Maintenance Manual SDR-1500

Direct Drive Rotary Cup Burner Type

SDR- 1500

Maintenance Manual

1-30, Nishinohata, Okubo-Cho, Uji, Kyoto, 611-0033, Japan TEL : 0774-41-3310

/

FAX : 0774-41-3331

INDEX

1. Burner general specification ・・・・・・・・・・・・・・・・・・・・・・・・・・   2. Outlines

(1)

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・(2 - 3)

Preparation for operation・・・・・・・・・・・・・・・・・・・・・・・・・・(4 - 5) Operation・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ (6 - 7) W.O.combustion・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ (8) Rotary Cup Burner Unit, Sectional drawing of part ・・・・・・・・・・・・・・・・  (9) Rotary Cup Burner Unit, Disassembling drawing 3.

・・・・・・・・・・・・・・・・・  (10)

Rotary Cup Burner, Burner, Assembling Assembling procedure ・・・・・・・・・・・・・・・・・ (11 – 30) Direct Drive Rotary Cup Burner, Sectional Sectional drawing ・・・・・・・・・・・・・・  (31)

4.

Accessories drawings of Burner  ・・・・・・・・・・・・・・・・・・・・・ (32 – 43)

5. Maintenance and cleaning of Burner ・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・・・・・・ 

(44)

List of Maintenance & Inspection Interval・・・・・・・・・・・・・・・・・・・・・・   (45)

INDEX

1. Burner general specification ・・・・・・・・・・・・・・・・・・・・・・・・・・   2. Outlines

(1)

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・(2 - 3)

Preparation for operation・・・・・・・・・・・・・・・・・・・・・・・・・・(4 - 5) Operation・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ (6 - 7) W.O.combustion・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ (8) Rotary Cup Burner Unit, Sectional drawing of part ・・・・・・・・・・・・・・・・  (9) Rotary Cup Burner Unit, Disassembling drawing 3.

・・・・・・・・・・・・・・・・・  (10)

Rotary Cup Burner, Burner, Assembling Assembling procedure ・・・・・・・・・・・・・・・・・ (11 – 30) Direct Drive Rotary Cup Burner, Sectional Sectional drawing ・・・・・・・・・・・・・・  (31)

4.

Accessories drawings of Burner  ・・・・・・・・・・・・・・・・・・・・・ (32 – 43)

5. Maintenance and cleaning of Burner ・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・・・・・・ 

(44)

List of Maintenance & Inspection Interval・・・・・・・・・・・・・・・・・・・・・・   (45)

DATE

TYPE : SDR-1500

CHARGE

SUNFLAME BURNING APAP APAPARAT ARATUS US

1. Burner general specification 1 – 1. Burner type

Direct drive Rotary Cup Burner

1 – 2. Capacity

6000－60,000 MJ/H (150 ～  1,500 Kg/H,

H.F.O.) H.F.O.) (Note 1)

10,000 －60,000 MJ/H (250 ～  1,500 Kg/H,

H.F.O.) H.F.O.) (Note 2)

(Note 1 : with Primary air control) (Note 2 : Primary air fixed) 1 – 3. Fuel

・Marine A-Oil（at cold start） ・Marine C-Oil (normal) ( ～500cSt) MAX 135Deg. C. Emulsif ied Fuel ・Emulsified

MAX 100Deg. C.

12 KPa ～ 1100 Nm3/H

1 – 4.

Primary Air 

1 – 5.

Combustion air 

1 – 6.

Calorific value

40.9 MJ/Kg fuel

1 – 7.

Cup revolutions revolution s

3500 mim-1 ～  8000 mim-1

1 – 8.

Vibration

Our internal standard ：

3 KPa ～  22000 Nm3/H

15μｍ(full vibration range ）TYP.

－１－

2. Outlines Sunflame Rotary Cup Burner (Fig.1)

This burner consists of Rotary Cup, Wind Box, and devices for ignition and safety combustion. The fuel oil is led to Rotary Cup and goes into Cup inside which is rotated with high speed.  And fuel oil is spread spread evenly evenly in Cup inside inside by centrifugal centrifugal force and thin thin oil film is formed at Cup outer end. The oil film is collided with the high speed air of normal and reverse directions from the Primary Air Nozzle at Cup outer end. Thus fuel oil is atomized and the spray angle is made. Secondary air (combustion air) is distributed evenly in Wind Box and circulated from the outer circle of Primary Air Nozzle for easy mixing with the oil particles.  As above, the atomizing atomizing of this burner burner done in the Rotary Cup, Cup, and then the pressure of of fuel oil can be low and the atomized particles are even. This makes complete combustion combustion and combustion to low load with low excess air ratio  Also ignition is ensures with Ignition Ignition Burner using using A-Oil.

－２－

Rotary Cup Burner Unit is f itted with the hinges, and can be opened without removing the air or oil pipes and electric cables. In a opened position, all parts can be observed for inspection and maintenance. Burner can be applied for both horizontal use or vertical use. The oil film is atomized by the primary air of 600 ～1,500mmAq. In case the pressure of furnace is plus side, it is required to increase primary air pressure depending on the furnace pressure. The volume of primary air will be approx. 7% of n ecessary combustion air volume. This burner performs the control of Rotary Cup rotation and control of primary air supplying volume as well as turn-down ratio 10 : 1.  Atomizing viscosity of the fuel oil is 24cSt (RW No. 1 : 1,000 sec) is standard but combustion can be done at 100cSt. For better ignition performance, lagging for oil pipe is provided and fuel oil return- line is provided for oil circulation in order to keep the fuel oil temperature.  Also following improvements for better ignition are applied : 1) Lagging is provided on the piping (from Main Sol. Valve outlet to Flexible connection). 2) Circulation line is provided near to Main Sol. Valve. 3) Also, the start/stop control of F. O. Circulating Pump due to the changing of oil temp. is done by Temperature Switch located at near to Main Sol. Valve. Thus, lowering of fuel oil temperature which is supplied at the ignition can be prevented and improve ignition performance.

－３－

ＰREP AR ATION  F FOR  O OPER ATION Ａ Check the followings before operating the burner.

1. Piping and valve operation of the feed water system.

2. Power source of the feed water control and control air

3. Water level in the boiler

4. Oil level in the service tank

5. Valve operation and no leakage from fuel oil piping (check the ignition burner suction line especially for air release and oil leakage.)

6. Fuel oil piping according to the flowchart (before commissioning in the yard) a) Position of the flow meter (to measure the flow rate correctly) b) Position of the relief valve (for proper oil circulation near the burner) c) Connecting position of the return line (for sufficient air release) d) Complete steam heat tracing and insulation (The air blown from the engine room should not cool the oil piping line.)

Ｂ Initial operation(including operation resumed after a long time shut down)

1. When the service tank cannot be heated, use marine diesel oil. (Whenever boiler steam is blown at docking, oil piping line is changed to marine diesel oil.)

2. Release air in oil piping completely. (Especially at commissioning, release air completely after hydraulic test; confirm if oil reaches to pump suction.)

3. Check wiring of the control panel, external terminals on the junction box, the pressure switches and the temperature switches

4. Check the rotating direction of each motor.

5. When the boiler is cool, start the operation with low combustion. After the boiler is heated (boiler pressure is over 0.1MPa), change to high combustion.

－４－

Ｃ Operation procedure and Notes

1.

The burner operation is basically automatic. Manual operation is available in an emergency. There are safety devices against burner cut for low water level, flame –off or stop of the FD fan overload. However, burner cut because of the rise if boiler steam pressure is not performed and therefore the boiler pressure needs monitoring. In ignition, check the flame of ignition burner first before turning on the fuel oil m ain solenoid valve.

2.

In case of using 2 F.O.Pump, select No.1 pump or No.2 pump at the control panel. Confirm the valve operation in the piping system as well.

3.

Confirm if each switch on the control panel is off before power is turned on.

4.

Open or close valves on the piping system and select the position of F.O.TEMP DETECT SWITCH on control panel according to the f uel oil used for combustion.( For Marine diesel oil ,turn the thermostat bypass on.)

－５－

OPERATION  A－MANUAL OPERATION 1. After confirmation of each points in preparation for operation, turn on main power source.

2. According to used fuel, confirm if each valve in oil piping line is open or close.

3. When Marine A-oil is used, set oil heater switch to “OFF”, and also set temperature detect switch to “CANCEL(D.O.)”.

4. Set ACC switch to“AUTO”or “Em'y”(Only in case PLC break down) “AUTO.”：Oil flow and damper adjustment is controlled automatically. “Em'y”：Oil flow and damper adjustment is controlled by digital indicating controller (SDC15). Combustion capacity is set by Em'y COMB. RATE switch. (When the burner starts/stops, set Em'y COMB. RATE switch to “START/STOP”.)

5. Set the burner operation switch (OPERATION) to “Em'y” position and start the burner operation. 5.1

In case of ACC“AUTO.” Prepurge is carried out for 30seconds automatically.  After prepurge finishes, lamp for “IGNITION READY” on the junction box lights up.

5.2

In case of ACC “Em'y” Carry out prepurge manually. Open air damper fully for 30 seconds by switch of Em'y AIR FLOW.  After that, set the damper to ignition position (where lamp for “IGNITION READY”lights up.) Next confirm FO Flow and adjust FO Flow by switch for Em'y F.O. FLOW not to generate smoke.

6. After confirm lamp for “IGNITION READY” lights up, start ignition.  After pushing switch for “IGNITION MANU” start, ignition starts within 3 seconds. If ignition does not start within 5seconds, switch off and investigate the cause.

7. After confirmation of ignition burner firing, remain pushing “IGNITION MANU” switch and turn on “SOLENOID V. MANU” switch. Then combustion starts.

－６－

8. When ACC switch is set to“AUTO.”, burner combustion is proportionally controlled according to steam pressure. When ACC switch is set to“Em'y”,set combustion capacity by Em'y COMB. RATE switch.

Position

Combustion capacity

START/STOP

≒10%

LOW

≒20%

MID.

≒30%

HIGH

≒40%

＊Number of combustion capacity in above table is the setting value at t he time of shipment from our factory. 9. When combustion is stopped, set the burner operation switch (OPERATION)to “STOP” position. D.O.MIX (cleaning in burner combustion line) is carried out and combustion stops. Then postpurge is carried out and burner stops completely. B－ AUTOMATIC OPERATION 1. Initial operation is same as 1-3 sections in MANUAL OPERATION.  After setting each switch to Auto position, set the burner operation switch to “AUTO” side.(If steam pressure is high, burner enters STAND-BY mode ) When the condition is right, burner is operated automatically based on program control.

2. When combustion is stopped, set burner operation switch to “STOP”.  After postpurge finishes, burner stops completely. Do not turn off main power source until postpurge finishes.

3. For time table of auto operation, refer to the attached flow chart.

－７－

＊ Waste Oil Combustion

（Waste Oil Combustion Only）

(a) Preparation for operation 1. Water and solid materials in the waste oil cause failure of the pumps and valves. And they also cause clogging of the strainer. Therefore, the tank needs proper drainage and the strainer must be cleaned before operation.

2.  At low temperature, waste oil does not flow smoothly and atomized particles become rough. Because combustion cannot be carried out at lower than ignition point, waste oil must be heated before combustion. Though heating temperature is normally from 80°to 100°,heating temperature is changeable depending on waste oil condition. Please adjust according to the c ombustion condition. Water in waste oil can be evaporated by heating. (If a lot of water is contained in case water is evaporated by heating, the temperature in the tank rises up to 100℃.(maximum is 100℃)) 3. Stir waste oil before feeding to the burner to equalize waste oil including microscopic water particles after drainage and stratifying by difference in specific gravity and temperature in tank. This can also facilitate evaporation of the water.

(b) Operation  After above mentioned preparation, stop the burner once. Changes the 3-way valve to waste oil usage and operate W.O.Pump.Then apply the same operations as those for heavy fuel oil. Depend on the waste oil condition, oil pressure must be adjusted. Increase oil pressure for the oil with low heat generation to increase oil flow and prevent from blow –off. Decrease oil pressure for the oil with high heat generation to decrease oil flow and prevent from generation of black smoke.

(c) Stop Stop the burner and W.O.PUMP once. Replace suction line of W.O.PUMP to marine diesel oil. Operate W.O.PUMP for 2 or 3minutes to replace W.O.line to m arine diesel oil and then change the 3-way valve to heavy fuel oil usage

－８－

Rotary Cup Burner Unit, Sectional d rawing

－９－

Rotary Cup Burner Unit,

Disassembling Drawing (Fig. 2)

Rotary Cup Burner Unit,

Disassembling Drawing (Fig. 2)

No. 部 品 名 称 1 2 3 4 5 6 7 8 9 10-A 10-B 11 12 13 14 18 19 20 38 X Y Z W S V

Main Shaft Main Shaft Casing Bearing cover (front) Bearing cover (rear) Primary Air Tube Primary Air Tube Disc Distributor Oil Guide (outer) Distributor Oil Guide (inner) Oil Pipe Connection Part Rotary Cup Cup Holder Primary Air Nozzle Fuel Oil Pipe Motor Base Blind cover for Cup hole Cup Mut Stopper of Main Shaft Casing Centering block for Air Tube Bearing Guide Roller Stopper Bolt Bearing Coupling Oil Seal Grease Nipple (Pin Type) O-Ring （Vi ton） O-Ring （Nitrile）

数量 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 2

備

考

M 18

M 24 6007Z : C3 ALS-055 AC2094EO PT 1/8 S24 JASO-1018

No. 部 品 名 称 T O-Ring （Vi ton） U O-Ring （Vi ton） I H B m n q F

Packing Key at Shaft Motor Key at S. Cup (boht round) Key at Motor Bearing Snap Ring Plug

A C D E G J K L M N O P Q R a

Cap Screw with S.W. Cap Screw Hexagonal bolt with s.w. Cap Screw with S.W. Cap Screw Hexagonal stopper bolt Cap Screw Air Nozzle fixing screw Washer of Air Nozzle Cap Screw with S.W. Spring Washer Cap Screw Cap Screw with S.W. Allen Cap Screw Snap Ring

数量

備

2 1 1 1 1 1 1 1 1

G55 P62

8 2 4 4 8 6 12 4 4 3 1 8 2 各3 1

考

□5×5 □5×5 6302ZZ S14 20A

M M M M M M M M

5×20 5×20 10×30 10×25 5×15 5×85 6×15 6×15

M 5×12 DB-18L M 5×15 M 8×15 M 8×20 / 25

S35

－１０－

3.

Rotary Cup Burner, Assembling procedure ＊ Tightening torque of screws Please tighten the screws for Rotary Cup Burner according To the standard of JIS. (50～70 N・m)

3-1. Fit Bearing (a) to Main Shaft A (1). The tolerance of fitting is “interference fit. Put Shaft vertically and insert the bearing with facing the opened side to Shaft. Set bearing to main shaft from cup side. Warm up by the bearing heater. Don’t wedge in.

Main Shaft (1)

Bearing (X)

Snap ring (a)

Main Shaft (1) Main Shaft is of precision Manufacturing of steel. It is well balanced with Polish. Bearing (X) One side : with shield. Insert opened side to Shaft.

Opened side

Shield side

Notice for inserting of the bearing!! Hammering the bearing or hammering partially using with the steel plate will affect the performance of the bearing so please insert the bearing to press it evenly.

Snap ring (a)

Bearing (x)

 Also, please do not press the outer ring in order to insert the inner ring since it will give a damage of the bearing.

－１１－

3-2. Put the shaft into main shaft casing (2) following to the direction below

Main Shaft Casing (2)

3-3. Set the bearing (X) to the motor side. Put the (U) O-ring in shaft casing before bearing installation. In this case open side of bearing faces inside. So drive in with hummer. Bearing sets by the interference fit as same as the other side. Put up the shaft vertically. And fit the bearing.

Bearing(X) Opened side O-Ring (U) Bearing ramming down

Bearing ramming down direction

O-Ring (U)

－７－ The motor side

The cup side

－１２－

3-4. Fit Oil Seal ( c) to Bearing Cover (Rear)(4). Insert Bearing Cover (Rear) fitted with Oil Seal t o Main Shaft Casing and Fix it by M5×15mm Screw. Please make sure to take off the spring in oil seal. Put the enough grease to Bearing Cover (Rear) (4)

inside of oil seal and shaft touching side of oil seal.

Oil Seal (Y)

Screw (M5x15mm) (G)

There is a loose space, approx. 1.5mm, between rear Bearing and Bearing cover in order to escape the heat expansion of Main Shaft.

Hole for grease filling Grease Nipple is provided at Bearing for filling the grease up regularly. Please use the grease for high temp. use.

－１３－

3-5. Fit Packing (i) to Primary Air Tube Disc (6). (Fit firmly with the bonding material such as a kind of Chloroprene Rubber) Put the round plate with packing to the shaft as the picture below

Primary Air Tube Dise (6)

Packing (I) Note: When Disc is fitted, please note that the hole for Fuel Oil Pipe is located 90 Deg. opposite to the hole of Grease Nipple. Hold of Grease Nipple

Fuel oil pipe hole

－１４－

3-6. (19)Set the (T) O-ring to the main shaft casing holder. Put the grease on (T) O-ring. Set the main shaft casing holder to round plate by screws (M5×20mm)(A).

Stopper of Main Shaft Casing (19)

Stopper of Main Shaft Casing (19)

with O-ring(T)

O-ring(T)  At first, put (T) O-ring to the casing holder.

Cap Screw with S.W. (M5 x 20mm) (A)

－１５－

3-7. Set the bearing cover (front) (3) to the main shaf t casing. Make sure if grease nipple holes of casing and bearing cover are in same position at that time. Next, set the oil guide (in) (8) of distributor in the direction as described below.

*Hole of Grease Nipple It merges the position

Bearing Cover (front) (3)

Distributor Oil Guide (inner) (8)

*＊ Assemble oil guide (out) of distributor First set (T) O-ring (G55) and (S) O -ring (S24) to the body part of distributor oil guide (out) (7) Next, set the oil connection piece (9)

to the body part by screws (M5×12mm) as described

below.

O-Ring (T)

Distributor Oil Guide (outer) (7)

 Assembling drawing

Disassembling Drawing

Oil Pipe Connection part (9)

O-Ring (S)

Cap Screw with S.W. M5x12mm (N)

－１６－

3-8 . Set the assembled distributor oil guide (out) as described below. Put the grease on both side of (T) O-ring and (S) O-ring. Make sure if hole for oil pipe on round plate and oil connection piece are in same position. Fix bearing cover(7) , distributor oil pipe (in)(8) and distributor oil pipe (out) by screws(J) (M5×85mm).

O-Ring (T) with Grease

Distributor Oil Guide (outer)

Distributor Oil Guide (outer)

Cap Screw M5x85mm (j)

－１７－

Disassembling drawing of Distributor (Fig. 3)

 A PART LIST Distributor part table Item

Qty

Description

Remarks

7

1

Distributor Oil Guide (outer)

Material : SS400

8

1

Distributor Oil Guide (inner)

Material : SS400

T

1

O-Ring

G55

S

1

O-Ring

S24

9

1

Oil Pipe Connection part

N

3

Cap Screw with S.W.

M5×12

3

1

Bearing Cover (front)

Material : SS400

J

6

Cap Screw

M5×85

P=0.8

P=0.8

－１８－

3-9 . Put O-rings (JASO-1018) to the oil pipe (12). Then inset oil pipe in the following direction.  After inset distributor tightly, fix by screws (Q) (M8×15m).

Fuel Oil Pipe (12)

O-Ring (V)

2sets

Make sure if O-rings of oil pipe work well to prevent oil from leaking.

Cap Screw with S.W. (Q) (M8×15mm)

－１９－

3-10. Fit Grease Nipples (pin type) (W).

Grease Nipples (pin type) (W)

Grease injection mouth

To see from rotary cup side, please set the angle to

Fuel Oil Pipe

be 90°between grease nipple and fuel oil pipe.

－２０－

3-11. Screw three Centering Blocks into Primary Air Tube (5). In each Centering Block, total two pcs of Allen Cap Screw (R) , M8 ×20×1pc

& M8×25×1pc,

are inserted for the centering of Main Shaft Casing.

Primary Air Tube (5)

Centering block for Air Tube (20)

3sets

Sectional drawing of Centering Block

－２１－

3-12. Assemble Primary Air Tube and Main Shaft Casing which is already combined. Please follow the matters that require attention of the chart below. Fix it by the screw of M5 X 15 with S. W..

Note: Be sure that both holes of Grease Nipple and of Primary Air Tube should be suited in the same position.

Primary Air Tube (5) Cap Screw M5x15mm (P)

Two pcs of Cap Screw (R) are inserted. （ﾎﾛｾｯﾄｽｸﾘｭｰ）

The left detailed drawing

Primary Air Tube

－２２－

3-13. Fit Shaft Key (H) to Shaft and fit Coupling (Z). The clearance between Coupling and Disc is kept approx. 10 ～12mm.

Shaft Key (H ) (at Motor side)

When fitting of Coupling, please be sure that coupling

diameters for the shaft at

Main Shaft side and motor side are different.

Coupling (Z) 3-14 . If assembly has proceeded correct, start centering Put the assembly on the board to make the cup attachment side up and to make the unit vertically. The following picture shows centering.

Make sure if shaft is vertically-emplaced.

 Adjust it with Centering block for Air Tube

－２３－

3-15. Assemble firstly Rotary Cup and Cup Holder by Cap Screw of M6 X 15mm. Insert Shaft Cup Key (B) in Shaft and f it Cup Holder which is fitted Rotary Cup. (At this time, please make sure that the key groove and the key should be in one line)

Rotary Cup (10-A) & Cup Holder (10-B)

Cap Screw (M6 x 15mm)(K)

Shaft Cup Key (B)

Fit a cup and work

－２４－

3-16-1.

①Insert Blind Cover for Rotary Cup hole (14) → ②Spring Washer (O) → ③Cup Nut (18) in order.

 Assembling attention Direction of plate spring Blind cover for Cup hole (14)

Rotary Cup and Cup Holder are fitted to Main Shaft by Shaft Cup Key (k) and Cup Nut (18). ( It is the right screw.) Spring Washer (O) Cup Nut (18)

Inside of Rotary Cup, hole for primary air intake is provided for the oil distribution evenly and for cooling / cleaning of Cup during the burner operation.

Note:  At the fitting of Cup Nut, H-Shape Device as shown in the sketch is used for the fixing Coupling and prevent the rotation of Shaft.  Also, please keep in mind not to forget to coat the grease for prevention of the burning.

*Tightening torque of screws Tightening torque for Rotary Cup Nut is 20N.m.

－２５－

3-16-2. Rotary Cup disassembling procedure

① Take out Primary Air Nozzle ② Take out Cup Nut (It is the right screw.) ③ Take out 3 pcs of Spring Washer. ④ Take out Blind cover for Cup hole. ・Tangle it out with straight slot screwdriver ・

When above mentioned parts are taken out, holes for cup holder screws appear Set provided spare tools for disassembling as below. And take out Cup holder ＊Do not hit with hammer! because these are made by Aluminum.  As the left diagram, set the tool. As the screw①is tightened, tool ② comes up ②,and cup comes off.

①Tool for disassembling -1 ②Tool for disassembling -2 ③Cap Screw 4-M6×40 ④ O-Ring 4-P5（viton）

－２６－

3-17. Fitting of Primary Air Nozzle (11)

Primary Air Nozzle (11)

The blades in Primary Air Nozzle are f or producing small articles with rotating the air from Nozzle in reverse of the Cup rotating and hitting to the oil.

Washer of Air Nozzle (M)

 Air Nozzle fixing Screw (M6 x 15mm) (L)

Note Screw Air Nozzle Fixing Screw firmly for preventing loosing or removing.

Outer end of Nozzle and Cup（０≦１≦２）

－２７－

3-18. Fitting of Motor Base (13)

((E) Cap Screw M10 X 20with S. W.)

Grease up Hexagonal Bolt (M10 with S.W.) (E)

Grease up

Motor Base (13)

3-19. Assembling completes. Put hexagon head sunk plug into the f ront hole for the grease insert. Then top of the plug and the primary air tube are flat.

Plug 20A (F)

Grease up

Please check the clearance between Primary Air Nozzle inside diameter and Rotary Cup outer diameter is evenly.

Gross weight of Burner Unit : 63kg Motor only

: 13kg

－２８－

3-20. After the completion of assembling, please test the rotation of the motor.  At this time please be sure that there is no vibration nor the abnormal sound. 3-21. Addition Insert Rotary Cup Burner to Burner Front Door (22) which is assembled in Wind Box (21).  And then screw Bearing Guide Roller into Rotary Cup Burner Unit.  At the screw in, please wind the tape seal on the thread for preventing the loosed screw in.

Bearing Guide Roller Bearing Guide Roller

 Assembly drawing of Bearing Guide Roller

＊Part screwed in Please screw in with ending the seal tape. 3-22. Burner Unit disassembling S15

－２９－

Note for Burner Unit disassembling *Please do not damage Cup when Cup is removing from Burner Unit.

*When Cup and Cup Holder are removed, please put Cup on the horizontal flat stand at where the cloth is spread to avoid the damage of Cup end. One man hold it and the other man pull out them horizontally.

The other man pull Cup Holder out straightly.

Cup Holder Cup One man hold Rotary Cup

Horizontal stand

Be careful for the leaking oil. Put the clothes under the Fuel Oil Guide.

*When pull Fuel Oil Guide out, please prepare the clothes for clean the leaked oil from Fuel Oil Guide.

Be careful for the leaking oil. Put the clothes under the Fuel Oil Guide.

－３０－

Sunflame Direct Drive Rotary Cup Burner, Sectional drawing (Fig. 4)

Primary Air Damper (30)

Primary Air in

Secondary Air in

Secondary Air Damper (28)

Spooked Bracket (26) Primary Air Housing with ring (25)

Flame Eye (R407)

GAP 3.5mm

Rotary Cup Burner Unit

Secondary Air Nozzle (27) Burner Front Door (22) Primary Air Housing (24)

＊Packing

Burner Wind Box (21)

 After adjustment lock pin, attach packing.

－３１－

4. Burner Unit parts drawing 4-1.

Fitting of Burner Front Door (22) Burner Unit is fitted to Spoke Bracket (26) and supported by eccentric shaft with rollers (bearing) in order to maintain the centering.  Adjust with rotating the eccentric shaft in order to move smoothly. Burner cannot be opened or closed if front part or rear part is not locked by Burner Unit Stopper (32).

4-2

Burner Wind Box (21) Burner Wind Box (21) takes primary and secondary air in from the fan separately located and distribute the combustion air evenly or adjust through Secondary Air Nozzle (27).

4-3

Secondary Air Nozzle (27) Secondary Air Nozzle is composed in two parts. (please refer to below sketch) Secondary Air Register Vane inside and Secondary Air Vane outside control the secondary air flow to the flame and maintain the stable combustion. By the angle adjusting of Secondary Air Vane, the flame shape can make suitable for the furnace shape.

Secondary Air Nozzle (27)

Secondary Air Vane Secondary Air Register Vane

－３２－

4-4 . The position of Burner Hinge Stopper (3 stoppers)

The position of the stoppers at Burner Hinge opening or closing

Flame Eye (R407) Burner Front Door (22) Burner Hinge Stopper (34)

Sight Hole (29)

Ignition Burner (R108) Hinge Arm Stopper (46)

Hinge Arm (33) Hinge Pin (36)

OIL LINE

－３３－

4-5. Spooked Bracket Eccentric Roller Assembling Drawing  Assemble eccentric roller (bearing) as described below.

Spooked Bracket

Pay attention to the direction of eccentric roller attachment.  Assemble to make Spooked Bracket Eccentric Roller (26)

touching surface of all bearings face to center.

No.

Qty

Name of part

Remarks

1

1

Eccentric shaft for Roller

2

1

Hexagon Nut

M16

3

1

Flat Washer

for M16

4

1

Bearing

6302

5

1

Snap Ring

for M16

 Above quantity shows for one set of Roller & six sets are used for one Burner.

－３４－

4-6. (22) Fix the spooked bracket to burner’s front door by t he hexagon bolt.

Then set to burner unit as following picture. Make sure if bearing roller works well.  Adjust spooked bracket by eccentric roller (bearing) to fit the center of burner unit.

Hexagonal Bolt

Burner Front Door (22)

4-5 . Assembly & Part Drawing of Burner Hinge Stoppers

Pay attention to the position of bearing

Spooked Bracket Eccentric Roller Adjustment

roller.

－３５－

4-7. Primary Air Housing Eccentric Roller Assembling Drawing

Pay attention to the direction of eccentric roller attachment.  Assemble to

make touching

surface of all of bearings face to center.

Primary Air Housing Eccentric Ring R oller No.

Qty

Name of part

Remarks

1

1

Eccentric Shaft for Primary Air Housing Ring Roller

2

1

Hexagon Nut

M10

3

1

Flat Washer

for M10

4

1

Bearing

6000

5

1

Snap Ring

for M10

( Above quantity shows for one set of Roller & three sets are used for one Burner.)

－３６－

4-7-2 . Set the primary air housing ring (25) assembled by 4 -7 procedure as previously described to the primary air housing (24).

Spring finish side Spring cutting side Direction attention of spring

Put the grease on to work well before attachment to the primary air housing.

Primary Air Housing Ring Stopper No.

Qty

Name of part

1

1

Cap Screw

2

1

Primary Air Housing ring Stopper Sleeve

3

1

Compressed Coil Spring

Remarks M6×30

wire die

: 1.5mm

Effective coils 3 / SWPA

4

1

Flat Washer

for M10

( Above quantity shows for one set of Roller & three sets are used for one Burner.)

－３７－

4-8. Assembly & Part Drawing of Burner Unit Stopper

Cap Screw (15) (M6x20mm)

No.

Qty

1

1

2

Name of part

Remarks

No.

Qty

Name of part

Remarks

Base of Bur. Unit Stopper

8

1

Hexagon Nut

M10

1

Burner Unit Stopper Pin

9

1

Washer for Stopper

t =3.2

3

1

Snap Ring

11

1

Compressed Coil Spring

 AP130-055-0.9

4

2

Flat Washer

d21 / D30 / t3

12

1

Flat Washer

d10.5 / D30 / t3

5

1

Coiled Spring

AP260-070-1.8

13

1

Nob

PC-30×M10

6

1

Hollow Set Screw

M10

14

1

Cramp Nut Lever

7

1

Spring Washer

15

4

Cap Screw

M6×20

－３８－

4-9. Assembly & Part Drawing of Burner Hinge Stopper

Burner Hinge Stopper (34)

Fix the burner hinge stopper byφ5 spring pin as the left picture shows. Stopper

No．

Qty

Name of part

Remarks

1

1

Lock Lever

2

1

Cramp Nut Lever

3

2

Spring Washer

4

1

Collar for height adjusting

t=6

5

1

Allen Cap Screw

M6

(Above quantity shows for one set of Stopper & three sets are used for one Burner.)

－３９－

4-10. Ignition Burner (Pilot Burner) (R108) This is the pilot burner which is ignited by A oil. The atomized oil (0.7MPa of A oil pressure) is ignited by the electric spark of 10,000V between two Electrodes. Ignition Burner is set, as our standard, as below sketch (Guide Pipe protrudes 20mm from Secondary Air Register). In case the malfunction is occurred depending on the setting condition by the vessel, please move Ignition Burner by 10mm pitch, pulling in or pulling out. The air from Secondary Air Register flows across Ignition Burner so the flame is changeable so much depending on this protrusion. Please set at the most suitable position by the vessel. Also, we recommend to record above dimension. (Please record C dimension.)

IgnitionBurner Burner Ignition

－３５－ －４０－

4-10-2. Ignition Burner (Pilot Burner) assembling drawing  Atomizer disassembling detail drawing For easy assembling of Atomizer, please use the hexagon wrench perpendicularly.  At the assembling, please confirm the direction of Disc (2).

－ ４ １ －

4-11. Flame Eye (detecting of the combustion) (R407) This detects flame and compose the safety circuit by amplification circuit of semi-conductor.

4-11. Flame Eye (detecting of the combustion) (R407) This detects flame and compose the safety circuit by amplification circuit of semi-conductor.

4-11-2. Flame Eye Relay

－４２－

4-12. Secondary Air Damper (28)

Direction of Air

Damper full opening

Damper closing

Secondary Air Dumper & Control Linkage No.

数 量

1

1

Body of Secondary Air Damper

2

2

Blade of Secondary Air Damper

3

2

Shaft of Secondary Air Damper

4

16

5

3

Secondary Air Damper Lever

6

2

THK Ring Ball

BL 10D

4

Bearing

FYH

Hexagon Bolt / Nut / Spring Washer

M10

7

For

each 8

部

品

名

称

Cap Screw

備

考

M8×25

UCFL 204

8

1

Hollow Set Screw

M10×75

9

2

Pulling Coil Spring

HP200-140-2.0

－４３－

5. Maintenance and cleaning of Burner * Inspection and maintenance at every day 1. Inspection of oil strainer. 2. Inspection of oil pressure & oil volume. 3. Inspection of furnace inside pressure and exhaust gas temperature. 4. Open Burner and clean Rotary Cup if necessary. It is possible to clean Rotary Cup without removing Main Shaft. But after long time operation, it is necessary to clean it with removing Cup, Primary Nozzle and Distributor from Main Shaft. When these are assembled, please coat the grease o il on Main Shaft slightly for easy disassembling at next time. * Inspection and maintenance at every week 1. Grease up Bearing of Burner Main Shaft depending on the condition. The bearing for Main Shaft is to be greased up at every 1,000 hours with the grease weight of 4 ~ 5g. Chevron Corporation industrial grease heavy or is use by Esso uni-Rex N3 equivalency.

2. Inspection and maintenance of Ignition Burner. 3. Inspection of Flame Eye function. 4. Inspection and greasing at each linkage. * Other notes Do not heat up Rotary Cup over 150 Deg. C.  Also do not use hard tool such as steel made without fail for the cleaning of Cup. If Cup inside is hurt, the combustion become not normal due to the insufficient atomizing. When Primary Air Nozzle is refitted after the cleaning, please check the distance between both outer ends of Nozzle and Cup as shown in below sketch.

B

List of Maintenance and inspection interval

－４４－