Vous êtes sur la page 1sur 38

Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.

0 Page 1

HAMWORTHY COMBUSTION

ELECTROtec II
Marine Oil
Burner.

Operating and Maintenance Manual


Hamworthy Combustion
Fleets Corner, Poole, Dorset.
England. BH17 0LA
Telephone U.K. + 44 (0) 1202 662700
Manual Number PR902428 O&M / rev 1.0
02/05/07
A. C. Pelling
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 2

Section Index

ELECTROtec II Burner

Section Contents Page

Revisions List 3
Copyright 4
Contract Specification 5
1.0 Health & Safety Considerations 6
2.0 General Information 9
3.0 General Description 12
4.0 Combustion Control 15
5.0 Burner Management Description 16
6.0 Automatic Controls Description 19
7.0 Light up sequence Description 20
8.0 Maintenance Guidance Notes 22
9.0 Installation Guidance Notes 26
10.0 Component Identification 29
10.1 Doorplate Assy. Cam & Cable (Oil Only) Drg. 300028009
10.2 Burner Machine Dual Fuel / Oil Only Drg. 300028003
10.3 Windbox Assy. Drg. 300028001
Notes 33
11.0 Appendices 34
Viscosity temperature chart 09:04:08 Iss. 2 35
Overall dimensions 36
Typical Fuel Oil Ringmain (Residual Fuels) 37
Typical Fuel Oil Ringmain (Diesel Fuels) 38
Diesel Igniter Assembly (363801732 ‘J)
Oil Pump Assembly (360901758 ‘A’)
Fancase Assembly ER MkII 12-20 (300004078 ‘A’)
ER MkII 12-20 Oil Pipework Assembly (300012170 ‘A’)
Back Pressure Valve Assembly (361905089 ‘A’)
G.A. & Secondary Quarl Details (1.01.20.01-71.944 ‘D’)
P&I Diagram (300011513 ‘B’)
Burner Wiring Diagram (373061083 ‘B’)
12.0 Supplier Data Sheets
Air Pressure Switch (Dungs GW…A6 5.01)
Main Flame Detector QRA2 (L&S 7712)
Pilot Flame Detector RAR7 (L&S 7713)
Low Oil Temperature Switch (Danfoss KPS 520B1861)
Atomiser Shaft & Oil Pump Sensor (Carlo Gavazzi Type IA)
Modulation Motor SQM5…. (L&S 7815)
Main Oil Valve (Coax Mk10 2/2 E3.04-01/2006)
Main Oil Valve (Coax Mk10 DR 3/2 E4.01-01/2006)
Pilot Diesel Valve (ASCO 2/2 Series 262)
Microswitch (OMRON D4N G-219)
ABB Marine Aluminium Motors (EN 12-2006)
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 3

REVISIONS:

Manual Number PR902428 Rev 1.0 (Original)


Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 4

Published by

HAMWORTHY COMBUSTION LIMITED

(“HAMWORTHY”)

OF

FLEETS CORNER, POOLE, DORSET. BH17 OLA

First Published: 10/01/2006

Copyright and Design Right 


Hamworthy Combustion Limited 2006

No part of this manual may be reproduced, stored in a retrieval system or transmitted in any form or by
any other means, electronic, electrostatic, magnetic tape, mechanical, photocopying, recording or
otherwise without the prior written permission of Hamworthy.
This manual may not be lent, sold, hired out or otherwise disposed of
by way of trade in any form whatsoever.

PRINTED IN THE UK.

NOTES:
1/ The information contained in this manual is intended as a guide only for use by suitably
trained and qualified personnel. Hamworthy can provide training. If in doubt about the
interpretation of this guide the user should contact Hamworthy.

2/ Hamworthy has made every effort to ensure that the information contained in this manual is
accurate at the time of publication. Its contents should be used however as guidance material
only and not as a replacement of current regulations or any contractual specifications.

3/ As the application of the subject matter of this manual will differ dependent upon the particular
circumstances Hamworthy accept no liability for any loss of any kind (including consequential
or indirect loss) occasioned by any person relying upon this manual.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 5

ELECTROtec CONTRACT SPECIFICATION SHEET

CONTRACT REFERENCE PR902428

BURNER MODEL ERO20

APPLICATION DETAILS
APPLIANCE TYPE VERTICAL MARINE BOILER

APPLIANCE MANUFACTURER GREENS SHAZHOU

RATING 8000 Kg/Hr ACTUAL FROM FEED WATER @ 60


DEG. C

DRAUGHT SYSTEM FORCED

APPLIANCE WORKING PRESSURE/TEMP. 7.0 BARG

GENERAL ARRANGEMENT DRAWING 1.01.20.01-71.944

FUEL OIL

TYPE HEAVY OIL

BS 2869 CLASS ‘G’

MAXIMUM VOLUME 591 Kg/Hr

PUMP SPEED / HERTZ Light Up 6.11 Low Fire High Fire 39.45

IGNITION FUEL TYPE DIESEL

CONTROL SYSTEM DETAILS


CONTROL SCHEMATIC -----------------

EXTERNAL CONNECTIONS 373061083

CONTROL PANEL G.A. -----------------

CONTRACTS ENGINEER: A. Pelling DATE: 21/09/07


Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 6

Section 1

ELECTROtec II Burner Health and Safety


GENERAL SAFETY -

Read this section before undertaking ANY work on the burner.

Before attempting to assemble, install or commission the burner it is important that this document is
read and understood completely.

It is essential that any maintenance, fault finding or commissioning operations carried out on
this equipment is performed only by a competent Engineer, i.e. one that is adequately trained,
experienced and qualified with this equipment and associated processes, i.e. gas, electricity
and oil requirements and regulations.

It is strongly recommended that Operators and maintenance staff be trained in the correct and safe
use of the burner. Training courses are available from Hamworthy.

It is important that the burner supplied in this contract is used only on the fuels for which it was
designed and at flows and pressures which are suitable for both the burner and the appliance on
which the burner is fitted.

It is also imperative that the burner geometry, design and ratings are not altered or modified in any
way other than by a Hamworthy Engineer or under the specific direction of Hamworthy.
No responsibility can be accepted by Hamworthy for the outcome of unauthorised tampering with
these crucial parts.

The ‘Health and Safety at work Act’ requires both the Manufacturer and the end user of the equipment
ensure that the equipment supplied can be, and is, operated safely. If the burner is fitted to a boiler or
appliance not manufactured by Hamworthy, then due regard MUST also be given to the operating
instructions supplied with the appliance.

Hamworthy Combustion cannot be held responsible for any consequential damage, loss or injury
resulting from improper commissioning or the failure to follow these instructions.

At all times the equipment should be installed and operated with due regard to good engineering and
safety principles. This cannot be over emphasised when dealing with inflammable or explosive fuels.

Due attention must also be given to any regulations applicable to the storage and handling of fuels.

The equipment has been designed to operate with the fuels and at the conditions detailed in the
contract specification sheet. Proposed changes to any part of this specification must be referred to this
company for prior approval, as must any other questions relating to the safe operation of the supplied
equipment. When reading these instructions always make reference to instructions given by
manufacturers of any associated plant, or appliance.

Hand protection must be worn if contact with the fuel oil is expected, e.g. during servicing work. Clean
up any spillage’s immediately.

Keep the area surrounding the combustion equipment and its associated equipment clear of debris.
Never remove any guards whilst the burner is operating.

It is recommended that adequate lighting and access is available around the burners, especially
during commissioning and servicing activities.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 7

All subsequent settings must progress from a fuel lean condition.

If the plant is operating at in an environment with noise levels in excess of 80dBA it is recommended
that the operators use suitable ear defenders.

If the burner is under repair or being serviced, ensure that warning notices are placed on the burner,
e.g. “Do not operate, machine being serviced”.

Attend to fuel leaks as they are reported. Do not delay.

Make no attempt to operate the associated plant whilst fuel is escaping, since this is dangerous.

Burner machine must not be run with the belt guards removed.

Regular maintenance of the flue ductwork is essential to provide a safe environment within the plant
room.

Ensure that hot pipes, such as those containing steam or water are lagged. Restrict access to any
area where hot metalwork or gases may be encountered.

Always adhere to the rigors of any site Permit-To-Work system.

Never stand directly in front of a burner whilst it is lighting-up.

COMBUSTION AND CONTROLS:

Setting or adjusting the fuel/air ratio must only be carried out by Hamworthy or other competent
personnel.

Do not make repeated attempts to light the burner. If a flame cannot be established after two
consecutive attempts, carry out an investigation into the cause. A succession of abortive attempts to
fire the burner, may result in the build up of a combustible or explosive mixture within the boiler or
appliance.

Pre-purge and post purge settings are set during commissioning and must not be subsequently
altered.

It is essential to ensure that, prior to initial light up during the commissioning phase, all fuel control
valves, proportioning valves, and similar devices are set to their minimum flow positions before any
source of ignition is introduced into the combustion space.

The initial fuel flow adjustments necessary to provide light-up conditions must only be made whilst the
burner is switched OFF.

Subsequent light up attempts being made each time progressing from a fuel lean condition until a
good light up is achieved. Once adequate fuel flow exists to enable the burner to light, then the fuel
flow to the flame may be optimised whilst the burner is lit.

ELECTRICAL

Do not leave control panels or junction boxes open whilst power is on. Should it become necessary to
do so, in the interest of rectifying faults, then only competent personnel should be involved and they
MUST adhere to the requirements of the local Electricity at Work Regulations.

Warning notices must be posted and the covers must be replaced as soon as possible.

Safety interlocks are mandatory. Once a fault on any interlock has been detected, then the fault(s)
must be corrected before the unit is operated.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 8

DO NOT BY PASS INTERLOCKS.

Isolate electrical supplies and fuel lines before attempting to work on the combustion equipment. Post
warning notices as necessary and ensure plant is sufficiently cooled and ventilated, etc.

Ensure that the protective earth bonding of the complete burner machine and gas train and associated
gas pipework remains intact and continuous at all times.
Continuity of the bonding must be maintained when a part, e.g. a gas valve, is removed from the gas
train. Jumper cables of adequate size, (no smaller cross section than the existing bonding cable), must
be connected across the gap.

Whilst the burner is under repair, ensure that the power cannot be reinstated by locking-off electrical
isolators.

High voltages, up to 14,000 volts, may exist around the ignitor plug caps.

This equipment must be earthed via the protected earth terminal.

! CAUTION !

The installation and commissioning of electronic equipment, must be carried out correctly to avoid
damage to plant. Ensure full Electrostatic discharge, (ESD) protection equipment is used during all
phases of handling and installation of this equipment.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 9

SECTION - 2

ELECTROtec II Burner GENERAL INFORMATION


GENERAL INFORMATION

The correct installation of a Hamworthy burner is as important as the design of the burner itself.

Each installation must be carefully planned to ensure a complete system in every detail. Reference must
be made to all the relevant standards and regulations regarding the installation and use of this burner
equipment.

The installer must be familiar with local regulations and insurance requirements, which will serve as a
valuable guide to a safe installation.

FUEL OIL SYSTEM

The system of storing and handling fuel oils, must be designed to ensure the transfer of oil at the correct
pressure and temperature from the storage system to the burner under all conditions of service. All fuel
systems for the Electrotec II burner must be designed and installed in accordance with the Hamworthy
Combustion data sheets.

See Oil ring main data sheets in Section 13.

MATERIALS

The use of correct materials and the highest standards of installation and workmanship will always pay
dividends when installing a burner. The burner operating conditions are often severe, reliability and
performance depends on good installation, commissioning, maintenance and general performance
monitoring.

PLANT IDENTIFICATION

Installation

A “Contract Number” identifies every installation. This is displayed on identification plates mounted on:

1. The burner machine


2. The windbox
3. The control panel

BURNER MACHINES

Each burner is fitted with a plate stating:

1. Contract number
2. Product number
3. Burner serial number
4. Burner designation.
5. Date of manufacture.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 10

PLANT CAPACITY

A plate is attached in a prominent position stating;

1. Burner size.

2. Burner serial number.

3. Oil firing - Maximum oil flow rate.

- Oil class type.


- Oil flow setting at maximum rate.

SPARE PARTS

On all orders for replacement parts and on all correspondence regarding individual burners, the burner
serial number, designation and contract number must be given. The information appears on the burner
nameplate. When ordering replacement panel parts the panel serial number must be quoted.

UNITS OF MEASUREMENT

The units quoted in this manual are generally SI.


Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 11

Electrotec II Burner Range Specifications


GENERAL DATA 5 7 8 10 11 12 15 17 20 22 25 30 35 40 45 50
Model 1.9 2.5 3.1 3.7 4.1 4.5 5.4 6.3 7.2 8.1 9.0 10.9 12.7 14.5 16.4 18.2
OIL DATA
Oil Input Litres/hr $ 170 227 284 341 375 414 496 577 659 741 827 996 1155 1318 1491 1659
Oil Input kg/hr Class “G” Fuel $ 159 211 264 317 349 385 461 537 613 689 769 926 1074 1226 1387 1543
Supply Pressure 0.2 – 4.0 Bar.g.
Fuel Type Class “D2 to Class “G” Fuel Oils
Nominal Turndown 3:1 3.5:1 4:1 4:1 4.5:1 4:1 4.5:1 5:1 5:1 5:1 5:1 6:1 6:1 6:1 6:1 6:1
Pump Type (Hamworthy Ref) A A A A A A B B B B B C C D D D
Typical Pump rpm @ MCR 1275 1702 2130 2560 2812 3105 1880 2189 2500 2800 3140 2470 2870 2610 2950 3288
Pump Motor Absorbed Power kw 0.15 0.15 0.15 0.15 0.16 0.16 0.19 0.22 0.25 0.28 0.31 0.39 0.45 0.5 0.57 0.63
Pump Motor Installed Power kw 0.37 0.55 0.75 1.1
GAS DATA
Natural Gas m³/hr (HCV) # 179 239 298 358 394 434 520 606 692 778 869 1046 1213 1384 1566 1743
Nominal Manifold Loss m.bar.g 24.9 37.4
Nominal Turndown 4:1 4:1 4:1 4:1 4:1 5:1 5:1 5:1 5:1 6:1 6:1 6:1 6:1 7:1 7:1 7:1
NOMINAL BURNER OUTPUT
Burner Output Gross MW 1.87 2.49 3.12 3.74 4.11 4.54 5.44 6.33 7.23 8.13 9.08 10.9 12.7 14.5 16.4 18.2
Burner Output Gcal/hr (Net) ~~ 1.61 2.14 2.68 3.22 3.54 3.90 4.68 5.45 6.22 6.99 7.81 9.39 10.9 12.4 14.1 15.7
BOILER OUTPUT
Steam f & a 100 ºC kg/hr ~~ 2476 3301 4126 4951 5446 6007 7196 8384 9572 10760 12015 14457 16768 19144 21653 24095
Hot Water Gcal/hr (Net) ~~ 1.33 1.78 2.22 2.67 2.94 3.24 3.88 4.52 5.16 5.8 6.48 7.8 9.04 10.32 11.68 12.99
Hot Water MW (Gross) ~~ 1.55 2.07 2.59 3.1 3.42 3.77 4.51 5.26 6.0 6.75 7.53 9.07 10.52 12.01 13.58 15.11
GENERAL
Igniter Input 30KW
Modulation Control High / Low – Fully Modulating – Alpha Link / Electrolink
Atomiser Shaft Motor rpm 5500 4897 5748 5669 5828
Atomiser M’tor Installed Power kw 0.37 0.37 0.37 0.55

$ Table based on residual fuel oil, gross CV 10167 kcal/kg (oil) S.G. 0.93 @ atomising temperature.
# Gas based on std. Conditions 1093 m.bar & 15 ºC. Gross CV 9731 kcal/Nm³ (Gas) Gas corrected for lower efficiency of 79%.
~~ Boiler efficiency 83%.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 12

SECTION - 3

ELECTROtec II Burner GENERAL DESCRIPTION

GENERAL DESCRIPTION

The Electrotec burner model range consists of 16 burner sizes. Individual burners are prefixed with “ER”
(representing Electrotec Rotary cup)

Following the burner model reference, e.g. ERO there will be a number that relates to the burner frame
size e.g. ERO 22. Following this will be another number that relates to the burner output in MW, therefore
an ER) 22 / 8.1 is a frame size 22 dual fuel Electrotec Rotary cup burner with a heat output of 8.1 MW.
The data sheet in this manual gives specific ratings (Page 11).

The Electrotec II burner is of the rotary cup type. The atomising cup is driven by a burner-mounted electric
motor via a belt drive.

Fuel oil is delivered to the burner cup from a variable speed pump mounted under the burner windbox.

Primary and secondary air is normally supplied by a compound fancase containing two separate fan
impellers contained within a single fancase (some applications with high system resistance require the
use of two independent fans each with their own motor drive and silencing equipment as required). These
fans are direct driven by an electric motor sized for the specific burner and boiler duty. Primary air for
atomisation of the fuel oil is ducted via a control damper contained within the burner hinge to the primary
air nozzle. High pressure air discharging from the primary air nozzle “shears” the oil film as it leaves the
atomising cup and breaks it into fine droplets. Secondary air at low pressure is delivered to the air register
through a modulating control damper.

The complete burner assembly comprising air register (windbox) and compound fancase can be
turned in any direction to suit the particular application, the burner machine remains in it’s original
orientation.

AIR SYSTEM

Air is drawn into the secondary fan impeller either directly or through an air inlet silencer (if
required). In both cases a simple baffle plate is fitted to act as a coarse damper for purposes of airflow
control. This impeller delivers the main combustion air requirement to the burner through the twin
bladed contra-rotating damper blades, from here it passes into the air register (windbox) and through
the secondary air discharge cone to the furnace.

A small amount of the secondary air passes through ports in the side of the nozzle shield, this airflow
is further sub divided such that some exits through the tertiary air space, the remainder exits through
the refractory face of the nozzle shield.

The primary air fan impeller takes approximately 7% percent of the secondary airflow from the
upstream side of the secondary damper. The primary fan elevates the pressure to the level required
for atomisation of the fuel this is delivered to the primary air nozzle via a separate discharge pipe and
control damper.

It is possible to operate the Electrotec II burner compound fan arrangement with a variable speed
motor drive subject to some special considerations. For details please contact your nearest
Hamworthy Combustion sales contact or our head office at Poole Tel + 44 (0) 1202 662700.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 13

SILENCER AND FAN MOTOR EQUIPMENT

This equipment is designed to reduce the sound pressure level of the combustion equipment only. The
presence of other noise sources such as pumps, I.D. fans, gas boosters, etc. can have a considerable
influence on overall plant noise measurements. Sound pressure levels will also vary according to the
acoustic properties of the plant room.

Compound Fan Intake Silencer

The silencer is designed to reduce the noise level at the inlet to the secondary air fan. The silencer
construction incorporates an outer shell of galvanised steel with an inner manufactured from perforated
plate the void between the two skins is filled with dense fibre. A wire guard and baffle plate is fitted at the
inlet end of the silencer. The baffle can be used as part of the airflow control as described in the “Air
System” section above.

Fan Motor Muffler

A motor muffler can be fitted if required for further noise attenuation.

BURNER OIL SYSTEM

Fuel oil is drawn from the ringmain into the burner machine by the burner oil pump (maximum fuel inlet
pressure 4.0 Bar.g).

The pump, which is of the positive displacement type delivers fuel oil to the burner valve assembly. The
pump motor is driven by a variable speed drive, this increases and decreases the fuel oil flow in response
to appliance heat demand, pump flow being proportional to speed.

During periods of re-circulation such as during the warm up time for heavy fuel applications or at other
times when the fuel shut off solenoid valves are closed such as during burner pre and post purge. The
fuel oil spills back to the oil ring main via the re-circulation position (Factory set at 6.0 Bar.g. at maximum
burner flow rate).

During periods of normal operation when the fuel shut off solenoid valves are open the fuel flow takes
the easier route through the back pressure valve to the burner atomising cup. For this to take place it
is necessary for the back pressure valve to be set lower than the re-circulation valve (Factory set at
5.0 Bar.g.).

Heavy fuel oil burners are quipped with low wattage heaters & electrical trace heating to maintain the
valve block in a warm condition when in standby.

Burner fuel oil meters are available as an optional extra.

A Diesel electric igniters is fitted. See Drawing No. 363801732.

COMBUSTION (Fuel Oil)

Fuel oil has to be delivered to the burner atomising cup in carefully controlled quantities and at the
correct viscosity to ensure good atomisation. Residual fuel oils will require pre-heating before the
burner to achieve the correct viscosity for atomisation. Distillate fuels will normally be used at ambient
temperature.

See Data Sheet 09:04:08 Issue 2 in Section 13 for details of viscosity and temperature requirements.

Fuel flow is controlled by varying the speed of the burner fuel pump motor, there are two separate air
streams to the burner (Secondary air and Primary air) controlled by dampers which are used to match
air flow to fuel flow throughout the burner modulating range.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 14

Fuel oil is delivered to the rear of the atomising cup by the pump, the atomiser is rotating at a speed in
excess of 4500 rpm, centrifugal force holds the oil to the side of the atomiser where it is formed into a
uniform film. The design of the atomiser allows this film of oil to move forward toward the discharge
end where it exits from the atomiser lip as a solid sheet of oil. Primary air shears the oil film into small
droplets, which are then propelled into the furnace under the influence of the air mass. Primary air flow
will increase with firing rate on the basis that more primary is required to atomise an increasing fuel
flow. At the ignition stage a pilot gas flame is projected from the tertiary air space the oil droplets pass
through this flame and are ignited. At a point in front of the burner nozzle shield the oil droplets meet
the secondary air, this is discharging from the windbox via the secondary air discharge cone, the flame
stabilises in this zone.

Throughout the length of the furnace the fuel oil mixes with the secondary air to ensure complete
combustion. There is a theoretical amount of air required to ensure complete combustion of any fuel,
in reality slightly more than the theoretical amount is required as mixing can never be 100% efficient,
this additional amount of air is referred to as “excess air”. Typically a heavy fuel oil burner firing into a
firetube boiler furnace will require excess air in the region of 15 – 17%, this is entirely dependent on
furnace size and is subject to selection on a project by project basis. As burner output reduces the
excess air will increase.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 15

SECTION - 4

ELECTROtec II Burner Combustion Control


STANDARD

This comprises of an Electronic modulation motor commanded by appliance demand either directly
from a potentiometer to give proportional only control through an in built balance relay or in response
to a command signal from a three term controller in the burner control panel.

This motor is mechanically linked directly to the input of a cam assembly mounted on the burner
secondary air damper. The servo motor will be set to travel through 90 degrees via the link rod this will
stroke the damper from fully closed to maximum required, intermediate settings are set on the cam
profile (set at commissioning).

On oil only burners a single drive cable is connected to the auxiliary end of the modulation motor, the
other end connects to the primary air damper contained within the hinge of the burner machine. The
stroke of the cable can be adjusted as required to deliver the correct amount of primary air to the burner.
This air flow is not characterised throughout the range as a special trailing blade on the damper acts to
make the flow linear throughout the operating range.

An auxiliary potentiometer within the modulation servo motor provides the command signal to the oil pump
variable speed drive.

The maximum and minimum pump speeds are set within the oil pump variable speed drive unit during
commissioning (see the burner specification sheet for details of the speeds required to match the
appliance duty).
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 16

SECTION - 5

ELECTROtec II Burner Management Description


GENERAL DESCRIPTION

Based on Electro-mechanical sequence timing the function of the Burner Management System (BMS) is
to monitor the status of the burner safety interlocks during standby, start up and normal operation. Often
other safety devices are monitored from the BMS panel such as boiler or heater interlocks.

National legislation in most countries of the world dictate the nature and type of safety monitoring devices
that are required, it is therefore important that these safety devices are set and maintained correctly.

During the light up sequence the BMS commands the modulation system into the purge and light up
positions.

The particular circuit drawing issued with the burner will detail the exact method of operation of the burner
to which they apply. The following description is therefore generic in nature, your burner will contain some
or all of the following control functions. The general sequence of operation will be the same in all cases.

BURNER MODULATION

Once the burner is operating and main flame has been established by the BMS, the Normal Run relay is
energised permitting the modulating system to operate. Modulation of the burner can be controlled
manually or automatically through the appliance demand circuit.

Standard Modulation

In the case the Standard system there is a switch on the burner panel that can select “Manual” or “Auto”,
when switched to “manual” the burner firing rate can be determined directly by the operator by turning a
hand potentiometer up or down as required. In “Auto” the burner firing rate is dictated by the appliance
demand signal. Occasionally this switch may have a third position “Remote” this would normally signify
that a demand signal is coming from another system such as a load sharing device (Sequence Control) or
building management system.

BMS SAFETY INTERLOCKS

Burner Hinge Microswitch

This prevents the light up sequence starting, or causes immediate shut down if the burner is firing when
not fully closed to the windbox front. The switch is mounted adjacent to the closing handle to the left side
of the burner machine.

Power Supply Failure

In the event of supply failure a relay is de-energised which causes the burner to lockout and remain
locked out when the supply is re-instated. This can only be re-set by manual intervention, the “reset”
button should be pressed.

Exit Damper and Flue Draught Switches, (if fitted)

These switches ensure that any manual exit damper is wide open and that a normal flue draught is
present before allowing ignition of the pilot flame.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 17

Primary Air Pressure Switch

This pressure switch ensures that correct primary air flow is present during pre-purge and firing periods.
Failure causes the burner to lockout. The primary air switch is mounted on the burner lid of the burner
junction box and connected to the burner primary air plenum by plastic tubing.

Secondary Air Pressure Switch

This pressure switch initially has to be proved in the “no air” position prior to permitting a light up sequence
to commence. One the burner light up sequence has started this switch ensures that the correct
secondary air flow is present during pre-purge and firing periods. Failure causes the burner to lockout.
The secondary air damper switch is mounted on the burner junction box and is connected to the windbox
upstream of the damper by plastic tubing.

Low Fire Air Proving Switches

This microswitch is on the air damper and proves that the damper is at the required low fire, (light up)
position before the burner ignition sequence can commence. Electrolink equipped burners also utilise a
signal provided from the Electrolink when the relevant servos are at the light up position.

Air Purge Pressure Proving Switch

This pressure switch monitors the pressure within the burner windbox during the light up sequence. This
switch must be made for the pre-purge to commence. Electrolink equipped burners also utilise a signal
provided from the Electrolink when the relevant servos are at the purge position.

Low Fire Oil Proving Interlock.

Monitoring the pump drive motor speed proves oil flow at the light up position. A signal from a sensing
device fitted to the motor is taken to an amplifier within the burner control panel. Provided the speed is at
light up or below the burner light up sequence is permitted to proceed.

Flame Proving

A RAR Photocell cell is fitted to the burner igniter to view pilot flame, a QRA Photocell monitors the main
flame. During the pre-purge period a high voltage check of the cell is made to ensure correct operation.
Should a “false” signal be present at this time a lockout will occur and the burner light up sequence will
stop. Once normal operation is established the U.V. detector is used to continuously monitor the flame,
locking out the burner in the event of flame failure.

Low Boiler Water (Boiler Mounted Switch

Two low water levels are used.


st
1 Low water alarm will cause the water level alarm and indicator lamp to activate. The burner will initiate
a normal safety shut-down and will automatically re-start when the condition has cleared.
nd
2 low water level, if reached, will shut-down the burner immediately and the burner will remain
shut-down. The alarm will cause the water level alarm and indicator lamp to activate. When the condition
clears the burner is at a locked out condition. Restoration can only be achieved by pressing the Reset
button.

Water level alarms may be muted with the Mute button to silence the alarm, however, the fault condition
will remain.

High Water Level

High water alarm initiate the alarm and indicator lamp, the burner remains alight. Water level alarms may
be muted with the Mute button to silence the alarm, however, the fault condition will remain.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 18

Boiler Limit Switch

A pressure operated device which is set to switch the burner on and off.

Boiler Modulation Switch

A boiler pressure operated device, which is used in conjunction with the modulation system to adjust the
burner firing rate to match the boiler load.

Oil check thermostat (Heavy oil only)

This thermostat monitors the fuel oil temperature at the burner. Should the fuel temperature be below
the set point the burner is prevented from firing. If the burner is selected “on” and the fuel temperature
is below set point the burner pump will circulate fuel until the thermostat is satisfied at which time the
ignition cycle will commence.

Atomiser shaft rotation sensor

The burner is equipped with a sensor to monitor the rotation of the burner atomiser shaft when firing
fuel oil. This sensor ensures that the atomiser shaft is rotating at the correct speed to atomise the fuel
correctly. The sensor is connected to an amplifier housed in the control panel, should the speed fall
below set point the sensor relay (amplifier) contact will open and inhibit the burner from firing.

Pump motor rotation sensor

The burner fuel oil pump is driven at varying speeds dependant on appliance demand. A rotation
sensor and amplifier / relay is used to monitor the pump speed and ensure that speed is correct for
burner light up. Should the pump speed be greater than the set point the burner will be inhibited from
lighting.

IGNITION

The Burner is fitted with the Hamworthy Diesel Igniter & dual outlet ignition transformer, upstream of
this are two Pilot Diesel Valves. The Diesel is required at an approximate pressure of 6.89 barg.
See Drawing No. 363801732 for details of the electrode settings & clearances. An RAR Photocell is
located within the housing for monitoring of the ignition flame.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 19

SECTION - 6

ELECTROtec II AUTOMATIC CONTROLS

GENERAL DESCRIPTION

The burner control system may be considered in two separate parts, the burner management system
(BMS), and modulation system, either may take differing forms dependant upon customer specification.

Electro-mechanical (cam timer),

Electro-mechanical control,

BMS SYSTEM

Electro-mechanical based the functions of the BMS is to monitor the status of the burner and boiler safety
interlocks all the time the panel isolator is energised so as to ensure that any unsafe situation will result in
immediate burner shut down. Also monitored are the normal operational interlocks that are responsible for
starting and stopping the burner whilst under normal operation.
During the light up sequence the BMS commands the modulation system into the purge and light up
positions.

MODULATION SYSTEM

Once the light up main flame has been established by the BMS, the Normal Run relay is energised
permitting the modulating system to operate. Modulation may be controlled by an electro-mechanical
system. Automatically tracking appliance demand or under manual control, or by the Electrolink /
Alphalink air/fuel processor system. Again either automatically tracking appliance demand or locally
manual or from a remote external control.

Automatic Modulation:

The modulation is controlled to continually balance the burner heat input to the appliance demand. The
burner will perform a normal shut down if the pressure set point is exceeded. Upon pressure drop the
burner will initiate a normal light up.

Local Manual Modulation:

Upon achieving Normal Run the modulation will drive to a position set on the manual control knob. The
burner will remain at that setting regardless of the boiler load. When the pressure set point is achieved the
burner will shut down. Upon pressure drop the burner will initiate a normal re-light and at Normal run
return to the previously set firing rate. Manual control does not balance heat input to boiler load.

BMS SAFETY INTERLOCKS

Whilst every burner application has a requirement for safety interlocks to meet certain statutory obligations
a variety of other customer or application specific interlocks will be fitted. Details of these are always
shown on the circuit diagrams supplied with the burner. Interlocks are important to pro9tect the plant and
operator and should always be kept in operation.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 20

SECTION - 7

ELECTROtec II LIGHT UP SEQUENCE


This is a typical description of the burner light up sequence:

Apply power to the burner panel.

The control panel will now be in the Standby mode.

The main safety interlocks are being monitored and, if activated, will cause a lockout, the power being
withdrawn from the sequence timer inputs/outputs.

Some of the relevant interlocks comprise:

Typical Standby Interlocks include:

• Second low water level


• Burner hinge microswitch
• Power supply failure relay
• Excess pressureswitch
• Fire detectors
• Emergency Stops

The Burner management System, (BMS) will be awaiting the Burner On/Off switch activation, (or a
remote start signal from an external source if fitted).

Upon receiving the start signal the BMS will initiate the start loop.

Typical start loop interlocks include:

• Secondary air pressure absent.


• Local or remote Burner start signal.
• Oil check thermostat -hot oil Heavy oil burners only).
• First low water.
• Pressure limit switch.

Note :- On a cold start up situation the oil check thermostat will be showing cold. In this instance the
burner will begin recirculation of the oil, (burner pump runs at 50% speed). Gradually hot oil will be
drawn into the burner, the thermostat will register the presence of the hot oil and show hot. The
recirculation will cease and the burner will await the completion of the loop before commencing).

Oil burners - the start loop is now complete and the BMS is ready to issue the “go to pre-purge
position”.

The start loop and gas test is now complete and the BMS is ready to start the prepurge.

The modulation system is signalled to go to the pre-purge position.

• Fan & burner motor started.


• Exit dampers signalled to open, (if fitted).

Interlocks to prove pre-purge position:

(differing specifications require the pre-purge to take place at either 50% or 100% of the
modulation range).
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 21

• Secondary air damper at pre-purge position.


• Secondary air pressure proved.
• Exit dampers open. (if fitted).

Pre-purge commences - 60 seconds.

At the end of the pre-purge the BMS will signal the modulation to drive to the light up/low fire position.

Interlocks to prove light up/low fire position:

• Secondary air damper at Low fire.


• Secondary air pressure present.
• Primary air pressure present.
• Oil pump speed equates to low fire light up rate.
• Atomiser cup rotation.
• Exit dampers open.

When all the light up/low fire interlocks are secure the BMS will initiate the ignition sequence

Ignition sequence:

• H.T spark initiated.


• Pilot diesel valves opened.
• Pilot flame proved.
• H.T. spark off.
• Pilot flame still proved.
• Main fuel valves opened.
• Main flame proved.
• Pilot flame off.
• Main flame still proved.
• Normal Run.

Normal Run:

Once at normal run the burner, if selected to automatic or external modulation signal, will modulate
and stop/start in order to match the appliance load. If selected to manual modulation the burner will
drive to the set firing rate and remain there. Stopping and restarting the burner will still be performed
by the BMS.

Lock out conditions:

From the normal run condition the failure of certain units/interlocks will cause a lock out:

• Failure of associated BMS units:


• Failure of interlocks:
• Lockout and post purge takes place;
• Photo cell - loss of flame signal.
• Secondary air loss.
• Primary air loss.
• Cup rotation loss.
• Exit damper not open.

Immediate shut down, lockout on re- instatement;

• Second low water.


• Burner hinge open.
• Fire systems.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 22

SECTION - 8

ELECTROtec II MAINTENANCE GUIDANCE NOTES

GENERAL

Before commencing static maintenance always ensure that all electrical supplies are isolated and fuel
valves are closed.

When re-assembling any dismantled components, ensure they are clean and undamaged. Renew as
necessary.

Assembly is generally a reversal of dismantling instructions unless otherwise stated. When re-assembling
components always fit new “O” rings, joints and gaskets.

After the completion of any maintenance operations, the re-commissioning procedure must be followed to
ensure the safety of the installation.

LUBRICATION

The bearings utilised on the burner machine are generally of the sealed type and require no routine
lubrication. On occasion fan motors will be of the larger type equipped with external means of greasing,
on these occasions the motor manufacturers guidelines should be followed.

Mechanical linkage burners - Keep all linkage joints, cams and associated bearings clean and lubricate as
necessary. In particular keep the characterising cam adjusters and cam follower strip clean and lightly
lubricated with a general purpose grease.

The burner hinge contains two grease nipples, ensure that these points are kept well greased with a
general purpose grease.

The main atomiser cup shaft runs in sealed bearings and does not require further lubrication.

Note :

Fitted on the main bearing housing is an air vent, this looks a little like a lubrication point do not apply
lubrication to this point.

CLEANING

Maintain the burner and it’s associated equipment in a clean condition.

Due to the nature of residual fuel oil it is important that frequent, regular cleaning and inspection of all
filters and strainers on the burner and fuel supply system is carried out, the frequency of cleaning will be
determined by operational experience.

Atomiser cup cleaning –

Regular cleaning of the atomiser cup is required when firing any fuel oil, minimum frequency is daily.

Routine cleaning of the atomiser may be carried out in situ as this will only require the use of cotton waste.

WARNING

If the cup is to be cleaned in-situ exercise great caution do not use a volatile cleaning liquid as
this could ignite on the hot surfaces exposed when the burner is open.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 23

If the atomiser is damaged or does not run true, a new one must be fitted.

ATOMISER CUP REMOVAL / REFITTING

Note: The atomiser cup must remain fitted when firing gas. When firing gas the atomiser is
stationary but it forms the primary air annulus around the atomiser cup.

The atomiser may be hot.

In the case of an atomiser cup that is heavily fouled. The cup should be removed from the burner
immersed in a suitable solvent and left to soak until the deposits are sufficiently softened to be removed
by light brushing.

Note; Do not use metal scrapers as these could damage the inner surface or edge of the atomiser.

The atomiser must be removed only as detailed below in order to prevent damaging the atomiser boss
and retaining bolt thread in the burner shaft.

The correct box spanner, extracting screw and Allen key are available from Spares department -
Hamworthy Combustion Limited.

If the cup is damaged do not attempt to machine it, the balance of the cup will be upset and damage to
the shaft bearings will occur.

A special box spanner, allen key and extractor bolt are available from Hamworthy Combustion Ltd to aid
atomiser removal and fitting.

To remove apply the box spanner to the atomiser retaining bolt, to break the “hold” of the bolt apply a
sharp tap to the handle of the box spanner remembering that this bolt has a “left hand thread”. When
loosened the bolt can be fully removed, the atomiser will remain in position as it is still “locked” to the taper
of the burner shaft. Apply the socket headed screw to the “jacking” thread on the inside of the atomiser
hub, this is a standard right hand thread. Wind this screw in until it is in contact with the end of the burner
shaft, fit the allen key to the screw and a sharp tap to the allen key to break the grip of the cup onto the
burner shaft. At this time a degree of care is required as when the cup breaks free from the taper it could
fall.

To re-fit ensure that both the taper on the end of the burner shaft and within the rear of the atomiser are
clean. Offer the cup onto the shaft ensuring, apply the left hand retaining bolt and tighten by hand. Apply
the box spanner and “lock” the atomiser onto the burner shaft by giving the end of the spanner a light tap
with a hammer. Now tighten the bolt using the box spanner by hand until resistance is felt. Finally give the
handle of the box spanner a light tap with the hammer to allow the retaining bolt to “bight” and fully lock
the atomiser in position.

CLEANING AND CHECKING THE ALIGNMENT OF THE PRIMARY AIR NOZZLE.

The Primary Air Nozzle and shroud assembly may be removed with or without the cup in
position.

The complete Primary Air Nozzle and shroud may be removed by extracting the 3 off M6 screws around
the shroud.

Mark the 12 o’clock position of the shroud to assist in re-assembling. Take care when releasing the last
(top) screw that the shroud does not fall and hit the male cup taper.

Ensure that the inside lip of the primary air nozzle is free from carbon or oil deposits.
Check that the outside lip of the nozzle is free of damage or heat erosion.

When the cup has been refitted check for the correct alignment of the primary air nozzle.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 24

The nozzle must be concentric with the atomiser cup, and there must be approximately 1.0 mm of cup
protruding concentrically from the lip of the primary air nozzle.

To adjust the 1mm dimension, release the 2 off M4 cap head screws and move the primary air nozzle
forwards or backwards as required, retighten the M4 screws.

DRIVE BELT

Ensure all power is isolated before working on the burner motor and drive belt.

The burner utilises a single “poly vee” type belt to drive the burner atomiser shaft. This can be accessed
by removing the burner glass fibre cover and removing the inner mounting plate.

The glass fibre burner machine cover can be removed by turning of the 2 off ¼ turn screws on the front of
the cover.

No special tools or techniques are required to remove the inner mounting plate, remove the four fixing
bolts and set the inner mounting plate to one side.

Under no circumstances must the motors be activated whilst this cover is removed.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 25

MAINTENANCE PROGRAMME

Routine checks.

Description Operation Frequency

Atomiser Remove deposits from surface Daily


and distributor holes at rear.
(when oil firing).
Inspect for damage and
concentricity.
Refractory Quarls Inspect for condition. Daily observation.
Photocell Remove any dust from cell face. Weekly (Unless very dirty
environment).
Oil Filters Remove baskets and clean. Once per month.
Fuel/Air Ratios Check settings and combustion Monthly.
performance.
Atomiser cup belt Inspect condition and tensioning. 3 Monthly.
Igniter Remove deposits check Weekly.
electrode.
Linkage Inspect screws for tightness and 6 Monthly.
lightly lubricate.
Burner Hinge Inspect for ease of opening and 6 Monthly
grease if necessary.
Silencers Check integrity and security of 6 Monthly.
materials.
Air passages Clean out any deposits. 12 Monthly.
Pressure switches Check operation and accuracy 12 Monthly
and compliance with the
commissioning log.
Photocell Test signal values 12 Monthly
Motor Windings Inspect condition and check 12 Monthly
resistance to earth.
Electrical Terminations Check for tightness 12 Monthly
Panel Relays Ensure that relays are located 12 Monthly
correctly in their bases.
Burner Bearings Replace housing Every 5 years.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 26

SECTION – 9

ELECTROtec II Burner INSTALLATION GUIDANCE NOTES

GENERAL

Burners should be installed by competent staff only, in accordance with the contract
installation drawings. All lifting equipment must be of an approved type - refer to contract
specification sheets for weights of main components. Handle asbestos products as
recommended in the relevant safety codes. Many burners appear to be of the same
physical size, their capacities will, however, vary dramatically. Therefore, on multiple
burner installations, ensure that the correct sized burner and air system is fitted to the
correct boiler!

See application data sheet in Section 13 for overall dimensions.

COMBUSTION AIR SYSTEM AND REFRACTORY

The windbox, secondary air damper and compound fancase assembly is all sized to suit
the individual installation and must be installed strictly in accordance with the drawings
provided. Refractory is required to protect any un-wetted or un-insulated surfaces of the
boiler or appliance to prevent overheating and damage. If in doubt or if in need of advise
call Hamworthy Combustion, Customer Service on + 44 (0) 1202 662700.

FLANGED BOILER FLUE

Check that the ring of studs on the boiler flange matches the ring of holes in the quarl
backring.

ALL BOILERS

Fit the quarl assembly to the backring or boiler flange making a joint with a ring of 50mm
x 6mm thick ceramic ladder tape. Check the orientation of quarl assembly with contract
drawing supplied. Backfill between quarl brick and boiler flue using correct grade of
mouldable refractory to secondary quarl contract detail drawing.

Fit the windbox to the quarl, making a joint with a ring of 50mm x 6mm thick ceramic
ladder tape either side of the windbox/quarl ring bolts. Fully tighten the bolts. Fill the gap
between the windbox assembly and the quarl segments with a ring of 19mm soft ceramic
rope soaked in alumina cement.

Assemble the fancase and silencers (if fitted) to the windbox, to the correct orientation
(see contract drawing), making a joint of 6mm (¼ in) soft ceramic rope.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 27

BURNER FUEL OIL METERING SYSTEM

The burner machine is supplied mounted on its windbox and pre-wired to the burner
mounted junction box. Flexible hoses connect between the windbox mounted burner
pump and the burner valve block.

The burner has been designed to operate on a variety of fuel systems. The pressure at
the burner inlet should be in the range 0.2 – 4.0 Bar.g. in the case of burners firing
residual fuel oil the temperature should be controlled to give a viscosity of between 55 –
70 Cst at the burner (There are no heaters on the burner other than those required to
keep the system warm at standby).

Refer to the Data Sheets in Section 13 for acceptable ring main systems.

LINKAGE CONTROL CABLES

The control cables are designed to transmit linear push and pull forces and must not be
subjected to twisting or excessive bending forces.

Correct installation of the control cables is important to backlash-free control, long life of
the cable, and to prevent overloading of the modulation motor.

Fit each cable to the required positions and check stroke, ease of operation and swivel
abutments etc. Make final adjustments where necessary, then tighten all locking nuts
holding the threaded sleeve and sliding rods by the spanner flats provided.

Ensure that the stroke of the cables as determined by the modulation motor can be freely
accommodated by the cam assemblies. If fouling, over or under travel exists, adjust the
sweep of the linkage arms - never reduce the travel of the modulation motor. The
0
modulation motor is always set to 90 rotation.

MOTOR ROTATION CHECKS.

Note: If the control panel is to be powered up for rotation checks etc. before the
commissioning engineer has checked and set the modulation linkage travels, then the
modulation motor /Electrolink unit must be electrically inhibited otherwise severe damage
may occur to the linkages/servos. Motors must be checked for free rotation by hand
before being electrically driven to ensure that all rotating parts are not fouling, e.g. rotary
cup, shaft rotation sensors, fans etc.

FUEL OIL SYSTEMS

The fuel oil system must be installed to the appropriate Hamworthy Combustion
Engineering data sheets or contract specific drawings. For heavy oil the ideal system
should include: a steam/electric or hot water/electric tank outflow heater, steam/electric
or hot water/electric line heater and suitably lagged and traced oil flow and return pipes
arranged to provide a true ring main system. Ensure that the feed connection from the
ringmain to the burner comes from the underside of the ringmain pipe.

ELECTRICAL CONNECTIONS

The internal wiring of the burner and its controls are completed at the factory and in
accordance with the wiring diagram supplied.
External wiring must be made strictly in accordance with the diagram supplied, using size
of cables, switches and fuses in accordance with requirements of the load to be handled.
Signal wires used for the installation and interconnection of electronic units must be of
the type specified within the contract documentation, i.e. screened or twisted pair etc.
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 28

Signal cable screens must be terminated strictly in accordance with the contract
drawings.
Items detailed within the contract drawings as being connected to the instrument earth
point must be connected to that point.
The earth bonding must be connected to the protected earth point. The earth bonding
must remain intact.
The complete burner package is “CE” compliant. In order to retain this status no
modifications must be performed that compromise the EMC, (Electro Magnetic
Compatibility), or LVD, (Low Voltage Directive) elements of the system.

Any parts that fail must be replaced with identical components.


Any wiring added by the customer providing auxiliary signals to or from remote panels
must be fed through auxiliary contact blocks added to the panel isolator. Such signals
must not feed live supplies into the burner panel when its isolator is in the off position.

CONTROL PANEL

The control panel must ideally be situated local to the burner so that the panel indicators
are easily visible from the burner firing position, preferably to the side of the boiler centre
line. Ensure that the panel is not placed under any water containing devices, (gauge
glasses or level controls). Ensure that the panel is not positioned such that the operator
is required to stand directly in front of the burner.

Do not place the control panel in direct sunlight as this could cause the internal
temperature of the panel to exceed the design limit.

AIR SUPPLY TO BOILER ROOM

Where the boiler room is ventilated by natural means the air necessary for combustion
and ventilation must be admitted by permanent openings at low level from the open air
2
having a free area of not less than 0.2 m for each 300 kW of installed boiler capacity. In
addition, permanent openings to the open air having a total free area of not less than 0.1
m² per 300 kW of installed boiler capacity, with a minimum of 0.012 m² should be
provided at high level to effect general ventilation.

In boiler rooms below ground level, special ducts may be necessary to admit the air and
these ducts must be enclosed and separated from the rest of the building by
non-combustible construction having the same standard of fire-resistance as that
required for the enclosure of the boiler room, or for the remainder of the building through
which ducts pass, whichever is the greater.

If in doubt take advice concerning local regulations.


Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 29

Section 10.0

ELECTROtec Burner Component Identification

The following exploded view drawings will help with component identification. When ordering spare
parts please quote the Contract Reference Number which can be found either on the burner, control
panel or in the specification sheet at the front of this manual. In the case where burners of differing
sizes have been purchased at the same time it would also assist if the Burner Serial Number is
quoted.

See exploded views of burner, windbox and fancase for details.


Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 30
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 31
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 32
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 33

NOTES
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 34

SECTION – 11

ELECTROtec II Burner

APPENDICES
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 35

OIL VISCOSITY vs TEMPERATURE CHART 09 : 04 : 08

ISSUE: 2
200.00
195.00 50 60 80 90 100 120 140 150
30 40 70 110 130
190.00
Kinematic
185.00 33 DEGREESC
cStokes
180.00 REDWOOD
3 No 1 seconds
175.00
170.00 35
3.5
165.00
160.00 4
155.00
150.00 5
145.00 40
140.00 6
135.00 7
130.00 45
8
125.00 9 50
120.00 10
115.00 55
110.00 12.5 60
105.00 15 70
100.00
80
95.00 20 90
90.00 70
25
85.00
30 125
80.00 35 150
75.00 40
175
70.00 50 200
65.00 250 ATOMISINGRANGE
60.00 75 300
55.00
100 400
50.00
500
45.00 150
40.00 200 750
35.00 250 1000
30.00 300
1500
25.00 400
500 2000
20.00
3000
15.00 750
1000 4000
10.00 5000
5.00 1500 7500
2000
0.00 10000
-5.0050 70 90 110 130 150 170 190 210 230 250 270 290 310
-10.00
OIL TEMPERATURE °F
TOUSE THE CHART. The viscosity of the oil at one temperature The vertical line which intersects with the black graph line
according to Redwood No.1, Kinematic (Engler or Saybolt) units at the required viscosity indicates the temperature to which
must be known. Thus, if it is known that the oil has a viscosity the oil should be preheated.
Redwood 1 at 100°F, of 1000 seconds, the point on t he 100°F, NOTE: Any number of additional graph lines may be added
vertical opposite 1000 seconds Redwood 1 is found and provided that they are drawn parallel to those existing.
the black graph line passing through this point is followed until The graph lines are a compromise on all the different types
it enters the area of the graph which defines the normal of oil which may be encountered but their accuracy is sufficient
range of burner viscosities. for the practical purposes for which they are provided.
Prepared by: I.J.H-B. Distribution: B.C.E.G.H.
IIIIIIIIIIIII Approved by: C.J.M.
Date: 30:6:89
HAMWORTHY
Combustion Systems
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 36

Electrotec II Overall Burner Dimensions (All dimensions in mm)

Burner A B C D E F G H J K L M
Frame Rad. Rad. Dia. Dia.
ER 5-11 355 70 412 1302 408 635 181 200 1068 480 800 810
ER 12-20 355 70 478 1436 478 730 198 220 1366 480 800 945
ER 22-30 355 70 563 1645 565 857 221 220 1366 555 1080 1125
ER 35-50 355 70 563 1830 580 972 288 220 1668 675 1080 1290
Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 37

RESIDUAL FUEL OIL RING MAIN (TYPICAL)

Please refer to the following guidance notes before installing burner equipment.

1. Refer to Data Sheet 09:04:08 Iss 2 for fuel temperature requirements.


2. Ensure fuel oil ring main pipework is adequately sized for the grade of oil to be used. Maximum
suction lift at ring main pump must not normally exceed 2m head.
3. It is recommended that any electric heater is sized sufficient for one burner low fire capacity as a
minimum. Additional plant interlocks may be required to limit operation during warm up.
4. A minimum pressure head at the burner inlet of 0.2 bar.g. should be maintained under all flow
conditions. Maximum pressure at the inlet to the burner should not exceed 4.0 Bar.g.
5. Ensure all pipework is traced and lagged in accordance with industry norms.
6. Inlet and return lines to individual burners should be of minimum 25mm bore.
7. An isolating valve can be installed in the return line from the burner provided that it is of the
“lockshield” type.
8. The burner return line hose should be trace heated.
9. Inlet and return connections on the burner should be a minimum 300mm apart.

When designing a fuel oil system the following points should be taken into consideration :-

Position of tank outflow relative to fuel pump.


Pressure losses through pipework.
Pressure loss through strainers.
Pressure loss through heaters.
Total system flow requirements.
Temperature loss through system.

Key :-

LV = Lockshield Valve V = Valve NRV = Non return valve F = Filter T = Temperature Gauge

P = Pressure Gauge CH = Check thermostat


Hamworthy Combustion ELECTROtec II Burner Manual No. PR902428 O&M / rev 1.0 Page 38

DIESEL OIL RING MAIN (TYPICAL)

Please refer to the following guidance notes before installing burner equipment.

1. Ensure fuel oil ring main pipework is adequately sized for the grade of oil to be used. Maximum
suction lift at ring main pump must not normally exceed 2m head.
2. A minimum pressure head at the burner inlet of 0.2 bar.g. should be maintained under all flow
conditions. Maximum pressure at the inlet to the burner should not exceed 4.0 Bar.g.
3. Supply pipework should be a minimum of 25mm bore.
4. An isolating valve can be installed in the return line from the burner provided that it is of the
“lockshield” type.
5. A “lockshield” valve should be fitted at the highest point of the supply pipework to facilitate venting.

When designing a fuel oil system the following points should be taken into consideration :-

Position of tank outlet relative to fuel pump.


Pressure losses through pipework.
Pressure loss through strainers.
Total system flow requirements.
A single pipe system can be used provided that means of priming and venting are addressed. The
supply pipe must also be of sufficient size to prevent fuel starvation at the burner inlet.