Training Course Gas Burner

45

40 35

30 15

2,5

25 20

50

Training course Gas burner type G Film

10 5

Copyright © 1997 by Max Weishaupt GmbH, Schwendi. Alle Rechte der Verbreitung, auch durch Film, Funk, Fernsehen, fotomechanische Wiedergabe, Tonträger jeder Art und auszugsweisen Nachdruck, sind vorbehalten. Das Copyright gilt für alle Komponenten des Kurses. Max Weishaupt GmbH, D-88475 Schwendi Tel. (07353) 830, Telefax (07353) 83 358, Druck-Nr. 83120301 January 1999

Film 1.1 Gas burner type G – training course

Function of burner in the heat exchanger system

Combustion chamber

Burner

2 3

1

Hot water boiler

Z

Air

Gas

Task of the burner: To produce heat by combustion of fuel and air

January 1999

Copyright © by Max Weishaupt GmbH, D- 88475 Schwendi


Composition of gas and air

Hydrogen H2

Gas

Carbon Monoxide CO

Hydrocarbon CnHm

Nitrogen N2 Carbon Dioxide CO2

Example for Hydrocarbon

Methane CH4

H

H

C

H

Propane C3H8

H

H

H

H

C

C

C

H

H

H

H

Oxygen O2

H

Nitrogen N2

Air Other gases

January 1999



Complete combustion

a) Carbon b) Hydrogen

+ Oxygen + Oxygen

a)

+ O2

C

= Carbon dioxyde = Water vapour

=

O C

+ heat + heat

CO2

H

H

O

= Combustion

2 H2O H

+ H

January 1999

H

heat

O

+ O2

2 H2

+

C O

b)

heat

O

Combustion

+

+

H O

O

H

O H



Quality requirements for a heat exchanger system High efficiency 1%

93% 6%

100%

2 3

Z z

1

Environmentally friendly

N2 CO2 CO

January 1999

NO

H2O NO 2 Cx Hy



Combustion with insufficient air

Carbon

+

2C

+

C

C

Oxygen

=

carbon monoxide

O2

=

O

Combustion

2CO

C

O

C

O

+

O

Disadvantages of insufficient air Danger of explosion! Poisonous carbon monoxide! Loss of efficiency!

January 1999



Combustion with excess air Air temperature Air pressure

Gas

Combustion chamber pressure

Air

Chimney draught Fan contamination

To revent a shortage of air being caused by external factors, excess air is used for combustion. Excess air +15…20%

Gas

Excess air = roughage

January 1999

Air

loss of heat


Type of fuel

Natural gas L

Natural gas H

Propane Butane

Propane/ Sewage Gas oil Butane gas 70/30 EL


Lower caloritic value Air requirement Specific air requirement

kWh/m3 m3/m3 m3/kWh

8,83 8,45 0,957

10,35 9,91 0,957

25,89 24,37 0,941

34,29 32,37 0,941

27,96 26,32 0,941

6,38 6,12 0,959

11,90 11,22 m3/kg 0,943 kg/kWh

Flue gas volume Wet Dry

m3/m3 m3/m3

9,37 7,72

10,82 8,90

26,16 22,81

34,66 29,74

28,23 24,12

7,05 5,84

11,86 m3/kg 10,46 m3/kg

Specific flue gas volume Wet Dry

m3/kWh m3/kWh

1,06 0,87

1,05 0,86

1,01 0,88

1,01 0,87

1,01 0,86

1,10 0,91

1,00 kg/kWh 0,879 kg/kWh

Max. carbon dioxide

Vol.%

11,65

11,92

13,70

14,00

13,74

16,85

15,31

Film 1.6.1 Gas burner type G – training course

January 1999

Properties of fuels


Connection between CO content and excess air

1. Optimum conditions for combustion

2. Good burner and boiler matching

Measurement:

CO2 12%

3. Poor conditions for combustion

Measurement:

CO << 50 ppm

CO2 11,5%

Measurement:

CO > 50 ppm

CO [ppm]

CO [ppm]

CO [ppm]

600

600

600

300

300

300

10 12 10

8

6

[%] 10 12 10 CO2

Setting

CO2 10,5%

January 1999

CO << 50 ppm

8

6

[%] 10 12 10 CO2

Setting

CO2 10%

CO > 50 ppm

CO2 10%

CO << 50 ppm

8

6

[%] CO2

Remedy

Check the installation


Combustion head

Pressure switch air

Solenoid valve DMV

Manometer

45

40 35

30 15

2,5

25 20

50

Test burner

10 5

Ball valve II

I

III

III III III


Filter

III III III

III

III

III

Compound regulation Motor

Pressure regulator Pressure switch Gas Valve proving VPS

Air inlet


January 1999

Burner type G


Filter for gas

Test point inlet pressure

Test point outlet pressure Filter element (replaceable)

January 1999



Pressure regulator

Adjustment spindle Spring

Safety diaphragm

Vent orifice

Working diaphragm Balancing diaphragm

Regulator disc Impulse pipe

Shut down position January 1999

Operating position Copyright © by Max Weishaupt GmbH, D- 88475 Schwendi


Solenoid valve DMV-D

Quantity adjustment Electrical connection

Solenoid coil

Strainer

Valve seat valve 1 Valve seat valve 2

January 1999



Pressure test points Double solenoid valve

Test points

4

5

1

2

3

2 1

3

4

5

1

2

3

Legend: 1 Pressure before of valve 1 2 Pressure between valve 1 and 2 3 Pressure after valve 2 4 Inlet flange connection 5 Outlet flange connection

January 1999



Pressure test points Double solenoid valve

Test points 6

1

7

3 2

2

3

5 4

4 5

6

7

1

V2

V1 1

2

3

4

5

Legend: 1 Pressure before of valve 1 2 Pressure before of valve 1 3 Pressure between valve 1 and 2 4 Pressure between valve 1 and 2 Ignition pilot connection 5 Pressure after valve 2 6 Inlet flange connection 7 Outlet flange connection

January 1999



Funktion of pressure regulator for gas Gas pressure

Electrical connection

Diaphragm

Spring

Electrical connection

Set at 50 mbar

60 mbar January 1999

Setting dial

Set at 20 mbar

40 mbar

40 mbar

10 mbar



Mixing head

Diffuser Ionisation electrode

Combustion head

Gasket

Gas butterfly valve

January 1999



Mixing head - version LN

Ionisation electrode Ignition electrode Nozzle insert Diffuser

Setting dimensions of ignition electrode: 5 mm to nozzle insert 2 mm to diffuser

Mixing head - standard version

Perforated diffuser Conical diffuser Ignition electrode

Ionisation electrode

Setting dimensions of ignition electrode: approx. 3 mm ignition electrode distance min. 25 mm distance to ionisation electrode January 1999



Flame monitoring Ionisation monitoring

Burner control LFL LFL Feuerungsautomat 22

24

RAN

FE on G8 – G11

/

GE

H DATA-

/∼ (A

FE on G1– G7

)

µA

/

Ω ∼V

mA·A

ADP

V OFF

3230

· V · ΩµA · mA

10A

COM

Microammeter min. monitoring current 6 µA

UV monitoring

Feuerungsautomat Burner control LFL LFL 22

UV

23

RAN H DATA-

/

GE

/∼ (A

/

Ω ∼V

)

µA

mA·A

ADP

V OFF

3230

· V · ΩµA · mA

10A

COM

Microammeter min. monitoring current 70 µA January 1999



Gas - air compound Air damper Position indicator

Setting screw

Servo-drive shaft

Gas butterfly valve

Reset spring

Linkage

Cam disk

Setting screw Guide

Rotation point Lever guide

Cam band

January 1999



Burner control with connections

Thermostat

Gas pressure switch

Air pressure switch

Ionisation electrode

Burner control: Receives signals Issues commands Coordinates time sequences

Servo motor

January 1999

Burner motor

Ignition transformer

Solenoid valve

“Fault” lamp



Checking the burner Burner name plate

45

40 35

30 15

5 2,

25 20

50

Max Weishaupt GmbH, 88475 Schwendi

10 5

0085

Burner type G3/1-E Version ZE LN CE-0085AP0385 Kat. DE/I2ELL Supply press. min 15 Rating 80 – 550 kW Oil accord. to DIN 51603BN ~ Voltage 230 V~ 50 Hz Elec. rating 0,76 kW Serial-Nr. 4012087

Gas type N max 500 mbar kg/h A gl kW Year of manuf. 1995 16

Capacity chart G3/1-E vers. LN

Back pressure [mbar]

Burner type type of combustion head rating kW, N

G3/1-E - NA G3/3a – 120 x 41 80 – 550

Mixing head Open Closed

10 8 6 4 2 0 -2 0

100

200

300

400

500

600

Burner rating [kW] January 1999



Checking the burner Burner name plate

45

40 35

30 15

5 2,

25 20

50

Max Weishaupt GmbH, 88475 Schwendi

10 5

0085

Burner type G3/1-E Version ZE CE-0085AP0520 Kat. DE/I2ELL Supply press. min 15 Rating 90 – 630 kW Oil accord. to DIN 51603BN ~ Voltage 230 V~ 50 Hz Elec. rating 0,76 kW Serial-Nr. 4012087

Gas type N max 500 mbar kg/h A gl kW Year of manuf. 1999 16

Capacity chart G3/1-E


Burner type type of combustion head rating kW, N F

G3/1-E G3/2a – 133 x 100K 90 – 630 90 – 630

Mixing head Open Closed

6

4

2

0

-2 0

200

400

600

800

Burner rating [kW] Januar 1999

Copyright  by Max Weishaupt GmbH, D- 88475 Schwendi


Burner installation

III III III III

III

III

III

III

III III III

Ensure burner can be hinged open

Combustion head installation position

Observe combustion chamber geometry

≥ 60°<)

Combustion head flush or protruding

Fill gap with movable insulating material January 1999



Valve proving Phase 1

Phase 2

DMV test point 3 open

Test points on DMV 1

2

3

5 4

6

7

1

2

3

4

4 5

1

V2

V1

3 2

5

Test requirements: Test pressure: 100…150 mbar Test period: 5 minutes Max. pressure loss: 1 mbar January 1999


III

III III

III

III

III

III

Venting the gas valve train III III III


III

Test burner


January 1999

Venting the gas valve train


Test burner To check that no air is present

Burner head

Primary air lockable

push-button cock

Important feature: Test burner with double nonreturn valve

January 1999


Start command Servo-motor OPEN

Servo-motor Ignition load Ignition

Nominal load pre-purge

Fuel release Safety time

▲ P

Burner control Gas pressure switch Burner motor Air pressure switch Copyright © by Max Weishaupt GmbH, D- 88475 Schwendi

OPEN Servo-motor CLOSED Ignition transformer Solenoid valve Ionisation electrode

▼

1

2 Gas pressure switch opens


January 1999

Function test


Combustion head setting


Capacity chart G3/1-E vers. LN 10 8 6

Zu

4

Auf

2 0

g

160

175

-2 0

100

200

300

400

500

600

Burner rating [kW]

g d

Combustion head and diffuser dimensions Burner type

Rating kW min – max

Combustion head type – d [mm]

Diffuser diameter [mm] outer x inner

Combustion head setting dim. g [mm]

G1/1-E G3/1-E G5/1-D G7/1-D

55 – 300 80 – 550 160 – 830 250 – 1550

G1/3a – 96 G3/3a – 109 G5/3a – 148 G7/3a – 170

105 x 36 120 x 41 162 x 50 190 x 60

155 – 140 175 – 160 192 – 172 219 – 199

January 1999



Combustion head setting


Capacity chart G3/1-E 6

4

2

0

-2 200

0

400

600

800

Burner rating [kW]

e

Combustion head and diffuser dimensions Burner type

Combustion Perforated Diff. head diameter [mm] type – d [mm] outer x inner

Diffuser diameter [mm] outer x inner

Combustion head setting dim. g [mm]

G1/1-E G3/1-E G5/1-D G7/1-D G8/1-D G9/1-D G10/1-D G11/1-D

G1/2a G3/1a G5/1a G7/1a G7/2a UG2/1a UG2/1a UG3/1a

95 x 40 100 x 40 100 x 50 110 x 50 120 x 50 130 x 70 130 x 70 155 x 70

139 – 154 158 – 178 168 – 193 193 – 218 193 – 218 217 – 247 217 – 247 274 – 304

January 1999

130 160 200 250 265 325 325 380

115 133 173 213 213 270 270 315

80 90 100 110 120 130 130 155



Valve train selection (Example) PF = + 4 mbar QF = 450 kW

2 3

1

Pin front of DMV

Pe = 25 mbar

Type G3/1-E, version LN

Burner rating kW

Low pressure supply (gas pressure in mbar into shut off valve) pe,max = 300 mbar)

High pressure supply (gas pressure in mbar into double solenoid valve)

Nominal diameter of valve trains

Nominal diam. of valve trains

3/4” 1” 40 50 65 80

3/4”

Nominal diameter of gas butterfly valve

Nom. diam. of gas butterfly valve

25

25 40 40 40 40

1”

40 50

25

25

40 40

25 33 42 51 61 73

10 13 15 17 19 22

7 10 11 12 13 15

Natural gas E (N) Hu = 10,35 kWh/mn3, d = 0,606 300 350 400 450 500 550

January 1999

44 59 75 91 110 132

19 25 30 35 41 47

12 15 17 19 21 24

10 13 15 16 17 19

10 12 13 14 14 16

9 11 13 13 13 15

7 10 11 12 13 14



Valve train selection (Example) PF = + 4 mbar QF = 450 kW

2 3

1

Pin front of DMV

Pe = 25 mbar

Type G3/1-E

Burner rating kW

Low pressure supply High pressure supply (gas pressure in mbar into shut off valve) (gas pressure in mbar into double solenoid valve) pe,max = 300 mbar) Nominal diameter of valve trains

Nominal diam. of valve trains

3/4” 1” 40 50 65 80

3/4”

Nominal diameter of gas butterfly valve

Nom. diam. of gas butterfly valve

25

25 40 40 40 40

1”

40 50 65

25

25

40 40 40

22 29 37 46 56 68 80 93

6 8 10 12 14 17 19 22

– – 5 – 6 6 7 7 8 8 9 9 10 10 11 11

80 40

Natural gas E (N) Hu = 10,35 kWh/mn3, d = 0,606 300 350 400 450 500 550 600 650 January 1999

41 54 69 86 105 126 149 174

16 20 25 30 36 42 49 56

9 10 12 14 16 18 21 23

– – – 8 – – 9 – – 11 9 – 12 9 9 13 10 9 15 11 10 16 12 11

– – – 6 6 7 8 9

– – – 5 6 6 7 8

Copyright  by Max Weishaupt GmbH, D- 88475 Schwendi


January 1999

Basic setting on burner type G (prior to burner start)

Adjust combustion head Pressure switch air to min. setting

45

40 35

30 15

2,5

25 20

50

Valve stroke maximum 10 5

III III III III

III

III

III

III

III III III


Pressure switch gas to min. setting Limit switch Closed 0° <) Limit switch Open 90° <) Auxiliary switch Partial load 30° <) Auxiliary switch Ignition load 20° <)

Open ball valve Pressure regulator to min. setting


Servo motor 1055/80

Motor drive can be disengaged for manual adjustment

Presetting of limit and auxiliary switches Description Limit switch CLOSED Limit switch OPEN Auxiliary switch stage 2 Auxiliary switch partial load gas Auxiliary switch ignition load Auxiliary switch partial load Oil

January 1999

switch 4 3 1 2 5 6

on wiring diagram IV III I II V VI

presetting 0° <) 90° <) only on dual fuel appr. 30° <) appr. 20° <) only on dual fuel



January 1999

Optimising nominal load

Air quantity setting

Flue gas measurement


M Z

2 3

1

Gas quantity adjustment

Gas quantity control


January 1999

Optimising partial load

Air quantity setting

Flue gas measurement


2

M Z 1 3


Setting the gas pressure switch

45

40 35

30 15

2,5

25 20

50

Close ball valve slowly

10 5

III III III III

III

III

III

III

III III III

AU S

mA ·A

∼V

AD P

Ω

/

µA

DA TA -H

/∼

RA NG E

(A)

/

EIN

NU

LL

▲ 20 P EA 0m K ba r

GB

20

0

∼ 20 STA 0 m T. ba r

▲

Gas pressure switch

V OF F

3230

· V · ΩµAA · mA

10A

Turn setting dial until the pressure switch contacts open

C OM

Sensor current

45 40

➞

5 mba r

5 2,

January 1999

15 10

➞

❙

50

20

GW 50 A2

TÜ 12/94 0164 AC 2A

ID–No: –No: CE CE-0085 A00012

p max = 500 mbar ~ (AC) 10A 250 V

30 25 35 Switch point

Regulating pressure

Instructions for setting: – Pay attention to the flame stability – Minimum required sensor current 10µA – CO-content less than 100 mg/kWh



Setting the air pressure switch With pressure side air regulation in nominal load

With differential pressure test independent of load

45 40

15 10

➞

❙

50

20

LGW 50 A2P

Ausf.

pmax = 400 mbar

Switch point

,5 mbar

➞

10

ar 50 45 b m

30 25 Typ LGW A2P Bereich 2,5 ÷ 50 mbar

Switch point

80.09 e 128

20 15

❙

➞

DIN–DVGW–Reg.Nr.

25

LGW 50 A2P

Ausf.

80.09 e 128

pmax = 400 mbar

DIN–DVGW–Reg.Nr.

5 2,5 January 1999

35

52

35 30 Typ LGW A2P Bereich 2,5 ÷ 50 mbar

40

Reset by 20%

➞

Find switch off point



Lockout position indicator Burner control LFL Start position Servo-motor open / pre-purge of nominal load

a

Air pressure switch control

Flame relay test

P

b´

Servo-motor closed / ignition load

End of 1. safety time

1

Fuel release

2

Pre-ignition

b

Release capacity regulation

Start of 2. safety time

January 1999


Burner control LFL Start command Servo-motor OPEN

Servo-motor Ignition load Ignition

Nominal load pre-purge

Fuel release Safety time

Release capacity regulation Operating position

Lockout indicator Gas pressure switch Burner motor Air pressure switch Copyright © by Max Weishaupt GmbH, D- 88475 Schwendi

OPEN Servo-motor CLOSED Ignition Solenoid valve Ionisation electrode

▲ P

▼

1

2


January 1999

Sequence diagram


January 1999

Basic operation of burner control LFL Function diagram Lockout indicator

P R O G R A M M W E R K SM

AR

Start position Servo-motor Open Air pressure switch test Flame relay test Servo-motor Closed Fuel release

P

1 2

Release capacity regulation Operating position Start position Copyright © by Max Weishaupt GmbH, D- 88475 Schwendi

1 ϑ

2

12 13 4

5

6

14

11 7

9

10

8

16 17 18 22 24 23 15

19 20

M

P

˜

ϑ

P

P

B/W

LP

ϑ

ZL Auf

R

Zu M

Input signal

˜

Output signal Flame signal

L N

UV

LR

P

SA

Flammenfühler

SA Z A


Basic wiring diagram burner control LFL

QRA5... UV

1

L

2 M

1 F

5

3

4

22

23

15

br1 a

N

FE

b a

24

22

b

ar2

ar1

QRA2

4

12 S10

S11

7

6 K1

UV

K1 QRE

23 24

22 F4

M1

M1

F5

5

V

N

13 14

FR fr1 a

fr3

fr2

b

ϑ

b a b

a a

a

❊

b

NTC

b

AR

a

b a b

ar3

S H

br2 E

M a

b

BR

a

b

a

a

b

b

a

b

A

SM

3

21

2

15

16

17

18

19

20

9

M

11 10

8

F6

1 Y6

V

A

S1

H6

M

Z

M

LK

T1

Y1

Y4

Y2

Y12

N

January 1999



Basic wiring diagram / function diagram LFL QRA5... UV

1

L

2 M

1 F

5

3

4

22

23

15

br1 a

N

FE

b a

24

22

b

ar2

ar1

QRA2

4

12 K1

S10

S11

7

6

UV

K1 QRE

23 24

22 F4

M1

M1

F5

5

V

N

13 14

FR fr1 a

fr3

fr2

b

ϑ

b a b

a a

a

❊

b

NTC

b

AR

a

b a b

ar3

S H

br2 E

M a

b

BR

a

a

b

a

b

b

a

b

A

SM

3

21

2

15

16

17

18

19

20

9

M

11 10

8

F6

1 Y6

V

A

S1

M

Z

M

H6

LK

Y1

T1

Y4

Y2

Y12

N

B

A t7

t 11

a b

C

t1

D t6

12 7

t3

a b

19

a b

10

a b

16 9

t 16

a b

9 11

t4

20 a b

18 t9

a b

17 t5 t 10

a b

t 13

a b a b

Steuerausgänge der Kontakte

a b

8

t 20

t2

a b

t8

▲

January 1999

P

▼

1

2


A1 LFL/LGK 1 2 4

16

13

12

14

5 18 22 24 3 6 N 8 1110 9

M1

20

Y6

M 3

M

K15 P

X4

S16 T1

S10

1

2

1413153 4

81

13

5 6

121110 9 8 7

X11 96

F2 43

61 33

24

95

K1 S1

H1

B1

44

h

P1

K17

82

14

62 34

23

2 4 6 1 3 5

h

P2

H2

S7

S2

ϑ

26 27 28

23 24 25

17 18 19 20 21 22

9

15 16

7 8

14

5 6

P

F4

3

1

P

S11

2

X9

ϑ

H6

1

H12

2

H11

L2

1

N

2

PE

3

X9

L1

F5

N

P

L1

ϑ

L2

S11 X9

PE


1 2 3 4

10 11 12 13

X3

1 P

F6

2

F3

GAS

F1

Y2 Q1 PE N L1 L2 L3 380V-400V 3/N/PE 50-60Hz


January 1999

Wiring diagram G1 - G7 version ZD

Training Course Gas Burner

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