Operating Instructions For TG5 Gas Burner

________________________________________________________________________________

GAS BURNERS

TG5
GENERAL INFORMATION
AND
OPERATING MANUAL TG5 Manual Rev 3

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 Operating Instructions For TG5 Gas Burner

Revision Table
Rev No. Description Date By
1
2
3 gas consumption added to table - section 1.5 7.6.13 R.S
emergency stop information added - section 5.9
exploded drawings revised – section 11
4 FGR details added. Burner drawings and codes 28.11.19 R.S
updated

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 Operating Instructions For TG5 Gas Burner

`TG` SERIES GAS BURNERS

GENERAL INFORMATION AND OPERATING MANUAL

IMPORTANT
Throughout this publication Dunphy Combustion Limited are referred to as `The Company`.

The manual, which is supplied with every burner should be read prior to the installation of the unit.

While giving information on the site work involved and on the burner commissioning procedure, the
content cannot include all of the data which may be necessary to achieve the design output of a burner
to a particular appliance because of the wide variety of heating and process plant for which the burner
is suitable precludes this.

The Company strongly advises that the commissioning of the burners is carried out by Dunphy
trained engineers and points out that it may be impossible to impart all the necessary information to
enable others to do so.

Under all circumstances the provisions of The Health and Safety at Work Act 1974 are the most
important consideration and if any doubts exist concerning the safe operation of the burner, The
Company should be contacted for advice. This provision also applies to the legislation of countries
to which the burners may be exported.

Where equipment, not of The Company`s supply, is used in conjunction with the burners, reference
should be made to specific instructions or regulations governing the installation and use of such
equipment.

The Company gratefully acknowledges the permission of component suppliers and others to
reproduce data sheets and technical information in this manual.

For reliable and efficient operation of the burner, it is essential that regular maintenance is carried
out in accordance with the instructions contained in the text of this manual. The fact that a burner
may be under warranty does not absolve the user from the responsibility for this and inadequate
maintenance may lead to claims, made under guarantees of materials or performance being denied

IF IN DOUBT - ASK!
Information contained in this manual is given without any responsibility on the part of the company
for the consequences of the actions of persons making use of such information.
Equipment is supplied strictly under the terms of The Company’s current `Conditions of Supply`
which are printed on the reverse of order acknowledgements and delivery notes.
Copies are available on request.

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 Operating Instructions For TG5 Gas Burner

Contents
1 GENERAL INFORMATION ...............................................................................................6
1.1 General ................................................................................................................................6
1.2 Working parameters .......................................................................................................6
1.3 Burner construction ........................................................................................................7
1.4 Burner details and power curve .................................................................................9
1.5 General arrangement details ....................................................................................10
1.5.1 TG5 with Unibloc Gas Valve ................................................................................10
1.5.2 TG5 with VGD 40 Gas Valve ...............................................................................11
1.5.3 TG5 with FGR ............................................................................................................12
2 Installation...........................................................................................................................13
2.1 Burner Mounting ............................................................................................................13
2.2 Gas Valve mounting......................................................................................................14
2.2.1 Burner fitted with Unibloc ....................................................................................14
2.2.2 Burner fitted with Siemens VGD40 gas valve..............................................17
2.3 Gas installation ...............................................................................................................18
2.4 Electrical connections ...................................................................................................18
2.4.1 Inverter Connection ...............................................................................................18
2.5 Ventilation requirements ............................................................................................18
3 Combustion Head Settings .........................................................................................19
3.1 TG5.800 Natural Gas setup .......................................................................................20
3.2 TG5.1000 Natural Gas Setup ....................................................................................21
3.3 TG5.800 Low NOx Burners ........................................................................................22
3.4 TG5.1000 Low NOx Burners ......................................................................................24
3.5 Nozzle Adjustment ........................................................................................................26
3.5.1 Gas Head ....................................................................................................................26
3.5.2 Multipipe Gas Nozzle adjustment .....................................................................26
4 Adjustments and Operating Principles ...............................................................27
5 Operation & User Interface ........................................................................................28
5.1 The Display / Keypad ...................................................................................................28
5.2 Start -up Sequence .......................................................................................................28
5.3 Modulation ........................................................................................................................30
5.4 Normal mode ...................................................................................................................31
5.5 Local mode .......................................................................................................................31
5.6 Non-volatile lockout ......................................................................................................31
5.7 Ratiotronic 6000 Inverter interface additional information ..........................31
5.8 Post Purge Operation ...................................................................................................31
5.9 Emergency Stop .............................................................................................................32
6 Component Setup Parameters .................................................................................33
6.1 Ratiotronic 6000 .............................................................................................................33
6.2 Danfoss VLT FC 102 ......................................................................................................39
7 Commissioning ..................................................................................................................41
7.1 Basic settings ..................................................................................................................41
7.2 Start Gas Heat Input ....................................................................................................42
7.3 Pre-commissioning ........................................................................................................43
7.4 Commissioning – Pneumatic Modulation burners .............................................44
7.4.1 Dry run ........................................................................................................................44
7.4.2 Check for leaks through the automatic gas valve. ....................................44
7.4.3 Check for correct control sequence. ................................................................44
7.4.4 Firing the burner .....................................................................................................45
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 Operating Instructions For TG5 Gas Burner
7.4.5 Combustion values and results..........................................................................45
7.4.6 Adjustment of Gas Proving Pressure Switch ................................................46
7.5 Electronic Modulation Burners ..................................................................................47
7.5.1 Gas Butterfly Valve.................................................................................................47
7.5.2 Adjustment of air pressure proving switch ...................................................47
7.5.3 Ratiotronic programming .....................................................................................48
7.5.4 Setting the servo motors .....................................................................................48
7.5.5 Burner Commissioning ..........................................................................................48
7.5.6 Combustion values and results..........................................................................49
8 Burner Maintenance Schedule ..................................................................................50
8.1 Opening the Burner ......................................................................................................51
8.2 Minor Maintenance ........................................................................................................51
8.3 Major Maintenance ........................................................................................................51
8.4 Dismantling and Re-assembly of Burners ............................................................52
9 Faults and fault finding ................................................................................................54
9.1 Ratiotronic 6000/6006 .................................................................................................54
10 Useful Information ..........................................................................................................55
11 Exploded Diagram and Spare Parts List .............................................................57
11.1 TG5 with Electronic Modulation Set-up .............................................................57
11.2 VGD40.80 Assembly for Electronic Modulating Burners .............................59
11.3 VGD40.100 Assembly for Electronic Modulating Burners ...........................59
11.4 VGD40.125 Assembly for Electronic Modulating Burners ...........................59
11.5 DN80 Unibloc Assembly ...........................................................................................60
11.6 DN100 Unibloc Assembly ........................................................................................60
11.7 DN1250 Unibloc Assembly ......................................................................................60
12 COMPONENT INFORMATION .....................................................................................61
12.1 Unibloc ............................................................................................................................61
12.1.1 Unibloc General Arrangements ......................................................................61
12.1.2 80mm Ratiotronic Unibloc exploded diagrams and parts list .............63
12.1.3 80mm Ratiotronic Unibloc with pilot exploded diagrams and parts
list 64
12.1.4 100mm Ratiotronic Unibloc exploded diagrams and parts list ..........66
12.1.5 100mm Ratiotronic Unibloc with pilot exploded diagrams and parts
list 67
12.1.6 125mm Ratiotronic Unibloc exploded diagrams and parts list ..........69
12.1.7 125mm Ratiotronic Unibloc with pilot exploded diagrams and parts
list 71
12.2 LFL1.333 Burner Control Box ................................................................................73
12.3 RWF 40 Burner temperature controller .............................................................81
12.3.1 RWF 40.000A97 Default Burner Settings .................................................86
12.4 Siemens VGD20 and VGD40 Gas Valve Blocks ..............................................87
12.4.1 Siemens SKP actuators .....................................................................................91
12.5 VPS 504 Valve Proving System ............................................................................97

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 Operating Instructions For TG5 Gas Burner
1 GENERAL INFORMATION

BOILER EFFICIENCY DIRECTIVE

( HOT WATER BOILERS ONLY )
In compliance with the Boiler Efficiency Directive, during commissioning, all adjustments to
the burner must be made in accordance with the boiler manufacturer's instructions and these
must include checking of flue gas temperature, average water temperature and
CO2 or CO concentration.

1.1 General

Burners must be checked at the time of delivery and any deficiencies or damage immediately reported
to the carrier or supplier. The company will make good any defects or replace missing items strictly
in accordance with their current conditions of supply.
The company has a policy of continuous development and therefore reserve the right to make
changes, without notice, in burner or other specifications.
Burners carrying the same model number may have major differences in their detailed specification,
such as draught tube lengths to suit the dimensions of a particular appliance, which makes it
impossible to give, in a single publication, precise information on the whole range of applications.
Data is readily available from the company and can be supplied on application.

Please give the burner serial number when requesting information.

All TG series burners are manufactured and tested to European Standards EN676: 2003 & A2: 2008
Automatic forced draught burners for gaseous fuels, Definitions, requirements, testing, marking and
EN 267 Forced draught oil burners – Definitions, requirements, testing, marking

It is essential that appliance and burner combinations are correctly matched.

If any doubt exists about the suitability of a particular combination the installer
must check with the manufacturers.

If a burner is to be fitted to an existing boiler, maximum combustion efficiency can only be achieved
if all heat transfer surfaces are cleaned prior to the installation. Generally `TG` series burners are not
suitable for use in areas of high humidity or in explosive atmospheres, but special units suitable for
use in adverse situations can be manufactured to a customer's specific requirements. Details of special
units are available, on request, from the Dunphy sales department.

1.2 Working parameters

Temperature 0 to +50°C

Relative Humidity 60 - 90% non-condensing

Atmospheric Air Pressure – will generally be in the range of 950 to 1100mbar, but this will change
with altitude, if there are any queries please consult the Dunphy technical department.

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 Operating Instructions For TG5 Gas Burner
1.3 Burner construction

Each ‘T’ series burner is constructed from 5 separate castings described as follows:

Hinge
In common with all other body castings, the mounting casting is manufactured from aluminium grade
LM6 with the front face drilled to the dimensions given in section 1.5 of this manual suitable for
mounting studs. The rear face has two external lugs which form part of the burner hinge and is drilled
to accept the studs that are used to lock the burner closed.

Note: The fuel pipework enters this casting and it is essential that all joints and connections on
the combustion head are checked for security before the burner is hinged to the closed position. See
the maintenance section for details.

This casting houses the burner draught tube and combustion head along with the appropriate
ignition cables and flame detection equipment.

Fan case assembly

This consists of two aluminium castings with machined faces, bolted together and enclosing
the fan (which is sized to suit the particular burner model according to output and combustion
chamber resistance).
Integral with and inside the front half of the fan cases are the compressor blades; on the outside,
external lugs are attached with pins and thrust bearings to the burner mounting casting to form the
hinges.
The rear half is tapped to take the burner lifting eye and pads are used for the attachment of the
components on various models of the burner. The rear face is machined to match the air shutter
assembly, which is attached to it.

A differential air pressure switch, piped across the air inlet and pressure outlet of the combustion air
fan is mounted on the front section. Its function is to prevent the burner from firing if a supply of
combustion air is not available or to lock out the burner if the air supply is interrupted during normal
running.

Air shutter
Combustion air is introduced through two concentric castings, one rotating about the other on
a PTFE bearing surface, regulating the combustion air supply through characterised slots to
accurately maintain the fuel air ratio. Close machining tolerances ensure almost zero leakage when
the damper is fully closed. The characterisation of the slots also ensures very high control of the air
supply at the important low fire end – typically 30 degrees of movement accounts for only 10% of
air throughput thus ensuring very high turndown capability.
The operation of the air shutter is activated by a reversible, mains voltage, synchronous motor (on
high/low burners) or a 240 (or 24V) motor with potentiometer control for fully modulating units.
Adjustable rigid linkage is used and the limits of travel are set by micro switches. Final
adjustments are made during commissioning.
On burners fitted with electronic modulation systems the air shutter and the fuel valves will all
be manufactured with individual drive motors controlled by the modulation system.
On burners which have air inlet silencers as standard a 0-10 scale is fitted to indicate the
opening of the air shutter (not the firing rate) and nylon support bearings ensure that the travel is as
smooth as possible.

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 Operating Instructions For TG5 Gas Burner
Burner Motor
The burner (fan) motor is a continuously rated 2-pole unit with class 'F' insulation, sized according
to the application. The motor is mounted the inside of the inner shutter thus allowing 100% heat
recovery from the motor into the combustion air offering efficiency ratings greater than EFF1. This
also ensures inherently quiet operation from the burner.

Combustion Air Fan

Mounted directly onto the motor shaft and positioned within the fan case assembly, the fan supplies
combustion air via the compressor vanes and mounting casting to the combustion head.
Because of the 'T' burner requirement for extremely low vibration and noise levels the fans are
manufactured in-house and balanced to the very highest standards (ISO 1940-1973).
All fans are colour coded according to size.

Combustion Head
The air for combustion passes from the burner fan at a pressure related to the resistance of the boiler,
down the draught tube to the combustion head. The latter is an assembly of components which cause
the gas to be discharged into the air flow in such a way that optimum mixing takes place.
Gas from the gas valve passes down the tube which forms the major component part of the
combustion head assembly, passing through a ring of drilled holes which form the nozzle.
The gas is then ignited by means of a high voltage spark which arcs to earth on the gas nozzle itself.
The resulting air-gas mixture then passes through and round the main flame ring which provides an
anchor when combustion takes place. Many types of combustion head are available depending on
appliance geometry, gas type, available gas pressure, NOx level requirement etc…

Note: On any burner, an almost infinite combination of combustion head components may be used
to achieve optimum efficiency and a flame shape to suit a very wide range of heat-raising appliances.

Burner Control Cabinet

Standard burners are supplied with a dust resistant damp-proof cabinet mounted on the side of the
burner. In many cases all the burner controls are fitted within the control cabinet. In more complicated
installations, this cabinet would house a terminal strip which would then interface to a control desk
via flying leads.

Air Inlet Silencer

Because of their design characteristics, 'T' series burners operate at very low noise levels, however,
further reduction of these levels can be made by fitting air inlet silencers which are designed to cover
the air shutter castings. The standard foam lined silencer typically offers sound levels in the region
of 75dBA.
An optional ‘Snorkel’ type silencer is available which will reduce sound levels to below 70dBA.
Silencers can also be tailored to suit ducted air supplies, filters or additional acoustic attenuation.
For extremely sensitive installations, 'hush boxes' which cover the entire burner can be individually
designed to suit most applications. Quotations are available on request.

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 Operating Instructions For TG5 Gas Burner

1.4 Burner details and power curve

Gas Volume
Firing Rate kW FIRING MODE OPTIONS
BURNER (m3.hr)*1 Running Starting
Motor kW Voltage Hz Ph
TYPE Electro / Pneumatic Electronic Current Current
MIN MAX MIN MAX High / Low
Modulation Modulation*2
TG5.800Z 1250 8500 120 817   18.5 380-420 50 3 44 Amp 107 Amp

TG5.1000Y 1550 10500 149 1010   22 380-420 50 3 54 Amp 136 Amp

*1 – Based on Nat. Gas C.V 10.4kW/m3

*2 - Fitted With a Ratiotronic 6000 System

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 Operating Instructions For TG5 Gas Burner

1.5 General arrangement details

Electronic modulation burners are fitted with on/off gas valves and electronically controlled butterfly
valves for the gas regulation. The gas valve is generally a Unibloc (see component section for details)
however other valves can also be used depending on site details or customer preference.

1.5.1 TG5 with Unibloc Gas Valve

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 Operating Instructions For TG5 Gas Burner
1.5.2 TG5 with VGD 40 Gas Valve

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 Operating Instructions For TG5 Gas Burner
1.5.3 TG5 with FGR

Flue Gas Recirculation lowers the Nox levels of a burner by decreasing the oxygen levels of the
combustion air, lowering the flame temperature. Flue Gas Recirculation burners are fitted with a
duct that feeds flue gas back into the eye of the fan. This flue gas is modulated by an actuated
butterfly valve.

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 Operating Instructions For TG5 Gas Burner

2 Installation
2.1 Burner Mounting
Care must be taken when mounting the burner not to damage the mounting gasket. The furnace pipe
(where fitted) is generally positioned at 12 o’clock on the mounting flange and care must be taken
not to damage it during the mounting process.

Note:- Ensure that the burner mounting gasket is correctly fitted when fixing the burner to the
appliance. This gasket creates a gas-tight seal between the boiler and burner and also insulates
the burner mounting casting.

It is important to check that the burner draught tube projection into the combustion chamber conforms
to the appliance manufacturers instructions.

Non standard draught tube projections are available on request, - please consult the Dunphy sales
dept.

In general, for reverse flame boilers the draught tube projection into the combustion chamber should
be between 50 and 100mm. For other boilers the burner draught tube should finish flush or slightly
proud of any boiler refractory or insulation.

If there is any doubt about the correct projection into the combustion chamber, the appliance
manufacturer must be consulted.

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 Operating Instructions For TG5 Gas Burner
2.2 Gas Valve mounting

2.2.1 Burner fitted with Unibloc

The Unibloc gas valve is a heavy item and will require two persons to lift it into position and secure
in place using bolts provided.

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 Operating Instructions For TG5 Gas Burner
Governor shown is supplied with every burner using a Unibloc gas valve and should be installed
according to guidelines illustrated below and approximately 10 pipe diameters upstream of the gas
valve. Pipe work and isolating valve are supplied by others.

Important:

The installer must install a 90° turn type isolation ball valve next to or in close proximity to the
burner and capable of rapid operation.

The manual valve must be capable of operating at a pressure equal to 1.5 times the maximum supply
pressure and where possible must be orientated in such a way that when the valve closes the handle
must fall from the vertical to the horizontal. The valve must have mechanical end stops to prevent
the ball valve from going below the 0° point or above the 90° point.

The gas supply pipework must be adequately supported to prevent undue stress on the burner casing
or the gas train components.

Gas supplies greater than 500mbar must be governed down to a suitable gas pressure below 500mbar
using a CE approved high pressure gas governor. The gas governor or should be fitted as per
manufactures instructions, copies available on request.

VGD Gas Valve Orientation

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 Operating Instructions For TG5 Gas Burner
Unibloc Orientation

Governor orientation

Fit governor in accordance with manufactures instructions.

With the gas isolation valve next to the burner closed, a pressure test should be carried out on the
main gas supply pipe work and all connections checked with a suitable, non corrosive leak detection
fluid.

If the installation is supplied with a gas pressure above 1 bar (14.5p.s.i.g.) and contains plant with a
heat input of more than 2MW, local authorities will generally ask for the fitting of remotely operable
fire valves. The national or other standards in countries to which the burners may be exported must
be identified and met.

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 Operating Instructions For TG5 Gas Burner
2.2.2 Burner fitted with Siemens VGD40 gas valve

The Siemens gas valve is a heavy item and

will require a two persons to lift it into
position and secure in place using bolts
provided.
8mm blue and black PVC pipes plus
fitting are supplied with the burner. The
blue line must be connected between the
“Air” connection on the SKP75 actuator
and the air pulse line situated on the top
flat of the burner hinge section. The black
line must be connected between the
“Combustion Chamber” connection on
the SKP75 and the furnace line connection
protruding through the mounting flange of
the burner.

.Important:

The installer must install a 90° turn

type isolation ball valve next to or in
close proximity to the burner and
capable of rapid operation.

The manual valve must be capable of operating at

a pressure equal to 1.5 times the maximum supply
pressure and where possible must be orientated in
such a way that when the valve closes the handle
must fall from the vertical to the horizontal. The
valve must have mechanical end stops to prevent
the ball valve from going below the 0° point or
above the 90° point.
The gas supply pipework must be adequately
supported to prevent undue stress on the burner
casing or the gas train components.

The Siemens gas valve has a built-in governor

and is suitable for gas pressures up to 500mBar.
Gas supplies greater than 500mbar must be
governed down to a suitable gas pressure below
500mbar using a CE approved high pressure gas
governor. The gas governor or should be fitted as
per manufactures instructions, copies available
on request.

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 Operating Instructions For TG5 Gas Burner
2.3 Gas installation

In all cases, gas installation work must be carried out by approved members of
Gas Safe

All relevant standards of The British Standards Institute, IGEM Standard's

and the equivalent European Standards must be adhered to.

Note: The national or other standards in countries to which the burner may be exported to must be
identified and adhered to.

2.4 Electrical connections

All electrical installation work must be carried out in accordance with the I.E.E. wiring regulations
17th Edition 2008, with further reference to the Health and Safety Executives `Memorandum of
Guidance on the Electricity at Work Regulations 1989 ( H.S.E. Booklet HS[R]25 )

Take note of the I.E.E. requirement for bonding main gas supply pipework to earth.

Connections to all terminals and the appliance should be made in accordance with the wiring diagram
supplied with each burner.

The final part of the electrical cable run must be made in flexible conduit, long enough to enable the
appliance door to be opened.
Ensure that the mains electrical supply to the burner is protected by a suitably sized fuse.

2.4.1 Inverter Connection

Burner motor connections can be found in dedicated aluminium enclosure situated on the side of
the burner control panel. Wiring diagram shows how to connect the inverter to this enclosure. To
ensure excessive leakage current conforms to EN/IEC 61800-5-1, an earth wire of at least 10mm2 or
two separate earth ground wires are used.

2.5 Ventilation requirements

Provision must be made for an adequate supply of combustion and ventilating air to be available
when all access doors, fire doors and windows are closed. Air supply fans or flue dilution systems
must be interlocked to prevent operation of the burner(s) in the event of fan failure or shutdown.

To ensure an adequate supply of combustion air, the room in which the burner(s) are installed should
have permanent ventilation according to local or national standards.

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 Operating Instructions For TG5 Gas Burner
3 Combustion Head Settings
On burners fitted with standard 'Z' and 'Y' type nose cones, the dimension 'A' between the end of
the burner nose cone and the front face of the flame plate, can be altered by releasing the three, M6
locking nuts inside the draught tube, and sliding the cone forwards / backwards, along its
adjustment slots until the required setting is obtained.

Important Notes:

 Factory setting of gas flow is as shown on the following combustion head arrangement
drawings. Position of gas nozzles must be finalised at commissioning to suit the particular
boiler in which the burner is fitted.
 When using low NOx heads, the projection must be at least 130-150mm past the boiler
refractory (into the furnace).

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 Operating Instructions For TG5 Gas Burner
3.1 TG5.800 Natural Gas setup

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 Operating Instructions For TG5 Gas Burner
3.2 TG5.1000 Natural Gas Setup

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 Operating Instructions For TG5 Gas Burner
3.3 TG5.800 Low NOx Burners

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 Operating Instructions For TG5 Gas Burner
3.4 TG5.1000 Low NOx Burners

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 Operating Instructions For TG5 Gas Burner

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 Operating Instructions For TG5 Gas Burner

3.5 Nozzle Adjustment

3.5.1 Gas Head

The Combustion head is attached to the gas inlet on the body. The gas flows through the gas pipe and
through the 4 holes in the gas nozzle.
The gas flow can be altered by adjusting the restrictor band, shown below. Undo the four M5 screws,
rotate the band to open or close the nozzle holes.

3.5.2 Multipipe Gas Nozzle adjustment

The Combustion head is attached to the gas inlet on the body. The gas flows through the 6 gas pipes and
through the holes in the gas nozzles.
The gas flow can be altered by rotating the nozzles to direct the gas either towards or away from the
centre of the burner.
The gas nozzles can also be adjusted along the multipipe head, this will either move the gas holes closer
or further away from the flameplate.
To carry out the above adjustments, loosen the 2x M4 grub screws on each nozzle securing the nozzle
to the pipe.

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 Operating Instructions For TG5 Gas Burner
4 Adjustments and Operating Principles

ME burners are fitted with electronic control

systems which have direct control over the air
damper and gas butterfly valve using high
precision digital servo motors.

The air gas ratio is defined by a profile curve which

is programmed into the controller during the
commissioning phase.

Ratiotronic 6000 series controllers are generally

fitted to these burners however Siemens LMV5..
series controllers may also be offered as an
alternative.

ME burners are relatively complex products and it

is recommend that they are commissioned by
qualified Dunphy personnel
.
Documentation on these controllers is too lengthy to incorporate into this document and therefore is
supplied as a separate manual. Both manuals must be used in conjunction with each other when
commissioning and operating the burner.

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 Operating Instructions For TG5 Gas Burner
5 Operation & User Interface
5.1 The Display / Keypad

The display is a 2 line, 20 characters per line, dot matrix vacuum fluorescent type allowing the use
of plain text messages for most display parameters. The keypad is a membrane construction with
tactile keys to give a positive feedback of the actuation.
The SCROLL keys are used to
view boiler and burner status
data during normal running
conditions.

In commission mode, these

keys select option parameters,
which are adjusted by the
UP/DOWN keys.

The UP/DOWN keys are

used to adjust the fire rate in
manual modulation mode.

In commission mode, they

are used for data value
selection.
Low
EK Fuel Burner
Fire

Fault Auto / Alternate key functions

Data Com
mute manual when in commission
mode.

Key Function
EK Selects Engineers Key mode.
LOW FIRE Pressing this key will force the burner to Low fire until the key is pressed
again to release the burner to modulate.
FUEL SELECT Changes Fuel/Profile. If the fuel is changed when the burner is firing, the
burner will go off then restart firing the new fuel selection.
BURNER O-I Sets the burner On/Off and changes between normal and local operation.
Note: the burner select input must be ON for this switch to start the burner.
FAULT MUTE/ Press this key to mute (open) the alarm relays, and then hold the key down
for approximately two seconds to remove any cleared faults.
AUTO / HAND Selects auto or manual burner modulation. In manual mode the UP/DOWN
keys are used to alter the fire rate.
DATA Selects different data types on the display window.
COM Changes operation to commission mode via a pass-code.

5.2 Start -up Sequence

When a fuel selection is made and the ‘burner select’ signal is given to start up the burner, the
control runs through the sequence described below. If a gas profile is selected, the control also
performs safety valve pressure proving in parallel with the start-up sequence (see section1.1).

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 Operating Instructions For TG5 Gas Burner

Stage Stage name Description

no.

0. Non-volatile The burner is held in this state until all faults are removed.
lockout

1. Burner off The burner is checked to make sure that it has switched off
completely. This includes main fuel safety valves closed, no
flame signal and a ‘no air pressure’ signal.

2. Wait for purge The control waits for both a burner select and a gas or oil select
signal. Progression to stage 3 or 5 maybe held off by external
influences, e.g. Communications control or digital input
controlled by an external stat circuit.

3. Open fuel valve If gas and valve proving are selected, the gas motor is moved up
for five seconds to allow any gas in the test section to be vented
easily during the proving sequence.

4. Hold fuel valve The fuel motor is held in position until step 1 of the safety valve
proving sequence (open main valve 2, or vent valve) is
completed.

5. Prove closed If gas is selected, the gas valve proving sequence begins. The fuel
positions and air motors are moved down until they stop. The final
positions are compared with the closed positions stored in
memory.

6. Prove air The burner motor is started and air pressure prove time t1 is
pressure initiated. The selected motors are moved up towards the purge
positionIf , unless the ‘fan start early’ option parameter has been
set in which case the motors will not move until the time has
expired.

7. Prove purge When the air pressure prove time t1 has elapsed, the air pressure
positions switch must give a ‘pressure’ signal or the control will lockout
the burner. If primary air is selected both primary and secondary
air signals must change from 'no pressure' to ‘pressure’ status.
The selected motors are moved up until they stop.

8. Pre-purge The timed pre-purge t2 is initiated.

9. Move to ignition When t2 has elapsed, the fuel and the air motors are moved to the
positions ignition position for the selected profile. The control will wait
for the gas valve proving sequence to finish if it is still in progress.

10. Pre-ignition Once the fuel and air motors are at their ignition positions, the
ignition transformer output is energized and pre-ignition time t3
is initiated.

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 Operating Instructions For TG5 Gas Burner
Stage Stage name Description
no.
11. Pilot ignition Once t3 has elapsed the ignition transformer, first main valve if
required for pilot (for gas firing) and pilot valve outputs are
energised and the first safety time t4 is initiated. If firing on oil
and ignition selected to be with both pilot and main valve, use
timing in the start-up sequence table for main valve 1. If firing on
oil and ignition with main valve is not selected the pilot ignition
will occur with only the pilot valve, use timing in the start-up
sequence table for main valve 2.

12. Pilot ignition When the first safety time t4 has expired, a flame must be
interval detected or the control will proceed to safety shutdown and
lockout the burner.

13. Main ignition Once the pilot interval time t5 has elapsed, the ignition
transformer is turned off, the second (and first if not already open)
main valve output(s) for gas or main oil valve output for oil is
energized and the second safety time t6 is initiated. If firing on
oil and ignition with main valve was selected the main oil valve
will have already opened for pilot ignition.

14. Wait for flame When the second safety time t6 has expired, the pilot valve output
established is turned off. If permanent pilot is selected and the burner is firing
on gas the pilot will remain open with the main valves. Main
interval time t7 is initiated.

15. Moving to low When interval time t7 has elapsed, the flame is considered
fire established and the fuel and air motors are moved from their
ignition positions to their low fire positions.

16. Modulation Once the fuel and air motors reach their low fire positions, they
are modulated according to the demand placed on the burner.

17. Move to post- start-upIf the fuel selection is changed or the ‘burner on’ signal is
purge removed, the main valve output(s) are turned off. The fuel motor
is moved to its closed position, and the selected motor(s) are
moved to their purge position(s), if a post purge is selected and
the post purge time is initiated.

18. Post-purge When the post purge time has elapsed, the burner motor is turned
off and the control returns to state 1 to wait for another start-up.

2.4 Modulation

During stage 16 (modulation), the control will position the fuel and air motors within the
programmed profile appropriate to the requirement for heat. The control has 2 modes of operation
using the standard RATIOTRONIC modulation function, Remote and Local. The mode of
operation is set via the keypad by pushing the “Burner ON/OFF” key and selecting the mode. Using
the programmable block function (option) within the control it is possible for the modulation
control to be generated with alternate options, these are not covered in the standard manual as they
may be generated by the user.

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 Operating Instructions For TG5 Gas Burner
2.4.1 Remote mode

In Remote mode, the modulation rate is determined by the internal PID control settings, Manual
modulation from the keypad,.or by one of the following remote influences:
1. Auxiliary modulation input,set point
2. Sequencing,
3. Comview.

5.5 Local mode

In Local mode, the modulation rate is determined by either the internal PID settings or Manual
modulation via the UP/DOWN keys. External modulation inputs and set point selection inputs are
ignored.

When “Local1” is displayed the burner is running using the Set point 1 PID settings.

When “Local2” is displayed the burner is running using the Set point 2 PID settings.

2.5 Non-volatile lockout

Non Volatile lockouts cannot be cleared without operator intervention and are remembered in the
event of power being removed from the control.

A non-volatile lockout will occur under the following conditions:

1. If any step of the gas proving sequence fails

2. In stages 1-9 (inclusive) if a flame is detected
3. In stages 11-16 (inclusive) if a flame is not detected
4. In stage 4 if the air pressure switch goes high (air pressure present)
5. In stages 7-18 (inclusive) if the air pressure switch goes low (air pressure not present)
6. In stages 5, 7 and 8, stages 10-16 (inclusive) and stage 18 if a motor is not in the correct
position
7. In any stage, if an internal or external fault not previously mentioned occurs which may
affect the safe operation of the burner

2.6 Ratiotronic 6000 Inverter interface additional information

The Ratiotronic 6000 can accommodate a daughter board within the main enclosure to allow
control of 1 or 2 inverter drives (daughter board dependent). Optionally the daughter board is also
available to allow feedback to be taken from directly from encoders measuring the speed of the
relevant motor, fan or pump shaft. There is also an option to allow the cup speed to be monitored
as an encoder input.

There are special wiring requirements for inverter feedback.

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5.8 Emergency Stop

The emergency stop or e-stop is a safety mechanism used to shut off the burner in an emergency
situation in which it cannot be shut down in the usual manner. Unlike a normal shut-down
switch/procedure, which shuts down the burner in an orderly fashion and turns it off without
damaging it, an e-stop is designed and configured to a) completely abort the operation at all costs
and b) be operable in a manner that is quick, simple (so that even a panicking user with
impaired executive function can operate it), and, usually, c) be obvious even to an untrained operator
or a bystander. The e-stop features a removable barrier to provide protection against accidental
activation.

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 Operating Instructions For TG5 Gas Burner
6 Component Setup Parameters
Before the commissioning process of the burner can take place, there are certain components like
the Ratiotronic 6000, inverter (when fitted), etc, which will need to be setup. The burner should be
factory set; however, if the parameters have been erased for whatever reason, then this section can
be used as a starting point. Please note that a fuel / air profile will not have been setup. Please also
note that this parameter set should be used in conjunction with the manual.

6.1 Ratiotronic 6000

Option Value Description Comments

0.1 xxx Site passcode last 3 digits of burner serial number
0.2 0 Serial communications control address
0.3 0 Reset hours run
0.5 0 Language Select
0.7 1 IsoComsAddress
0.8 2 IsoComsSetting
5=ignore alarms for 5 seconds at
1.0 5 Power up option power up
1.1 1 Keyboard auto/manual enable
1.2 0 Fault mute input enable
1.3 0 External profile select enable
1.4 0 Gas valve proof of closure select
1.5 0 Oil valve proof of closure
1.6 0 Second airflow switch (primary air) enable
1.7 0 Safety time configuration set
1.8 0 Force Mode Input
2.0 0 Drive 0 name not used
2.1 2 Drive 1 name gas servo motor
2.2 3 Drive 2 name oil servo motor
2.3 10 Drive 3 name air servo motor
2.4 11 Drive 4 name VSD drive
2.5 0 Drive 5 name
2.6 0 Drive 6 name
2.7 0 Drive 7 name
2.8 0 Drive 8 name
2.9 0 Drive 9 name
3.0 0 Drive 0 serial number not used
3.1 xxxx Drive 1 serial number - Gas Servo 1st 4 Digits of Ser No
3.2 xxxx Drive 2 serial number - Oil Servo 1st 4 Digits of Ser No
3.3 xxxx Drive 3 serial number - Air Servo 1st 4 Digits of Ser No
Found on side of servo motor
3.4 VSD1 Drive 4 serial number
3.5 0 Drive 5 serial number
3.6 0 Drive 6 serial number
3.7 0 Drive 7 serial number
3.8 0 Drive 8 serial number
3.9 0 Drive 9 serial number
4.0 0 Drive 0 profile assignment not used
4.1 1 Drive 1 profile assignment profile 1
4.2 2 Drive 2 profile assignment profile 2
4.3 3 Drive 3 profile assignment profiles 1 + 2 = 3

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 Operating Instructions For TG5 Gas Burner
4.4 3 Drive 4 profile assignment profiles 1 + 2 = 3
4.5 0 Drive 5 profile assignment
4.6 0 Drive 6 profile assignment
4.7 0 Drive 7 profile assignment
4.8 0 Drive 8 profile assignment
4.9 0 Drive 9 profile assignment
5.0 0 Drive 0 rotation 0 = anti-clockwise / 1 = clockwise
5.1 0 Drive 1 rotation 0 = anti-clockwise / 1 = clockwise
5.2 0 Drive 2 rotation 0 = anti-clockwise / 1 = clockwise
5.3 0 Drive 3 rotation 0 = anti-clockwise / 1 = clockwise
5.4 0 Drive 4 rotation 0 = anti-clockwise / 1 = clockwise
5.5 0 Drive 5 rotation 0 = anti-clockwise / 1 = clockwise
5.6 0 Drive 6 rotation 0 = anti-clockwise / 1 = clockwise
5.7 0 Drive 7 rotation 0 = anti-clockwise / 1 = clockwise
5.8 0 Drive 8 rotation 0 = anti-clockwise / 1 = clockwise
5.9 0 Drive 9 rotation 0 = anti-clockwise / 1 = clockwise
6.1 1 Fuel train for profile 1 gas
6.2 1 Fuel train for profile 2 oil
6.3 0 Fuel train for profile 3
6.4 0 Fuel train for profile 4
7.0 0 Fan on early time
7.1 15 Air Proving time
7.2 30 Pre-purge time Do not reduce this timing
7.3 1 Pre-ignition time Do not extend this timing
7.4 3 Pilot ignition time Do not extend this timing
7.5 3 Pilot hold time Do not extend this timing
7.6 3 Main ignition time Do not extend this timing
7.7 3 Ignition hold time Do not extend this timing
7.8 5 Low fire hold time Do not extend this timing
7.9 30 Post purge time Do not reduce this timing
8.0 0 Ignition spark output check
8.1 1 Flame failure response time
8.2 0 Extend false flame response time
9.0 0 Inverter control accuracy 0 = low / 1 = high
9.1 1 Inverter error tolerance 0 = low / 1 = high
9.2 100 Inverter closed loop gain
9.3 30 Inverter stop time
9.4 30 Inverter acceleration time
9.5 0 VSD1 speed encoder scaler
9.6 0 VSD2 speed encoder scaler
9.7 0 Low speed cup limit
9.8 0 Oil warning speed
10.0 0 Gas pressure sensor select 1 – valve proving via sensor,
0 – valve proving via pressure
switches

10.1 0 Gas pressure sensor span

10.2 70 Gas pressure nominal Parameters 10.2, 10.5 and 10.6 will
give a valve proving time of approx
40secs. This is an optimised set of
figures – do not alter
10.3 0 Gas pressure low limit
10.4 0 Gas pressure high limit
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 Operating Instructions For TG5 Gas Burner
10.5 1 Test volume
10.6 7.5 Maximum permissible leakage rate
10.7 0 Vent valve select

10.8 1 Valve proving select 1 – VPS enabled, DO NOT DISABLE

10.9 3 VPS Power Time
12.0 0 Photocell / IR flame detection select
12.1 0 Pilot flame threshold photocell
12.2 0 Main flame threshold photocell
12.3 0 Centre frequency photocell
12.4 0 Frequency pass ban photocell
13.0 x UV/Ionisation flame detection 1=non-shuttered/2=shuttered
13.1 x Pilot flame threshold non-shuttered = 20, shuttered = 10
13.2 20 Main flame threshold
14.0 6 Primary fault relay
14.1 0 Limit relay
14.2 0 Oxygen + fuel temperature limit relay
14.3 0 Permanent gas pilot select
14.4 1 Pilot with/without main valve select 0 = without / 1 = with
14.5 1 Direct ignition on oil
14.6 0 Spark termination
14.7 1 Oil pump relay function 1 = light oil / 2 = heavy oil
14.8 0 Extended oil pilot
15.0 2 Modulation input sensor type 2 = 4-20mA
15.1 x Modulation input decimal places 0 = temp / 1 = pressure
15.2 0 Modulation input zero value
15.3 xx Modulation input span value default: temp = 150, pressure = 16.0
15.4 x Set-point display units 1 = bar / 3 = deg c
15.5 0 Boiler high safety limit
15.6 20 Modulation time
15.7 0 Bumpless transfer
15.8 1 Low fire before off 0 = no / 1 = yes
16.1 0 Go back to pilot
16.2 0 Allow profile swap online
16.3 011 HV input 12 alarm/lockout function Boiler high limit stat, on PE7
16.4 012 HV input 13 alarm/lockout function Fan trip, on PE8
16.5 xx HV input 12 display message 11 – high temp, 13 – high pressure,
on PE7
16.6 17 HV input 13 display message Fan interlock, on PE8
17.1 0 Relay 1 output function (display unit) PR1,PR2,PR3
17.2 20 Relay 2 output function (display unit) PR5,PR6,PR7
17.3 19 Relay 3 output function (display unit) PR7,PR8,PR9
17.4 20 Relay 4 output function (controller) PD6,PD7,PD8
17.5 19 Relay 5 output function (controller) PD4,PD5,PD6
17.6 0 Relay 6 output function (controller) PD1,PD2,PD3
17.7 26 Relay 7 output function (26 = VSD1 start circuit) PZ17-PZ18
17.8 0 Relay 8 output function PZ15-PZ16
18.1 0 LV input 1 function PB9-PB10
18.2 0 LV input 2 function PB9-PB11
18.3 0 LV input 3 function PB9-PB12
18.4 0 LV input 4 function PB9-PB13
18.5 22 LV input 5 function Low Gas Pressure PB14-PB15
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18.6 21 LV input 6 function High Gas Pressure PB14-PB16
18.7 0 LV input 7 function PB14-PB17
18.8 0 LV input 8 function PB5-PB6
18.9 0 LV input 9 function PB5-PB7
19.1 0 LV input 1 message PB9-PB10
19.2 0 LV input 2 message PB9-PB11
19.3 0 LV input 3 message PB9-PB12
19.4 0 LV input 4 message PB9-PB13
19.5 5 LV input 5 message Low Gas PB14-PB15
19.6 4 LV input 6 message High Gas PB14-PB16
19.7 0 LV input 7 message PB14-PB17
19.8 0 LV input 8 message PB5-PB6
19.9 0 LV input 9 message PB5-PB7
20.0 0 Set-point select input 1-7 or 12-13
20.1 0 Boiler shutdown input 1-7 or 12-13
20.2 0 Low fire hold input 1-7 or 12-13
20.3 0 Oxygen trim disable input 1-7 or 12-13
20.4 0 Ignition wait input 1-7 or 12-13
20.5 0 Purge hold input 1-7 or 12-13
20.6 0 Purge time start input 1-7 or 12-13
20.7 0 Analogue input 5 option aux mod input
20.8 0 Lead boiler select 1-7 or 12-13
21.0 0 Set-point 1 enable
21.1 x Set-point 1 control value default: temp = 80, pressure = 8.0
21.2 0.5 Set-point 1 proportional value default: temp = 1, pressure = 0.5
21.3 1 Set-point 1 integral time
21.4 0 Set-point 1 derivative time
21.5 2 Set-point 1 control limit type Deviation
21.6 0.5 Set-point 1 low limit control value default: temp = 10, pressure = 0.5
Burner On 0.5 below SP

21.7 0.5 Set-point 1 high limit control value default: temp = 10, pressure = 0.5
Burner Off 0.5 above SP
21.8 0 Remote set-point 1 zero (4mA) value
21.9 0 Remote set-point 1 span (20mA) value
22.0 0 Set-point 2 enable
22.1 0 Set-point 2 control value
22.2 0 Set-point 2 proportional value
22.3 0 Set-point 2 integral time
22.4 0 Set-point 2 derivative time
22.5 0 Set-point 2 control limit type
22.6 0 Set-point 2 low limit control value
22.7 0 Set-point 2 high limit control value
22.8 0 Mod Max Enable Input
22.9 0 Mod Max Value
23.0 0 Warming enable
23.1 0 Warming limit
23.2 0 Warming time
24.0 0 Number of sequence lag boilers enables into sequencing
24.1 0 1st lag boiler address
24.2 0 2nd lag boiler address
24.3 0 3rd lag boiler address

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 Operating Instructions For TG5 Gas Burner
24.5 0 Lead assign type
24.6 0 Lag on rate
24.7 0 Lag on delay
24.8 0 Lag off rate
24.9 0 Lag off delay
29.0 0 Analogue output 1 function VSD1 overrides if selected
29.1 0 Analogue output 1 zero (4mA) value
29.2 0 Analogue output 1 span (20mA) value
29.3 0 Analogue output 2 function VSD2 overrides if selected
29.4 0 Analogue output 2 zero (4mA) value
29.5 0 Analogue output 2 span (20mA) value
29.6 0 Analogue output 3 function
29.7 0 Analogue output 3 zero (4mA) value
29.8 0 Analogue output 3 span (20mA) value
30.0 0 Oxygen probe interface serial number
30.1 0 Oxygen probe calibration offset value
30.2 0 Oxygen probe calibration gain value
Oxygen probe calibration gas
30.3 0 concentration
30.4 0 Flue & inlet temp sensor units
30.5 0 Oxygen input function
30.6 0 Oxygen probe calibrate enable
30.7 0 Boiler transport delay
30.8 0 Reset oxygen trim profile
30.9 0 Automatic trim commissioning
31.0 0 Limit modulation range
31.1-
31.4 0 Trim type for profiles
32.0 0 Trim limit default
32.1-
32.4 0 Trim limits
33.1-
33.4 0 Trim integral gain
34.0 0 Trim proportional gain default
34.1-
34.4 0 Trim proportional gain
35.0 0 Inlet temp sensor serial number
35.1- Hydrocarbon ratios for each fuel
35.4 0 respectively
35.5- Calorific values of fuels / profiles 1-4
35.8 0 respectively
35.9 0 Boiler radiated heat loss
36.0 0 Flue temperature alarm select
36.1-
36.4 0 Flue temperature low alarm value
37.1-
37.4 0 Flue temperature high alarm value
38.0 0 Oxygen alarm select
38.1-
38.4 0 Oxygen low alarm value at low fire
39.1-
39.4 0 Oxygen low alarm value at high fire
40.1-
40.4 0 Oxygen high alarm at low fire

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 Operating Instructions For TG5 Gas Burner
41.1-
41.3 0 Oxygen high alarm at high fire
42.0 0 Second oxygen probe select
42.1 0 Second oxygen probe calibration offset
42.2 0 Second oxygen probe calibration gain
42.4 0 Maximum oxygen variation
42.5 0 Maximum flue temp variation
42.6 0 Second oxygen probe calibration enable
44.0 0 Set real time clock
44.1 0 Set year
44.2 0 Set month
44.3 0 Set day of month
44.4 0 Set day of week
44.5 0 Set hours
44.6 0 Set minutes
44.7 0 Set seconds
44.9 0 Clear fault history
45.0 0 Erase/Restore enable
45.1 0 Erase command
45.2 0 Restore command

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 Operating Instructions For TG5 Gas Burner
6.2 Danfoss VLT FC 102

PNU NAME FACTORY DEFAULT DCL SETTING

0-20 DISPLAY LINE 1.1 REF % ANALOG INPUT 53
0-21 DISPLAY LINE 1.2 MOTOR AMPS
0-22 DISPLAY LINE 1.2 POWER KW
0-23 DISPLAY LINE 2 FREQUENCY HZ
0-24 DISPLAY LINE 3 KW/H COUNTER SPEED RPM
0-40 LCP HAND START ENABLE DISABLE
0-41 LCP STOP ENABLE DISABLE
0-42 LCP AUTO START ENABLE DISABLE
0-43 LCP RESET ENABLE
1-00 CONFIG MODE OPEN LOOP
1-03 VT CHARACTER AEO FUNCTION
1-20 MOTOR POWER xxxKW Use Motor Dataplate Info
1-22 MOTOR VOLTAGE 400 V
1-23 MOTOR FREQUENCY 50 HZ
1-24 MOTOR CURRENT xxx A Use Motor Dataplate Info
1-25 MOTOR NOM SPEED xxxx RPM Use Motor Dataplate Info
1-29 AUTO MOTOR ADAPT NO AMA ENABLE COMPLETE
1-90 MOTOR THERM PROTECTION ETR TRIP 1 THERMISTOR TRIP
1-93 THERMISTOR SOURCE NONE ANALOG INPUT 54
3-02 MIN REFERENCE 0.0 HZ 20.0 HZ
3-03 MAX REFERENCE 50.0 HZ
3-13 REFERENCE SITE HAND / AUTO REMOTE
3-15 REFERENCE 1 SOURCE ANALOG INPUT 53
3-41 RAMP UP TIME 45.0 SEC 15 SEC
3-42 RAMP DOWN TIME 90.0 SEC 20 SEC

PNU NAME FACTORY DEFAULT DCL DEFAULT

4-10 MOTOR SPEED DIRECTION BOTH DIRECTIONS CLOCKWISE
4-12 MOTOR SPEED LOW LIMIT 0.0 HZ 20.0 HZ
4-14 MOTOR SPEED HIGH LIMIT 50.0 HZ
4-16 TORQUE LIMIT MOTOR MODE 110 % 150 %
4-18 CURRENT LIMIT 110 % 150 %
4-19 MAX OUTPUT FREQUENCY 100 HZ
4-50 WARNING LOW CURRENT 0.0 A
4-51 WARNING HIGH CURRENT 99.0 A
4-52 WARNING LOW SPEED 0.0 RPM
4-53 WARNING HIGH SPEED 3000 RPM
5-01 TERMINAL 27 MODE INPUT
5-10 TERMINAL 18 DIGITAL INPUT START
5-11 TERMINAL 19 DIGITAL INPUT NO OPERATION
5-12 TERMINAL 27 DIGITAL INPUT COAST INVERSE
5-13 TERMINAL 29 DIGITAL INPUT JOG NO OPERATION
5-14 TERMINAL 32 DIGITAL INPUT NO OPERATION
5-15 TERMINAL 33 DIGITAL INPUT NO OPERATION
5-40 RELAY 1 FUNCTION ALARM RUNNING
5-41 RELAY 1 ON DELAY 0.01 SEC
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 Operating Instructions For TG5 Gas Burner
5-42 RELAY 1 OFF DELAY 0.01 SEC
5-40 RELAY 2 FUNCTION RUNNING ALARM
5-41 RELAY 2 ON DELAY 0.01 SEC
5-42 RELAY 2 OFF DELAY 0.01 SEC
6-12 TERMINAL 53 MIN SCALING 4.00 mA
6-13 TERMINAL 53 MAX SCALING 20.00 mA
6.14 TERMINAL 53 LOW 0.00 20.00
REF/FEEDBACK VALUE
6.15 TERMINAL 53 HIGH 50.00
REF/FEEDBACK VALUE
6-20 TERMINAL 54 MIN SCALING 0.07 V
6-21 TERMINAL 54 MAX SCALING 10.0 V
6-50 TERMINAL 42 ANALOG OUT SPEED – 0 HIGH LIMIT SPEED 4-20mA
6.51 TERMINAL 42 MIN SCALING 0% 40 %
6.52 TERMINAL 42 MAX SCALING 100 % 100 %
8.30 PROTOCOL FC MODBUS RTU
8.31 ADDRESS 1 2
8.32 BAUD RATE 19200 BAUD 9600 BAUD
8.33 PARITY/STOP BITS EVEN PARITY/1 STOP BIT NO PARITY/1 STOP
BIT

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 Operating Instructions For TG5 Gas Burner
7 Commissioning
7.1 Basic settings

It is essential that heat output of the appliance is known in order that the correct fuel input can be
calculated and set. If there is any doubt at all with regard to the appliance rating, the manufacturer
should be consulted before the burner is fired. The calorific value of the fuel must be known and
measurement of the fuel input should be by meter wherever possible.

Do not leave the burner firing at a rate which is known to be or which may be excessive, this will
result in damage to the appliance.
The nett flue gas temperature should be taken throughout the process of setting combustion. The
figure will vary according to the construction of the appliance but will normally be in the range
of 180° to 250°C gross. – if in doubt what this figure should be, please consult the boiler/appliance
manufacturer.

Calculation of burner firing rate ( output ).

Qn
Qf  [ kW ]
k

Qf = Burner Firing Rate ( Output ) kW

Qn = Boiler nominal thermal output ( kW )
k = Boiler Efficiency

Calculation of Gas Throughput at Nominal Boiler Output

Qn
Vb  [ m 3 h]
HU * k

Vb = Gas Throughput ( Fuel Input ) m3h.

Qn = Boiler nominal thermal output ( kW )
k = Boiler Efficiency
HU = Calorific Value of Fuel under Normal Conditions ( kWh/m3 )

Calculation of Gas Throughput for Boiler Firing Rate

Qf
Vb  [m3h]
HU

Vb = Gas Throughput ( Fuel Input ) m3h.

Qf = Burner Firing Rate ( Output ) kW
HU = Calorific Value of Fuel under Normal Conditions ( kWh/m3 )

Burner output ( kW ) = Boiler output ( kW )

Boiler efficiency

The indicating scale on the air damper motor is calibrated so that zero represents the fully closed
position for the air damper. The indicated low fire and high fire positions will be the result of the

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 Operating Instructions For TG5 Gas Burner
adjustments described below, there are no pre-determined positions applicable to a particular burner.
The scale reading only represents the air damper opening and not the firing rate!
Adjustments to the burner combustion head (for example the position of the flame ring in the nose
cone) may be necessary during the `setting up` of a burner.
Details of the settings for a particular burner, firing a given make of boiler, cannot be given in a
manual of a realistic size, however, standard basic settings are given in section 3 of this manual.
The size and relative position of the flame ring to the cone will have an appreciable effect on the
volume and velocity of air passing over the flame ring and this must be taken into consideration when
setting the combustion efficiency, with adjustments made as necessary. Adjustment of the flame plate
in relation to the nose cone can be made by loosening the screws holding the nose cone in place and
moving the nose cone backwards or forwards. After adjustments have been made, ensure that screws
are retightened and sealed in place.

NOTE:
ON ANY BURNER, AN ALMOST INFINITE COMBINATION OF COMBUSTION
HEAD COMPONENTS AND SETTINGS MAY BE USED TO ACHIEVE OPTIMUM
EFFICIENCY AND A FLAME SHAPE TO SUIT A VERY WIDE RANGE OF HEAT-
RAISING APPLIANCES. THE MOST SUITABLE COMBINATION/SETTINGS
MUST BE DETERMINED DURING THE COMMISSIONING PROCEDURE.

7.2 Start Gas Heat Input

For burners with a heat input of 120kW and above, and on which the start gas supply is taken from
between the main gas safety shut-off valves, the downstream main gas safety shut-off valve shall be
de-energised prior to start up.

The table below summarises the ignition gas rates for different burner configurations.

The start gas heat input must not exceed 120kW or the value given by the equation :

ts x Qs ≤ 100

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 Operating Instructions For TG5 Gas Burner
where:

ts is the safety time in seconds (s):

Qs is the maximum start gas heat input expressed as a percentage of the main gas rate

This approximates to an ignition rate of less than one third of the maximum firing rate.

If the burner is fitted with a separate pilot, the start gas heat input of the ignition burner must not
exceed the value given by the equation:

ts x Qs ≤ 150

where:
ts is the safety time in seconds (s):
Qs is the maximum start gas heat input expressed as a percentage of the main gas rate

7.3 Pre-commissioning

Note: The following tests must be carried out before commissioning is started.

 Check that the appliance has been filled to the correct level
 Check that the appliance isolating valves are fully open.
 Where fitted, check that the flue damper is locked in the open position.
 Check that the flue-draught stabiliser moves freely
 Check that the gas supply is guaranteed and is at the correct pressure.
 Check that the gas meter is the correct size.
 Ensure that a manual gas isolation valve is positioned as close as possible to the burner and
that all gas pipe work is adequately supported.
 Check that the external electrical connections are in accordance with the appliance
manufacturers wiring instructions.
 Make certain that both fuel supplies and electrical supplies have been isolated.
 Ensure that all gas and electrical connections are tight as connections may come loose during
transportation.
 Check the electrode gap to be 3mm at the narrowest point of the ignition electrode (twin) and
the tip of gas ignition electrode is 3mm away form the gas nozzle outlet.
 Set the firing rate control switch to `low fire` to ensure that the burner will remain at low fire
after light-up.
 Hot water boilers - check operation of the control and limit thermostats and that the boiler
has been filled with water.
 Steam boilers - confirm the operation of the boiler feed pump and switch, and check that the
water level controls are working.

After the initial firing of the boiler, do not leave the unit operating in an unmanned boiler house
unless the boiler on/off control has been operated and set at a suitable figure and the flame
failure system on the burner has been checked.

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 Operating Instructions For TG5 Gas Burner
7.4 Commissioning – Pneumatic Modulation burners
7.4.1 Dry run
Note: Gas leak checks must be carried out using a suitable non-corrosive leak detection fluid.

 Check for gas leaks on meters, governors and all mains gas supply pipe work.

 Ensure all pipework leading up to the burner main gas valve has been purged according to
IGE/UP/1 Soundness testing and Purging of Industrial & Commercial Gas Installations

 Ensure that the burner manual isolation valve is closed.

 Check that all isolation valves in the main gas supply pipe work are open.

 Remove or loosen the gas inlet pressure test point on the inlet side of the gas valve and open
the burner isolation valve until all air has been purged between the isolation valve and the
burner gas valve.
When this has been done, close the isolation valve.

Note: For the following tests a digital manometer will be required.

7.4.2 Check for leaks through the automatic gas valve.

Connect the manometer to the gas inlet test point on the automatic gas valve, open the manual gas
isolation valve for two seconds and then close it again.

The pressure shown on the manometer should remain constant.

7.4.3 Check for correct control sequence.

 Open manual gas isolation valve for two seconds and then close it again, sealing the gas
between the automatic gas valve and the isolation valve.

 Check that all time switches, room thermostats etc are in the `on` position and that the boiler
thermostat is set to the required temperature.

 Switch on the mains electrical supply.

The control box will commence the starting sequence which, depending on the control box,
will average:-
Prepurge time 30 seconds
Pre-ignition time 3 seconds
Pilot proving time 3 seconds

 When the pilot proving time is reached, the automatic gas valve is energised and will release
the gas trapped between the valve and the closed isolation valve.
The burner will then stop because the pressure acting upon the gas pressure proving switch
will be reduced due to the isolation valve being closed.

 Switch off the electrical supply on completion of this test.

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7.4.4 Firing the burner

 Connect a DC micro ammeter into the ionisation probe cable by splitting the in-line plug and
socket.

 Unscrew or loosen the outlet gas pressure test point on the gas valve and connect a
manometer.

 Open the manual gas isolation valve.

 Switch on the mains electrical supply and, if the control box is locked out (indicated by the
reset button being illuminated) press the lockout reset button.

 Provided all control devices, thermostats etc are in the `on` position the burner control box
will start the operating sequence. For information relating to sequence of operation please
refer to section 5.

 If the control sequence fails to start, check for correct setting of the gas pressure proving
switch.

 The amount of gas flowing through the valve can be adjusted by using the ‘ ’ and
‘ ’ and is proportional to the amount of combustion air set by the air damper
motor. Cam setting for the air damper have been described in section 3.1.

 ‘ ’ is used to set the Low Fire rate and ‘ ’ is used to adjust the high fire
rate. A combination of the two settings will define an operating line between high fire and
low fire and the valve will maintain the air/gas ratio across this range. Full information on the
gas multiblock may be found in section 5.

 Adjustment of ‘ ’ will have an affect on the setting of ‘ ’ and visa-versa.

It may take 3 or 4 fine adjustments at both high fire and low fire to ensure good combustion
at both ends.

ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS.

7.4.5 Combustion values and results

All combustion readings must be taken with an approved and correctly calibrated test kit.
The following combustion values should be reached:-
Low Fire
CO content 0 - 20 ppm
CO2 content 9 - 11 %
O2 content 5.4 - 2%
High Fire
CO content 0 - 20 ppm
CO2 content 10 - 11%
O2 content 3.6 - 2%
In all cases the CO figure should not exceed 100mg/m3 maximum.
The nett flue gas exit temperatures should be taken throughout the process of setting the combustion.
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The figures will vary according to the type of appliance but for shell and sectional boilers will be in
the range of 180 - 250C gross.
Always keep the exhaust flue gas temperatures within the manufacturers recommended range
and ensure that the appliance is not over or under fired

7.4.6 Adjustment of Gas Proving Pressure Switch

Loosen the screw in the gas inlet measuring point, connect a manometer and remove the clear plastic
cover from the gas pressure detector.
Switch on the burner and allow to fire.
Close the burner manual gas isolation valve slowly until the gas pressure is reduced to 50%.
Adjust the numbered black plastic ring on the gas pressure detector until the burner switches off.
Switch off the mains electrical supply to the burner, remove the manometer and seal the test point
screw.
Open the manual gas isolation valve and switch on the burner.

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7.5 Electronic Modulation Burners

IMPORTANT!
When commissioning burners fitted with Electronic Modulating Control Systems, the
respective operating manuals must be followed. Only competent and trained personnel are
permitted to commission burners fitted with these controls.

7.5.1 Gas Butterfly Valve

Control of the gas supply to the burner is performed using a butterfly valve.
Material specification of blade and spindle can be altered depending on gas
type, E.G. Stainless Steel can be specified for Bio-gas.

Check the butterfly valve has been correctly set to zero - Please consult
manual for details. More details on the butterfly valve can be found in the
component section.

7.5.2 Adjustment of air pressure proving switch

Check the air pressure proving switch and, if necessary, set to 50% of
differential pressure.
Example of adjustment:-
Negative pressure (–) measured 4 mbar
Positive pressure (+) measured 5 mbar
Differential pressure is - 9 mbar
Switch off point of pressure switch is 4.5mbar

From this point all commissioning procedures are dictated by the Ratiotronic 6000 manual.

ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS

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7.5.3 Ratiotronic programming

The Ratiotronic 6000 burner control system is generally pre-programmed in the factory prior to
despatch. However it is important that the parameters are checked against the lists supplied with the
test data supplied with the burner.
The combustion engineer must be competent with such a controller and be fully trained in burner
commissioning before proceeding any further.
This manual must be used in conjunction with the Ratiotronic 6000 manual at all times.

7.5.4 Setting the servo motors

Please refer to section 5 of the Ratiotronic manual.

In general the drive servo motors are allocated as follows:

Drive 1: Gas Butterfly valve

Drive 2: Oil Metering Valve
Drive 3: Air damper servo motor
Drive 4: Inverter

7.5.5 Burner Commissioning

Important:

It is recommended for T5 burners, that a variable speed drive should be fitted to avoid
excessive axial forces on motor bearings when commissioning. Initially set the inverter speed
to approximately 30-35 Hz and use all available stroke on air damper first. Once the air
damper is fully open, any additional air required can be achieved by increasing the inverter
speed.
See table below as an example setup.

GAS PROFILE

GAS (degree) AIR (degree) INVERTER

P0 10 10 600 (30Hz)
P1 20 25 600 (30Hz)
P2 30 40 700 (35Hz)
P3 40 55 700 (35Hz)
P4 50 70 700 (35Hz)
P5 60 85 700 (35Hz)
P6 70 90* 800 (40Hz)*
P7 80 90 900 (45Hz)
P8 90 90 999 (50Hz)
P9
P10

*NOTE AIR DAMPER IS MECHANICALLY FULLY OPEN BEFORE INVERTER

FREQUENCY IS RAMPED UP.

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Please now refer to ‘Section 6.6 Commission Ratio Mode’ of the Ratiotronic 6000 manual for details
on how to commission the burner.

7.5.6 Combustion values and results

All combustion readings must be taken with an approved and correctly calibrated test kit.
The following combustion values should be reached:-
Low Fire
CO content 0 - 20 ppm
CO2 content 9 - 11 %
O2 content 5 - 2%
High Fire
CO content 0 - 20 ppm
CO2 content 10 - 11%
O2 content 3.6 - 2%
In all cases the CO figure should not exceed 100mg/m3 maximum.
The nett flue gas exit temperatures should be taken throughout the process of setting the combustion.
The figures will vary according to the type of appliance but for shell and sectional boilers will be in
the range of 180 - 250C gross.
Always keep the exhaust flue gas temperatures within the manufacturers recommended range
and ensure that the appliance is not over or under fired. Warm up the boiler, or raise steam in
accordance with appliance manufacturer’s instructions.

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8 Burner Maintenance Schedule

REMEMBER!
ELECTRICAL AND FUEL SUPPLIES MUST BE ISOLATED BEFORE ANY
MAINTENANCE WORK IS CARRIED OUT ON THE BURNER.

The following schedules are only to be taken as a guide to those persons responsible for day to day
maintenance of the burners. Details of a service agreement covering the major items of routine
servicing are available on request.
An annual check by factory trained technicians is strongly advised.
All control circuit components, fire valves and other safety devices should have a functional check
at not greater than annual intervals.
Maintenance and inspection of boilers or other appliances must meet the requirements of the
manufacturers' schedules and of the insurers. It is usually more convenient to carry out burner
maintenance after the completion of the boiler inspection or cleaning, so that the burner can be fired
and the combustion reset to optimum figures.
The measurements given in the various combustion head drawings in this manual are to be regarded
as datum figures only. During commissioning, alterations may be made to the relative positions, or
to the components themselves, to suit the particular application.
Therefore, before dismantling the combustion head, take note of the measurements concerned and
record them on the manual's drawings. It is important that where possible components of the same
type and size are fitted as replacements.
The commissioning certificate for the burner should be available, to be used as a reference for
the fuel input and combustion figures which will give boiler MCR and the highest efficiency level.

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8.1 Opening the Burner

To open the burner, the two nuts securing the hinge section to the fan section must be removed. The
burner will swing open on its hinge offering full access to all combustion head components.

When necessary checks/repairs have been carried out, close up in reverse order ensuring that the
locking nuts are fully tightened.

8.2 Minor Maintenance

(a) Check the operation of the flame failure system daily by deliberately locking out the burner. This
can be achieved by either removing the UV cell, or on burners fitted with ionisation probes
isolating the gas supply to the burner.
(b) Where fitted, check and regularly clean the UV cell window with a soft cloth.
(c) Inspect the burner control cabinet to ensure that all indicator lamps are serviceable.
(d) Make a general check for cleanliness and security.
(e) As convenient, make an inspection of the combustion head components for cleanliness, security
and serviceability.
(f) Check the main gas valves for external hydraulic fluid leaks.
(g) Confirm the security of all linkages, locking nuts and any component parts fitted to the burner.
(h) Where a micro-ammeter is fitted make regular checks to confirm that the UV cell output does not
significantly deteriorate.

8.3 Major Maintenance

Take adequate safety precautions against the small amount of gas which escapes when gas train
components are removed.

Carry out all of the maintenance tasks listed above, plus the following:

(a) Remove the upstream pilot valve and determine the amount of dust etc. which is present. If a
substantial quantity is found, remove the upstream main gas valves from the burner and clean the
seats (Unibloc only, see 'Unibloc' section of this manual for actuator removal). The Siemens valve
is a sealed unit – any unauthorised opening will invalidate warranty.
(b) Check and clean any gas filters in the site pipework if significant quantities of dust or scale are
found. Make a request to the gas region for similar work on the service filter which protects the
meter
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(c) Confirm correct operation of electrical components, e.g. control boxes, motor starters etc and
check tighten all electrical terminals.
(d) The nominal life of a U/V cell is 10,000 hours, subject to regular checks of the cell output as
registered on the micro-ammeter (which might indicate an earlier deterioration) the cell should
be changed every third year.
(e) Disconnect the air shutter linkage at the shutter spigot. Move the shutter by hand to confirm
freedom of movement. Clean as necessary (the PTFE bearing surfaces need no lubrication but
will require replacement when worn)
(f) Inspect the refractory of the burner mounting plate. Make good any defects in refractory or sealing
(g) Ensure that boiler furnace sight glasses are clean and that their sealing is flue gas-tight.
(h) When the inspection and any rectification work has been completed on the burner/boiler, bring
the unit up to working temperature (slowly).
(i) With the boiler on line, confirm that the fuel throughput and combustion efficiency are equal to
the 'commissioned' figures.

8.4 Dismantling and Re-assembly of Burners

Combustion Head Removal

The combustion head can be removed, as a unit, for maintenance purposes. Before commencing
refer to the combustion head drawings in the exploded diagram section at rear of this manual for
relevant positions of the various components.

(a) Open the burner, as described in the burner maintenance schedule.

(b) Disconnect the probe/HT lead and, where a UV cell is fitted, remove this from its retaining clip
and move to a safe place.
(c) Loosen the jacking screw in the mounting hinge section opposite the gas entry.

(d) Pull the nozzle line spigot out of the gas entry.
(e) Withdraw the nozzle line complete, out of the blast tube.

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(f) Re-assemble in reverse order, ensuring that a new gas head seal is fitted.
(g) Check the combustion head is correctly aligned in the blast tube and that the seal is gas tight.
(h) Close and lock-up the burner

Burner Motor Replacement

a) Disconnect the probe and ignition leads from the combustion head and withdraw them and, where
necessary the UV cell from the mounting casting.
b) Disconnect air pressure switch and hinge switch cables. Ensuring that all cables are properly
marked for ease of re-connection.
c) Ensure that the burner door locking nuts are fully tightened.
d) Disconnect all mains power connections and other electrical wiring between the burner panel and
the boiler or other electrical panels again ensuring cables are marked.
e) Disconnect the motor wiring at the panel end (ensure that all cables are identified and that the
wiring connections on the replacement motor are the same as on the original).
f) Remove the air damper drive linkage.
g) On the TG3, TG4 and TG5 burners it will be necessary to electrically disconnect the air damper
modulation motor.
h) Take out the four fixing bolts and remove the modulation motor mounting bracket .
i) Using suitable lifting gear take the weight of the burner by its lifting eye.
j) Remove the ring of screws which secure the two halves of the fan case.
k) Remove the rear half of the burner (half fan case, motor, fan, panel) and place on a bench or clean
floor area.
l) Remove the fan retaining bolt from the end of the motor shaft and carefully remove the fan taking
care not to misplace the drive key.
m) Remove the motor by releasing the four retaining bolts at the rear of the main air shutter casting.
n) Re-assemble in reverse order, ensuring that the motor shaft is properly greased before the fan is
fitted.

Gas Valve Actuator -Removal/Replacement

Removal of gas valve actuators must only be carried out by suitably qualified personnel. Full
details of removal/replacement procedures for all standard actuators fitted by Dunphy Combustion
are given in the 'Unibloc' section of this manual.SS MUST BE

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9 Faults and fault finding
9.1 Ratiotronic 6000/6006

Faults relating to electronic modulation burners must refer to the Ratiotronic 6000 controller manual
– Section 9.

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10 Useful Information

Common Conversion Tables

To Convert Into Multiply by
Bars kg/m2 1.020 x 104
Bars p.s.i. 14.5
Bars kg/cm2 1.01972
Btu J 1054.8
Btu kg.cal 0.2520
Btu/hr kW 2.928 x 104
Btu/lb MJ/Kg 2.326 x 10-3
ºC. ºf. (Cº x 9/5) + 32
cm.Hg. ft. of H20 0.4451
cm.Hg. p.s.i. 0.1928
ft. metres 0.3048
gallons (US) litres 3.785
gallons (Imperial) litres 4.546
gallons (US) gallons (Imperial) 0.83267
Hp kW 0.7457
hp (boiler) kW 9.803
Inches cm. 2.54
Inches of H2O mb. 2.54
J Btu 9.48 x 10-4
kg.Cal. Btu 3.968
kg/cm² p.s.i. 14.2233
kW Btu/hr. 3412
kW kg.cal/min. 14.34
Litres gallons (Imperial) 0.21997
Litres/minute gallons(Imp.)/second 3.669 x 10-3
Metres ft. 3.281
p.s.i. bars 6.895 x 10-2
p.s.i. mbars 69

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RECORD OF COMMISSIONING VALUES

SITE: ADDRESS:

BURNER TYPE: SERIAL NUMBER:

BOILER TYPE: SERIAL NUMBER:

BOILER OUTPUT: OPERATING TEMP/PRESS:

DATE OF COMMISSIONING: ENGINEERS NAME:

FUEL: PUMPED RING MAIN/GRAVITY SUPPLY?

NOZZLE TYPE & SIZE OIL PUMP

WIRING DIAGRAM NO
Low Fire High Fire
Firing Rate Position 1 2 3 4 5 6 7 8 9 10

Burner Output

CO2

CO

O2

NOX

Nett Flue Gas Temperature ºC

Smoke Number

Ambient Temperature

Efficiency

Electronic Channel 1 - Fuel

Modulation Channel 2 - Air

Furnace Pressure

Fan Pressure

Pump Outlet Pressure bar

Oil Return Pressure ( Spill ) bar

Boiler Temperature ºC

Boiler Pressure

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11 Exploded Diagram and Spare Parts List

11.1 TG5 with Electronic Modulation Set-up

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TG525 TG530
ITEM QTY. DESCRIPTION
PART No. PART No.
TG5 LOW NOx COMBUSION HEAD ASSEMBLY GA23636 GA23638
1 1
TG5 COMBUSTION HEAD ASSEMBLY GA23635 GA23637
2 1 T5 VANE CASTING GA14933 GA14933
3 1 T5 IMPELLOR IMPELL00320 IMPEL00300
4 1 T5 FAN MOTOR MOTORF01270 MOTORF01280
5 1 T5 PLAIN CASTING GA14932 GA14932
6 1 T5 INNER SHUTTER GA17211 GA17211
7 1 T5 OUTER SHUTTER GA17290 GA17290
8 3 NYLON ROLLER FOR AIR SHUTTER (OUTER) GA5761 GA5761
9 3 NYLON ROLLER FOR AIR SHUTTER (INNER) GA5761 GA5761
10A 1 T5 SNORKEL SILENCER GA21376 GA21376
10B 1 T5 ACOUSTIC SILENCER GA6437 GA6437
11 4 MOD PLATE SPACER GA7961 GA7961
12 1 MOD PLATE GA17188 GA17188
13 2 SERVO CONNECTING ROD BEARINGS BEAROS00250 BEAROS00250
14 1 SERVO LINK ARM GA18765 GA18765
15 1 RATIOTRONIC 6027 SERVO MOTOR ETCRAT00745 ETCRAT00745
16 1 BRIDGE HANDLE CONTOL02285 CONTOL02285
17 1 CABINET HANGER BRACKET GA6433 GA6433
18 1 UNIVERSAL HANDED BURNER CABINET CABUN00140 CABUN00140
19 1 BURNER CABINET DOOR CABCPD00160 CABCPD00160
20 2 M16 EYE BOLT EYEBLT00100 EYEBLT00100
21 1 T5 BURNER MOUNTING GASKET GASKET00150 GASKET00160
3B 1 T5 INPELLOR HUB GA15360 GA15360

T5 UNIBLOC SIDE ENTRY ASSEMBLY (DN80) GA23519A GA23519A

23A 1 T5 UNIBLOC SIDE ENTRY ASSEMBLY (DN100) GA23519B GA23519B
T5 UNIBLOC SIDE ENTRY ASSEMBLY (DN125) GA23519C GA23519C
T5 VGD.40 SIDE ENTRY FOR ELECTRONIC
MODULATING BURNERS (DN80)
GA23530A GA23530A
T5 VGD.40 SIDE ENTRY FOR ELECTRONIC
23B 1 GA23530B GA23530B
MODULATING BURNERS (DN80)
GA23530C GA23530C
T5 VGD.40 SIDE ENTRY FOR ELECTRONIC
MODULATING BURNERS (DN80)
24 1 100NB PN6 BUTTERFLY GAS VALVE C/W 6026 MOTOR BUTFLY02141 BUTFLY02141
25 2 100NB PN6 GASKET (FULL FACE) GASKET00975 GASKET00975
26 1 T5 SIDE ENTRY PLATE (100NB PN6) SIDENT00130 SIDENT00130
QRA53 FLAME DETECTOR (230V) PHOTOL00152 PHOTOL00152
27 1
QRA53 FLAME DETECTOR (110V) 110VLG00365 110VLG00365)
28 1 OIL ENTRY BLANKING PLUG GA13048 GA13048
29 1 JACKING SCREW FASHEX00160 FASHEX00160
30 2 1/4"BSP DOWTY BONDED SEAL SEADOW00105 SEADOW00105
31 1 1/4"BSP x 10mm MALE STUD COUPLING COMPAD00485 COMPAD00485
32 - n10mm BUNDI TUBE BUNDIT00090 BUNDIT00090
33 1 1/4" COPPER WASHER COPWAS00075 COPWAS00075
LGW50 A2P AIR PRESSURE SWITCH PRESWI00245 PRESWI00245
34 1
KROMSCHRODER DG50U6 PRESWI00450 PRESWI00450

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11.2 VGD40.80 Assembly for Electronic Modulating Burners

11.3 VGD40.100 Assembly for Electronic Modulating Burners

11.4 VGD40.125 Assembly for Electronic Modulating Burners

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11.5 DN80 Unibloc Assembly

11.6 DN100 Unibloc Assembly

11.7 DN1250 Unibloc Assembly

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12 COMPONENT INFORMATION

12.1 Unibloc

12.1.1 Unibloc General Arrangements

All Unibloc gas trains are manufactured and tested in accordance with EN 161 : 1991 'Automatic
Shut-off Valves for Gas Burners and Gas Appliances'

The Unibloc body is cast iron to BS 1452 grade 220 (the 100 N.B. body conforming to EN161 is
S.G. cast iron to BS 2789 grade 2712). All bodies are manufactured in one piece and are precision
machined to accept the various gas valve actuators that are described in section 2.
The standard unit is designed for use with 2nd and 3rd family gases and is fitted with plated carbon
steel valve seating rings. For other gas applications, e.g. bio or producer gas, the valve seating rings
are manufactured out of grade 321 stainless steel, because of the corrosive nature of these gases.
Where hydrogen sulphide (H2 S) is present in the gas advice must be sought from Dunphy Technical
Department.
A gas filter is fitted around the seating of the first stage valve to prevent foreign bodies entering the

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Unibloc and causing valve seating problems. Gas filters are available to suit the various specifications
as required.

Valve actuators are supplied as standard with plated carbon steel seat assemblies fitted with nitrile
rubber seating discs.
If valves are required to be used on bio, producer or other corrosive gases, the valve seat assemblies
will be manufactured in 321 stainless steel with viton seating discs.

Gas Pilot Lines

In line with the new European legislation, burners with a rating over 1,200 kW are required to have
a separate pilot facility. Unibloc gas valve systems supplied for ratings above this figure will be
supplied with a pre- wired, built on pilot line which will comprise of pilot gas valve, pilot gas
governor and gas isolation valve. See exploded diagram further in this section.

Installation
Select a location where the ambient temperature will be within the range of 15°C to +60°C, ensure
that the gas supply pipework is clean and contains no loose particles, fit valve to pipework so that the
gas flow travels in the direction of the arrows on the valve casing.
Please note that the 40, 50, 65, 80 and 100 mm N.B. valve bodies should be mounted with the inlet
flange facing vertically downwards. The 125 mm. N.B. valve body has an adjustable inlet flange
section that can be rotated to face in various directions
Due to the size and weight of the 100mm N.B. Unibloc, it is recommended that after installation
in the gas pipework the valve body is supported using the hole drilled in the valve body rib.

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12.1.2 80mm Ratiotronic Unibloc exploded diagrams and parts list

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12.1.3 80mm Ratiotronic Unibloc with pilot exploded diagrams and parts list

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12.1.4 100mm Ratiotronic Unibloc exploded diagrams and parts list

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 Operating Instructions For TG5 Gas Burner

12.1.5 100mm Ratiotronic Unibloc with pilot exploded diagrams and parts list

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12.1.6 125mm Ratiotronic Unibloc exploded diagrams and parts list

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12.1.7 125mm Ratiotronic Unibloc with pilot exploded diagrams and parts list

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12.2 LFL1.333 Burner Control Box

To avoid injury to persons, damage to property or the environment, the following

warning notes should be observed!

Do not open, interfere with or modify the unit!

 Before performing any wiring changes in the connection area of
the LFL1…, completely
isolate the unit from the mains supply (all-polar
disconnection)
 Ensure protection against electric shock hazard by
providing adequate protection for the burner control’s
connection terminals
 Check to ensure that wiring is in an orderly state and that the wires are firmly connected (refer
to «Commissioning notes»)
 Press the lockout reset button only manually (applying a force of no more than 10 N), without
using any tools or pointed objects.
 Do not press the lockout reset button on the unit or the remote lockout reset button for
more than 10 seconds since this damages the lockout relay in the unit
 Fall or shock can adversely affect the safety functions. Such units may not be put into
operation, even if they do not exhibit any damage.
 In the case of flame supervision with UV detectors QRA..., it should be noted that sources of
radiation such as halogen lamps, welding equipment, special lamps, ignition sparks, as well
as X-rays and gamma radiation, can produce erroneous flame signals.

Mounting notes
 Ensure that the relevant national safety regulations are observed.
 When using 2 UV detectors QRA..., make certain that the detectors cannot see one another

Installation notes
 Installation work must be carried out by qualified staff.
 Always run the high-voltage ignition cables separately while observing the greatest possible
distance to the unit and to other cables.
 Do not mix up live and neutral conductors

Electrical connection of ionization probe and flame detector

It is important to achieve practically disturbance and loss-free signal transmission:
 Never run the detector cable together with other cables.
 Line capacitance reduces the magnitude of the flame signal.
 Use a separate cable of low capacitance
 Observe the maximum permissible detector cable lengths (refer to «Technical data»)
 2 UV detectors QRA... can be connected in parallel.
 The ionization probe is not protected against electric shock hazard.
 Locate the ignition electrode and ionization probe such that the ignition spark cannot arc over
to the ionization probe (risk of electrical overloads).
 In connection with the QRA..., earthing of terminal 22 is mandatory.
 Supervision with both ionization probe and UV detector QRA... is possible, but for safety
reasons – with the exception of the second safety time «t9» – only one flame detector may be
active at a time. At the end of the second safety time, one of the detectors must be inactive,
however, that is, the detected flame must have extinguished, e.g. by switching off the ignition
valve at terminal 17.

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Flame supervision with ionisation probe

Voltage at the ionization probe:

 Operation:
AC 330 V ±10 %
 Test: AC 380 V ±10 %

Short-circuit current max: 0.5 mA

Required ionization current min: 6 µA

Recommended range of measuring

instrument: 0...50 µA

Perm. length of detector cable:

 Normal cable, laid separately.
(multicore cable not allowed) max. 80 m
 Shielded cable: max. 140 m (e.g.
high-frequency cable, shield connected
to terminal 22

Flame supervision with QRA…

Supply voltage:
 Operation: AC 330 V ±10 %
 Test: AC 380 V ±10 %
Required detector current min: 70 µA
Possible detector current:
 Operation: max. 680 µA
 Test: max. 1000 µA ¹)

Perm. length of detector cable:

 Normal cable, laid separately
(Multicore cable not permitted): max. 100m
 Shielded cable: max. 200 m (e.g. high-frequency cable,
shield connected to terminal 22)

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Note1) During the pre-purge time with higher test voltage: self-ignition and extraneous light test

LFL Technical Data

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LFL Characteristics

Mains voltage AC 230 V –15 / +10 %

AC 100 V –15 %...AC 110 V +10 %

Mains frequency 50...60 Hz ±6 %

Unit fuse (built-in) T6,3H250V to DIN EN 60 127

Primary fuse (external) max. 10 A (slow)

Power consumption approx. AC 3,5 VA

Perm. input current at terminal 1 max. 5 A continuously, peaks up to 20 A for 20 ms

Perm. load on control terminals 3, 6, 7,

9...11, 15...20 max. 4 A continuously, peaks up to 20 A for max. 20
ms, total max. 5 A

Required switching capacity of switching

devices 1 A, AC 250 V
- Between terminals 4 and 5 1 A, AC 250 V
- Between terminals 4 and 12 min. 1 A, AC 250 V
- Between terminals 4 and 14 depending on the load on terminals 16...19

LFL Operation

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General

 Detector and extraneous light test are resumed immediately on completion afterburn time
«t13». Fuel valves that are not closed, or not fully closed, immediately initiate lockout on
completion of the afterburn time «t13». The test terminated when the prepurge time «t1» of
the next startup sequence.
 The proper functioning of the flame supervision circuit is automatically during each startup
phase of the burner
 During the postpurge time «t6», the control contacts for the release checked to ensure they
have not welded.
 The built-in unit fuse protects the control contacts against overloads.

Preconditions for start up

 Burner control must be reset

 Sequence switch must be in its start position - voltage at terminals 4 and 11 present and air
damper closed
 End switch «z» for the CLOSED position must feed voltage from terminal 11 to terminal 8
 The contacts of control thermostat or pressurestat «W» and other contacts of switching
devices connected between terminal 12 and «LP» must be closed _ e.g. control contact for
the oil preheater’s temperature.
 Terminal 4 must be live
 The N.C. contact of the air pressure switch must be closed - «LP» test

Start up sequence

A Start command (delivered by «R» for instance)

A-B Startup sequence
B Operating position of the burner
B-C Burner operation (according to the control commands delivered by «R»)
C Controlled shutdown via «R»
C-D Sequence switch travels to start position «A», postpurging
During burner off periods, only control outputs 11 and 12 carry voltage and the air
damper is in its CLOSED position as defined by end switch «z» of the actuator. Also,
in order to perform the detector and extraneous light test, the flame supervision circuit
is live (terminals 22 / 23 and 22 / 24).

A Start command delivered by «R»

→ «R» closes the start control loop between terminals 4 and 5
- The sequence switch starts running
- Only prepurging, power is immediately fed to the fan motor
connected to terminal 6
- Pre and postpurging; on completion of «t7», power is fed to the fan
motor or flue gas fan connected to terminal 7
- On completion of «t16», the control command to open the air damper is
delivered via terminal 9
- No power is fed to terminal 8 during the positioning time
- The sequence switch continues its travel only after the air damper has fully
opened.

t1 Prepurge time with air damper fully open

- During «t1», the correct functioning of the flame supervision circuit is tested
- If test is not successful, the burner control will initiate lockout

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Shortly after the start of «t1», the air pressure switch must change over from terminal
13 to terminal 14.
- Otherwise lockout
- Start of air pressure check

At the same time, terminal 14 must be live since the ignition transformer will be
powered and the fuel released via this current path.

On completion of the prepurge time, the burner control will drive the air damper
to the low-fire position via terminal 10, which is determined by the changeover
point of auxiliary switch «m». During the positioning time, the sequence switch
stops again. A short time later, the motor of the sequence switch will be
switched to the control section of the burner control. This means that, from now
on, positioning signals delivered to terminal 8 have no impact on the burner’s
further startup sequence (and on subsequent burner operation):

t5 Interval
- On completion of «t5», power is fed to terminal 20; at the same time, control outputs
9...11 and input 8 are galvanically separated from the unit’s control section.
- The LFL1... is now protected against return voltages from the power control
loop.
- The startup sequence of the LFL1… ends with the release of «LR» at terminal 20
- After a number of idle steps (steps with no change of the contact position), the
sequence switch switches itself off

Expanding flame burners

TSA Ignition safety time

On completion of «TSA», a flame signal must be present at terminal 22. It must not
be interrupted until controlled shutdown takes place
- otherwise lockout

t3 Pre-ignition time
Release of fuel via terminal 18

t4 Interval «BV1 – BV2» or «BV1 - LR»

- On completion of «t4», terminal 19 is live
- That powers «BV2» connected to the actuator’s auxiliary switch «v»

Control sequence under fault conditions and lockout indication

In the event of any kind of fault, the sequence switch will stop and, with it, the lockout indicator.
The symbol above the indicator’s reading mark gives the type of fault:

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If lockout occurs, the burner control can immediately be reset:

- Do not press the lockout reset button for more than 10 seconds

The sequence switch always returns to its start position first

- After resetting
- After correction of a fault which resulted in plant shutdown
- After each power failure
During that period of time, power is only fed to terminals 7 and 9...11.

Then, the LFL1... begins with a new burner startup sequence.

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LFL Glossary of symbols

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12.3 RWF 40 Burner temperature controller

The RWF40 is used to control the boiler temperature.

It is configured to modulate the burner up and down when firing on gas and
provide high/low thermostat functions when firing on oil.

In modulating operation the RWF40 operates as a PID controller. In 2-stage

operation the RWF40 provides control based on the set switching threshold.
The setpoint of the RWF40 can be adjusted either on the controller itself or
externally.

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12.3.1 RWF 40.000A97 Default Burner Settings

SETTING FACTORY DCL DEFAULT REMARKS

DEFAULT
C111 9030 F000 PRESSURE
0000 TEMP
C112 0010 0000
C113 0110 0110
SCL 0.0 0.0
SCH 100.0 16.0 PRESSURE
100 TEMP
SCL2 0.0 0.0
SCH2 100.0 100.0
SPL 0.0 0.0
SPH 100 16.0 PRESSURE
100.0 TEMP
OFF1 0.0 0.0
OFF2 0.0 0.0
OFF3 0.0 0.0
DF1 1.0 1.0
DF3 1278 1278
OLLO -199.9 -199.9
OLH1 999.9 999.9
DTT 30 30
AL 0.0 0.0
HYST 1.0 1.0
PB.1 10.0 1.0 PRESSURE
10.0 TEMP
DT 80.0 25.0
RT 350 100.0
DB 1.0 1.0
TT 15.0 15.0
HYS.1 -5.0 -5.0
HYS.2 3.0 3.0
HYS.3 5.0 5.0
Q 0.0 0.0
H 1.0 1.0
P 0.0 0.0
SP1 60.0 8.0 PRESSURE
80.0 TEMP

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12.4 Siemens VGD20 and VGD40 Gas Valve Blocks

Double gas valves for use on gas trains, consisting of 2 class «A»
safety shutoff valves.
Suited for use in connection with gases of the gas families I...III.
The double gas valve is to be combined with 2 actuators of the
SKP… series (e.g. to provide the functions of 2 safety shutoff valves
connected in series, with different types of gas pressure governor if
required).
Supplementary data sheets on the actuators is located at the end of
this section.
VGD20
To avoid injury to persons, damage to property or
the environment, the following warning notes
should be observed!

Do not open, interfere with or modify the double gas valve,

except when fitting the service replacement set! _ When used in
connection with gas, the valves constitute part of the entire safety
system. Fall or shock can adversely affect the safety functions.
Such valves may not be put into operation, even if they do not
exhibit any damage. VGD40

Protect the actuator against excessive temperatures (caused by radiation, for example), to ensure the
maximum permissible ambient temperatures will not be exceeded.

Mounting notes
Ensure that the relevant national safety regulations are complied with. To mount the double gas valve
VGD20..., 2 flanges type AGA41... / AGA51... are required.
To prevent cuttings from falling inside the valve, first mount the flanges to the piping and then clean
the associated parts. On the gas train, the valve can be mounted in any position, but the permissible
mounting positions of the associated actuator must be observed (refer to the relevant
Data Sheet)
The direction of gas flow must be in accordance with the arrow on the valve body.

When used in combination with the SKP10..., SKP15..., SKP25... or SKP75...,

the minimum gas pressure switch must always be mounted upstream of the double gas valve!

The electrohydraulic SKP15... actuator, which is used for shutoff functions, must always be mounted
on the inlet side while the actuators with integrated governor (SKP25..., SKP75...,) must always be
fitted on the outlet side of the valve (with a contoured disk).
Check to ensure the bolts on the flanges are properly tightened . Check to ensure the connections
with all components are tight. Mounting and replacement of the actuator can take place while the
valve is under pressure. Sealing materials are not required. Ensure that the O-rings are fitted between
the flanges and the valve body.

Installation notes
Installation work must be carried out by qualified staff.
If the available gas pressure exceeds the valve’s maximum permissible operating pressure, the gas
pressure must be reduced by a pressure regulator upstream of the valve.

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Commissioning notes
Commissioning work must be carried out by qualified staff.
If environmental conditions produce corrosion (e.g. sea climate), apply protective coating.
Check wiring carefully prior to commissioning.
Standards
CE conformity in accordance with the directives of the European Union
- Directive for pressure equipment 97/23 EEC
- Directive for gas appliances 90/396 EEC

Service notes
Check the correct functioning and the internal and external tightness of the VGD... each time a valve
has been replaced. The valve may only be replaced by qualified staff.

VGD20
The double gas valves VGD20... are of the normally closed type and have 2 disks, one non-contoured
disk on the inlet side and one contoured disk on the outlet side. The stems are guided on both sides
of the disks, thus ensuring precise alignment and tight shutoff. The high closing force of the return
spring is supported by the prevailing gas pressure (class «A» to EN 161). A strainer on the inlet side
protects the valve and downstream controls against dirt. Valve body and connecting flanges are made
of die-cast aluminium, the seals of nitril rubber, and the stems of stainless steel. The double gas valves
feature a pilot gas connection Rp¾" . Gas valve, flanges and actuators are supplied as separate items.
The 4 screws required to fit
the SKP... to the valve are
contained in the terminal
compartment. No special
tools are required for
assembly. The connecting
flanges have a test point.
They are internally threaded
and supplied as separate
items, together with the
necessary accessories, such
as bolts, nuts, seals, etc. The
overall flange dimensions and bore-holes are identical, so that all types of flanges can be fitted to the
double gas valve, irrespective of nominal size. This means that a 1½" flange can be fitted to a 2"
VGD... valve, and vice versa. Each double gas valve requires 2 connecting flanges, which are to be
ordered as separate items.

General Data
Class A (EN 161)
Group 2 (EN 161)
Types of gases gas families I, II, III (to G260 of DVGW) air
Built-in strainer, mesh size 0.9 mm
Perm. medium temperature -15...+60 °C
Mounting spring housing horizontal or vertical, pointing downward
Flanges for VGD40... to ISO 7005; PN16
Materials
- VGD20... die-cast aluminium
- VGD40... sand-cast aluminium

VGD40

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The double gas valves VGD40... are double seat disk valves of the normally closed type. The stems
are guided on both sides of the disks, thus ensuring a precise stroke and tight shutoff. To improve the
control performance, the disks at the bottom are pro-filed.
The patented double seats are closed by 2 springs. The high closing force of the return spring is
supported by the prevailing gas pressure (class «A» to EN 161). The spring of each stem exerts a
pressure on the disk so that there is a defined closing force acting on each disk. The surface area
proportions of the 2 valve disks per stem
are such that the closing force increases as the inlet pressure increases (class «A» valve to EN 161).
A strainer on the inlet side protects the valve and downstream controls against dirt. The 4 screws
required to fit the SKP... to the valve are contained in the terminal compartment. The double gas
valves DN40…150 correspond to the standard valve sizes of single valves (EN 558).

The VGD40... are supplied with a pilot gas

flange having a ¾“ connection for the pilot gas
line and a ¼“ connection for an impulse line.
This impulse line connection between the 2
valves and another impulse line connection on
the outlet flange can be connected directly to
the constant pressure governor SKP20... fitted
to «V1» or «V2».
A universal mounting plate facilitates
attachment of a number of commercially
available pressure switches or valves proving
devices. Both the pilot gas flange and the
universal mounting plate are exchangeable and
can be fitted on either side of the valve.

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Power Output Curves

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12.4.1 Siemens SKP actuators

The combination of actuator and valve provides the following functions:

- Safety shutoff valve (SKP15...)
- Safety shutoff valve with gas pressure governor / controller (SKP25..., SKP55..., and SKP75...)
The electrohydraulic SKP... actuators together with the valves are designed for use with gases of gas
families I...III and air. They are used primarily on gas-fired combustion plant. The actuators open
slowly and close rapidly. They can be combined with any of the above mentioned valve types and
nominal sizes. The actuator can be supplied with end switch (for indicating the fully closed position).
The SKP25... operates as a constant pressure governor with a setpoint spring.
Its field of use are primarily forced draft gas burners
- with mechanical fuel / air ratio control
- with electronic fuel / air ratio control
The SKP55... operates as a differential pressure
governor. Its field of use are primarily
- combustion plant with combined heat recovery
systems
- plant where pressure conditions in the burner and in
the combustion chamber do not change in proportion
to load changes - burners with adjustable fuel / air
mixing devices in the burner head - plant with negative
pressure levels on the gas or air side.

The SKP75... operates as a ratio controller and

provides control of the gas pressure
depending on the pressure of the combustion air, ensuring that the gas / air ratio remains
constant across the entire load range. Its field of use are primarily modulating forced draft gas
burners.

To prevent injury to persons, damage to property or the environment, the following warning notes
should be observed! Do not open, interfere with or modify the actuators!
• All activities (mounting, installation and service work, etc.) must be performed by qualified staff

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• Check to ensure that the impulse pipes are properly fitted and tight
• Fall or shock can adversely affect the safety functions. Such actuators must not be put into operation,
even if they do not exhibit any damage.
• If mains voltage is fed to the end switch via the second plug-in space, protective earth must be
connected to the actuator via the same plug.
• Use of connectors conforming to DIN EN 175301-803-A is mandatory
• The connectors used must have cable strain relief
• The pump’s stem must not be pulled out using the overstroke element since that part could become
loose.

If the available gas pressure exceeds the maximum permissible operating pressure of the valve /
SKP..., it must be lowered by an upstream pressure controller. The pressure switch for lack of gas
must always be fitted upstream of the gas valve when used in connection with the SKP… The inside
diameter of the impulse pipes must be a minimum of 6 mm. The impulse pipes must be installed such
that the differential pressure can be acquired with no disturbance (unfavourable flow conditions).
Pressure test points must not protrude and be flush with the inside diameter of the pipe or duct wall.
The impulse lines to the governor / controller should be as short as possible, enabling the governor /
controller to respond quickly should sudden load changes occur.
• Installation of impulse pipes
In the case of unsafe combustion chamber pressure pipes (e.g. resulting from potential leaks), the
setting must also be checked during operation without having the combustion chamber pipe
connected, especially with respect to maximum burner capacity. The impulse pipes must be fitted
such that the differential pressure can be acquired with no disturbance. With gas / air ratios > 3, the
impulse pipes for the combustion air and the combustion chamber pressure must have an inside

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diameter of at least 8 mm. The impulse pipe for the combustion chamber pressure must be fitted such
that the gases will cool down in the vicinity of the impulse pipe and condensing gases cannot enter
the controller but will return to the combustion chamber.
Recommendations:
– The gas pressure should be acquired at a distance of 5 times the nominal pipe size downstream
from the valve.
– Do not use the lateral test points on the VG... valve body for picking up the pressure
• Considering the combustion chamber pressure
If the resistance value of the combustion chamber / heat exchanger / stack system is constant, the
combustion chamber pressure changes in proportion to the gas and combustion air pressure as the
burner’s output changes. In that case, the combustion chamber pressure need not be fed to the
SKP75... as a disturbance variable. However, if the combustion chamber pressure does not change to
the same extent as the gas and air pressure – as this is the case in plants with flue gas fan or modulating
flue gas damper – the combustion chamber pressure must be fed to the SKP75... as a disturbance
variable, enabling the controller to counteract.

• Ensure that the relevant national safety regulations are complied with
• The quadratic arrangement of the fixing holes allows the actuator to be fitted in 4 different positions,
each step being 90°
• The actuator can be mounted or replaced while the system is under pressure; sealing
materials are not required
• Electrical commissioning may only be performed when the SKP… is fitted to the valve; otherwise,
the SKP… can be damaged.
• Power is supplied and connection of the end switch is made directly via a connecting cable
(conforming to DIN EN 175301-803-A)
• The end switch is factory set.
When power is applied, the pump will be activated and the control valve closed. Oil is now pumped
from the chamber below the piston to the pressure chamber above the piston. The oil pressure causes
the piston to move downward, thereby opening the valve – against the pressure of the closing spring.
The pump remains energized until the closing command is given. When power is removed, or in the
event of a power failure, the pump will be deactivated and the control valve opened so that the closing
spring pushes the piston back. The return flow system is sized such that the counterstroke required
for reaching the fully closed position is completed within about 0.6 seconds.

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12.5 VPS 504 Valve Proving System
The VPS 504 is the valve proving system used for double
block gas valves. The valve proving system complies with
EN 1643:
1. Equipment operates independent of residual
pressure in the range of the permissible operating
range
2. Test volume ≤ 4 l
3. Setting work not necessary on site
4. Short test period: min. 10 s, max. 26 s
5. Tightness or leaks are displayed by an LED
6. External fault display possible for series 02, series
04 and series 05.
7. Group fault alarm optional for series 01 (SSM)
8. Suitable for TRD systems
9. Electrical connection possible by plug connection
series 01, 02, 03. No rewiring is required for contact
allocation as per DIN 4791.
1. Series 04 and series 05: electrical connection at screw terminals via PG 13.5 cable entry.

Suitable for gases of gas families 1, 2, 3 and other neutral gaseous media.
No suitable for use with hydrogen – VDK 200 H2 to be used for hydrogen.

Approvals
EC type test approval as per EC Gas Appliance Directive: VPS 504… CE-0085 AP 0168
EC type test approval as per EC Pressure Equipment Directive: VPS 504… CE0036

1 Hall switch
2 Solenoid
3 Pressure switch diaphragms
4 Compression spring
5 Filter
6 Solenoid valve anchor
7 Solenoid valve coil
8 Pressure pump
9 Unlock switch
10 Fault lamp
11 Operating lamp
12 Test nipple
13 Volume restrictor
14 Pump diaphragm
15 Pump linkage
16 PCB
17 Plug connection
18 Equipment fuse
19 Spare fuse

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Specifications
Operating pressure max. 500 mbar (50 kPa)
Test volume 4.0 l
Pressure increase by motor 20 mbar
pump
Nominal voltage 230 V AC (-15%) to -240 V (+6%), VPS 504 series 05: 24 VDC
(Permissible voltage range) For further voltages, refer to type overview
Frequency VPS series 01-04: 50 Hz or 60 Hz
Series 05: DC
Rating requirement During pumping time approx. 6 VA, in operation 17 VA
Prefuse (provided by 10 A quick-acting or 6.3 A slow-acting fuse
customer)
Fuse installed in housing Microfuse 6.3 slow-blow L 250 V; IEC-127-2/III (DIN 41 662)
cover, replaceable
Switching current Operating output VPS 504 Series 01, 02, 03, 04, 05: max. 4 A
Interference output VPS 504 Series 02, 04, 05: max.1A
Refer to motor startup current!
Degree of protection VPS 504 Series 01, 02, 03: IP 40
VPS 504 Series 04, 05: IP 54
Ambient temperature 50 Hz 230 VAC -15°C to +70°C
others: -15°C to +60°C
Release time Approx. 10 - 26 s, depending on test volume and input pressure
Sensitivity limit max. 50 l/h
At inlet pressures of < 50 mbar, limit pressure rates well below
50 l of air
per hour occur due to the mode of operation. This allows for
applications
involving low inlet pressures.
Switch-on duration of control 100 % ED
Max. number of test cycles 20/h. Wait for at least 2 minutes after carrying out more than 3
consecutive
test cycles.
Installation position vertical, horizontal, not upside down
Media
• Standard model Gas families 1, 2, 3 and other gaseous media.
Not suitable for butane.
• Liquefied gas model Gas family 3 and butane

The VPS 504 operates depending on pressure

build-up. The program module starts to
function when heat is requested. Test is
performed depending on the burner functional
procedure: Check prior to burner start or
check during pre-purge period or check after
burner shut-down

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DUNPHY COMBUSTION LTD

QUEENSWAY ROCHDALE ENGLAND OL11 2SL
Tel +44 (0) 1706 649217 Fax: +44 (0) 1706 655512
Internet – http://www.dunphy.co.uk

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