JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO.

, LTD

JDH- STEP CONTROL SYSTEM

INSTRUCTION MANUAL

JIANGYIN CHUANGJIE ELECTRICAL EQUIPMENT CO., LTD.

1. The system constitutes

The system is constitute of DHK- step control cabinet , JGD-30 high
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

power ignition equipment, JZRS 400 Q R vortex burner, JZYQ

2000/R HFO gun JZYQ 2000/1550R HFO/LDO gun valves and
meters . They can complete step igniting function safely and reliably .And
at the same time they supply connecting signal for the DCS distance
control .They are good choice for small scaled boilers to ignite.
2. Main control in system logic (basic function)
Step control the ignition of high power ignition equipment by hand;
Step control the propulsion device is enter or back by hand;
Step control the purge ,reliefoil/ gas and stop oil/gas returning valves
by hand;
Can adopt one method among three kinds of fire method : locale step
control by hand, distance step panel control , DCS distance program
control;
The shift of the automatic control (remote operation room) or hand step
control (at the locale)
Show the running condition (signal light);
Flames surveillance;
Provide for the DCS right on the spot action signal of carrying out the
device (with no- source touch).
3. Working condition
Working power supply: Control part and Igniting part:
AC240Vvalves and air propulsion deviceDC24V
Power Rating: 1.5KW
Working temperature: Not more than 50C for step control
box Not more than 80C for ignition equipment and
propulsion device
Height over sea :Not higher than 1000ms
Working environment: No serious chemistry contaminative, no
the large quantity of hanging metals floats .
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

4. The principle diagram and ports diagram (See the attached)

5. Operation process
Locale step control igniting method
Check circuitClose the general switch in step control box (the signal
light of power is bright)Close together the related air switch in the
corner to be ignited Make the revolve button to locale ignition Check
if the instructions lights of the ignition gun returning ,oil gun returning
oil valve closing, purge valve closingatomizing valve closing are bright;
Check if the instructions lights of the ignition gun entering, oil gun
entering oil valve opening, purge valve opening atomizing valve
closing and flame signal are dark; If satisfied, it is time to ignite.
Igniting process:

A angle use HFO igniting:

Open the main valves first
Make the revolve button to locale ignition Open the main
HFO valveIts signal light is brightand returning HFO valveIts
signal light is brightOpen steam valve (Its signal light is bright).
Then we can ignite all angles (A, B, C), for the example with A angle:
Press the button A enter oil gun(Its signal light is bright) Open
the A purge valve(Its signal light is bright), purge the oil pipes for
3minutes,then close

the A purge

valve(Its signal

light

is

bright)Press the button A enter ignition gun(Its signal light is

bright)Press the button A ignition (Its signal light is bright),Press
the button open A atomizing valve(Its signal light is bright) and open
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

A HFO valve (Its signal light is bright) at the same time. When the
instructions light of the flames scanner is bright (Or check if the oil
gun is lighting through observation port), ignition gun is burning for
10 seconds Press the button A withdraw ignition gun The fire
process will be completed when the ignition gun returning the original
position and its signal light is bright. If there is no fire after the
ignition gun igniting for 10 seconds, it is stated that igniting fails.
Close the A HFO valve quickly (The instruction light of A HFO
valve is bright). When the oil gun stops working, purge must be
carried out, finish purging close A purge valve and withdraw A oil
gun . And purge should be carried out again before igniting beginning
again.
A use LDO igniting:
Open the main valve first:
Make the revolve button to locale ignition Open the main
HFO valveIts signal light is brightand returning HFO valveIts
signal light is brightOpen the main LDO valveIts signal light
is bright and returning LDO valve Its signal light is
brightOpen the compressed air valve (Its signal light is bright).
Then we can ignite every angles (ABC),B angle and C angle are
same as above. Introduced emphatically A angle:
Press the button A enter oil gun(Its signal light is bright) Open
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

the A purge valve(Its signal light is bright), purge the oil pipes for
3minutes,then close

the A purge

valve(Its signal

light

is

bright)Press the button A enter ignition gun(Its signal light is

bright)Press the button A ignition (Its signal light is bright),Press
the button open A atomizing valve(Its signal light is bright) and open
A LDO valve (Its signal light is bright) at the same time. When the
instructions light of the flames scanner is bright (Or check if the oil
gun is lighting through observation port), ignition gun is burning for
10 seconds Press the button A withdraw ignition gun The fire
process will be completed when the ignition gun returning the original
position and its signal light is bright. If there is no fire after the
ignition gun igniting for 10 seconds, it is stated that igniting fails.
Close the A LDO valve quickly (The instruction light of A LDO
valve is bright). When the oil gun stops working, purge must be
carried out, finish purging close A purge valve and withdraw A oil
gun . And purge should be carried out again before igniting beginning
again.
NOTE:
1.In this system ,the compressed air valve interlock with the
steam valve ,so the steam valve will closed when the compressed air
open ; vice versa.
2. In this system, the A LDO valve interlock with the A HFO
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

valve, so the A LDO valve will close when the A HFO air open; vice
versa.
The igniting method through distance step panel control
Make the button revolving to distance control to ignite. The control
signal lines is connected with the ports for distance panel step control
according to igniting system principle diagram , lines diagram and ports
diagram. The igniting operation can be carried out through the buttons
controlling on distance panel (supplied by customer) or computer. Step
control to igniting will be finished through distance step panel control
in operation room.
The igniting method through distance DCS program control
Make the button revolving to distance control to ignite. The control
signal lines and signal reflecting lines are connected with the ports for
distance DCS program control according to igniting system principle
diagram, lines diagram and ports diagram. And the program in DCS
system should be made according to ignition logic (See the attached).
The igniting operation can be carried out automatically through distance
DCS program control in operation room.

6. Installment
1.

DHK- step control box

The cupboard is for the style of waterproof

()

Cupboard in dust palliative design, it is close

At hand steady to placed that the better

1400

environment, convenient in operation.

The shape of cupboard is(High*Breadth*Deep):
1400*750*600, the connecting lines can go
Through from the hole at the end of step control
Box (how to connect line, please see the attached diagram).

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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

2. JGD-30 type high -power ignition equipment

The high-power ignition control box and lighter are connected through
high power cable (Both ends of high power cable must be screwed
tightly), the control box should be hung to install near its lighter. The
size of Installment sees the detailed instruction manual of high power
ignition equipment.

3JZRS400QR vortex burner

The device is mainly used in boiler warmer and ignition, the main
function is to control ignition gun oil gun is adjustable, steady oil gun
fire, etc. This device make stable-combustion cover, propulsion
system , oil gun and ignition gun is an organic whole repeatedly,
improve all system`s performance, make installation operation more
convenient and reliable. At the same time, this device also can deserve
to choose among components, in order to meet the needs of different
users.

JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

4. JZYQ2000/R HFO gun JZYQ2000/1550R HFO/LDO

gun and soft metal tube

This oil guns are HFO gun and HFO/LDO gun. Its designed parameter
is: The output of oil guns are 2000Kg/h2000/1500Kg/h; the pressure of
pipeline is not more than 2.0 Mpa ,The installing method sees the
detailed installment diagram. The oil atomizing test should be carried
out every time before using. Ignition can not be begun until atomizing
well.
The size of soft mental tube is M30*1.5, its pressure grade is designed
for2.0Mpa; Its length is 2 meters.

5. Valves and pipeline

Distribution of valves and pipeline should be made according to oil
transport system diagram. The circulating oil test and purging pipeline
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

tests must be carried out.

7. Maintenance and Test for Equipment
1) Maintenance and test for step control box
1.1 Lines should be connected rightly and carefully according to ignition
principle diagram, line-connecting diagram and port diagram.
1.2 Check connecting lines. The connecting lines between step control box
and locale equipment should be checked if it is right. The connecting
lines between step control box and DCS control system should be
checked if it is right.
1.3 Power should be connected. The revolving button Locale/Distance
should be made to locale station and the related locale light should be
bright. Button, Revolving Button, signal light and other parts should be
check if they are right.
2) Test for Propulsion Device
2.1 Press the button entering ignition gun to check if the hoop of
propulsion device is moving forward, then the related light is bright
Press the button withdraw ignition gun to check if the hoop of
propulsion device is moving backward, then the related light is bright.
2.2 Press the button entering oil gun to check if the hoop of propulsion
device is moving forward, then the related light is bright Press the
button withdraw oil gun to check if the hoop of propulsion device is
moving backward, then the related light is bright.
2.3 If into place and out of reach the designated position indicator, back in
place and into reach the designated position indicator light that limit
switch signals at the opposite position; If clamping claw in place
position in place semaphore not all bright, the limit switch signals
should be faulty pick up right or fluctuation adjustment limit switch
position.
3) Test for High Power Igniting Equipment.
3.1 Screwed the lighter in the hoop.
The position of hoop should be determined as follows : When the
ignition gun is entered enough ,the ignition gun should be inserted
into atomization area of the oil gun)
3.2 The high-power ignition control box and lighter are connected
through high power cable. And both ends of high power cable must
be screwed tightly. Igniting is forbidden before screwed tightly.
3.3 The time of delay in step control box is set in 10 seconds.
3.4 Press the button igniting and watch there is fire .The bright light
should be watched from the watching hole in burner and the sound
of fire should be heard when the lighter had been entered in its
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

position.
8.Ready for ignition.
1. Clear away welders (Important)
It is necessary to clear away welders in pipes by the way of sore
washing, water washing and purging when finished installation to
prevent the welders blocking valves and flow meters but flow meters
must be discharged when carried out the above action in first time.
2Purging Test (Important, Purged for 4-12 hours)
All pipes should be purged and the rust and welding must be
cleaned by smoke air or compressed air and all valve should be
opened at the same time before igniting.
Goal: a. To protect the valves from being blocked and closed
loosely.
b. To protect the nozzle of oil gun from being blocked.
3 Circulating Oil Test and Oil Atomizing Test (Important, for 2-4
hours)
3.1 Oil valves before oil gun should be closed and Returning Oil
valve should be opened. Oil pump should be run. Returning
Oil valve should be adjusted to watch the change of oil
pressure. The oil pressure should be 0-25Kgf.
3.2 Oil atomizing test should be carried out after one hour oil
circulating. Oil gun should be put to empty barrel and valves
before oil gun should be opened. Then Returning oil valve
should be adjusted until the oil pressure of pipe is 0-20Kgf and
the atomizing condition of oil gun should be watched.
3.3 Atomizing Test must be carried out every ignition.(The oil
pressure atomizing should be about 12-20 Kgf) .Igniting
should be carried out until oil atomizing well.
3.4 The output of oil gun can be adjusted through atomizing part
in oil gun according to the use of oil gun. The screw of nozzle
must be screwed tightly to prevent from the leakage of oil
every change of atomizing part .At the same time, atomizing
test should be carried out until the oil gun atomized well.
Goal: a. To check if the oil pump work well
b. To check if the pipe has the leakage of oil
c. To check if the nozzle of oil gun is screwed tightly
d. To check if the pipe is cleaned.
e. To prevent the coal pit from making
agglomeration or burning badly or spoiling
9. Formal igniting
1 Igniting (on the basis of atomizing well for oil gun)
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

a) The oil pump should be run and the entering-oil regulate valve
should be adjusted until the oil pressure of pipe is about 12
18Kgf.
b) Igniting Process (by locale step igniting): The revolving button
locale and distance should be in locale position and its related
bulb is bright. Then the lighter should be entered until the bulb
lighter returned to its position is brightIgnitingOpen oil
valveReturn lighter until the bulb lighter returned to its
position is bright after the bulb igniting is dark
c) If the igniting fails, please close the oil valve quickly.
Reasons of Fails as follows:
a) The matched air is not appropriate
b) The atomizing part of oil gun is blocked
c) Atomizing test is not good (The atomizing part of oil gun is
blocked or distorted.)
d) Pipe is blocked
e) The lighter is not in the atomizing position.
2 Burning load regulation (Oil guns flux regulation)
a) Please lower oil pressure/ Adjust the gas valve position or
increase burning wind or change little flux atomizing part if the
temperature of the chamber of boiler is risen too quickly;
b) Please lower oil pressure if the temperature of the burning room
is risen too quickly;
c) Please lower oil pressure if the temperature of the first wind
room is risen too quickly; at the same time, it mustnt affect
with the oil gun/gas gun burning.
3 When the oil gun stop working, please shut off the oil valve
quickly ,when the gas gun stop working ,please shut off the gas
valve and open the relief valve ,after any time ,close relief
valve .Then the oil or gas system all need purge for 3-5 minutes
must be carried out.
10. Others
1. Igniting test should be carried out every formal ignition to check if
the igniting equipment is working well and guarantee igniting
succeeded one time.
2. The nozzle should be cleaned or atomizing part should be changed
before used again when the oil gun was unused for a long time.
3. Valves and oil strainer should be cleaned in regular time.
4. Valves and oil strainer should be cleaned in regular time. Power
should be broken after unused for a long time.
5. Please according to the instruction manual when operating.
6. Please take right measure to dustproof and waterproof ; examine
and repair.
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Jiangyin Chuangjie Electric Equipment Co., Ltd

Add:11 Yuedong Road,Yuecheng Town,Jiangyin City
Tel:+86-510-86581652;86584652
Fax:+86-510-86581522
E-Mail:Chuangjiedianqi@sina.com.
Post Code:214404