Comtherm PP Series, Installation & Maintenance Manual

Page 1: ... 44 0 1905 775 783 www comtherm co uk sales comtherm co uk Installation Maintenance Manual PP Burner ...

Page 2: ...oning guidance Page 10 Fault Finding Guide Page 1 1 Fault Finding Guide Page 12 Fault Finding Guide Page 13 Fault Finding Guide Page 14 Fault Finding Guide Page 15 Fault Finding Guide Indirect Heaters Page 16 Parts List Key Page 17 Suggested Service Program Page 18 Suggested Service Program Page 19 Burner Service program Page 20 Burner Commissioning Record Page 21 Additional Commissioning Notes Pa...

Page 3: ...lications and selection TWO HEAT INPUT RATES The PP burner is manufactured in two basic gas manifold and air plate designs making possible a burner range with heat input concentrations of 290kW and 580kW per 300mm length of burner gas manifold The flame length produced by the PP burner is obviously shorter than that produced by conventional burners and does depend on burner setting combustion cham...

Page 4: ... The burner flame safety sequence control unit unit A1 receives the electrical start signal and begins to cycle through an air pre purge and light up sequence The air pre purge is for a specified preset time and allows for dilution of any fuel leakage to safeguard against the possibility of explosive fuel air mixture being present in the burner duct when the ignition is energized After the complet...

Page 5: ...mponents pressure switches control operators etc The burner should be securely fixed and the transmission of vibration and heat should be minimised GAS SUPPLY Gas piping to the burner should be of sufficient size to provide the correct gas pressure at the burner valve assembly inlet see specification in document M1 If in any doubt concerning the size and design of the gas supply pipe work consult ...

Page 6: ... vent pipe to the breather holes of governors Vents from governors must not be manifolded and should terminate in a safe place preferably above roof level Any additional vent pipes that are required will be shown in document M4 The gas supply pipe will be full of air and will require purging This purging should only be carried out by a suitably qualified gas engineer With regard to the soundness l...

Page 7: ...l electrical codes of practice All conduits should be kept clear of heat zones Local means of electrical isolation should be installed close to the burner Ensure that the electrical voltage does not vary from the specified by more than 6 High temperature wire tri rated or better should be used for all electrical connections The electrical connections to the burner shown on diagram M5 should be str...

Page 8: ...ing will be somewhat higher than when the burner is in operation 6 Ensure that the burner on off switch is in the off position 7 Switch the electrical supply on 8 Check for gas leaks on the burner as follows a Close the manual valve V1 and pilot manual valve V6 b Vent burner pipe work downstream of V1 by opening a suitably positioned test nipple c Use a manometer test pressure downstream of V1 for...

Page 9: ...leakages 9 Release the spring pressure on the gas governor item G2 10 Set the combustion air pressure switch item P1 25 below the specified air pressure required 1 1 Start the fan supplying the combustion air and ensure that the fan rotation direction is correct Check the running current of the motor and crosscheck this with the data on the Motor label Ensure that the motor overload protection is ...

Page 10: ...ut button The burner should cycle and light up onto the main flame 21 Slowly open up the manual test valve item V2 to the full position and adjust the main gas governor item G2 to produce the required flame size With the burner on full fire temperature control calling heat check that the gas pressure at the nozzle is as specified for the required thermal fuel rating this will be indicated on the b...

Page 11: ... flame signal NOTE Once correctly commissioned the burner settings should only be altered by suitably qualified personnel and only when changes to the process requirements deem it necessary At no point should the settings of any safety device be altered to overcome changes in process conditions without the burner again being fully commissioned in line with those process conditions Initial Light Up...

Page 12: ...ressure switch not made Check setting on switch if this is correct check the gas pressure Start cycle begins but the burner locks out or shuts down before initiating the ignition sequence Low combustion air pressure differential Reset burner pressure switch P1 If pressure switch P1 is set correctly open the air damper on the combustion air fan Check that the combustion air fan motor is rotating in...

Page 13: ...as Check pilot gas flow adjuster and pilot gas regulator Pilot blown out Reduce process air flow if possible Increase pilot gas rate Pilot lights but locks out when ignition de energised Pilot gas rate too low Adjust pilot gas rate Pilot lights but the burner locks out before the main valves are energised Flame sensor not detecting the flame Or Faulty sensor Check sensor for damage or moisture Cle...

Page 14: ...and main gas regulator Main flame lights but shuts down after a short period of time Pilot gas rate too high Adjust pilot gas rate Control circuit operating Check control circuit over temperature limits etc Burner gas or air ports blocked Check and Clean Identify source of blockage and rectify Flame sensor not detecting the flame Over firing and flame is lifting off reset main flame firing rate Ch...

Page 15: ...r Low fire set too low Check and adjust Control circuit operating Check control circuit over temperature limits etc Burner gas or air ports blocked Check and Clean Identify source of blockage and rectify Flame sensor not detecting the flame Combustion air failure Over firing and flame is lifting off reset main flame firing rate Check flame sensor installation and position Inspect combustion air fa...

Page 16: ...ire Low fire air set too low modulating gas and air burners only Check and adjust Control circuit operating due to temperature creep Check control circuit over temperature limits and low fire settings Flame sensor not detecting Flame Check flame sensor installation and position Main flame too long Too much gas Check main gas pressure and reset Check gas control valve and reset Check fuel type Comb...

Page 17: ...into system Source and rectify Burner shuts down see also sheets M8 1 to M8 4b Control circuit operating Check control circuit process airflow switch over temperature limits and low fire settings Flame sensor not detecting the flame Check flame sensor installation and position Too much pressure in chamber Check Flue Unit Produces condensation Burner turned down too low Check the adjustment of the ...

Page 18: ...burner run L3 Indication light valve fault L4 Indication light power on L5 Indication light instruments on L6 Indication light burner fan failure L7 Indication light burner fan run L9 indication light process fan run L10 indication light exhaust fan run MF Burner fan M1 Burner fan motor M2 Burner fan impellor P1 Burner fan pressure switch P2 Process air pressure switch P3 Low gas pressure switch P...

Page 19: ...ch the bulb itself 3 Remove combustion fan motor and impellor clear impellor blades of any blockage or build up of material drawn in by the fan 4 Clear fan inlet guard of any blockage or restriction if the combustion air is ducted to the fan assembly then the duct should be removed to check for any blockage 5 Remove back door to main burner body clear burner body of any dirt or debris which has be...

Page 20: ...6mm head retaining screws inside the casing The valve assembly union prior to the burner casing would need to be undone in order to withdraw the head At the time of the above inspection any burner air wings found to be significantly damaged split deformed should be replaced Small cracks and fishers or slight distortion in the wings would not be detrimental to the operation of the burner This down ...

Page 21: ...Date of Service Service Company Engineer Name Date of Next Service Burner Service Program Page 19 Comtherm Ltd Installation Maintenance Manual Burners Heaters Combustions Systems ...

Page 22: ...age Flame Control unit Flame Sensor Burner Commissioning Record Safety Pressure Switch Operation Set Off Set Off Set Off Set Off Combustion Fan p sw Process Air p sw High Gas p sw Low Gas p sw Valve Providing p sw Exhaust p sw Combustion Analysis where applicable O2 CO2 CO CO CO2 v Fuel Temperature Page 20 Comtherm Ltd Installation Maintenance Manual Burners Heaters Combustions Systems ...

Page 23: ...Additional Commissioning Notes Page 21 Comtherm Ltd Installation Maintenance Manual Burners Heaters Combustions Systems ...

Page 24: ...Burners Heaters Combustions Systems PP Burner Exploded Diagram 17 ...

Page 25: ...Installation Maintenance Manual If you have any questions Call Us On 44 0 1905 775783 Comtherm Ltd Comenco Works Union Lane Droitwich Worcestershire WR9 9AZ Burners Heaters Combustions Systems PP Burner ...