozzle it comes out as a fine spray atomization The secondary air which is rushing down the black blast tube 12 and swirling when it passes through and around the windmill shaped disc called the diffuser plate 15 controls the shape of the spray of this atomized oil and supplies the oxygen that enables it to be ignited by the electrodes 14 which are throwing a strong spark throughout this whole purge and firing up process The spark stops about 14 seconds after the flame starts Listen carefully for the click of the electrovalve 33 and a slight change in note of the burner which signals the end of the purge period Sometimes the click is so soft you need to place your finger on the electrovalve to feel it click The burner gun should fire up within 2 or 3 seconds of the click At the end of the purge period The PE cell 6 which during the purge period was checking to make sure there was NO light present reverses its role It is now checking to make sure there is a light present and if it doesn t see one within about 10 seconds it will shut the burner down on flame failure 10 PRIMING THE BURNER GUN WITH OIL You cannot attempt to fire up the burner gun until it is primed i e inlet pipe and most importantly the pre heating tank are full of oil Also if the pre heating
18. ape away at it and finish it off on a wire wheel WHILE THE HEATING ROD AND THE LARGE STRAINER ARE OUT IT IS VERY IMPORTANT THAT YOU FLUSH OUT THE PRE HEAT TANK This sludgy material is made up of carbon that has flaked off the heating rod and contaminants that have settled out of the oil in both the upper and lower galleries of the pre heat tank This can be done using petrol or diesel and a toothbrush or similar small brush 13 NOZZLE PIPE ASSEMBLY It s very important that the components are mounted according to the specifications If the clearances between the nozzle diffuser plate and electrodes are not correct the burner may not start and run properly Use a ruler initially to ensure that the clearances are about right See image below BR 5 ignition Electrodes amp Diffuser Positioning H o EN DIFFUSER PLATE By looking through the sight glass when the burner is running you can monitor the build up of carbon on the diffuser plate 15 It s important that the vents are not clogged You should not let it build up too much because even though it may accumulate over a week or two it reaches a certain point and then the build up and efficient combustion can accelerate rapidly There s no easy way to clean it You just have to scrape it off We have had some success with spraying it with oven cleaner and leaving it sit for a while To clean it thoroughly you really need to take it off the nozzle
19. around which don t burn well on their own These are usually exotic high performance oils used in racing cars or specialized mining machinery so they re not usually found in large volumes High performance brake fluid is also synthetic Used synthetic oil normally burns without problems It s the new synthetic oil that is difficult to burn If small amounts of synthetic oils are present in your waste oil it s not a problem They travel through and are burned up But it is the mineral base oil which provides the heat In fact waste oil has the same calorific value heating energy as conventional heating oil The contaminant to be most vigilant for is paint thinners Logically you d expect this to be volatile and dangerous but in fact paint thinners usually reacts with sump oil to form a jelly like substance which will not burn properly Your Kroll burner will not run on a mixture of sump oil and paint thinners Fortunately thinners have a fairly distinctive smell If you re collecting your own oil you ought to be able to detect and avoid it If you re buying your oil from a waste merchant it is important that you tell him that paint thinners is absolutely unacceptable It will cause rapid damage to your burner gun TOPIC 3 Mounting the Burner Gun onto the boiler Insert the blast tube part 12 see the appendix for part break down into the furnace opening and mount it using the pair of C shaped alloy clamps and insulating gaske
20. eveal the plunger and spring Wash everything in petrol blow it out with compressed air if available and reassemble END OF HEATING SEASON After long operating intervals after the heating season for example carry out the following operations 15 Put some lubricating oil possibly light oil into the primary air inlet pipe 66 of the compressor Start the burner for a short while a few rotations only to allow the lubricating oil to be well distributed into the rotor and blades of the compressor This will inhibit eventual corrosion and the eventual sticking of the blades in the compressor rotor as water can always be present in waste oil TOPIC 7 FAULTS POSSIBLE CAUSES AND REMEDIES Goes out on flame failure at the end of purge period ie magnetic valve does not click No ignition PE cell is faulty Faulty or dirty electrovalve 33 is allowing oil through to the nozzle during the purge period and the burner is firing up prematurely Control box 8 is faulty Check for ignition spark or Electrodes not positioned properly or need cleaning Mixture too lean Close air down a bit and try again No oil getting to nozzle Check that pre heat tank is full and that the pipes and magnetic valve aren t blocked Check that the hand wheel 53 is set OK Too high water content in fuel Oil is not combustible for some reason eg contains paint thinners or a high percentage of some 100 synthetic oils Drain
21. it out get a Known sample that you re sure of and try again Oil too cold Check pre heat thermostat 62 is set to 80 C and give it time to warm up Nozzle blocked Diffuser plate 15 too dirty Too much back pressure in heater or boiler Overdue for cleaning Flue blocked Perhaps the hat has fallen down Burner fires up okay but then shuts down on flame failure soon after Check PE cell for soot Perhaps it can t see the flame PE cell faulty Control box faulty 16 Burner fires up okay runs for a while but then starts to run very badly pulsating and making black or grey smoke Mixture too rich Open air up a bit Wet oil in furnace When it warms up it vapourises and erupts into a ball of flame Remove burner gun and dry out the furnace as much as possible with rags If the wet oil is sticky and stubborn soak it with some diesel of degreaser and then dry it out DO NOT USE PETROL If furnace is hot let it cool down before cleaning and attempting to re start If fire bricks are used in the furnace let them cool down remove them clean as well as possible and refit them Turn the gun down to a small flame ie set metering knob to 1 and close the air down accordingly Fire it up adjust the air a bit if necessary and let it run on a small flame until it dries itself out maybe half an hour or so If even on a small flame the furnace erupts again and the burner starts pulsating switch it off wai
22. main 240 VAC supply switch ON first then wait for about 15 minutes until the oil is heated and then turn the operating toggle switch 8a of the burner on The burner will now work correctly with hot oil This should be read together with Topic 6 routine maintenance of the Installation and Operating 18 KROLL WASTE OIL FIRED BURNER GUN MODEL BR5 suuds Sutr dno ajo duioo 9 ZZONI aje d puey 1197 puey 1H3 J pjoy poy a zzon 15918 loje n3oJ Arepuosas 4 pu JeW 3 lo9 O01 u07 Huong spear uoisua y31H louLio SueJ UOTIUST 122 2129 9 0 0ud uv IOON NOILdld9OSsAd SLYVd LI 91 I XSp rl VEI I ZI LI 01 VL wo D 20 21 adid a zzou 0 Apog jnu Ajddns Areiuud adig adid a zzou Jossaiduioa adig Surdnos apeuay pue a2ard Sursses a 1 pue Surgau 10 12407 yur yeay aud 10 SOULS asad 2015528 01 adig pol Suna pol Suneay aysen dund Suuajaw suisnopy ETH SE UES 12452 01 adig nu oot puer suds L9 99 ts cs NOILdIHOS3G S1HVd LX 6 X 9 E95 TIO 211u2222 10 yoddng
23. ne silt and metallic dust will stay suspended in the oil This doesn t affect reliability in the short term because it passes easily through the burner gun However the fuel is also the lubricant for the moving parts inside the burner gun and all this abrasive material can cause premature wear A tank of between fifty and one thousand litres called a day tank or header tank should be located near your heater and fed from your main storage tank The standard domestic heating oil tank is ideal It s about 400 litres and can usually be found just by asking around because many homes have switched to gas heating In conjunction with a good filter this decanting of the waste oil eliminates much of the abrasive material and reduces the ash build up in your heater boiler Even after settling and filtration of your oil you can still expect a certain amount of wear and tear in your burner gun In a greenhouse heating application where the burner is working 7 days a week virtually all year round you could be looking at up to 1 500 in a worst scenario to recondition your burner gun each year In a factory or workshop heating situation you can expect to go for 4 5 or 6 years before any major wear occurs Piping from Bulk Tank to Day Tank Your Kroll agent can advise you on the best arrangement for the main storage tank pipeline day tank and filtration It will vary according to the topography and layout of your
24. no fuel present and hence no flame If there is a flame present then the PE cell will not allow the burner gun to proceed to the firing up stage It will purge for a bit longer than normal and then shut down on flame failure ie the red light which is also the reset button comes on on the control box When the burner goes off on flame failure at the end of the purge period it s because the PE cell can see some light The most likely cause of this is strong sunlight shining through the viewing glass The PE cell is very sensitive and thinks it can see a flame Some tape over the viewing glass will fix this problem Assuming that all is in order at the end of the purge period ie no light visible the PE cell sends a message to the control box which then sends power to the three way electrovalve 33 During the purge up to this point the warm oil in the pre heating tank is being pumped around in a circle ie it is drawn out of the pre heating tank via the inlet pipe 38 into the metering 57 goes along the pipe 55 into the electrovalve 33 out the top and back along the other pipe 61 and falls back into the pre heating tank via the de gassing T piece 64 At the end of the purge the electrovalve closes off the top outlet and opens the lower one to a small elbow that leads directly into the compressor This is where the warm oil is mixed or emulsified with the primary air and sent on to the nozzle
25. rod 50 is activated without oil around it for more than about 10 minutes it may suffer damage Open the day tank outlet and watch the oil flow down into the gun After a short delay while it fills the pre heat tank of the gun the oil will appear in the de gassing pipe and climb up until it has reached the same height as the oil level in the day tank see right for an example of a BR5 mounted on a furnace The degassing pipe is circled PRE HEATING When you re starting from scratch ie the burner gun and oil are cold you ll need to allow 30 minutes to ensure that the oil in the pre heat tank is up to temperature If you wrap your hand around the bottom of the pre heat tank you ll get a feel for how hot it gets The waste oil must heat up to 80 C for automotive waste oil FUEL TYPE RECOMMENDED THERMOSTAT SETPOINT Automotive Waste Oil 75 85 C Light Oil Diesel or Kerosene Bunker Oil Fuel oil Waste Oil blend 80 90 Vegetable oils 40 60 C STARTING THE BURNER If you are starting the burner for the first time or if you have just sorted out a problem such as water in the burner gun or a blocked filter then we suggest you start at 1 on the hand wheel At this oil setting you ll only need a fairly small opening of the secondary air regulator 11 a window opening of about 5mm or 6mm STARTING By now you have fitted the de gassing pipe primed the gun with oil allowed it to heat up to 80 C set your
26. s can leak if some grit gets under the seat You need a safety back up You could fit an electric motorized valve or solenoid valve to the main pipe activated by a float level switch mounted in the day tank above the float valve Or it can be very simple From an overflow outlet near the top of your day tank excess oil would fall into a sizeable container twenty litres or so When it gets heavy enough the container pulls on the lever of a ball valve thereby closing off the main pipe See diagram below awartiow pipa Fioal Valve i Lus gg prs E pe Day Tank 50 Litres bucket Day tank with gravity feed from storage tanks showing safety shut off valve in case of overflow Pump Transfer System If you cannot gravity feed to the tank you will have to pump the oil There are a variety of pumps available for this job Your Kroll agent can advise you A simple float switch fitted in the day tank will stop and start the pump to maintain the desired level in the day tank Again we believe it is imperative that you have a safety back up system in case the float switch fails to switch off the pump We suggest a simple system From an overflow outlet near the top of your day tank excess oil would fall into a sizeable container twenty litres or so Remember that oil is coming into the day tank under pump pressure so you ll need a generous sized overflow outlet say 2 inch 50mm
27. site Here are some options but first a few words about the pipe itself If the pipe is exposed to risk of damage or rupture from vehicles or machinery etc it should be of galvanized steel Otherwise high grade poly or flexible petrol and oil resistant hose is fine provided it complies with local regulations Give your choice of pipe careful consideration and be vigilant Sump oil spillage or leakage is a very serious matter The risk is extremely low provided you plan your installation well and take proper precautions Gravity Feed System If you have some fall from the main tank to day tank this works well but be aware that oil gets very thick when the temperature falls A generous flow in summer Through a inch 19mm pipe can reduce to a pitiful trickle when winter comes Allow for this by using large diameter pipe up to 2 inch 50mmi if it s traveling 30 metres or more having only gentle curves not right angle bends and if possible run inside the building or underground where it s not so cold If the distance from your storage tank to your day tank is less than five metres 1 inch 25mm pipe is adequate provided you have at least a one metre fall 6 Of course you have to control the flow of oil into the day tank A conventional full flow float valve eg Philmac brand can be mounted in the day tank If it has rubber O rings they should be replaced with a neoprene type which is unaffected by oil Float valve
28. t five minutes and try again When it s been running with a stable flame for a while you can ease the flame back up to your normal settings What causes wet oil in the furnace Possibly a blocked filter or too much back pressure or an empty day tank The burner is running but as the filter blocks it gradually starves for oil It struggles on running badly before it dies and during this time the poor combustion means unburnt oil accumulates If you were near the heater when it was struggling you d notice and do something But if it happens in the middle of the night before you can fire it up again you need to fix the original cause of the wet oil Flame too big for furnace Too much wear in burner gun specifically in the compressor If the compressor liner 26 and rotor blades 25 are too worn Your burner will not atomize properly Instead of getting a nice fine mist at the nozzle you could be getting large droplets of oil which do not burn well This sort of wear does not occur overnight so there is usually plenty of warning If your gun is noisy and is not burning well contact your Kroll agent before winter Don t ignore the signs and leave it till the last minute Pre heat tank is hot but burner won t even start to purge Check flame failure light Push to reset Check room thermostat is calling for heat Check safety thermostat in heater boiler It might be tripped 17 Model BR 5 Short Maintenance Guide ATTENT
29. t this extra maintenance then to be blunt you have bought the wrong burner We believe that in order to look after your burner you need to have a good understanding of how it works So please read through this manual TOPIC 1 Principle of Waste Oil Burning Waste oil has a high flash point compared to conventional heating oil This means it does not burn easily Your Kroll burner gun is designed to filter pre heat and emulsify the waste oil with air bubbles before sending it to the nozzle where it is atomized into a fine mist for reliable and efficient ignition amp combustion The pre heating is the key feature and for standard waste oil from car sumps this should be 80 to 85 degrees C This heating makes the oil easy to vapourise Any burning after ignition requires a fuel supply and air supply The Kroll burner therefore requires adjustment of the fuel and also the air mixture for successful smoke free combustion When the burner arrives amp is unpacked it will be preset to a successful combination of air fuel The high furnace temperature reduces the contaminants in the waste oil to a grey coloured residual ash which is trapped in the furnace and heat exchanger chambers or tubes of your air heater or water boiler TOPIC 2 What is Waste Oil When we talk about waste oil we mean almost any kind of used automotive oil engine oil diff oil gearbox oil and automatic transmission oil There are some synthetic oils
30. th the help of the interface adapter OCI400 and PC soft ware ACS400 or flue gas analyzers of different makes refer to Data Sheet 7614 Visual diagnostics In normal operation the different operating states are indicated in the form of color codes according to the color code table given below Interface diagnostics is activated by pressing the lockout reset button for at least 3 seconds refer to Data Sheet N7614 If by accident interface diagnostics has been activated in which case the slightly red light of the signal lamp flickers it can be deactivated by pressing again the lockout re set button for at least 3 seconds The instant of switching over is indicated by a yellow light pulse Operating position Operating position Visual diagnostics Operational status indication Color code table for multicolor sic Statu Waiting time tw other waiting states Oil preheater on waiting time tw Ignition phase ignition controlled e o o e Flashing yellow _ Operation flame o k _ LL Hic reel Operation flame not o oo a Flashing green _ Extraneous light on bumer startup DOADAD ACAD A Green red ERES Red us ST A A AA A ee TI Legend wwe Steady on Red Of e Yellow O Green 9 13 Siemens Building Technologies CCIN7130en HVAC Products 12 12 2005 26 27
31. ts provided see right The drip hole in the blast tube end should always face down Have an electrician wire up the seven pin plug 9 to your air heater boiler Note If the BR 5 is being inserted into a cast iron boiler a stainless steel fire tube of 250 mm diameter by 250 mm length should be centralized around the flame location inside the combustion chamber of the boiler This will assist in achieving a clean burning of any peripheral spatter of the waste oil The spatter waste oil hitting the fire tube is burnt off by the flame The pictures right amp below show fire tube inside the combustion chamber of Sime 1R 9 Water Heater Heat exchanger amp combustion chamber of typical cast iron water heater shown right Note the fire tube inserted in the combustion chamber at the bottom TOPIC 4 Waste Oil Supply Main Storage Tanks The great appeal of a Kroll burner is it s very low running cost But this is also its Achilles Heel The fuel is cheap because it s dirty Your Kroll burner is very tolerant It will run on just about any kind of waste automotive oil but it will not run on water or sludge The best way to eliminate fuel related problems is to have a good storage tank arrangement We strongly discourage feeding your burner directly from 205 litre drums even as a temporary measure We recommend you put in two proper storage tanks of between five thousand and twenty thousand litres capacity depending on
32. up in the pre heating tank it gives off small amounts of gases and water vapour Also as it heats up the oil expands We have provided a short length of 12 inch copper pipe attached to a hydraulic coupling on top of the pre heating tank 64 to vent these gasses off We want you to fit a length of inch hose to this run it up to the roof of the shed or at least higher than your day tank The oil will rise in the de gassing pipe to the same level as the tank that is feeding it Its normal practice to leave the pre heating on all the time during winter This way your burner will always be ready to fire up If you switch the power off to the burner you ll have to wait about ten or fifteen minutes each time to allow the oil to heat up before you can start it It is most unlikely to start reliably with cold oil It s best to use a transparent or semi transparent PVC hose that can handle warm oil up to about 50 C Its much better if you can see the oil level in this de gassing pipe THE VOLUMETRIC PUMP amp OIL CONSUMPTION The amount of oil your burner gun will use is determined by where you set the hand wheel 53 This chart shows the approximate consumption for the BR 5 Position on Hand Wheel The higher the setting the bigger the flame To adjust the hand wheel loosen the knurled lock nut line up the desired position of the hand wheel with the index mark amp tighten it up again CHOOSING THE CORRECT SETTING
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