Description and Maintenance: OF Thermal Fluid Installation

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AALBORG
I N D U S T R I E S
DESCRIPTION AND MAINTENANCE
OF
THERMAL FLUID INSTALLATION
Astillero Barreras
Hull no. 1594-1595
Project no. 10019A.OO- 10020A.OO
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Digitally signed
by Ermo
Reason: Ex
AALBORG Libris OVIMU-
I N D U S T R I E S 43-33
Location:
Odessa
I. GENERAL
Thermal fluid installation for:
Shipyard: Astillero Barreras

Hijos de J.Barreras S.A.
36208 Vigo
Spain
Hull no. 1594-1595
Class Det Norske Veritas
Delivered by Aalborg Industries NL BV

P.O. Box 145
3200 AC SPIJKENISSE
The Netherlands
Telephone (31)181-650500
Telefax (31)181-650501
E-mail [email protected]
Project no. 10019A.OO-10020A.OO
Piping diagram D11328
Electrical diagram D11343
Fuel oil diagram D11379
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INDUSTRIES
II. SPECIFICATION
Thermal fluid heater
Type 25-VO-08
Capacity 1,000 kW
8,60,000 kcal/h
Burner
Make Weishaupt
Type RMS 7
Flue gas sensor
Make Jumo
Type ATH-7
Scale 200 - 500 °C
Maximum thermal fluid sensor
Make Jumo
Type ATHs-2
Scale 50 - 300 °C
Differential pressure switch
Make Wiesloch
Type 702.02.100
Temperature controller oil fired heater
Make Wiesloch
Type 93 WOO 701
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Temperature sensor
Make Wiesloch
Type PT 100 Ohm
Circulating pumps
Make Allweiler
Type NTT 50-200
Capacity 68 m3/h
Delivery head 75 m.l.c.
E-motor 22 kW
Current 3 x 440 Volt -60 Hz
Motor make
Economiser 1
Type EXV631-31-57.0-1150 DD
Capacity • 900 kW
Number 1
Economiser 2
Type EXV 631-31-57.0-1150 DD

Capacity 900 kW
Number 1
Temperature controller economiser
Make Wiesloch
Type 93 W01 701
Pneumatic actuator economiser
Make Bar
Type GTE 163/090-10
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Minimum flow valve
Make ARI
Bore DN 65
Type valve 23441
Type actuator PR2.2
Electronic pressure controller for minimum flow
Make Wiesloch
Type 93 W01 70E
Range 0 - 6 bar
Pressure transmitter for minimum flow
Make Danfoss
Type MBS 33 Mrel
Range 0 - 8 bar
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I N D U S T R I E S
III. DESCRIPTION OF THE THERMAL FLUID PLANT
Yardnr. : 1594-1595
Flow diagram nr. : D11328
Electric diagram nr. : D11343
Pneumatic diagram nr. :
Aalborg Project nr. : PP10019A.OO/PP10020A.OO
The thermal fluid plant is built up from the following components:
A fired thermal fluid heater / eco flowtherm type 25-VO-08 having a capacity of 8,60,000
kcal/h(l,OOOkW).
Two economisers type EXV631-31-57.0-1150 DD, each having a capacity of 774,000

kcal/h (900 kW).
These economisers are mounted in the exhaust gas pipelines of the main engines.
Two thermal fluid circulating pumps type NTT 50-200 of which one pump is stand-by. One
pump takes care of the liquid circulation through the entire system. Should the running
pump break down, the stand-by pump will automatically start up.
A minimum flow controller mounted between the supply and return line of the system.
These controllers take care of the maintenance of the minimum flow through the fired
heater and the economisers.
An expansion tank to compensate the increase hi volume of the thermal fluid.
The venting possibility at the highest point of the plant must not be forgotten.
The heat consumers are connected behind the afore-mentioned components, such as bunker
tanks, settling tank, daily service tank, separator-heaters, booster heater, heater for central
heating systems and so on.
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I N D U S T R I E S
A) The oilfired thermal fluid heater
The fired heater is provided with a burner, make Weishaupt type RMS9, automatically set
to the required temperature.
The fired heater is provided with the following control and safety devices:
-1 Electronic temperature control device, make Wiesloch type 93 WOO 701 in combination
with 1 PT 100 ohm temperature measuring element.
The measuring element is mounted in the supply manifold of the fired heater. This
combination is set to a temperature of 190°C for partial load and for full load to a
temperature of approx. 185°C. Should the temperature of the thermal fluid drop below
these values, which implies that the heat consumers require more heat than provided by the
economisers, the fired heater will automatically start.
-1 Maximum thermostat, make Juchheim type ATHs-2 (TA-HH), mounted in the supply
manifold of the fired heater.
The heater coil is guarded by a max. thermostat, set point 220°C.
In case this temperature is exceeded, the fired heater is disconnected and interlocked.
-1 Flue gas thermostat, make Juchheim, type ATH-7 (TA-HH), mounted in the flue gas outlet
of the fired heater. This thermostat should be set to a temperature being 50°C higher than
the flue gas temperature measured at a clean fired heater.
Set point approx. 350°C.
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-1 Minimum flow pressure transmitter, type MBS 33 Mrel, fitted in the outlet manifold of
the fired heater.
The flow safety system cuts off the heating when the flow quantity of the thermal fluid
drops below the allowed minimum.
At a nominal flow quantity, the pressure difference is 0,3 bar.
In order to prevent cracking of the thermal fluid and damage to the fired heater it is
necessary to maintain a minimum flow quantity through the fired heater. Set point 0,25 bar.
When the thermal fluid is cold (lower than 50°C) the viscosity is so high that the minimum
flow quantity through the fired heater is not obtained.
Under these conditions the min. flow switch is by-passed in combination with the second
contact of the min. flow switch which is set lower. Set point 0,1 bar.
As long as the min. flow quantity through the fired heater is not obtained the burner flame
remains in the lowest load position.
B) The economisers
Each economiser is built up from concentric coils. The hot exhaust gases of the engine flow
between these coils and transfer their heat to the thermal fluid.
Each economiser is provided with two combined exhaust gas valves. These valves are
controlled by means of a modulating pneumatic cylinder in combination with an electronic
controller make Wiesloch type 93 W01 701. Set temperature for max load 185°C.
When i.e. the temperature of the thermal fluid rises above the set value of the electronic
controller the exhaust gas valve of the concentric spirals closes and the exhaust gas valve
of the external by-pass opens so that more hot exhaust gases passes through the internal by-
pass.
Each heater is provided with the following safety devices:

- A maximum thermostat make Jumo type ATHs-2.
- A flue gas thermostat in the exhaust gas pipe after the heater make Jumo type ATH-7.
- A flow safety system consisting of a measuring orifice in accordance with DIN 1952 and
differential pressure switch type 702 02 100.
When activated, these safety devices cause an alarm in the electric panel of the oilfired
heater and a central alarm in the central switch board.
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When an alarm occurs on the control panel of the economiser, for example:
Max. temperature thermal fluid.
Max. temperature exhaust gas.
Thermal fluid flow insufficient etc.
No electric supply.
Low level expansion tank.
The exhaust gas valve of the internal by-pass opens so that all the exhaust gases passes
through the internal by-pass.
In case of a fault in the automatic electronic temperature controller it is possible to control

the exhaust gas valves by hand.
Each economiser in combination with its electronic controller, pneumatic cylinder and its
combined exhaust gas valves maintains a constant supply temperature to the heat
consumers.
The electronic controller is set to a temperature of 185°C for max. load.
When the heat consumers require less heat than produced by the economiser, the exhaust
gas valve of the internal by-pass opens and less hot gases passes through the concentric
spirals.
When the heat consumers require more heat than can be produced by the economisers, the
fired heater will automatically starts in order to replenish the heat shortage.
As with the fired heater, the minimum quantity of thermal fluid flowing through the heater
tubes must be maintained in order to prevent cracking of the thermal fluid and damaging
the heater tubes.
During port operation the economisers have to circulate also. This in order to prevent dew
point corrosion.
Each economiser is provided with one central cleaning nozzle, which is mounted in the
bottom part and connected to the water system of the ship.
During operation the valve before the nozzle can be opened and the heater will be cleaned.
To keep the heat surface of the economiser clean, it is advisable to open this valve once a
week, during 2-3 sec. with intervals of approx. 3 minutes until the economiser is clean.
The bottom of the heater is provided with drain connections, which can be connected to a
pot with a level switch.(leakage device)
In case of a leakage the level switch will give an alarm in the control panel of the fired
heater. ~
The economiser is also provide with two extinguish nozzles, which are mounted in the top
connection of the heater, and connected to the so called technical water tank of the ship.
These nozzles are only to be used in case of fire.
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I N D U S T R I E S
C) The thermal fluid pumps
The two thermal fluid pumps are connected in such a way as to effectuate automatic
switching on of one pump in case of failure of the other. This changing over takes place at
the command of the minimum pressostat PC. Set pressure: 3,5 Bar.
In order to be able to start the pumps automatically, the shut-off valves in the suction and
delivery pipe should be open.
The delivery pipelines of the pumps are equipped with non return valves to prevent flowing
back of the thermal fluid through the pump which is not in operation.
D) The minimum flow control
The economiser and oilfired thermal fluid heater are provided with flow switches.
It can happen that a lot of the temperature control valves of the heat consumers will be
| closed and in that case the flow over the heaters would be insufficient.
To avoid an alarm, a minimum flow control set is installed between supply and return line.
The valve will be electrically opened by means of the actuator. The pressure will rise in
case the flow is reduced and by opening the valve a constant flow is assured over the oil
fired heater and economiser.
The min. flow controller in the system ensure that at all times a min. flow quantity flows
through the heaters. Should the quantity passed in the systems be reduced as a result of the
closing of the temperature control valves or hand operated valves of the heat consumers,
the pressure before the min. flow controller will rise and the min. flow control valve will
open so far as to maintain the minimum flow through the heaters.
The procedure for adjusting the min. flow controller is as follows: Close down all heat
consumers and adjust the setpoint of the pressure controller of the min. flow equipment in
' such a way that the min. flow quantity flows through the heaters. Each heater has its own
' flow indicating switch as a safety guard. The setpoint is at 0,25 bar. At a pressure
difference of 0,4 bar the heater has its nominal flow.
The setpoint of the pressure controller of the min. flow equipment should be adjusting in
such a way that the flow indicating switch of the heater registers a value of approx. 0,4 bar.
During commissioning the setpoint of the electric pressure controller is found through
experience.
The min. flow equipment is equipped with a by-pass line with a manual regulating valve.
If the min. flow controller is out of order, the min. flow through the heater has to be
regulated as good as possible by means of the by-pass valve following the procedure
mentioned before.
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E) The expansion tank
The expansion tank, normally being installed at the highest point of the installation is
connected to the system by means of the expansion pipe and the cooling pot.
By heating the thermal fluid there will be an increase in volume which will be compensated
through the expansion pipe in the expansion tank. Possible vaporisation and volatile
components will escape through the de-aeration pot, de-aeration pipes, expansion tank and
drain/collecting tank Into the open air.
A cooling pot is mounted between the de-aeration pot and the expansion tank.
The heat supply to the expansion tank as a result of internal circulation in the expansion
pipe is blocked by the cooling pot.
The thermal fluid in the expansion tank is to be kept as cold as possible. A maximal
thermal fluid thermostat make Jumo type ATHs-2 is mounted Set temperature: 50°C.
The expansion tank is provided with a magnetic level indicator.
On this level indicator one reed contact is mounted for low a level (pre-alarm).
The expansion tank is also provided with two level switches one as a switch for low low
level and one for high level.
The switch for too high a level will block the burner when connected, and the switch for
low low a level will switch off the burner and pumps.
There are boiling out pipes between the heaters and the expansion tank. These boiling out
pipes are only used during the first starting up and after a long period of stand still. They
serve to evacuate vapour and volatile components through the expansion tank and the
drain/collecting tank into the open air.
Immediately hereafter the boiling out valves should be closed and kept closed, as the
ageing process of thermal fluid is accelerated by a higher temperature in the expansion
tank.
The expansion tank is also provided with an emergency quick opening valve with limit
switch. This valve has to be operated only in case of fire by means of a steel pull cable.
This valve must be operated from a safe place.
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IV. General instructions
Thermal fluid should at all times flow through the economisers also in case of port
operation, when the fired heater is only stand-by. This is necessary to prevent corrosion of
sulphur in the economisers.
When thermal fluid has penetrated into the insulation as a result of leakage, it should be
removed at once. This with a view to fire-risk.
It is desirable to have the thermal fluid tested for its quality by the fluid supplier, at least
once a year.
The boiling out valve(s) is (are) only used during the boiling out process of the system.
During operation this (these) shut-off valve(s) should be closed.
The thermal fluid in the expansion tank must not get warm, as otherwise an accelerated
ageing of the fluid will take place.
When the thermal fluid has cooled to the ambient temperature after the first putting into
operation, all the nuts/bolts of the flanges, fittings and such have to be checked.
After about 2500 hours of operation it is advisable to have the plant checked by one of our
service engineers.
Before putting the main engine into operation, one of the thermal fluid pumps should be
running. The thermal fluid should always flow through the economisers. If there is no flow
through the economisers, the temperature of the thermal fluid will rise too high as a result
of the hot exhaust gases and the thermal fluid will start cracking.
When the low level switch is actuated, the pumps and the fired heater will immediately be
switched off. Too low a level might imply a leakage of thermal fluid from the system. It
is imperative to take immediate action in order to eliminate the leakage or to shut off the
leaking device.
When the pumps are switched off, the flow through the economiser will stop. The power
\ of the main engine has to be reduced to such an extent as to cause a temperature drop of the
' exhaust gases to a temperature that is lower than the film temperature of the thermal oil.
Film temperature ca. 320 °C. This temperature depends on the kind of thermal fluid used.
When the high level switch is actuated, the fired heater will be switched off. However the
pumps continue their operation.
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4.1 Flue gas thermostat of the fired heater
Actuation of this thermostat may mean that:

a) The heater is polluted on the flue gas side,
b) The flow of thermal fluid through the boiler has stopped, without functioning of the flow
protection.
4.2 Exhaust gas thermostat of the economiser
Actuation of this thermostat might mean that:

a) The heater is polluted on the exhaust gas side,
b) The flow of thermal fluid through the heater has fallen out,
c) The thermal fluid is leaking and burning,
d) One or more exhaust valves of the engine are leaking.
The resistance on the exhaust gas side is too high
An increased resistance on the exhaust gas side may mean that the economiser is polluted.
4.3 Cleaning of the fired heater
A polluted heater should be cleaned with water to which strong alkaline agents are added.
By removing the heater cover which is fixed to the heater by means of chain keys, the
combustion chamber, the first and the second drought of the flue gases will be accessible
for cleaning purposes. The polluted water can be drained from the bottom of the heater.
When mounting the cover attention should be paid to the sound condition of the gasket
between the cover and the heater, and to the uniform tightening of the cover in order to
prevent leakage of flue gas.
After cleaning, the heater should be brought as soon as possible to the required
temperature, this with a view to the possible presence of sulphurous acid.
4.4 Cleaning of an economiser
A polluted economiser should be cleaned with water to which strong alkaline agents are
added.
The water jet to be directed between the openings of the concentric coils and, if necessary,
clean the pipes with a brush.
The polluted water can be drained from the bottom of the heater.
During cleaning, attention should be paid to prevent water flowing into the turbo charger
through the exhaust gas pipe.
After cleaning, the heater should be brought as soon as possible to the required
temperature, this with a view to the possible presence of sulphurous acid.
For Water washing of the economiser during engine running, see pagel^.
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4.5 Stopping the fired heater
When the fired heater is put out of operation for repairs or cleaning activities, the following
procedures are to be adhered to:
1) Close the shut-off valves before and behind the heater,
2) Open the by-pass valve in order to maintain the circulation through the economiser and
the heat consumers.
In doing so one should prevent that, owing to the too far opened position of the adjusting
valve, the quantity passed will increase to such an extent as to cause thermal failure of the
motor of the thermal fluid pump.
4.6 Stopping the economiser
When, on account of repairs, the economiser has to be stopped, the shut-off valves before
and after the economiser should be closed, and the by-pass valve be opened. In case of
leakage of thermal fluid, the thermal fluid should also be discharged from the economiser
next to the above mentioned procedures.
With pressurised nitrogen the thermal fluid can be pressed out of the heater. This procedure
with nitrogen pressure is only applicable to heaters in horizontal execution.
4.7 Adjustment of the control valve in the by-pass piping of the fired heater
The by-pass pipe has a dual purpose:

1) To admit part of the quantity of thermal fluid in circulation when the heater is in
operation. This occurs when a larger quantity of thermal fluid is flowing through the
economiser than through the fired heater.
2) To maintain the circulation quantity for the economiser, when the fired heater is out of
operation.
The position of the control valve should be such as to realise the nominal flow of thermal
fluid through the fired heater. The indication of the differential pressure switch of the fired
boiler should be 0,4 bar.
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4.8 Adjustment of the economiser
The fired heater and the two economisers are connected in series. The two economisers are
connected parallel
At a nominal flow the pressure difference FIA is for:
Economiser: 0.4 bar
By means of a common control valve or by means of a separate control valve, the before-
mentioned value is to be obtained.
4.8.1 Adjustment of the minimum flow controller
The procedure is as follows:

1) Shut off all heat consumers,
2) The set point is to be adjusted in such a way as to maintain the minimum flow through
the fired heater and the economisers. (see also the description of the minimum flow
equipment)
4.8.2 Adjustment of the heat consumers
The adjustment has a triple purpose:

1) To prevent a short circuit (on the flow side),
2) To maintain a constant thermal fluid supply temperature to the heat consumers,
3) To prevent that the return temperature of the thermal fluid will be lower than 140°C. A
temperature lower than 140°C will bring about sulphurous corrosion in the heater.
The heat consumers, with the exception of the tanks (bunker tanks, lub. oil tanks, and so
on) should be adjusted by means of the control valve in the return line, at a temperature
difference between the supply and return line of 40°C.
The tanks should be adjusted in such a way as to create the possibility to transfer the heat
required and to prevent the common return temperature to the heater dropping below
140°C. The temperature difference between the supply and return temperature is in general
greater than 40°C.
4.8.3 Adjustment of the control valve in the by-pass pipe of the minimum flow controller
In case the minimum flow controller gets out of order, the control valve of the by-pass
should be opened so far as to maintain the minimum flow through the fired heater and the
economiser, with the heater consumers closed.
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V. Operational instructions of the thermal fluid plant
See flow diagram nr. :D11328

Electric diagram nr. : D11343
Boiling out the system

Boiling out implies:
The removal of water and gases from the thermal fluid system.
Boiling out is necessary:
- During the first starting up,
- When the installation has stopped for a longer period (more than 4 weeks).
5.1 Open the necessary valves in the circuit.
5.2 Check the level in the expansion vessel - minimum 50 mm

to maximum 100 mm above the low level switch LA-LL.
5.3 Check the level of the thermal fluid in the bearings of the two pumps. The bearing of the
pump shaft is lubricated with thermal fluid. Check the alignment of the pumps.
5.4 Check the minimum adjusted value of the differential flow switch (FIA).
Setpoint 0,25 bar.
Check the minimum setpoint of the second control of the same differential flow switch.
Setpoint: 0,1 bar (only for starting procedure with a thermal fluid temperature lower than
50°C).
5.5 Adjust the partial load of the temperature control at 100°C.

Adjust the full load of the temperature control about 10°C lower than the partial load.
5.6 Adjust the maximum thermostat TA of the fired heater at 220°C.
5.7 Adjust the flue gas thermostat of the fired heater at 280°C for the time being.
When the fired heater is running at its operational temperature, adjust the flue gas
thermostat at a value which is 50°C higher than the measured flue gas temperature.
5.8 Adjust the pressure switch that effectuate the automatic change-over of the pumps when
one had broken down, at 3,5 bar.
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5.9 Adjust the maximum thermostat (thermal fluid side) of the economiser at 220°C.
5.9.1 Check the function of the electronic temperature controller TIC and its pneumatic cylinder
of each economiser.
5.9.2 Adjust the electronic temperature controller TIC at 185°C.
5.9.3 Check the function of the electric pressure controller PIC and the electric control valve
(min. flow controller).
5.9.4 Adjust the electric pressure controller at 2,4 bar above the static pressure of the system for
the time being. When the plant has reached its operational temperature, adjust the pressure
controller to the correct value.
The procedure is as follows:
a) Shut off all heat consumers,
b) Adjust the set point in such a way as to maintain the minimum
flow through the fired heater and economisers.
Adjust the extra controller of the electric minimum flow control set for the time being at
approx. 50 °C. After the installation has reached its working temperature adjust the extra
controller at its setpoint of 140 °C. This to prevent dewpoint corrosion in the heaters.
5.9.5 Check the fuel circuit of the burner.
5.9.6 Check the capability of the heat consumers to process the supplied heat.
5.9.7 Switch on the main switch of the fired heater.
5.9.7.1 Switch on the switches of the thermal fluid pumps.
5.9.7.2 Switch on the burner switch.
When necessary release the safety circuit and the automatic device of the burner.
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The burner starts automatically and will stay at its low load position as long as the return
temperature of the thermal fluid is lower than the set point of the inlet minimum
thermostat. After that the minimum flow through the heater has been obtained and the
burner will switch over to its full load position.
The burner has the following sequences of operation: purging the combustion chamber -
ignition - operation.
Maintain the temperature of the thermal fluid at 100°C for half an hour. Boil out the system
with the boiling out valves of the fired heater and economiser and expel the air through the
expansion tank and the drain/collecting tank.
Also de-aerate with the air relays valves if any.
When no pressure fluctuations are to be seen at the pressure gauges of the pumps and the
flow safety device, the temperature is to be raised by approx. 10°C. The adjusted value of
the temperature control is 110°C.
Turn to this temperature for about 15 minutes.
When there are no more pressure fluctuations to be seen, raise again the temperature by
10°C and run the plant at the new adjusted temperature for about 15 minutes.
Repeat these procedures until the desired temperature of 185°C has been reached. Keep the
system at 185°C until no more pressure fluctuations are to be seen at the pressure gauges
of the pumps and flow safety devices.
These temperature gradations and the indicated times are reference values.
Boiling out the system should be done slowly and carefully.

If there is water in the system, and the temperature gradations taken are too large,
vaporisation may suddenly occur.
The vapour pressure pushes the thermal fluid into the expansion tank. When the expansion
tank cannot receive this thermal oil, the fluid leaves the expansion tank through the safety
valve into the drain/ collecting tank, the so-called boiling out.
It is necessary to discharge this escaping hot thermal fluid to a safe place, for instance by
collecting this fluid in a drain tank located at a lower level.
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In order to accelerate the boiling out process the heaters and the heat consumers should be
boiled out one by one.
Example:
One starts with the fired heater and allows the thermal fluid to circulate through the
minimum flow controller back to the fired heater. The economisers and heat consumers are
shut off (keep only the delivery valve of these devices closed, always keep the valve in the
return pipe open).
Once this circuit has been boiled out, then have one economiser join the circulation. When
this circuit has been boiled out, shut off this economiser and boil out the second one then
boil out for instance the circuit of the fired heater and a heat consumer.
Once this circuit has been boiled out, than for instance the circuit of the fired heater, bunker
tank, minimum flow controller.
Repeat this procedure with all the other heat consumers until the entire plant has been
boiled out.
During boiling out the water present in the expansion tank is to be drained.
When possible the filter has to be cleaned when the thermal fluid has cooled down. A filthy
filter can i.a. be ascertained by the reduced differential head and by the reduction of the
liquid quantity through the heater (flow meter FIA).
If necessary regularly open the by-pass valves of the fired heater, economiser, minimum
flow controller and heat consumers for a moment during boiling out of the system in order
to discharge the present water.
Once the system has been boiled out the boiling out valves should be closed and blocked.
When the system has reached the operational temperature the following components are
to be adjusted: See chapter "General".
- Adjustment of the by-pass valve of the fired heater.
- Adjustment of the economiser.
- Adjustment of the minimum flow controller.
- Adjustment of the heat consumers.
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Set points of the control devices
Temperature control device of the fired heater:

Partial load 190°C
Full load 185°C
Electronic temperature controller of the economiser
Max. load 190°C
Set points of the safety devices
Maximum thermostat(s) of the fired heater 220°C

Maximum thermostat of the fired heater (pre-alarm) 210°C
Maximum flue gas thermostat of the fired heater: 325°C
Flow safety device of the fired heater 0,25 bar
Pressure switch for the automatic stand-by of the
thermal fluid pumps 3,5 bar
Maximum thermostat(s) of the economiser
(on the side of the thermal oil) 220°C
Flow safety device of the economiser 0,25 bar
Maximum exhaust gas thermostat in the exhaust gases
of the engine after the heater 325°C
Minimum flow controller of the system 2,4 bar
Maximum fuel fluid thermostat for M.D.O. °C
Minimum fuel fluid thermostat for M.D.O. °C
Inlet minimum thermostat (cold start thermostat) 50°C
Flow safety device of the fired heater for inlet
minimum thermostat (cold start thermostat) 0,1 bar
Maximum thermostat expansion tank 50°C
page 22
AALBORG
I N D U S T R I E S
VI. Maintenance of the thermal fluid plant
Daily:
Check all the flanges and gaskets for tightness.

The flue gases of the fired heater should be colourless.
If this is not the case, check the burner and the combustion.
Check the level in the expansion tank. Mark the level at the operational temperature on the
gauge glass and maintain this as a reference level.
Check the correct operation of the photocell.
Switch on the burner and cover the photocell.
The burner should show a malfunction within 10 seconds.
Check the correct operation of the fuel filter.
We refer to the enclosed maintenance instructions for the maintenance of the burner and
pump.
Weekly:
Check the correct operation of the maximum thermostat(s) and the flue gas thermostat of
the fired heater.
Check the correct operation of the flow safety device FIA of the fired heater, the pressure
switch PC for the automatic stand-by, the switching of the pumps and the flow safety
device FA of the
economiser by squeezing the delivery valve between the pump and the fired heater.
Drain the water (if any) from the expansion tank.
Check the correct operation of the maximum thermostat(s) (on the liquid side) and of the
exhaust gas thermostat of the economiser.
Check the soot number and the CO2 percentage of the combustion of the fired heater.
Check whether the exhaust gases of the fired boiler are free from
CO.
Check the correct operation of the temperature and pressure controls in the thermal fluid
system.
Check the correct operation of the pneumatic cylinder and its combined exhaust gas valves
(Hand operation on the electronic controller).
Clean the ignition electrodes and the nozzles.
Check the distance of the ignition electrodes.
For the burner, pump and other equipment we refer to the maintenance instructions
enclosed.
\PDC_AALBORG\Adm_AJgemeen\.SIaBiiaJs\200 L\bar_ LOO L9_! (X)20a 00 doc page 23

AALBORG
INDUSTRIES
Every six months:
The time mentioned is a reference value. Maintenance is dependent on i.a. the operational
conditions of the thermal fluid plant and the adjustment of the main auxiliary engine with
reference to the exhaust gases.
Check the interior of the fired heater for seat formation and for the sound condition of the
insulation in front and at the rear of the heater.
For cleaning procedure see chapter "General".
Check the interior of the economiser.
For cleaning procedure see chapter "General".
Clean the filters in the thermal fluid system.
Have the quality of the thermal fluid checked by the fluid supplier.
\PDC_AALBORG\Aitai_ \ljonOT\Manuali\2001\baO0019_10020a 00 doc page 24

AALBORG
I N D U S T R I E S
VII. Water washing of the economiser
The economiser is provided with a central Water washing nozzle, mounted in the bottom
connection of the heater.
To obtain good cleaning results, the wash water should satisfy the following conditions:
The water pressure must be between 2 and 4 bar.

The temperature of the water should be between 50°C and 70°C.
The water should be Alkaline with a pH value of about 11.
When it is not possible to obtain the above mentioned quality of wash water you may
use fresh water instead.
The water connection VT. G must be connected with a quick closing valve.
The main engine must run at normal speed.
The temperature of the thermal fluid must be minimal 140°C.
In this situation you have to open the quick closing valve for about 5 seconds.
This action must be repeated for several times, with intervals of circa 3 minutes, until the
economiser is clean.
As a reference temperature see the temperature of the exhaust gasses after the economiser.
(Note: the cleaning time must be established experimental during sailing time.)
This repetition depends on the pollution of the heater.
The existing temperature in the economiser will change the waterhaze into steam and this
steam will remove the sootblacking.
At a water pressure of ca. 3 bar the capacity of the wash water is ca. 6000 litres/h.
The degree of pollution is determined by the type of fuel and the quality of the combustion
in the main engine.
\\POC_AALBORG\Adm_AJgenj«n\MantiaIs\200l\barJOOI9_l<x>20a00 doc page 25

9.2 Regulating system - RL8 to RL11, RMS7 to RMS11
Operation Attention!
Operational diagram 1 The shut off devices (solenoid valves (6) and (7)) are
During burner shutdown and the prepurge period, the shut electrically connected in series. The voltage of the
off devices (6), (3) and (7) are closed and shut off device solenoid coils is therefore 115V with 230 V mains voltage I
(4) is open.
On the shut off device (solenoid valve) (7), the directional
The ring main pressure during burner shutdown or the arrow O on the solenoid valve must point towards the
pump pressure during prepurge is present at shut off nozzle. This means that the solenoid valve in the nozzle
devices (6) or (7). return is fitted against the flow direction -^ during burner
operation.
Operational diagram 2
After the prepurge period has elapsed on RL burners (the The shut off device in the nozzle head (nozzle shut off
servomotor is in ignition position), the shut off devices (6), valve) acts as a safety shut off device in the flow and the
(3) and (7) open and shut off device (4) closes. The fuel is return.
then released for combustion.
Together with the safety shut off devices (6) and (7) and
On RMS burners, shut off devices (6) and (7) only open for the safety shut off device in the nozzle head, the
oil circulation. After the oil circulation period has elapsed requirement for two shut off devices in both the supply and
(max. 45 s), shut off device (3) opens and shut off device 4 return is fulfilled.
closes and releases the fuel oil for combustion.
For legend and notes on the wiring and installation
The integral pressure switch (17) checks the pressure in direction of the solenoid valves see chapter 8.
the return. If the pressure increase is too high, the burner
shuts down. In shutting down, Shut off devices (6), (3) and
(7) close and shut off device (4) opens simultaneously.
RL and RMS burner nozzle head
Supply control circuit Supply I Closing needle Nozzle

plate
Swirl
Return control circuit Return Regulator nozzle type W plate
Operational diagram 1 (RL) Operational diagram 2 (RL)
12
18
9.3 Oil meters and oil regulators
Installation of oil meter Setting example: key on number 00
When meters are fitted in the supply and return, the system
must be protected from excess pressure by a pressure Primary setting
relief valve installed in the return (see pipeline diagrams in shaft identification No.
our worksheets). oil regulating cam
A blocked return meter can cause the following:
- Bursting of oil hoses

- Pump damage (glands on pump leaking).
- Changes to the oil flow without changes in combustion
air can occur during burner operation if the meter is
blocked. The return pressure which results renders the
oil regulator ineffective. Renewed burner start may lead
to an explosion.
Isolating elements in the return should be protected from

unintended closing (e.g. ball valves by mechanical
connection). Non-return valves must not be installed. With
residual oils all pipework and fittings must be adequately
heated.
Oil regulator - RL5 to RL11; RMS7 to RMS11

The oil regulator is driven by the servomotor. The variable
oil throughput is controlled by a V-slot grove.
Each regulator has two regulating groves, which can be Selected shaft identification No. visible from above
changed. Each regulator has two identification numbers
marked on the shaft, e.g. 00-0 (see illustration).
The slot depths are assigned by both identification Cam identification

numbers. The following illustration shows the assignment e.g. cam 6
to the oil throughput.
Primary setting
Oil regulator Use regulating cam 1
identification number oil throughput kg/h
00 0- 50
0 51 - 70
1 71 -120 /
Shaft key
•2__ 121 - 280
3 281 -380
4 381 -420
5 421 -700
In order to regulate the oil quantity via the correct

metering slot, the key has to be set to the appropriate
identification number.
If radiated heat affects the nozzle head, the oil regulator

can be limited in its regulating movement (e.g. to position
100, see servomotor). This results in a greater oil spill back Full load setting
which cools the sealing ring and pressure spring in the
nozzle head.
19
off devices (6), (3) and (7) are closed and shut off device solenoid coils is therefore 115V with 230 V mains voltage
(4) is open.
The ring main pressure during burner shutdown or the arrow t> on the solenoid valve must point towards the
devices (6) or (7). return is fitted against the flow direction -^l during burner
operation.
servomotor is in ignition position), the shut off devices (6)T valve) acts as a safety shut off device in the flow and the
Supply control circuit Supply Closing needle Nozzle

plate
Swirl
Return control circuit Regulator nozzle type W plate
I I
18
- Bursting of oil hoses

- Pump damage (glands on pump leaking).
- Changes to the oil flow without changes in combustion
to an explosion.

heated.


Primary setting
00 0 - 50
0 51 - 70
r
3
_ .
- -
71 -120 s
121 - 280/
281 -380
Shaft key
4 381 -420
5 421 -700


nozzle head.
19
Installation and operating instructions 83040202-1/99
Weishaupt oil burners L, RL, M/MS. RM/RMS,

Sizes 5 to 11
weishaupt-
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Contents
1. General instructions 4
2. Burner installation 5
3. Oil supply 6
4. Installation instructions for metallic oil hoses 8
5. Oil preheating system 10

Conformity certification 5.1 Preheaters 10
5.2 Heated components 10
We hereby confirm that Weishaupt oil burners conform to
the basic requirements of the following EU guidelines: 6. Oil pumps 12
- 98/37/EC Machinery Directive 7. Attaching the fan 14

- 89/336/EEC Electromagnetic Compatibility
- 73/23/EEC Low Voltage Directive 8. Burner fuel systems 15
Therefore the burner carries the CE Label. 9. Regulating systems 17

9.1 Regulating system -RL5 and RL7 17 17
Extensive quality assurance is guaranteed by a certified 9.2 Regulating system - RL8 to RL1 1 ,
Quality Management System to DIN ISO 9001. RMS7toRMS11 18
9.3 Oil meters and oil regulators 19
Max Weishaupt GmbH
Burner and Heating Systems 1 0. Nozzle recirculation on MS burners 20
D-88475 Schwendi
11. Capacity graphs 23
11.1 Capacity graphs
for burner types Land RL 23
1 1 .2 Capacity graphs
for burners type M/MS and RM/RMS 29
1 2. Nozzle selection 33
1 2.1 Two and three stage burners 33
1 2.2 Sliding two stage and modulating burners 35
1 3. Adjustment of the combustion head 37
1 4. Ignition electrode setting 39
1 5. Air regulation, two and three stage burners 40

15.1 Description of functions for
servomotor type 1 055 42
1 5.2 Setting the cam's limit and auxiliary
switches on servomotor type 1 055 43
1 6.Oil/air compound regulation, sliding two stage

and modulating burners 44
1 6.1 Setting the cam's limit and auxiliary
switches on servomotor type SQM 45
17. Commissioning 46
17.1 Checks prior to first commissioning 46
17.2 Setting 46
1 S.Sequence of operations 48
18.1 Prerequisites for burner start 48
1 8.2 Symbols on the lockout indicator 49
1 8.3 Basic wiring diagram for
LAL2/LOK16... burner controllers 50
1 8.4 Switching times 52
1 8.5 Technical data 52
19. Fault conditions and procedures 53

1. General instructions
Safety Installation
To ensure safe burner operation, the burner has to be The installation of oil fired plant must be carried out in
installed and commissioned by qualified personnel accordance with extensive guidelines and regulations. It is
and all guidelines in these operating instructions have the duty of the installer to familiarise her/himself with all
to be followed. regulations. Installation, commissioning and maintenance
must be carried out with care. Fuel oils used must comply
In particular, attention must be paid to relevant with DIN 51 603.
installation and safety requirements (e.g. DIN, VDE).
Electrical wiring diagram
Flame monitoring devices, limit controls, correcting A detailed electrical wiring diagram is included in every
elements and all other safety devices may only be burner delivery.
commissioned by the manufacturer or their authorised
agent. Maintenance and service
In accordance with DIN 4755, the whole installation
Failure to comply can lead to serious injury or death including the burner should be inspected once a year by a
and can cause considerable damage to the plant. representative of the manufacturer or a competent and
qualified person. The combustion figures should be
Qualified personnel checked after every service and each time a fault has been
Qualified personnel according to this operating rectified.
manual are persons who are familiar with the
installation, mounting, setting and commissioning of Ambient requirements
the product and who have the necessary qualifications The burners material, construction and type of protection is
such as:- designed for use indoors. The permissible ambient
temperature is -15°C to +40°C.
- Persons who are trained to operate electrical
circuits and units to the safety standards given and Electrical installation
are qualified to earth and mark these. When installing the electrical connection cables ensure
that these are long enough to allow the burner and boiler
Operating instructions door to be hinged open.
The operating instructions included with each burner must
be displayed clearly in the boiler room. In conjunction with Control circuits, which are taken from one of the supply
this we refer to DIN 4755, Point 5. The address of the phases, must only be connected with an earthed neutral
nearest service centre must be entered on the reverse side conductor.
of the operating instructions.
On an unearthed mains supply, the control voltage must be
Instruction of personnel supplied via an isolating transformer.
Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with The pole of the transformer that is to be used as a
regard to the operation of the burner. With frequently neutral conductor must be earthed.
occurring burner faults, the nearest service centre must be
notified. The control circuit phase and neutral conductors must
be connected correctly.
Ensure the correct fuse ratings are not exceeded. Earthing

and neutral conductors must conform to local regulations.
2. Burner installation
The drawing is an example of refractory for a heating Mounting the burner on the heat exchanger
• appliance without cooled front. The refractory must not
L extend beyond the front edge of the combustion head Example of installation on a
(dimension I,). The refractory may, however, take a conical heating appliance with refractory
shape from the combustion head front edge (> 60°).
Refractory may not be required on boilers with water Sizes Size
cooled fronts, depending on the boiler manufacturers 5-10 11
instructions.
The boiler front plate must be prepared in accordance with

the above dimensions. The burner hinged flange can be
used as a template for the drilling. The threads of the bolts
and tappings must be coated with graphite prior to fitting.
Example for burners with head extension see page 13.
The gap between combustion head and refractory must

be filled with flexible insulating material. Do not make
solid.
Burner Combustion Dimensions in mm \! Combustion head

size head type di d2 d3 d4 ds open closed
5 M5/1a 180 M10 210 185 220 145 154

5 M5/2a 160 M10 210 185 190 130 144
7 M6/1a 200 M10 235 210 240 216 228

7 M7/1a 220 M10 235 210 260 226 238
8 M7/1a 220 M10 235 210 260 226 238

8 M8/1a 240 M10 235 210 280 236 248
8/2 M9/1a 240 M12 298 275 280 226 251
8/2 U2/1 220 M12 298 275 260 229 239
8/2 G7/2a 265 M12 298 275 300 264 270
9 M9/1a 240 M12 330 278 280 225 240

10 M10/2 265 M12 330 278 300 268
11 M11/1 325 M10 400 340 365 362
Hinged flange Limit switch

The burner can be hinged to the left or right depending on The limit switch is arranged so that the electrical circuit is
the position of the hinge pin and by releasing the locking closed when the burner is hinged closed. The circuit is
nut. broken by the release of the tripping pin in the limit switch
as the burner is hinged open.
Locking nut
Oil hose connection according to burner type
Oil hoses
DN Length mm Connection Connection
thread thread
Supply Return pump side installation side
L5Z 13 1000 1000 R1/2" R1/2"
L5T 13 1000 1000 R1/2" R1/2"
L7Z 13 1000 1000 R1/2" R1/2"
L8Z 13 1000 1000 R1/2" R 1 /2"
L8Z/2 13 1000 1000 R1/2" R1/2"
L9Z 13 1000 1000 R1/2" R1/2"
L7T 13 1000 1000 R1/2" R1/2"

L8T 13 1000 1000 R1/2" R1/2"
L8T/2 13 1000 1000 R1/2" R1/2"
L9T 13 1000 1000 R1/2" R1/2"
L10T 13 1000 1000 M 30x1.5 R1/2"
RL5 13 1000 1000 R1/2" R 1 /2"

RL7 20 1000 1000 M 30x1.5 R1"
RL8 20 1000 1000 M 30x1.5 R1"
RL8/2 20 1000 1000 M 30x1. 5 R1"
RL9 20 1000 1000 M 30x1.5 R1"
RL10 20 1000 1000 M 30x1.5 R1"
RL11 25 1300 1300 M 38x1.5 R1"
M5Z 13 1000 700 R1/2" R1/2"

MS7Z 20 1300 1000 M 30x1.5 R1"
MS8Z 20 1300 1000 M 30x1.5 R1"
MS8Z/2 20 1300 1000 M 30x1. 5 R1"
MS9Z 20 1300 1000 M 30x1.5 R1"
RMS7 20 1300 1000 M 30x1. 5 R1"

RMS8 20 1300 1000 M30x1.5 R1"
RMS8/2 20 1300 1000 M 30x1.5 R1"
RMS9 20 1300 1000 M 30x1.5 R1"
RMS10 20 1300 1000 M 30x1.5 R1"
RMS11 25 1500 1300 M 30x1.5 R1"
4. Installation instructions for metallic oil hoses (residual oil S)
General Example
The oil and pressure hoses used are of corrugated high
grade steel with a high grade woven wire sleeve cover.
The oil hoses and pressure hoses are well suited for
residual oil operation if the following application rules are
observed. Resistance against the chemical effects and
temperature of the fuel oil is designed for long term
service.
The new TRD 411, DIN 4787 and DIN 4755 standards
specify metallic hoses for residual oil installations.
Oil and pressure hoses must be protected from external

mechanical damage. When installing care must be taken
that the hose is not twisted. It must not receive torsion Use second spanner for counter holding
strain either during installation or during later movement. It
is important that the two hose ends and the movement
lie at one level.
In order to guarantee torsion free installation, the hose

should first be only loosely fixed at one end, then moved
through the required hose movement 2 to 3 times so that
the hose can a\\gn without distortion, and only then be
tightened in position.
It is important to use a second spanner to counter hold

when tightening.
Care should be taken that the hoses do not come into

contact with each other or other equipment (burner, oil
lines or boiler) during operation.
Connect hose without twisting
Adequate curve radii and minimum hose lengths must be
adhered to during installation. In addition the hose must in
most cases be supported when installed horizontally.
The hose connection can be installed for either burner

hinge direction as required.
Specifications and technical data For oil EL, oil hoses to DIN EN ISO 6806 are supplied.
Oil hoses in oil supply installations (flow and return) Technical data:
On installations using residual oil S the hoses must be Nominal pressure PN = 10bar
suitable for an operation pressure of 10 bar and an Test pressure _PP=15bar
operating temperature (medium) of 160°C. Operating temperature TT = 70° C
When allowing for the temperature factor for high grade Pressure hoses (between pump and nozzle)
steel the following applies for these hoses:
For this application the pressure hose should be suitable
Nominal pressure. _PN = 16 bar for an operating pressure of 30 bar and an operating
Test pressure _PP = 21 bar temperature of 160°C.
Operating pressure _PT=10bar
Operating temperature TT = 160°C When allowing for the temperature factor the following
applies:
When installing the oil hoses in the flow and return
(between pump and rigid pipe installation) the product Nominal pressure PN = 64 bar
related technical drawings should be observed. Test pressure _PP = 82 bar
Operating pressure _PT = 30bar
Operating temperature TT=160°C
The minimum curve radius of the hose depends on the
nominal clearance on the application, the material and the
type of manufacture.
The hose application on our products has been agreed

with the manufacturer, using original parts.
For free usage and installation, the following minimum radii \

must be adhered to as given in the installation instructions. 1
Minimum radii
i i 2\
DN r = Minimum
curve radius in mm
6 70
8 100
10 110 Hoses should be selected of sufficient length. An
additional length must be allowed for on the hose ends.
110 This length must remain straight, i.e. the curve radius must
12
210 not commence until after this straight section.
16
20 240
250 Additional length
25
DN Z = Additional length in mm
When installation has been carried out the minimum radii
must be checked in the most adverse position. If 6 80
necessary a fixed stop must be fitted on site to limit the 8 85
movement. 10 90
12 100
16 125
20 130
25 135
The minimum curve radius of the hose depends on the
nominal clearance on the application, the material and the
type of manufacture.
The hose application on our products has been agreed

with the manufacturer, using original parts.
For free usage and installation, the following minimum radii

must be adhered to as given in the installation instructions.
Minimum radii
DN r = Minimum
curve radius in mm
6 70
8 100
10 110 Hoses should be selected of sufficient length. An
additional length must be allowed for on the hose ends.
12 110 This length must remain straight, i.e. the curve radius must
16 210 not commence until after this straight section.
20 240
25 250 Additional length
DN Z = Additional length in mm
When installation has been carried out the minimum radii
must be checked in the most adverse position. If 6 80
necessary a fixed stop must be fitted on site to limit the 8 85
movement. 10 90
12 100
16 125
20 130
25 135
5.1 Preheaters
The oil can be heated electrically or with a heating medium, The ball valve fitted between the media and electrical
or by a combination of both electrical and media preheater. preheater (see technical description of electrical and
Hot water, low pressure steam, high pressure steam or media preheaters) is closed when the heating medium is
thermal fluid can be used as heating media. available. The valve must only be open during start up on a
cold plant and remain open until the final working
On installations with a media preheater and without temperature or pressure of the installation is reached.
electrical preheater, the following minimum pressures and During this period only the electric preheater heats the oil
temperatures are required for heating the residual oil S: and the throughput of the burner must be adapted to the
preheat capacity of the electrical preheater during the
High pressure steam over 7.5 bar starting time of the cold plant.
Hot water from 180 - 200° C
Thermal fluid from 200 - 300° C On downward firing burners, media preheaters are rotated
through 90°C. The oil preheaters MV9 and MV10 can only
These temperatures and pressures must always be be fitted with the media outlet on top for liquid media or
available so that the oil can be heated to the temperature below when using steam. If the burner is ordered for
and viscosity required for atomisation. downward firing, this is already allowed for. If the burner to
be changed to downward firing at a later stage, then extra
brackets are required to fix the media preheater.
Cj>.2 Heated components

/ All burners have nozzle head heating controlled by an NTC heating elements in the pump body as standard. Heating
/ sensor. The ROB regulating control can be set to 65° or allows the oil to be kept in a pumpable condition and the
[ 130°C and is pre-set to 65°C for delivery. The heating pump to be protected from damage. The heating
I elements in the burner are usually controlled by the burner cartridges in the nozzle head and pump are active as long
\^pperating switch. as the burner operating switch is on.
Pump heating
When oil viscosities of 152 mmVs at 50°C are exceeded,
we recommend heating the pump. Pumps are always fitted
with heating facilities. On type E pumps the gearing cover
has a pocket for the heating element, and if required, the
element can thus be fitted. TA pumps are fitted with
Burner heating elements
Heat rating in W
Burner Burner Heating Nozzle Solenoid valve Valve Oil Pressure
type pump type head flow/return block regulator regulator
M5Z E4 80 100 20 20
MS7Z E6 80 100 20 20 - 20
MS8Z E7 80 100 20 20 - 20
MS8Z/2 E7/TA2 80/100 100 20 20 - 20
MS9Z E7/TA2 80/100 100 20 20 - 20
**~~~*^.
RMS7J TA2 100 100 20 20 20 20
"RMSB TA3 100 100 20 20 20 20
RMS9 TA3 100 100 20 20 20 20
RMS10 TA3 100 100 20 20 20 20
RMS11 TA4 100 100 20 20 20 20
10
(4) is open.
The ring main pressure during burner shutdown or the arrow D> on the solenoid valve must point towards the
operation.
Supply control circuit Supplyl Closing needle
Return control circuit Regulator nozzle type W
18
... •'*" -
Bursting of oil hoses

Pump damage (glands on pump leaking).
Changes to the oil flow without changes in combustion
to an explosion.

heated.


Primary setting
00 - 50
0 51 - 70
1 71 - 120
2 121 -280 Shaft key
281 -380
4 381 -420
5 421 -700


nozzle head.
19
Installation and operating instructions
83040202-1/99
Weishaupt oil burners L, RL, M/MS. RM/RMS,

Sizes 5 to 11
weishaupt
2. Burner installation
The drawing is an example of refractory for a heating Mounting the burner on the heat exchanger
appliance without cooled front. The refractory must not
extend beyond the front edge of the combustion head Example of installation on a
(dimension I,). The refractory may, however, take a conical heating appliance with refractory
shape from the combustion head front edge (> 60°).
Refractory may not be required on boilers with water Sizes
cooled fronts, depending on the boiler manufacturers
instructions.
The boiler front plate must be prepared in accordance with

the above dimensions. The burner hinged flange can be
used as a template for the drilling. The threads of the bolts
and tappings must be coated with graphite prior to fitting.
Example for burners with head extension see page 13.
The gap between combustion head and refractory must

be filled with flexible insulating material. Do not make
solid.
Burner Combustion Dimensions in mm I, Combustion head

size head type di d2 da d4 ds open closed
5 M5/1a 180 M10 210 185 220 145 154

5 M5/2a 160 M10 210 185 190 130 144
7 M6/1a 200 M10 235 210 240 216 228

7 M7/1a 220 M10 235 210 260 226 238
8 M7/1a 220 M10 235 210 260 226 238

8 M8/1a 240 M10 235 210 280 236 248
8/2 M9/1a 240 M12 298 275 280 226 251
8/2 U2/1 220 M12 298 275 260 229 239
8/2 G7/2a 265 M12 298 275 300 264 270
9 M9/1a 240 M12 330 278 280 225 240

10 M10/2 265 M12 330 278 300 268
11 M11/1 325 M10 400 340 365 362
Hinged flange Limit switch

The burner can be hinged to the left or right depending on The limit switch is arranged so that the electrical circuit is
the position of the hinge pin and by releasing the locking closed when the burner is hinged closed. The circuit is
nut. broken by the release of the tripping pin in the limit switch
as the burner is hinged open.
Locking nut Hinge pin

Nozzle head heating M5Z to MS9Z Nozzle head heating(RMSfy)o RMS1;
NIC sensor
Heating cartridge Heating cartridge
Valve block heating M5Z to MS9Z Valve block heatin^RMS7}to RMS11
Heating
cartridge
Heating cartridge
Pump heating M5Z to MS9Z Pump heating foMSTFto RMS11 \(
Heating
cartridge
ctt
Heating
cartridge
Solenoid valve flow and return M5Z to MS9Z,(RMS7} to ""^\

RMS11 O/7 regulator(RMS7}to RMS11
Heating cartridge
Heating cartridge
-, r ,. >, t ; V t •
г V'-O. /'Г "'?
11
6. Oil pumps
The pumps are supplied suitable for connection in a two The pump filter will require cleaning from time to time,
pipe oil system. depending on the degree of fouling. With a highjjegree of
fouling, the vacuum on the suction side increases. To
Pumps are supplied with pressure regulating and shut off remove the filter for cleaning, extract the eight screws (12)
valves. The pressure regulating valves keep the pressure on the pump cover.
constant.
After replacing the filter ensure that the pump cover is
Adjustment tightly sealed.
• The oil line on the suction side must be primed and the
pump vented prior to commissioning, otherwise the Single pipe operation
pump will be damaged due to running dry. In some instances when operating with oil EL, J and ТА
pumps can be used with one pipe systems.
• Insert gauge to check the vacuum or supply or ring
main pressure on the suction side of the pump. The following should be noted:
• A pressure gauge must be connected into tapping (5) As there is no suction lift by the pump in a single pipe
to measure the pump pressure. system, the oil supply must have a guaranteed positive
head at the pump inlet.
• To adjust the oil pressure, remove cap nut (4) and set
the required pressure. The bypass plug in the pump should be removed and the
,i Clockwise rotation = pressure increase pump return connection plugged.
Anticlockwise rotation = pressure decrease
The supply line should always be vented when
• The suction resistance should not exceed 0.4 bar. commissioning.
Max. supply pressure on pump type J . 2.0 bar As it is not possible to vent via the pump return on single
on pumps types E and ТА 5.0 bar pipe installations, the supply line must in this instance be
(measured at the pump). fully vented when commissioning.
Maximum oil supply temperature Pump coupling

on pumps type E and ТА 90°C A flexible coupling is fitted between fan rotor and pump.
Filter for J and E pumps When adjusting the intermediate coupling ensure that
A filter is incorporated in the pump to protect the pump there is no axial tension on the pump drive shaft.
gears.
The coupling element on the pump should have an axial
There are two different types of filters. The filter for E movement of 1.5 mm.
pumps has a large mesh.
12
Pump coupling Pump J6 + J7
8 10 11
1 6 7 4 2 5 3 12
Pump E4, E6, E7 PumptiA2\TA3, TA4
;
'• '?» •" -^С<Л
;ч
6 7 4 5 2 2a 3 12 1 7 4 6 2 5 2a 3 ^ !> '''
Legend
1 Suction connection 7 Locking screw
2 Return connection 8 Intermediate coupling piece
2a Spill back connection 9 Axial movement 1.5 mm
3 Nozzle supply line 10 Socket head screw
4 Pressure adjusting screw 11 Pump coupling
5 Pressure gauge connection 12 Cover screw
6 Vacuum gauge connection
13
'""*'*_;*::
7. Attaching the fan
Attaching the fan Removing the fan
Burner size 5 Burners sizes 5 and 7 - 8
The fan fits onto a cylindrical shaft. A key on the shaft The extractor part No. 111 111 0001 /2 can be applied to
transmits the power. The fan is secured to the motor shaft the two M6 threaded holes and the fan removed.
by an Мб х 25 screw with washer.
Burners sizes 9-11
Burner sizes 7-8 and 9-11 To remove the fan, the extractor part No. 121 362 0013/2
On burners size 7 to 8 the fan fits onto the cylindrical shaft. is applied to the two M10 threaded screws.
A key on the shaft transmits the power. The fan is secured
to the motor shaft by an M8 countersunk screw and
washer.
On burners size 9 to 11 the fan fits onto a cone shaft. The

self locking cone transmits the power to the motor fan. The
coupling piece is connected to the fan cylindrical pins. For
security, the coupling piece is connected to the motor
shaft by an M10 x 40 screw with left hand thread.
Burner size 5 Burner sizes 7 - 8 Burner sizes 9-11
14
8. Burner fuel systems
L5Z L7ZtoL9Z
L5T L7TtoL10T
[ЖЗ—I
RL5toRL7 RL8toRL11
10 14
115V 115V
CK EJ
115V 115V 115V
P 1
h-J
I
^^
5 17 15 7 17 15 4
• Burner types RL5 to RL7 Burner types RL8 to RL11

The two solenoid valves (3) are electrically connected in Solenoid valve (6) in the supply and (7) in the return are
series. Solenoid valves (3) and (5) are fitted in the return electrically connected in series. Solenoid valve (7) is
line against the flow direction. fitted in the return line against the flow direction.
15
M5Z MS7Z to MS9Z
5 16 11
:
ЧН~
17
Burner types M5Z, MS7Z to MS9Z, RMS 7 to

RMS11
14 6 16 18 3 13 12 Solenoid valve (5) / (6) in the supply and (5) / (7) in the
return are electrically connected in series. Solenoid
valve (5) / (7) is fitted in the return line against the flow
direction.
17 15
1 Pump without integral solenoid valve * Rp = Whitworth pipe thread (internal) DIN 2999
2 Solenoid valve type 121C2323 9 W coil
(normally closed) Rp 1 /8* The given voltages refer to 230 V. For 115V control
3 Solenoid valve type 121K2421 19 W coil voltage, 115V and 55 V devices are used.
(normally closed) Rp 1 /8*
4 Solenoid valve type 122K9321 19Wcoil
(normally open) Rp 1/8*
5 Solenoid valve type 1 21K6220 20 W coil
(normally closed) Rp 1 /4*
6 Solenoid valve type 321H2322 20 W coil
(normally closed) Rp 3/8*
7 Solenoid valve type 121G2320 20 W coil
(normally closed) Rp 3/8*
8 Two stage EL nozzle head
(without integral shut off device)
9 Three stage EL nozzle head
(without integral shut off device)
10 Nozzle head R (without integral shut off device)
11 Two stage nozzle head M (with integral shut off device)
12 Nozzle head R (with integral shut off device) in flow and
return
13 Restricting orifice
14 Filter
15 Oil regulator
16 Oil preheater
17 Pressure switch 0 1 0 bar (set to 5 bar for EL
Return set to 7 bar for MS)
18 Thermostat
16
9. Regulating systems
9.1 Regulating system - RL5 and RL7
The oil system is not fitted with a nozzle shut off valve. Operational diagram 2
The solenoid valves control the oil shut off function. Full load is obtained by reducing the metering slot in the oil
regulator. This is done rotation of the oil regulator
Operation (clockwise as viewed from the shaft). This throttles the flow
During prepurge solenoid valves (3) and (5) are closed. Oil of oil in the return and the oil quantity increases at the
is supplied under pressure by the pump to the closed nozzle outlet. On shutdown the solenoid valves close and
solenoid valve in the supply (5). Solenoid valves (3) and (5) shut off the flow of oil to the nozzle and from the oil supply.
are electrically connected in series.
Operational diagram 1 direction of the solenoid valves see Chapter 8
After the prepurge period has elapsed, solenoid valves (3)
and (5) open. Oil flows to the nozzle via the nozzle supply
and to the oil regulator (15) via the return. The oil regulator
is in the open position (ignition load position). Due to the
lower return flow pressure, less oil leaves the nozzle. The
greater proportion of oil flows via the nozzle return to the oil
regulator or the pump return line. The return flow pressure
is approx. 8 bar at partial load position. The integral oil
pressure switch (17) shuts down the plant if the pressure
is too high.
RL5 and RL7 nozzle head
Nozzle flow Regulating nozzle
P TT
^^Цм£ит»||С
Hi
Nozzle return
Operational diagram 1 Operational diagram 2

(^, 9.2 Regulating system - RL8 to RL11 i'R*M$}
'"-^ ^ to RMS11
(4) is open.
The ring main pressure during burner shutdown or the arrow [> on the solenoid valve must point towards the
operation.
Supply control circuit Supply! Closing needle
Return control circuit Regulator nozzle type W plate
12
* t
18
10. Nozzle recirculation on MS burners
Nozzle recirculation on two stage MS burners When the burner shuts down solenoid valve (3) is de-
After the minimum temperature has been reached by the energised and opens. The atomising pressure reduces
thermal switch contact in the ROB regulating control and immediately and the nozzle shut off valves close.
oil preheater, burner start is released. The two switches are
switched in series. The oil pump circulates the oil via filter Nozzle head maintenance and cleaning
and solenoid valve to the oil preheater, the oil is heated and Both nozzles can be replaced without affecting the
the viscosity reduced. function of the hydraulic nozzle shut off valves.
If the nozzle shut off valves 1 or 2 are removed, the
The heated oil forces the oil in the supply system through isolating device in the oil supply and return must first be
the burner supply, nozzle head, the normally open solenoid closed.
valve 1 to the pump return. Hot oil is now present
throughout the whole system. The shut off device in the <N.ozzle head heating ot\RMS7 jto RMS 11 burners
nozzle head remains closed and oil cannot flow through As with two stage burners, regulating burners for residual
the nozzle. oils are also fitted with temperature controlled nozzle head
heating. This enables the nozzle head to be kept at a
Various burner components are also heated by a heating constant temperature. The heating cartridge, whose
cartridge (see chapter 5.1). thermal output is controlled by the ROB regulating control,
has a 100 W capacity. The ROB control can be set to a
After termination of the pre-purge period, the solenoid temperature of 65°C or 130°C. The factory pre-set is
valve (3) in the nozzle return is energised and closes. The 65°C.
oil pressure increases in the nozzle shut off valve and at a
pressure of approx. 12 bar the nozzle shut off valve opens An NTC sensor is fitted on the heating cartridge support to
to commence stage 1 operation. measure the temperature.
After a delay the solenoid valve (2) for stage 2 is opened The temperature release switch in the regulating control is
by the burner control. Oil pressure is applied to the nozzle connected in series with the oil preheater release
shut off valve which opens stage 2. Nozzle dribble is thermostat and only allows burner start after the selected
largely prevented by the secure closure of both nozzles. nozzle head temperature and minimum oil preheater
temperature has been reached.
Nozzle head heating
Heating takes place directly in the nozzle head which is
insulated. A heating cartridge with a 100 W capacity is
fitted in the nozzle body. The nozzle temperature is
controlled by an electronic P type controller. The sensor is
fitted adjacent to the oil line inlet. The ROB control can be
set to a temperature of 65C or 130C according to the fuel
quality (Factory pre-set 65C).
Duse 1
Duse2
1 Pump without integral solenoid valve
2 Solenoid valve type 121K2421 19 W coil
(normally closed) Rp 1 /8
(normally open) Rp 1/8
(normally closed) Rp 1 /4
5 Solenoid valve type 321H2322 20 W coil
(normally closed) Rp 3/8
6 Solenoid valve type 121G2320 20 W coil
(normally closed) Rp 3/8
7 Nozzle head as shut off device
8 Filter
9 Oil preheater
10 Pressure switch 0 1 0 bar
(set to 5 bar for EL, set to 7 bar for MS)
11 Thermostat Solenoid valves (4) / (6) in
12 Heat insulation the return are fitted
13 Heating cartridge against the direction of
14 Nozzle shut off valve flow.
20
Cold start with 2 purge times
120
100
V;
о
о
о
ф
СЛ
Safety valve open _ Safety valve closed
Time [ s ]
Start in warm conditions with oil line temperature in supply > 60°C
А Pre-purge
120
100
V-
o
Ъ
о
ф
СЛ
Time [ s ]
21
Additional start circuit with two purge times for RMS7
to RMS11 burners, DIN 4787
Operation
After prepurge has taken place and the ignition position
has been reached, the safety valves are opened for 35 s to
enable the burner fuel system components to be heated.
The safety solenoid valves are then closed for approx. 40
s. In the meantime the oil preheater will regain heat and
can give the maximum temperature after the 40 s have
elapsed.
After this period the safety solenoid valves are re-opened

and at the same time a return signal is given to the burner
control to continue the start up sequence. An interval,
determined by the burner controller, of about 6 s produces
a second purge time up to the oil release where the
temperature peak of the oil preheater is utilised for the The circuit is designed in such as way that there is a ballast
moment of ignition. effect as far as the switching condition of the thermostat is
concerned. This means that once start up has begun, any
So that the cold start process does not take place when thermostat response will not produce an alteration in the
starting from warm conditions or after a short shut down sequence of operations, so that either a cold or a warm
period, a thermostat fitted in the burner fuel line system start always clearly takes place.
between oil preheater outlet and distribution piece
determines whether it is a cold start or a warm start with If the oil temperature stipulates a warm start, the start up
short purge period. The thermostat switching point is time of the burner is shortened by 45 s, the time usually
approx. 55 - 60°C. If the oil line temperature is more than used as the delay period.
this figure before the boiler regulator switches on, then
only the short purge time of 6 s is used for the subsequent The circulation return is always fitted into the pump return.
burner start. This monitoring assures that there will be no
unnecessary delays during the start process.
Nozzle heads are tested safety devices and according

to DIN 4787 must not be interfered with.
22
11. Capacity graphs
11.1 Burner types L and RL
Fig. l Fig. II «* I •»-
[ t
H
d d _ —4
\
I
-»- «*-
0-10 0- 10 0-10 0-10
Important information relating to capacity charts

The capacity charts show the oil throughput relative to the
combustion chamber pressure. They are maximum values
measured on idealised test flame tubes to DIN 4787.
All ratings data given relate to an air temperature of

20°C and an installation elevation of 500 m.
Size 5
Dimensions mm
No. Combustion head Fig.
(1) + (2) M5/2a-1 25x40 II 50 160

M5/1a-1 25x40 II 65 180
M5/1 a- 145x40 II 65 180
(2)
mbar Burner types L5Z, L5T mbar Burner types RL5
Comb, head M5/2a-125x40 M5/1a- 145x40 M5/1a-125x40 Comb, head M5/2a-125x40 M5/1a-145x40 M5/1a-125x40
Rating kg/h 15-68 18-77 26-100 Ratingkg/h 15-70 16-79 25-100
kW 180-810 215-915 310-1190 kW 180-835 190-940 300-1190
kW 0 400 BOO 1000 1200 kW 0 600 800 1000 120

Size?
Dimensions mm
No. Combustion head Fig I d No. Combustion head Fig. I d
(1) M6/1a-1 5 5 x 5 0 II 90 200 (4) M6/1a-1 5 5 x 5 0 II 90 200

M7/1a-1 5 5 x 5 0 II 90 200 M7/1a-1 55x50 II 90 200
(2) M6/1 a-165x50 II 90 200 (5) M6/1a-1 6 5 x 5 0 II 90 200

M7/1a-1 6 5 x 5 0 II 100 220 M7/1a-1 6 5 x 5 0 II 100 220
(3) M6/1a-1 7 5 x 5 0 II 90 200 (6) M6/1a-1 7 5 x 5 0 II 90 200

M7/1a-1 7 5 x 5 0 II 100 220 M7/1a-1 7 5 x 5 0 II 100 220
(1) (4
Comb, head M6/1a- 155x50 M7/1a- 155x50 Comb, head M6/1a- 155x50 M7/1a- 155x50
Rating kg/h 41-150 55-165 Rating kg/h 42 - 1 55 55 - 1 65
kW 490-1785 655-1965 kW 500 - 1 845 655 - 1 965
ч
S *" ч
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2
kW 2 00 400 600 BOO 1000 1200 1400 1600 1800 2000 kw
200 400 600 800 1000 1200 1400 1600 1800 20C
kg/h
(2) (5
Comb, head M6/1a- 165x50 M7/1a- 165x50 Comb, head M6/1a- 165x50 M7/1 a -165x50
Rating kg/h 34 - 1 20 52 - 1 65 Rating kg/h 39 - 1 29 48 - 1 65
kW 405-1430 620-1965 kW 405-1535 570-1965
/ л "x
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x i ч 1,^
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kW 200 400 600 800 1000 1200 1400 1600 1800 2000 kW 200 400 600 800 1000 1200 1400 1600 1800 200
(3) (6)
mbar Burner types 172, L7T mbar Burner types RL7
Comb, head M6/1 a - 1 75x50 M7/1 a - 1 75x50 Comb, head Мб/1 а- 175x50 M7/1a- 175x50
Rating kg/h 27 - 1 05 50 - 1 60 Rating kg/h 27-110 48-165
kW 320- 1250 595-1905 kW 320-1310 570-1965
12 /~
V
/ Ч
fj
/
^-ч^
"^x
10 /
s\ чч
/ ч ч,
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kW 200 400 600 800 1 000 1 200 1 400 1 600 1 800 200 kW 200 400 600 800 1000 1200 1400 1600 1800 2000
24
SizeS
Dimensions mm
No. Combustion head Fig. 1 d No. Combustion head Fig. 1
(1) M7/1a-1 5 5 x 5 0 II 100 220 (4) M7/1a-1 5 5 x 5 0 II 100 220

M8/1a-1 5 5 x 5 0 II 110 240 M8/1a-1 5 5 x 5 0 II 110 240
(2) M7/1a-1 6 5 x 5 0 II 100 220 (5) M7/1a-1 6 5 x 5 0 II 100 220

M8/1a-1 6 5 x 5 0 II 110 240 M8/1a-1 6 5 x 5 0 II 110 240
(3) M7/1a-1 7 5 x 5 0 II 100 220 (6) M7/1a-1 7 5 x 5 0 II 100 220

M8/1a-1 7 5 x 5 0 II 110 240 M8/1a-1 7 5 x 5 0 II 110 240
(1) (4
Rating kg/h 57 - 1 95 70 - 230 Rating kg/h 51-210 65-230
kW 680 - 2320 835 - 2740 kW 605 - 2500 775 - 2740
10
/ X
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ч
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^^
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ч \ ч S
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KW 500 1000 1500 2000 2500 30C 0 KW 5()0 1000 1500 2000 2500 300
(2) (5
Rating kg/h 53-181 65-220 Rating kg/h 50-190 63-225
kW 630-2155 775-2620 kW 595 - 2265 750 - 2680
N
zz
/
10 10
s X
/ N
А\ N
8
/ /
/ / ч~ X
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KW 5 DO 1000 1500 2000 2500 30 Ю KW 5 30 1000 1500 2000 2500 300
(3) (6

Comb, head M7/1a- 175x50 M8/1 a -175x50 Comb, head M7/1a- 175x50 M8/1a- 175x50
kW 595-1975 715-2345 kW 595-2015 680-2500
12
Г
/ V
Ч- 10 / /~^ \ N
10
/ Хч / / \ \
у чV
f 8 f / ™
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/ \
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6
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KW 5 00 1000 1500 2000 2500 3000 KW 500 1000 1500 2000 2500 30C
25
Sizes 8/2
Dimensions mm
No. Combustion head Fig. 1 d No. Combustion head Fig. I d
(1+5) M9/1a-1 65x50 III 90 240 (4) U2/1 -165x50 I 85 220

M9/1a-1 85x50 III 90 240 G7/2a-1 65x50 II 1 20 265
(2) U2/1 -145x40 I 85 220 (6) U2/1 -155x50 I 85 220

G7/2a-1 65x50 II 1 20 265
(3) U2/1 -155x50 I 85 220
G7/2a-1 7 5 x 5 0 II 120 265 (7) U2/1-165x50 I 85 220
G7/2a-1 7 5 x 5 0 II 1 20 265
(1) (A
mbar Burner types L8Z/2, L8T/2 mbar Burner types L8Z/2, L8T/2
Comb, head M9/1a- 165x50 M9/1a- 185x50 Comb, head U2/1- 165x50 G7/2a- 165x50
Rating kg/h 64-240 52-203 Rating kg/h 52 - 200 90 - 265
kW 760-2860 620-2420 kW 620-2380 1070-3155
/ \
/ ч
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KW 500 2500 3000 KW 500 1 000 1 500 2000 2500 3000
(2) (6
mbar Burner types L8Z/2, L8T/2 mbar Burner types RL8/2
Comb, head U2/1 - 145x40 Comb, head U2/1 - 1 55x50 G7/2a - 1 65x50
Rating kg/h 60-217 Rating kg/h 52 - 230 90 - 277
kW 715-2585 kW 620 - 2740 1 070 - 3300
/
j sч
/
/ ч > j
/
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/ \ / ч
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KW 500 1000 1500 2000 2500 3000 35C KW 500 1500 2000 2500 3000 3600
(3) (7
mbar Burner types L8Z/2, L8T/2 mbar Burner types RL8/2
Comb, head U2/1- 155x50 G7/2a - 175x50 Comb, head U2/1 - 1 65x50 G7/2a - 1 75x50
Rating kg/h 57 - 220 80 - 258 Rating kg/h 48 - 205 80 - 266
kW 680-2620 955-3075 kW 570-2440 955-3170
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s ч
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1000 1500 2000 2500 3000 3500 KW 500 1500 2000 2500 3000 3500
26
Sizes 10 and 11
Dimensions mm
No. Combustion head Fig. 1 d No. Combustion head Fig. 1 d
(1+2) M1 0/2-1 8 5 x 5 0 IV 140 265 (3) M1 1/1 -245x70 IV 170 325

M1 0/2-200x50 IV 140 265 M1 1/1 -260x70 IV 170 325
(1) (3
mbar Burner types L10T mbar Burner types RL11
Comb, head M1 0/2 - 1 85x50 M1 0/2 - 200x50 Comb, head M 1 1 /2 - 245x70 M 1 1 /2 - 260x70
Rating kg/h 95 - 380 85 - 325 Rating kg/h 1 30 - 440 1 20 - 385
kW 1130-4525 1010-3870 kW 1550-5240 1430-4585
/ s
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KW 5()0 1 000 1500 2000 2500 3000 3500 4000 4500 50( 0 KW 10 00 1500 2000 2500 3000 3500 4000 4500 5000 55C
(2)
эаг Burner types RL10
Comb, head M10/2 - 185x50 M10/2 - 200x50
Rating kg/h 90 - 380 80 - 31 5
kW 1 070 - 4525 955 - 3750
f s
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KW 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
28
(5)
mbar Burner types RL8/2
Comb, head M9/1a- 165x50 M9/1a- 185x50
Rating kg/h 58-248 52-218
kW 690-2955 620-2595
/ "*
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чч
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ч чч
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KW 5 DO 1000 1500 2000 2500 3000 35C
SizeS
Dimensions mm
No. Combustion head Fig. I
(1-3) M9/1a-165x50 90 240

M9/1a-185x50 90 240
(1)
mbar Bur ler types L9Z mbar Burner types L9T
Conib. head M9/1a- 165x50 M9/1a- 185x50 Comb, head M9/1a- 165x50 M9/1a- 185x50
Rat ig kg/h 68 - 260 63 - 250 Rating kg/h 67 - 290 63 - 250
kW 810-3095 750-2980 kW 800-3455 750-2980
/ NX /
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ч\ ч
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KW 500 1000 1500 2000 2500 3000 3500 4000 KW 50 0 1000 1500 2000 2500 3000 3500
(3)
mbar Burner types RL9
Comb, head M9/1a- 165x50 M9/1a- 185x50
Rating kg/h 63-310 60-250
kW 740-3690 715-2980
/
f
N
sv
// s, \
.// 4, S,s
P
I _v s\
f Ч
V Чц
J
f ч чч.
4^
s\ ч \
\
чs
_]
1000 1500 2000 2500 3000 3500 4000
11.2 Burner types M/MS and RM/RMS
Combustion of residual oil

With residual oil burners types MS and RMS, the oil
throughput in relation to nominal rating must not be
less than 100 kg/h. It is also recommended that sliding
two stage RMS burners are used when burning this
fuel.
Size 5
Dimensions mm
(1) M5/2a-1 25x40 II 50 160

M5/1a-1 2 5 x 4 0 II 65 180
M5/1a-1 45x40* II 65 180
* Special combustion head
(1)
mbar Burner types M5Z
Comb, head M5/2a-125x40 M5/1a- 125x40 M5/1a-145x40
Rating kg/h 20-70 28 - 106 25-81
kW 225-810 310-1190 280-915
Note burner M5Z

Size 5 M burners cannot be used in Germany. The data
given in the capacity charts are the maximum values. The
figures actually obtainable depend on the combustion
chamber and should be determined by testing on the
appropriate heating appliance.
Size?
Dimensions mm
(1) Мб/1 а-1 55x50 II 100 220

М7/1а-1 55x50 II 100 220
(2) Мб/1 а-1 65x50 II 90 200

М7/1 а-1 65x50 I 100 220
(3) Мб/1 а-1 7 5 x 5 0 II 90 200

М7/1 а-1 7 5 x 5 0 II 100 220
(1) (2)
mbar Burner types MS7Z, RMS7 mbar Burner types MS7Z, RMS7
Comb, head Мб/1 а- 155x50 M7/1a- 155x50 Comb, head M6/1a- 165x50 M7/1a- 165x50
kW 560-1785 785-1965 kW 505-1430 730-1965
/ ""-x, / У- x
/~ X,"X. / / 4, N
/ / ^•s
s\
/ /
^
s
Su,--
/ / / / Ч
/ f
^•x,
\. f
sV
/
<^_-
/
s.
/
/ f
i
чv x
s
>v
4
ч
2 \ V
S
s1 0 \
1
2
200 400 600 800 1000 1200 1400 1600 1800 2000 kW 2 00 400 600 800 1000 1200 1400 1600 1800 20C
(3)
эаг Burner types M S7Z, RM S7
Comb, head M6/1 a - 1 75x50 M7/1 a - 1 75x50
Rating kg/h 40 - 1 1 1 60 - 1 70
kW 450-1250 675-1905
/ s "^x
/ "4S>
/
/
/
/ \ ч s~^-
4,
/ \
/1
/ чч ч
\
2 •
I S
\ ч
.9
200 400 600 800 1000 1200 1400 1600 1800 2000
30
Sizes 8,8/2 and 9
Dimensions mm
No. Combustion head Fig. 1 d No. Combustion head Fig. d
(1) M7/1a-1 55x50* II 100 220 (4) G7/2a-1 65x50 II 120 265
M8/1a-1 5 5 x 5 0 II 110 240 G7/2a-1 7 5 x 5 0 II 120 265
(2) M7/1a-1 6 5 x 5 0 II 100 220 (5 + 7 + 8) M9/1a-1 6 5 x 5 0 III 90 240
M8/1a-1 65x50* II 110 240 M9/1a-1 85x50 II 90 240
(3) M7/1a-1 7 5 x 5 0 II 100 220 (6) U2/1 -155x50 I 85 220

M8/1a-1 75x50 II 110 240 U2/1 -165x50 I 85 220
(D (4
mbar Burnertypes MS8Z, RMS8 mbar Burnertypes MS8Z/2, RMS8/2
Comb, head M7/1a- 155x50 M8/1a- 155x50 Comb, head G7/2a - 1 65x50 G7/2a - 1 75x50
Rating kg/h 70 • 206 75 - 244 Rating kg/h 95 - 280 90 - 274
kW 785 - 2320 845 - 2740 kW 1070-3155 1010-3075
•
/
/ s
6 s
/
/
\
—vN s \ч
4
/
*1*~^*
_^- \
4,
\
X, '
у'.^ \чЧЧ
.---^ \ x^ \\
0 {
\
^*
4. X.
1 YS
11
2
KW 5C 0 1000 1500 2000 2500 3000 KW 500 1000 1500 2000 2500 3000 350(
(2) (5
mbar Burnertypes MS8Z, RMS8 mbar Burnertypes MS8Z/2, RMS8/2
Comb, head M7/1a- 165x50 M8/1a- 165x50 Comb, head M9/1a- 165x50 М9/1а- 185x50
Rat ng kg/h 65 - 1 92 65 - 233 Rating kg/h 60-254 60-215
kW 730-2155 730-2620 kW 675 - 2860 675 - 2420
10
/
/ \ s,^
8
/ N4
_/\ \ / ~7_
' /" чч ч
ч,ч, чч
/ / \ / . \
6 '
/
^\ ^ ' /
\
ч ч4
/
чч чч
4 S S.
^r ,/
2
ч у sV S
0 ч1 ч
1 Ч
1
-2
KW 5 00 1000 1500 2000 2500 3000 KW 500 1000 1500 2000 2500 3000 350
(3) (6
mbar Burnertypes MS8Z, RMS8 mbar Burner types MS8Z/2, RMS8/2
Comb, head M7/1 a -175x50 M8/1a- 175x50 Comb, head U2/1 - 1 55x50 U2/1 - 1 65x50
Rating kg/h 60 - 1 76 65-209 Rating kg/h 80-233 85-212
kW 675-1975 730-2345 kW 900 - 2620 955 - 2380
12
/
10
1 \
ч\ ч
\^
f /
чч ч\ч
8
f V /1
\ //
ч\
/
6 X
/ / N f I
ч 1 ч ч
ч\ чч чч
>
4
/ ' Ч / f
1
2 f
\
ч1 ч чI
L
V
Ч
0
I
-2
KW 5 00 1000 1500 2000 2500 3000 KW 500 1000 1500 2000 2500 3000 350
31
(7) (8)
mbar Burner types MS9Z mbar Burner types RMS9
Rating kg/h 90 - 275 80 - 265 Rating kg/h 90 - 328 80 - 265
kW 1010-3095 900-2980 kW 1010-3690 900-2980
1 ^\ r S
f \ Vv
/
l—r~
f
/ ^
sN s"V s
^
I
, 4,
SI
s 4.
77 д X,
If s fl \. ^s.
s\ s^
N
f
fj \ \
f j I x
6
чч ^4 s. 6
1 \ ч
4
>
\ 4 ч\ у
Ч.
чч ч s
2
ч ч.ч s
0 0
-2 -2
KW 5C 0 1000 1500 2000 2500 3000 3500 40C 0 KW 5C 0 1000 1500 2000 2500 3000 3500 400
Sizes 10 and 11
Dimensions mm
No. Combustion head Fig. No. Combustion head Fig. I d
(1) M10/2-185x50 N 140 265 (2) M11/4-245x70 N 170 325

M10/2-200x50 N 140 265 M11/1-260x70 N 170 325
(1) (2
mbar Burner types RMS1 0 mbar Burner types RMS11
Comb, head M1 0/2 - 1 85x50 M1 0/2 - 200x50 Comb, head M1 1/2 -245x70 M1 1/2 -260x70
Rating kg/h 1 00 - 403 90 - 334 Rating kg/h 140-466 130-408
kW 1 1 25 - 4525 1 01 0 - 3750 kW 1575-5240 1460-4585
"\_ f .f \ >
/ у s _SJj
16 •
s 16 - .f / S чX
1 4 j
/
f s\ ч J
f
/ s\ >^_
~j f f
/
v "*
ч
JF
12 •
/ s >v
12 • f , S s
s
/
s\
S V
10 -
4v
x.
J
10
j f
/
s ч ^v.
^y
ч.
"V
£_ \ \ V
6 -
6 - . V
s ч S
4 ^ \ 4 • "Ч
\ ч X >
? s s 2 \
x^Ч
0 0 - Ч
-9 -2
KW 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 KW 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
32
12. Nozzle selection
12.1 Two and three stage burners
It is recommended that solid or semi-solid nozzles are used Nozzle spray characteristic
with a spray angle of 60° or 45°. Due to the various
configurations of combustion chambers encountered on
individual heating appliances, no binding information can
be given.
Please note that nozzle spray angles and patterns alter

with the atomising pressure. The data given on the nozzle
only applies with a pressure of 7 bar. Hollow spray Semi-solid spray Solid spray
On two stage burners the total burner capacity must be Spray angle
divided between two nozzles. Usually nozzle 1 is sized to
have sufficient capacity for basic load at approximately 2/3
of the total load. At peak demand nozzle 2 is added to the
throughput of nozzle 1. A different nozzle ratio may be
required depending upon the heat demand and the design
of the heating appliance (e.g. boilers with high combustion
chamber resistance).
Nozzle selection for residual fuels

Nozzles that are too small are frequently used for residual
fuels and therefore soon become blocked. We recommend
the following nozzles sizes as minimum sizes:
from 2 - 3 USgph up to approx. 76 mm2/s at 50C

from 3 USgph up to approx. 450 mm2/s at 50C
On two stage burners neither nozzle should be smaller

than indicated.
The charts are based on distillate oil EL with a viscosity of

4 mm'/s at 20°C.
Removing and replacing nozzles

When removing the nozzle, the nozzle head must be held
with a spanner. Before replacing the nozzle ensure that the
nozzle insert is a tight fit.
Cleaning the nozzle

/ It is not recommended to clean the nozzles. A new nozzle^.-'*
i should be used.
Atomising pressures
Oil EL 10-16 bar
OilM + S .20-25 bar
Note
On type Т burners we recommend the higher
atomising pressure is set.
Nozzle selection charts

The charts are based on details supplied by the nozzle
manufacturer. With variations in viscosity and
manufacturers tolerances a deviation in throughput of ±
10% may result. It should be noted that on residual oil
burners variations in throughput may occur.
These variations are due to differences in fuel density and

viscosity range (atomising viscosity up to max. 17 mmVs
depending on burner size). Pressure losses in the
preheater and burner fuel system should be taken into
account. The precise oil throughput can only be
determined by weighing.
33
-1 /| Л A // /y^Vf >[ > Wyy^f-T
0 2 4 6 8 10 12 t 14 16 18 20 22 24 26 28 30 H/h ]
3
Distillate oil 7= 0.84 [kg/dm ] [kg/h] [ kg/h ]
0 2 4 6 8 10 12 14 16 18 20 22 24
Oil throughput Residual oil у = 0.93 [kg/dm3] [kg/h] [ kg/h ]

8 10 12 14 16 18 20 22 24 26
Residual oil у = 0.97 [kg/dm3] [kg/h] [ kg/h ]

I ' I i I i I I ' I ' I—' I ' I
1
'—Г" —!—"—I—'—I < I
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
Pressure bar ,
24--
j ' ' ' r r
' ?
Z - ! . . . . ) ,i, i
-j
f.- . ? _ L .
^-i-j--
' ^
' ' 1 I' '' I
: :::.ju !., , i ,
Г J
22
7 ,
_ .. ,'. , j /i .
Ш
jffi Bttl! i i ' -У i
<- 1 ! Ж ?л&
» r ЧГ"
''•Oj/j
c^5l ^ /^^b
' O^
jf С) УЪ/^уоУ1 ^
ÂSl ^ 3^ O/^^W
/К>Ж Й.
I ЧУ*>^( "W^dvQftC^S^c^^yCi ^^"
^ПШШШШЩЙ ' ; ,;?:;!:;!:;!.;!.;': z!

TO
P>
£>
4^1 U ''^П^г^^К^Лт^'^&Р
"^/"^J ~^^ **J "V "^ "^ ^^
^/ o^
vCS
$ж£ J
^Q^S C^
- , - ^ -- -* ? j r .,... j . . . . . . , _ _ „ . . , . ^ . , . . . , . / ^ ,
}0 _
i / ^ / ' ' У
/ x \\\i\\\
^ « t » ' t' i ' , ' ' ( ' , ' > *
j~ i' ( ' ' ' i' i ' ^ ^^
1
' i?* ?^ «; ' ' '^ ; ' 'I • ' 'I '' ' ?
~*l'.\\ti;' У;;• , р | ЙЙЙ
,.'',•' '
i i
^^
ti - ^
? (^ ? Z ' g ! '
<CU îJ OU JU -4U t<J UU J
Distillate oil у = 0.84 [kg/dftÎkg/h] [ kg/h ]

" I ' M i ' I I. |
, . i. I. I.I ,|. ШЧТЧ'Чищ!
. , , . . , . . .ЦП.Ц-ГГ1 I ; 1Г1 I |||И|1ИЦ111Ц I |
18 20 25 30 Гв 40 45 50 60 70 80 90 100 110
Oil throughput Residual oil y^0.gg^g/drn3][kg/h] [ Kg/h ]

| < , . | « l r l T ' > i | > ' ' I | i i i i | i ' > T | . . . . | . . . . |
20 25 :*C 35 40 . 45 5O 60 70 вО 90 100 120
1
•П 25 30 35 40 45 50 60 70 80 "T 100' I '120'"
90 "" 140
Pressure bar j L Ш j£ щтгп

+
> K
J
1 [f fl
. 1 t
( V
* / / /
t t - -
"1"
n
Л-
ts ::t\ Ii [t',1 Г I
1
/ /:^ _l } "t
,
.Ц_
Y-i-l \ '/,/ /
у ,
'•'• Г 7 3 """
•$"Ш $?I I1
г f
î
IKt
"\ ~Ш^ "to)
? 't -j / r
t&A Ф^рЧф ~rtyj
o/ °i
J t ' jf / /^ Ж. "^
f !_2 2
f.t j ! . ' i
_
; *a j (
^
L.
'
'
?
/, ' * !.,!,! (' \'1

/ f
/ vJ
i i ^ <' ,/ '
t .' ^
' i '< ' ' <>
s f ~?
t
•* * 4 '* •'' *''' ' t ^ -t у

/
100 120 140 160 180 200 250 300 350 400 500 6OO [ |/h ]
Distillate oil -/ = 0.84 [kg*dm3][kg/h] [kg/h]

••-"•' ' ' ' f г f * |r | , | , , .| , , , , , |, , , , j , , , , | , , , , |
ЯО 1СО «20 140 160 180 200 250 300 350 400 500
12.2 Sliding two stage and modulating burners
The charts shows the throughput of the spill type nozzle in Atomising pressure
relation to the supply pressure. The pump pressure on RL
burners should be between 20 and 30 bar. Burner type Atomising pressure
It should be ensured that the minimum pressure does bar (approx.)
not fall below 20 bar even at the lowest regulator cam
RL5toRL11 20-30
/ Un
On KMbbjjrner§,the
RlvlSTjuTnersJhe pump pressure must not not tall belgy£>
fall"beiov RMS7 to RMS11 25-30
L_25 bar/When/due to nozzle sizing, the burner rating with
the return flow closed (regulator position 10) can only be
achieved at a pressure below 25 bar, the pump pressure Sp;7/ type nozzles
must be increased to 25 bar and the higher oil throughput
that results is reduced by limiting the oil regulator
movement. This is done by adjusting the limit switch in the
servomotor to the appropriate lower regulating position.
The range of regulation is reduced by this action.
Nozzle return pressure ••, >• ,

Spill type Nozzle КЗ / WB3 : : h V Cv, .,1ч
The nozzle return pressure must be measured wheni*.*•£:/•'
commissioning. In normal cases it sh;ould,not be set below
5 bar for partial load. < fftl),, Note
Each' burner is4additionany; subjected to an oil throughput
Spill type nozzle WS4 'ratings'test witMhe spill type nozzle during final testing.
The nozzle return pressure must be measured when fThis ratifies, test-is/u^felly carried oqt with oil EL. The
commissioning. In normal cases it should not be setbelow differences^Hich'eJicur on oil §' i.e. on RMS burnens"?
8 bar for partial load. (density ana viscosity) are taken into Jiceourtt wftb a
correcting factoE'Tfiese test bed measurements can only
be used-as guid£|the,s; Exact-measuring has to be carried
out op ske. Site specific Gbndifions, such as oil quality and
ring-main pressure гтшз!Йэе taken into account.
Solenoid valve group, sizes 5 to 7 the nozzjesf! Ц ; I \

'is disniferitled intblife jndividual parts and
i. trje filter should always be
are
faulty or worn, the
. I •; ;\W" i%\. ;'-S.v... *.• 'if

Nozzles$election Charts*
:-rjrbe;chprt$ar|i based;on'iêâi[ssupplied by the nozzle
i m^rlufactu'rer VVith variaHpW'jn^yiscosity and
• |flar|ufactefrers tblerafipfe!&^|JeV|ation in throughput of
K± 10% mi^ result. It sboutob^noted that on residual oil
:l bbr|i4rsxyanatlopsiin tfefpughpuf may occur.
These varrations aretfue to differences in fuel density and

viscosity range, (atomising viscosity up to max. 17 mmVs
depending,on burner size). Pressure losses in the
preheat'er and burner fuel system should be taken into
Solenoid valve group, sizes 8 to 11
accbunt'The precise oil throughput can only be
determined by weighing:
Return pressure 1/4" test point
35
Nozzle selection chart type WB3/K3 s" Nozzle selection chart type W, series 4
Spill type nozzle type WB3 to 70 kg/h Spill type nozzletype W, series 4
type КЗ 80 to 180 kg/h V Spray angle 50°
Spray angle 50°
190 190 460- W460 и
180 180 440
420 W420
170 170
400
160 160
W390
380
150 150
360 W360
140 140
340
130 130 W330

320
120 120
300 W300
110 110
280
W275
CO
100 100 260
«и
^
Q.
W250
2-
90 90 240
N
N
О W225
80 80 220
200 W200
70 •70
180 W 180
65 65
CO
CO
5 160 W 160
60 60 Щ
a
г- 140 W 140
55 N
N
О
W125
120
я
50 50 W110
100
W90
0)
D) 80 W80 >
W70
3
| 40 а 60 W60
0)
О)
W55 N
О) W50
W45
1 «
О
и. о
о W40
N
N
О
30 20
20 25 30 20 25 30
Supply pressure bar Supply pressure bar
Example of nozzle selection, type WB3 Example of nozzle selection, type W

Oil throughput required: 50 kg/h Oil throughput required: 160 kg/h
Nozzle size from chart: 55 Nozzle size from chart: _W160
Supply pressure from chart: _ 24 bar Supply pressure from chart:_ 24 bar
36
Jl №12(50)
декабрь 2004
Главный редактор Содержание

Сергей Бирюков
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Сергей Кузнецов
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Редакционная коллегия
CoolRunner-II фирмы Xilinx
Павел Асташкевич
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ООО "ИД Скимен"
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Конкурс радиокружков (с. 20)ч Выставка ЭлектроТехноЭкспо-2004 (с. 30).
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• • • •*

DESCRIPTION AND MAINTENANCE

THERMAL FLUID INSTALLATION

Hull no. 1594-1595

Project no. 10019A.OO- 10020A.OO

Thermal fluid installation for:

Shipyard: Astillero Barreras

Hull no. 1594-1595

Class Det Norske Veritas

Delivered by Aalborg Industries NL BV

Project no. 10019A.OO-10020A.OO

Piping diagram D11328

Electrical diagram D11343

Fuel oil diagram D11379

\\PDC_\ALBORG \dm_MstmcaHMajluals^OO]'fc»_100l9_10020i 00 doc page 4

Thermal fluid heater

Flue gas sensor

Maximum thermal fluid sensor

Differential pressure switch

Temperature controller oil fired heater

\\PDC_AALBORG\Adm_Algcineen\Maniiab\200l\tar_100I9_10020a. 00 doc pageS

Type EXV 631-31-57.0-1150 DD

Temperature controller economiser

Pneumatic actuator economiser

\\PDC JWLBORC\AdmJUgemea*M>™il*200l\b«r_l0019J0020a.OO doc page 6

Minimum flow valve

Electronic pressure controller for minimum flow

Pressure transmitter for minimum flow

\\PDC_ AALBORC\Adin_AI|cmcci<\MaliBll\2001\bar.lOOI^I0020a 00 doc page?

III. DESCRIPTION OF THE THERMAL FLUID PLANT

The thermal fluid plant is built up from the following components:

Two economisers type EXV631-31-57.0-1150 DD, each having a capacity of 774,000

An expansion tank to compensate the increase hi volume of the thermal fluid.

A) The oilfired thermal fluid heater

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Each heater is provided with the following safety devices:

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In case of a fault in the automatic electronic temperature controller it is possible to control

C) The thermal fluid pumps

D) The minimum flow control

E) The expansion tank

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IV. General instructions

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4.1 Flue gas thermostat of the fired heater

Actuation of this thermostat may mean that:

4.2 Exhaust gas thermostat of the economiser

Actuation of this thermostat might mean that:

The resistance on the exhaust gas side is too high

4.3 Cleaning of the fired heater

4.4 Cleaning of an economiser

4.5 Stopping the fired heater

4.6 Stopping the economiser

The by-pass pipe has a dual purpose:

4.8 Adjustment of the economiser

4.8.1 Adjustment of the minimum flow controller

The procedure is as follows:

4.8.2 Adjustment of the heat consumers

The adjustment has a triple purpose:

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