Sunflame Boiler Burner Instruction Manual SDR-1500

TEC-080715-Ko1

TYPE ；

Name ；

Revision history 15 JUL.2008 23 JUN.2011

Make doc. Grammar and vocabulary check

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Maenishi Kagawa

TEC-080715-Ko1

CONTENT 

PREFACE

・・・・・・・・・・・・・・・・・・・・・・・ ３PAGE

MAINTENANCE

・・・・・・・・・・・・・・・・・・・・・

ABOUT ROTARY CUP BURNER STRUCTURE OF EACH DEVICE

・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・

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４PAGE ９PAGE

１４PAGE

TEC-080715-Ko1

PREFACE 

 This document describes what engineers of this vessel should understand when they use the system.

For also boiler makers and engineers of shipyards, we hope that this book will give useful information.

This user’s manual includes optional functions. For some ships, this book may give information that is not relevant. Confirm your specification for information of your optional function.

WARNING

CAUTION

 This indication gives you a warning when mishandling the products, it will lead to serious injuries or result to death for the user. It also may result to serious damage for the products as well.

 This indication gives you a warning when mishandling the products, it may lead to minor injuries to the users, or physical damage to the products.

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TEC-080715-Ko1

MAINTENANCE  CHECKUP 1.1. DAILY CHECK  The 6 topics below are needed to be done every day. ■ Confirm if there is no F.O. leakage out of pipes, pumps, valves and for the connection part. ■ Inspect the oil pressure, quantity. Inspect the temperature as well when the H.F.O. is used. ■ Inspect the furnace pressure and the exhaust gas temperature. ■ Check the combustion condition. ■ Confirm if there is no smoke generation (Be careful of smoke when the temperature of the engine room is high.) ■ Check if the steam heat tracing is working. 1.2. WEEKLY CHECK  The 7 topics below are needed to be done once a week. (or every 200 hours operation).  These topics are also needed to be checked when the system is not operated for over a week. ■ Clean the oil strainer screen. ■ Drain water and air from the oil heater. ■ Clean the inside of the rotary cup. ■ Check if there is no incombustible deposition in the burner tile and the furnace. If necessary, clean the burner tile and the furnace for removal. ■ Inspect the tension of the burner belt (this is needed for the SSR type and the R type rotary cup burners) ■ Check and clean the ignition burner (pilot burner) ・ See if there is no crack in the insulator of ignitor. ・ Clean the insulator and the electrodes. Check if the distance of  the electrodes is correct. ・ Clean the strainer in the atomizer ・ Clean the disc and the jet nozzle in the atomizer by air blowing. ↑ Vertical direction

The electrodes size

 Assembly of atomizer

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TEC-080715-Ko1 ■ Inspect the function of the Flame eye and clean it if necessary. Hold the flame eye up to the light and confirm if the flame eye relay is working. Wipe the flame eye’s front glass. 1.3. MONTHLY CHECK  The 6 topics below are needed to be checked once a month. (or every 1000 hours operation).  These topics are also needed to be inspected when the system is not operated for over a month. ■

■

Lubrication for the main shaft ・ For the rotary cup burners with a grease nipple, inject 4 ～5g grease to the nipple. (for type R, type SDR-1000 and type SDR-1500 rotary cup burner) ・  Too much grease will cause damage to the bearing. ・  The equivalent type of the grease for the main shaft should be, Grease heavy (CHEVRON), or Unirex N3 (ESSO). Way of dismantling and cleaning of the rotary cup ・ Open the burner and take out the primary air nozzle. ・ Fix the main shaft, and then loosen the fixation screw in the cup and take out the cup. ・ For the R and SDR-1500 type burner, the tools for fixing the shaft and for taking out the cup are in the spare parts box. ・  The Cup fixation screws for each type of the rotary cup are described below.  Type R SDR－1500 SSR SDR

Cup fixation screw Right screw Right screw Left screw Left screw

Loosening

Tightening

Counterclockwise Counterclockwise Clockwise Clockwise

Clockwise Clockwise Counterclockwise Counterclockwise

Dismantle and clean the rotary cup and the rotary cup hub.

A diagram example（R-15 Rotary cup burner）

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TEC-080715-Ko1 The rim of the rotary cup is the most important part for the F. O. atomization. Careful treatment is needed when handling the rotary cup. No damage is indispensable.

Caution

・ ・ ・

Lightly spread grease on the main shaft （so that the cup will be removed easily the next time when taking it off ） After cleaning, return the cup and the cup hub to the original. Set up the primary air nozzle and create an equal space between the outer circumference of the rotary cup and the inner circumference of the primary air nozzle. Adjust and fix the distance between the rim of the rotary cup and the rim of the primary air nozzle to size “A” in length.(A is described in the following table.)

 Type R9 R15 R25 R40 SDR-350～500 SDR-1000、1500

SSR3.5 SSR5～８ SDR１～２．５

Distance between the rim of the rotary cup and the rim of the primary air nozzle A[mm] Standard value Minimum value Maximum value １．５ １．５ ２．０ １．５ １．５ ２．０ ２．０ ２．０ ３．０ ３．０ ３．０ ４．０ ０．５ ０ １．５ １．０ ０ ２．０ ０．５ ０ ０．５ ０．５ ０ ０．５ ０．５ ０ ０．５

1) Confirm if the clearance between the outer circumference of  Caution

2)

the rotary cup and the inner circumference of the primary air nozzle is even. Confirm if  the distance between the rim of the rotary cup and the rim of the primary air nozzle is as per the table above.

3) These measurements will have major effect on the combustion.

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TEC-080715-Ko1 ■

Inspect each connection and each fixation screws, and check if they are not loose or if there are no backlashes. ■ Check the vibration of the rotating body, backlashes of the bearing and if  there is no abnormal noise. Repair if necessary. ■ Inject oil to the rotating part and to the slide part. ■ Confirm the tension of the burner belt and see if there is no crack. (If the belt is used the first time (renewed or replaced), adjust it again after 50 ～ 100hours operation.) 1.4. OTHER CHECKS ■ Check each sensor for the boiler and the burner operation regularly. (pressure switch, thermostat, and e.t.c.) ■  Tighten the fixing screws of each part every 6 month. ■ For the burners that have a piping heater in the flexible pipe, (Type R and SSR) it is better to clean the flexible piping every year. ■  To prevent black smoke that is caused by choking of the gas passage of the boiler, back fire, and oscillating combustion, record the UP-TAKE GAS temperature and the furnace pressure, and clean the boiler regularly. ■ For systems that are using the electric oil heater, it is better to remove the scale that is on the surface of the heater every year. ■ Check if the drain trap, which is in the end of steam heat tracing line, is not blocked every month.

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TEC-080715-Ko1 CHECK LIST ITEM

No. 1 2

3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

JOB

INTERVAL

Piping, Pump, Valve

Visual check, Leakage of fuel

F.O. pressure and F.O. temperature

Visual check

Furnace pressure and up-take gas temperature

Visual check

Flame condition

Visual check

Black smoke

Visual check

Steam

Touch with gloves

trace

Daily 

Oil strainer

Cleaning of the basket

Oil heater

Removal of drain and air

Rotary cup

Cleaning and

Burner tile, Furnace

Visual check of the soot

Burner belt

Visual check of crack

Ignition burner

Cleaning and check

Flame eye

Cleaning of glass and check

Main shaft bearing

Grease up

Rotary cup

Disassembling and Cleaning

Air/Oil linkage

Visual check

Each motor

Auditory (noise) Check

Each bearing

Oiling

Burner belt

Check of tension

check Weekly 

Monthly 

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REMARKS

TEC-080715-Ko1

Rotary cup burner  Features of the rotary cup burner 1.1. Principles of the rotary cup burner 1) By guiding the fuel oil to the inner surface of the rapidly spinning rotary cup, the rotary cup burner sprays fuel oil from the rim of the cup by the centrifugal force of the rotation.

Secondary Air Air Vanes Primary Air (1000mmAq) Rotary Cup

Cup Nut Distributor Oil Guide Pipe Secondary Air Fuel Oil

Air

Rotating parts

2)  The F.O. film that is sprayed from the cup will be stroked and converted to oil mist by the primary air pressure and will form a sprayed flame pattern in front of the rotary cup burner.

 The F.O. film formed by the centrifugal force. 3)

 The F.O. film atomized and converted to mist by the primary air

Functions of the rotary cup. ■ By the centrifugal force, the F.O. will be formed into a thin oil film in the inner surface of the rotary cup ■ By the centrifugal force, the F.O. will be pushed into the cup. ■ By the centrifugal force, the F.O. will move forward until it is thrown off  the cup rim as a very thin uniformed film. ■  The rotary cup will make the primary air pass between the primary air nozzle.

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TEC-080715-Ko1 4)  The high-velocity (High pressured) primary air will turn to the opposite direction of the rotary cup rotation by the air vane, and will strike the F.O. film. In this way, F.O. will break up and will be converted into mist of fine oil particles. 5)  This system can be applied to the fuel in wide ranges of viscosity. The F.O. forms a film by the centrifugal force described above, and this F.O. film will be stroked by the primary air and will be sprayed. 1.2. Features of the rotary cup burner 1)  The advantages of the rotary cup. ■ By sending the F.O. in low pressure (0.3～0.5MPa, depending on the type of the burner), the pump will last for a long time. In addition to this, the low pressure pump will decrease the risk of leaking from the connection parts and other parts of the flanges. (Long lasting pump, safety operation) ■ Oil flow channels of the rotary cup are wide and there are no nozzles in between, so it has no possibility from being chocked by foreign particles. (Higher reliability against most obstacles) ■  The F.O. viscosity has very little effect on the burner combustion because the thin oil is formed by the centrifugal force.(High stability to the F.O. in a wide range of viscosity) ■  The combustion capacity has very little effect on the burner combustion because a good combustion can be secured under any oil flow rate due to good atomization with oil film made by the centrifugal power. ■ By striking the F.O. with the primary air, the F.O. will be sprayed, and by  this, the F.O. is exposed to the air quickly and will enable a stable combustion. (Combustion will be possible at a low excess of air ratio ） ■ By the large diameter of the oil spray mist, the F.O. will be exposed to the secondary air quickly, and the flame made by the rotary cup will be wider and shorter.

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TEC-080715-Ko1 2.

The composition of the Rotary cup burner 2.1. The F.O. supply and the circulation 1)  The Oil in the F.O. tank and the D.O. tank will be selected by the valve and will be supplied to the F.O. circulating line.

 AIR SEPARATOR

RETURN

TO F.O.PUMP

2)  The supplied oil will join the oil that returned from the air separator, and will be forwarded to the F.O. PUMP by the head pressure. 3) Before the F.O. comes to the F.O. pump, the strainer (R201) removes the large foreign particles (standard #60), and prevents the pump from getting stuck.

4)  The Oil pressure will be increased by the F.O. pump (the standard pressure of  the built-in safety valve is; 0.55MPa) and will be delivered to the F.O. Heater.  The capacity of the F.O. pump is 1.5 to 2.5 times larger than the rated combustion capacity.

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TEC-080715-Ko1 Temperature Controller Sensor

STEAM FOR HEATING INLET

From F.O. Pump

To the burner side 5)  The oil that comes into the F.O. heater will be heated, and then will be guided to the burner side.

RETURN

From F.O. Heater

Burner side

6)  The relief valve (Pressure adjustment valve R237), which is installed near the

burner, keeps the oil pressure fixed and will supply oil to the burner constantly.  The relief valve will return the amount of oil, which has subtracted the amount of oil supplies to the burner, from the gross volume of the oil from the pump, to the RETURN pipe.

7)

By running the F.O. pump, the temperature of the warm oil will come to the pipe, and will avoid the oil pipe from cooling down.

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TEC-080715-Ko1 2.2. Burner side 1) A thermometer（R812）is equipped at the entrance of the burner side, and will enable a visual temperature confirmation.

To IGN.Burner

From D.O. PUMP

RETURN

F.O. IN

2) Between the FLANGE of the F.O. IN （A FLANGE）and the flexible tube (R255) that is connected to the burner, the adjusting valve（R231）and the main valve (R608）are equipped in a line, and is controlling the combustion capacity. 3) Between the flanges of the F.O. IN (A FLANGE）and the flexible tube (R255), the D.O. MIX. Line (R609 and R247 ）is connected to send the D.O. from the output line from the D.O. PUMP to the main burner at each normal stop of the burner.  The D.O. MIX. valve（R609）opens when the burning stoppage is demanded, and closes when the main valve closes. This system works with the D.O. pump when it is in mode H.F.O. (when the switch of the F.O. TEMP. DETECT is active)  The D.O. MIX. mixes the oil (H.F.O) that is in the burner with the D.O. to prevent the oil from having high viscosity at cooling. It also makes it easy to put fire when using it the next time.  The D.O. MIX. valve will open for 30 seconds (as standard) for small sized burners. For medium and large sized burners, the time can be instituted by the touch panel. 2.3. THE IGNITIION BURNER 1)  The D.O. sent from the D.O. pump is supplied to the ignition burner（R108）by the IGN. valve (R606).

From PUMP

D.O.

The structure of each device (exploded diagram etc.)  13 ／ 14

TEC-080715-Ko1

Read the following diagram and the explanation documents for information about the structure of each device.  The diagrams, which have been overlapping with the submitted diagrams, are omitted.

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