PANCHAL ASSOCIATES

DESCRIPTION OF PA INDUSTRIAL OIL BURNER

(A) BURNER:

PA INDUSTRIAL OIL BURNERS are pressure jet and spill return type
burner with the turn down ratio of 1:3 and 1:4 i.e. 1/3rd or 1/4 th of the oil
capacity is atomized at low flame position and remaining 2/3rd or 3/4th
capacity is modulated by burner modulating drive between high flame to low
flame positions. The principle of modulation is by regulating the return oil
pressure after the nozzle. The return oil pressure is regulated by return oil
pressure regulating valve or (Back pressure regulating valve) BPRV which
is actuated by a cam disc arrangement driven by a modulating servo motor
through the gear drive mechanism. The air damper is mechanically coupled
with the drive unit to keep the air fuel ratio constant throughout the
modulating range.
A photoresistor is mounted on the burner front as a part of the combustion
safety control. The photoresistor, when exposed to the flame provides electrical
continuity to the burner program cycle in the sequence controller. In case of
flame failure condition, photoresistor shuts off the burner firing system.
A rated capacity of the nozzle is fitted on the burner rod assembly or
nozzle rod. Burner rod is actuated by a DC operated solenoid assembly. The
oil is atomized and ignited by means of a high voltage ignition spark
established at the ignition electrodes end near the nozzle. The ignition voltage
of 14.5kv is provided by an Ignition Transformer mounted on the burner.

(B) COMBUSTION AIR:

The fuel oil combustion is supplied with sufficient combustion air by a forced
draught fan mounted below the burner. The required quantity of air at
required delivery head is provided for operating the boiler/Furnace/Heat
generator under forced draught condition. Forced draught fans are normally
coupled directly with motors. The burner and the force draught fan are coupled
by means of a leather bellow to prevent the transfer of vibration to the
burner. The PA burners are suitable to operate on ambient air temperature.
Special burners are available for High combustion air Temp. applications.

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(C) GEAR OIL PUMP:

The pressure jet Oil burner requires higher fuel oil pressure to obtain the better
atomization & higher combustion efficiency. The high pressure positive
displacement type Gear oil pumps are specially designed for handling viscous
fuel oils (Heavy Oil) like furnace oil etc. It is capable of developing very
high pressure up to 25 kg/cm2. A control valve with built in by-pass is
provided in the pump for controlling delivery oil pressure. A set screw is
provided for setting the required oil pressure.

(D) INLET PRESSURE REGULATING VALVE: (FIG 1A)

The burner inlet oil pressure can be adjusted and maintained by this valve.
Normally inlet oil pressure for the burner is maintained within 20 kg/cm2 to
25 kg/cm2 range for proper atomization of the fuel oil. This is a spring
loaded control valve with built in by-pass arrangement. Inside the pressure
control valve, a piston (1), moving in a valve body, is forced against the
valve needle (3) by a spring (2). If the pressure on the valve needle side is
greater than the pressure exerted by the spring, the piston will rise and the
oil will flow over the un-pressurised side. Hand wheel (4) is provided to set
the required oil pressure. The following instructions are important for installing
this IPRV valve. The spring side is always the return side i.e. the un-
pressurised side. The direction of overflow is from the pressure side to the
spring side. For functioning of the valves, it is immaterial whether they are
installed in continuos lines or at the end of lines, clockwise rotation of the
hand wheel corresponds to an increase in the oil pressure, and Anti-
clockwise rotation to decrease the oil pressure.

IPR Valve size 3/4” - Max. Flow 2000 LPH

IPR Valve size 3/8” - Max. Flow 800 LPH

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(E) RETURN OIL PRESSURE REGULATING VALVE: (FIG-2B)
OR
BACK PRESSURE REGULATING VALVE (BPRV)

As mentioned earlier, quantity of the oil atomized by the nozzle depends upon
the return pressure or the back pressure of the Fuel oil, hence Fuel oil
output of the burner is regulated by changing the return oil pressure. A cam
disc is provided with this valve to vary the back pressure. The cam disc is
driven by a modulating drive assembly.

ADJUSTMENT PROCEDURE OF BPR VALVE AND CAM DISC:

Adjust back pressure regulating valve on the compound control with cam
disc. Switch on the burner Fuel oil pump in manual mode, check the oil
circulation and read the back pressure on the return oil pressure gauge.
Remove cover from the modulating drive unit, depress the clutch (16), and
rotate manually up to max high flame position. In order to prevent the return
of the drive unit to normal, disconnect proper wire from the control circuit.
The maximum pressure on the return line can again be read on the pressure
gauge.
- To attain the control ratio of 33% -100% , the return oil pressure should
be approx. 2 -18 kg/cm2.
- If the pressure have to be altered. slacken the hex. socket head screws
on cam disc (8) , by rotating the set screw (9) of cam disc clockwise, the
lifting difference will be reduce, i.e. the difference between the min and max
pressure will be less.
- By rotating the set screw in an anti-clockwise direction, the lifting
difference will increase, i.e. the difference between min and max pressure
will be greater.
- By slackening the lock nut (4), and rotating the spindle, the tension of
spring (3) in the return control valve can be altered.
- A steadily increasing pressure between min and max can be achieved by
means of the tension of spring (3) and the eccentric cam disc (2).
- After completing the adjustment, tighten the hex. socket head screw (8)
and lock nut (4).
- Take the trial run by taking the drive unit to high flame and low flame
positions, to obtain the required return oil pressure.
- Depending upon the nozzle capacity & size, return oil pressure variation
may be observed on firing the burner.
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(F) MODULATING DRIVE UNIT TYPE PA / AR-63: (FIG-4A)

The drive unit PA / AR-63 consist of 1 no. reversible AC servomotor (1) with
brake assembly, driving the set of reduction gears (2) and cam disc spindle
(3). Air regulating drum (4) is mounted on the cam disc spindle. The spindle
rotation from low flame to high flame position is limited to 180 deg by 4
nos. cam operated micro switches.

Burner air damper is mechanically coupled to the air regulating drum by

steel band arrangement. By this arrangement Precise regulation of the air
quantity is possible for all firing positions, between low flame to high flame
for obtaining optimum combustion efficiency.

FOR STEAM BOILER APPLICATION:

Proportionate burner modulation control is achieved with the modulating drive

unit PA / AR-63. The above system will operate in conjunction with
positioner controller type PEPC-10, pressure transmitter with potentiometer
(mounted on the boiler) and feed back potentiometer mounted in the burner
modulation drive unit. (As an optional accessories). Depending upon the steam
pressure variation, burner modulation will be adjusted automatically, to
maintain the constant steam pressure at all the variable loads. For details refer
the attached literature.

(OPTIONAL ACCESSORIES)

1: Positioner controller type PEPC-10. (Panchal Associates make)

2: Pressure transmitter with 135 ohms potentiometer.

(Honeywell L91B)

3: Feed back potentiometer 135 ohms or 150 ohms. (Burner modulation Unit)

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FOR FURNACE, HOT AIR GENERATOR APPLICATION:

Proportionate burner modulation control is achieved with the modulating drive

unit PA / AR-63. The above system will operate in conjunction with the PID
controller with potential free Heat/Cool relay output, Rtd, Pt-100 input,
Temperature sensor (mounted on the Furnace) and feed back potentiometer
mounted in the burner modulation drive unit. (As an optional accessories).
Depending upon the temperature variation, burner modulation will be adjusted
automatically, to maintain the constant temperature at all the variable Heat
loads. For details refer the manufacturer literature.

MODULATING DRIVE UNIT TYPE PA / AR-63: (FIG-4A)

The two media oil and air can be adjusted independently as regards of their
quantity and ratio, by means of PA / AR-63 modulating drive unit.

1- Reversible servomotor with brake

2- Reduction gear train drive
3- Cam disc spindle
4- Air regulating drum
5- micro switch cam
6- micro switch no 3 for low flame motor supply
7- micro switch no 4 for min limit position (low flame position check)
8- micro switch no 2 for High flame motor supply
9- micro switch no 1 for low flame motor supply

Refer Burner wiring diagram for micro switches connection

NOTE: Improper micro switches connection may over-run the gear drive unit
and may get damaged .Check the gear drive unit for low and high flame
limit positions.

MODULATING DRIVE UNIT PA / AR-63

TECHNICAL DATA

Reversible servomotor motor with built in brake assembly

AC input voltage : 230v , 50 Hz
Power input : 2 X 110 watt
Load on end shaft : 3 kg-m cont-6-
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Running time : min-max aprrox. 27 sec

Normal Rotation : 180 deg for adjustment.
Complete shut-off of air : additional running time with
Dampers additional rotation of 90 deg

AIR ADJUSTMENT PROCEDURE ON DRIVE UNIT PA / AR-63

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- Set the required quantity of air on the regulating drum (1) by means of
6 mm. hex. wrench.

- 16 adjustable cams (2), holding the flat spring steel band, are fitted to
the regulating drum. 5 nos. cams are for the air shut-off, the remaining 11
nos. cams are for regulating the air damper.

- The adjusted curve of the spring steel band (4) is transmitted to the air
dampers by means of a pick-up arm (3).

- The air quantity is adjusted by rotating screw (5) . clockwise rotation of

screw (5) will reduce the air quantity and anti-clockwise rotation will
increase the air quantity.

- The drive is manually rotated, from one adjusting cam to the next

- starting at the minimum oil operation position and the air is allocated to
the corresponding screw 5.

- At least Three cams must be successively adjusted each time. The

position distance between the cams should not exceed 4 mm otherwise
spring steel band might break.

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(G) NOZZLE ROD OR BURNER ROD:

Nozzle rod distributes the oil flow to the nozzle and balance to the return
line. Rated capacity nozzle is fitted to the nozzle rod. Different length of
nozzle rods are selected for different types of burners. (Length between two
blocks of nozzle rod)

SPECIFICATIONS:

Temperature of medium - max. 150 Deg C

Operating pressure - max. 30 bar
Oil throughput - 30 - 1000 kg/hr
Switching frequency - max. 20/min.
Nozzle fixing thread - M 14 x 1.5

OPERATION:

Oil at a regulated pressure, from IPR valve and strainer filter is supplied to
the nozzle rod inlet port (6). and return from the nozzle is to the return
port (7). When the nozzle rod is in a closed position by-pass passage in the
front block is open and the oil circulates through the by-pass. Spring loaded
needle valves 3&4 are in a closed position. At the time of firing, the DC
operated nozzle solenoid (11) gets energized and opens the needle valves at the
same time, piston (5) block the bye-pass passage and the oil will flow through the
needle, seat and to the nozzle for atomization. Balance oil will return through
needle valve (4) and to the return port.

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BURNER ROD PART DESCRIPTION (FIG-9A)

NO PART

1 - Cap nut M6
2 - Lock nut M6
3 - Needle valve rod (Inlet)
4 - Needle valve rod (return)
5 - needle rod pistons
6 - Inlet oil port
7 - Return oil port
8 - Bracket
9 - Sealing plugs
10 - Springs
11 - Needle rod seats
12 - Seats sealing copper washers
13 - Front sealing plugs
14 - Plugs sealing washers
15 - By-pass cleaning screw
16 - Spring retainer
17 - ' U ' oil seal
18 - ' U ' oil seal holder
19 - seal holder plug
20 - Transmission lever
21 - Mating plate
22 - Spring tension adjuster
23 - Fork connection pin
24 - Allen screw for rod mounting

L = 460 mm for burner type PA 15

L = 610 mm for burner type PA 20
L = 710 mm for burner type PA 25
L = 960 mm for burner type PA 35
L= mm for burner type PA 45
L= mm for burner type PA 50

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ADJUSTING THE TRANSMISSION LEVER (FIG-10A)

To adjust the transmission lever (5), the nozzle solenoid (1) must be
de-energized.

(1) Pull out plunger (2) as far as it will go.

(2) The distance between the transmission lever (5) and its mating plate
should not exceed 1.00 mm.

(3) ADJUSTING THE CORRECT SETTING:

- Slacken lock nut (3) and rotate plunger (2) until the
correct setting is obtained.
- Check the needle valve opening for approx. 4.00 mm to 5.00 mm. When
nozzle DC solenoid is energized.
- Tighten lock nut (3).

IMPORTANT:

- Both the needle valves (6) must be actuated simultaneously.

- If a correction is required, slacken the cap nut (9) , reset with the aid of
the nut (10) and re-tighten the cap nut.

DISMANTLING THE NOZZLE ROD:

1. Close all the isolating valves on the burner Fuel oil lines.

2. Remove the pin (23) connecting the transmission lever to the DC

solenoid assembly fork.

3. Remove screw (24) holding the nozzle rod and oil distributor together.

4. Slightly lift and withdraw the nozzle rod.

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IMPORTANT:

Before removing the screw (24), depress the transmission lever to release
the oil pressure inside the nozzle rod.

(H) NOZZLE: (TYPE PA/DZ)

The nozzle type PA/DZ is fitted to the PA make pressure jet oil burners.
Nozzle capacity depends upon the max. Oil firing capacity selected for the
burner.

Inlet oil pressure in the range of about 20 kg/cm2 to 28 kg/cm2 is

supplied to the nozzle through the nozzle rod. Fuel oil at the higher pressure
enter the swirl chamber of the Nozzle and gets mechanically atomized in the
form of a fine oil spray . This spray is ignited by ignition spark to establish
the oil flame. Spray angle depends upon the type of nozzle selected. As the
inlet oil pressure increases the quality of atomization gets improved and
better fuel combustion is achieved.

Depending upon the return oil pressure, oil firing rate will vary from
partial load to full load. At the max. Recommended return oil pressure, max.
oil firing capacity can be obtained. The spray angle varies between high
flame to low flame positions. The angle increases as the capacity decreases.

If the return pressure or the supply pressure is too high, there will be
excess pressure at the nozzle tip i.e. the oil will be discharged in the form
of a straight jet and will no longer be atomized . In this case, the return oil
pressure must be reduced.

Excess oil after the atomization from the nozzle, return through the center
bore of the swirl chamber and flow to the return pressure regulating valve.

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RETURN PRESSURE VS CAPACITY DIAGRAM FOR NOZZLE PA - DZ:

Spill Return type nozzle PA-DZ

With regulated return flow

Fuel oil: Light oil/Heavy oil

Inlet oil pressure : 24 kg/cm2
Connection : Thread M 14 x 1.5

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SPILL RETURN TYPE NOZZLE PA -DZ

1 - Nozzle Body
2 - Swirl chamber OR Atomizer
3 - Nozzle Tip with brass washer

SPECIFICATION:

Inlet oil pressure - 20 kg/cm2 to 28 kg/cm2

Return oil Pressure - 3 kg/cm2 to 18 kg/cm2
Viscosity range - 1.8 to 2.2 deg Engler
Capacity - 50 kg/hr to 1000 kg/hr
Spray angle - 45/55 deg for standard version
Control range - 1 : 3 turn down ratio for standard version
1 : 4 turn down ratio (Optional)
Application - Suitable for mounting with
PA NOZZLE RODS / BURNER RODS
Remarks - Do not interchange the swirl chamber and the
nozzle tip , since they are mutually matched

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DISMANTLING:

- Hold the nozzle body (1) in the vice clamp.

- Dismantle threaded sleeve (6) with a spanner.
- Slacken, and dismantle swirl chamber (2) with 6 mm Allen key.
- Push back the nozzle tip (3).

ASSEMBLY:

- Place the brass or copper washer (4) on the nozzle tip (3) in the correct
position and insert in the nozzle body (1) up to the front end .
- Screw in and tighten swirl chamber (2) by a 6 mm Allen key
- Place Brass or copper washer (5) on the threaded sleeve (6) and
tighten with spanner.

CLEANING:

- Clean all the dismantle parts with clean kerosene or petrol by a soft
brush.
- DO NOT use metallic brush, cotton waste , emery paper, wool or any
similar type of material for nozzle cleaning.
- DO NOT clean nozzle tip bore with any type of metallic needle, wire etc.
- Clean and dry all the parts with compressed air and assemble as stated
earlier.
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NOZZLE PROBLEMS:

Leakage:

(A) - If nozzle washers (4) , (5) & (7) are not tighten fully, leakage of Fuel
oil from this washers may give smoky combustion or oil may splash on the
diffuser plate and furnace walls, forming carbon clinkers.

Imperfect atomization:

(A) - If inlet and outlet of nozzle is interchanged there will not be proper
atomization but the spray will be in the form of a jet.
(B) - Swirl chamber (2) is NOT FULLY tighten against the nozzle tip (3)
by 6 mm Allen key.
(C) - The swirl chamber sealing face is damaged.
(D) - Nozzle tip bore or swirl chamber slots may get clogged with foreign
particles.
(E) - Supply oil inlet pressure and temperature may be too low.

Precaution:

Nozzle is a critical component for the burner as far as combustion is

concerned. DO NOT interchange tip or swirl chamber from different
nozzles since they are mutually matched & tested.

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SOLENOID ASSEMBLY (CONTINUES CURRENT MAGNET) (FIG-16A)

PART DESCRIPTION

(1) MS Body
(2) MS removable front cover
(3) MS rear cover
(4) Brass front plunger guide bush
(5) Brass rear plunger guide bush
(6) MS Plunger with SS shaft
(7) Solenoid DC Coil
(8) Brass washer
(9) Coupling fork
(10) Lock nut

SPECIFICATION:

- Pulling force - 14 kg
- Stroke length - 23 mm
- DC Voltage - 180-230 VDC
- DC Current - 0.35 to 0.45 Amp
- Plunger thread - M12
- DC Coil resistance - 500 Ohms approx.

IMPORTANT:

1) Prevent dust, Oil , entering the solenoid assembly. Provide rubber dust
cover.
2) Check for free movement of the Plunger.
3) Lubricate the plunger shaft with lub. Oil, as & when require.
4) Check DC supply voltage for any pulling problem, Min. DC voltage
require 180 VDC. Use Bridge rectifier of proper voltage & current
capacity.
5) If the Dc voltage is proper & still pulling problem persist, check the spring
tension of the Burner rod.

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DESCRIPTION OF OIL FLOW SCHEMATIC (P & I DIAGRAM) (FIG-18A)

1 - The fuel oil from the main storage day tank is supplied to the circulating
header through ' y ' type strainer oil filter. The oil holding capacity of the
circulating header depends upon the type of burner selected.

2 - The oil outlet from the circulating header is connected to the inlet of
Duplex type Fuel oil filter. The filtered oil is supplied to the suction port of the
positive displacement type Gear oil Pump of rated capacity.

3 - The oil pump discharge end is connected to the Inlet Oil Pressure Regulating
Valve (IPRV) where burner oil Inlet pressure is regulated and remaining excess
oil is returned back to the circulating header through IPR Valve internal bye-pass.

4 - The fuel oil at a regulated pressure is supplied to the series of oil

preheaters such as steam pre-heater , electric pre-heater etc. for preheating the
heavy fuel oil. Temperature of the oil is regulated by oil thermostats
provided on the oil preheaters. Light fuels like LDO (Light Diesel Oil ) do
not require any type of preheating for firing.

5 - Preheated oil a regulated temperature and pressure is supplied to the

micro filter and finally to the nozzle rod inlet port in the burner. Oil
circulates through the nozzle rod by-pass & returned to the back pressure
regulating valve (BPRV). From BPRV outlet, oil is returned to the circulating
header. Oil circulation continues till the required oil temperature is achieved.

6 - Before installing the new oil pipe lines be ensure that the rating & size of
the oil lines are suitable for burner inlet and return pressure.

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OIL FLOW DIAGRAM PARTS DESCRIPTION (FIG-18A)

NO PART

1 Service oil tank with oil preheater (Day tank)

2 Isolation valve
3 Oil strainer
4 Isolation valve for circulating header oil inlet
5 Isolation valve for circulating header vent line
6 Oil circulating header
7 Isolation valve for circulating header burner return
8 Isolation valve for circulating header burner oil inlet
9 Drain valve
10 Duplex oil filter
11 Isolation valve to oil pump suction line
12 Isolation valve to oil pump discharge line
13 Inlet oil pressure regulating valve (IPRV)
14 Steam preheater
15 Isolation valve for steam preheater
16 Electric oil preheater
17 Isolation valve to burner inlet oil line
18 Micro oil strainer with thermometer
19 Burner inlet oil pressure gauge with needle valve
20 Burner rod assembly (Nozzle rod)
21 Burner return oil pressure gauge with needle valve
22 Back pressure regulating valve (BPRV)
23 Isolation valve burner return line
24 Cam disc assembly
25 Oil pump
26 Oil Burner

Burner type PA 15 - Circulating header capacity 40 liter

PA 20 - Circulating header capacity 50 liter
PA 25 - Circulating header capacity 50 liter

Burner type PA 35 - Circulating header capacity 100 liter

PA 45 - Circulating header capacity 100 liter
PA 50 - Circulating header capacity 100 liter
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BURNER COMMISSIONING

Check prior to igniting the burner:

- Flush out all the oil pipelines by compressed air or water by tapping it at regular
intervals to remove residual welding flux, foreign Particles etc.

- Tighten all the joints and check the gaskets provided in the oil Circulating
system.

- Open and check all the strainer for proper filter elements.

- Open all the air vents in the oil lines and oil isolating valves as require .

- Check all the safety interlocks provided on the equipment for their normal
functioning.

- Ensure that the electrical wiring and connections are in order

- Check the direction of rotation of the combustion Air blower, Fuel Oil
pumps & other equipment installed.

- Adjust the thermostats settings on the oil preheaters.

- Keep the IPR valve settings at min. positions for initial start up.

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Igniting the burner (Manual mode)

- Switch on the blower, Fuel oil pump and oil preheaters.

- Adjust the Fuel oil pump discharge pressure by built in relief valve and
burner inlet oil pressure by IPR valve between 20 - 28 kg/cm2 by hand
wheel provided on IPRV.

- Adjust the return oil pressure from BPR Valve top side, between 3 – 6 kg/cm2
by Allen wrench.

- Check burner damper in min. position (low flame) and fuel oil
temperature before igniting the burner.

- Switch on the ignition spark at the nozzle tip.

- Check Ignition spark from the burner view glass for normal bright Spark.

- Operate the nozzle DC solenoid to release the fuel oil from the nozzle.

- Check the flame from the burner view glass, once the burner is ignited.

- If the flame is found normal, adjust the air fuel ratio by adjusting the
return oil pressure and combustion air for low flame and high flame
positions as described earlier for obtaining max. output and efficiency.

CAUTION: WHEN BURNER IS FIRED IN MANUAL MODE, OPERATORS

CONTINUOUS ATTENTION IS REQUIRE AS FLAME FAILURE SAFETY
FEATURE MAY NOT BE AVAILABLE IN THE MANUAL FIRING MODE.

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Ignition of the burner in (Auto mode )

- Switch on the burner control switch in auto mode.

- The blower , oil pump and oil preheaters are switched on automatically.

- If the combustion air pressure (If Air Pr. switch is provided) and Fuel oil
temperature are normal and the burner is in min. position. The burner
sequence controller is switch on for auto operation.

- Burner goes to pre-purge cycle (If provided) by opening the air damper at
max. open damper position . (High flame )

- On expiry of pre-gauge cycle burner returns back to min. damper position

(low flame )

- On preset delay of the controller, the High Voltage ignition spark is

established at the nozzle tip.

- Nozzle DC solenoid operates to release the fuel oil from the nozzle.

- The flame is established and sensed by the photoresistor for further

Burner sequence.

- Burner goes to modulating mode and max. damper opening position (High
flame ) depending upon the load demand of the equipment.

- If the flame is not established during safety period of the controller,

burner goes to lockout automatically, giving audio visual alarm.

NOTE: Burner auto sequence may vary depending upon the type of
sequence controller is used .

It is advisable to operate the burner in AUTO mode only, to ensure the

optimum safety of the burner, operating personnel and the equipment.

IT IS ALWAYS ADVISABLE TO FIRE THE BURNER IN AUTO MODE ONLY.

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COMMON BURNER FAULTS AND THEIR REMEDY:

(1) Burner does not start:

FAULT REMEDY

(A) Power supply to the equipment Check power supply.

is disconnected.

(B) The safety interlocks of the Check the interlocks

equipment is interrupted.

(C) Air pressure switch for combustion Check the Air Pr. switch.
air is not switched on. (If provided)

(D) Sequence controller is defective Replace it.

(E) Motor protection overload relays Check it.

for blower or oil pump is tripped.

(F) Limit switch in the flue gas damper Check it.

is not operated. (If provided)

(G) Min. oil temp. thermostat is defective Check it.

or the oil temp. is too low.

(H) After pre-purging, min. damper micro Check it.

switch for starting position is not
pressed or may be defective.

(I) Flame sensor receives stray light from Check photoresistor

the external sources. Check nozzle rod
for leakage, or there may
be oil accumulation in
the furnace.

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(2) Burner does not ignite:

FAULT REMEDY

(A) No ignition spark, there may not Check Ignition Transformer

be voltage at ignition transformer

(B) Ignition electrodes point gap too Adjust the point gap for
big or too small 6 to 8 mm.

(C) Porcelain insulator of the electrode Check and replace it.

is cracked or dirty.

(D) Ignition electrodes tips are dirty. Clean it.

(E) Too much combustion air at starting Reduce the Air from air
position. drum in the modulating
unit by 6 mm Allen key.

(F) Sequence controller is defective. Replace it .

(G) The DC solenoid is defective. Check the rectifier and

solenoid coil. Check DC
voltage around 180-230v

(H) Nozzle is clogged or defective. Check and clean, or replace it.

(I) Oil temp is too low, quality of Check oil temp.

atomization is inadequate for Check oil preheaters.
firing. Check oil thermostats.

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(3) Burner ignites but immediately switches off:

FAULT REMEDY

(A) Flame sensor receives insufficient Photoresistor sensor side

light . is not facing towards the flame
Check for any type of
obstruction in front of the
photoresistor OR flame sensor.

(B) Flame sensor is dirty or defective Clean it or replace it.

(C) Sequence controller is defective Replace it .

(D) Flame is unstable due to excessive Adjust the air on air drum
combustion air supply .

(E) Variation in inlet oil pressure and Check the burner oil
return oil pressure . pressure.

(4) Burner smokes heavily:

FAULT REMEDY

(A) Too much oil output from Check return oil pressure.
The nozzle. If require adjust the BPRV
and cam disc

(B) BPR valve is faulty. Replace it.

(C) Burner return line isolation In this case burner inlet

valve may be closed. oil pressure and return
oil pressure will be equal,
find out the blockage.

(D) Cam disc eccentricity is too high, Adjust the cam disc
return oil pressure increases Reduce the return oil pressure

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(E) Air damper opening is too low Increase the air by adjusting
the air damper .

(F) Heavy leakage from the nozzle and Check the sealing washers
Nozzle rod sealing washers at the for nozzle and tighten it
time of firing . fully by proper spanner.

(5) Problems related to the air regulating unit PA – AR63

FAULT REMEDY

(A) Air regulating unit is not reaching
to the min. and max. limit positions
and overshoots.
Check the micro switches
for min. and max. limit
positions.
Check the connections of the
reversible servomotor.

(B) Air regulating drum is jammed and
can not be rotated by hand when
de-clutching gear is pressed .
Check the Allen bolts
provided for clamping the
BPRV bracket and unit. If
longer bolts are used it may
press the gears, change
the bolts. Check burner air
damper for jamming, lubricate
the Bearings. Check the gear
train and if require lubricate it.
Modulating drive unit is faulty.

IMPORTANT:

Jammed air regulating unit may overload the gear drive and servomotor may
burn out.

Cont -27-
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-27-

MAINTENANCE BY THE OPERATING STAFF

(A) Daily inspection

- Check flame through the burner sight glass to ascertain the formation of
the soot or clinker in the combustion chamber.

- Check the diffuser plate and flame tube for cleanliness by viewing
through the sight glass.

- Check the burner oil pressure and temperature.

- Observe the ignition spark and nozzle DC solenoid movement .

- Check the burner tripping by pulling out and masking the flame sensor.

(B) Weekly inspection

- Clean and check all the oil filters.

- Attend all the oil leakage from the oil lines.

- Monthly inspection

- Clean the diffuser plate and the flame tube if the clinker or soot
formation is observed on it.

- Clean the ignition electrodes tip by solvent to remove the carbon

particles.

- Clean and lubricate the AR63 modulating unit gear drive assembly .

- Check the burner electrical connections.

- Clean and lubricate the nozzle DC solenoid plunger by lubricating oil.

- Clean and check the porcelain insulators of the ignition electrodes

- Clean and check the nozzle.

Cont -28-
 PANCHAL ASSOCIATES
-28-

(D) Quarterly inspection

- Check and lubricate the air dampers Bearings.

- Lubricate the AR63 servomotor motor bushings/Bearings by lubricating oil.

- Check BPRV cam disc for any wear and tear.

- Check the ' U ' seals of BPRV, Nozzle rod, IPRV etc.

FLAME TUBE ARRANGEMENT: (FIG-29A)

Flame tube is a cylindrical shell with two slotted holes on both the sides.
These are required for forward and backward adjustment of flame tube with
respect to diffuser and nozzle. After the adjustment, the adjustment bolts (2)
are tightened fully. Two nos. fixing bolts (1) are provided (one at the top
and other at the bottom) for preventing the flame tube from sagging during
operation.
The distance between the diffuser plate and flame tube as shown X in the
diagram, has been specified for each type of burner on sheet no

ADJUSTMENT OF DIFFUSER PLATE AND NOZZLE TIP

Diffuser plate is fitted to the nozzle rod guide bar end forks. Nozzle rod is
inserted through the guide bar. For adjusting the distance Y between nozzle
tip and the diffuser plate (inner surface)

1. Loosen 4 nos. Allen screws (3) on the fixing plate.

2. Nozzle rod guide bar can be shifted forward or backward for

increasing or decreasing the distance Y

3. After the adjustment, Allen screws (3) are to be tightened.

Cont -29-
 PANCHAL ASSOCIATES
-29-

NOTE:

A. The distance X and Y are for nozzles type PA/DZ with the spray
angle of 45/55 deg

B. If the distance is greater than the specified there may be clinker

formation on the flame tube or diffuser plate. In this case distance must
be reduced.

C. After the adjustment ensure that the flame and diffuser plates are in the
center with respect to the nozzle tip for proper distribution of the
combustion air.

D. Ensure that the ignition electrodes are not fouling in the nozzle spray.
PANCHAL ASSOCIATES
PANCHAL ASSOCIATES
PANCHAL ASSOCIATES
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-30-

FLAME TUBE AND DIFFUSER PLATE ADJUSTMENT (FIG-29A)

BURNER TYPE DISTANCE X DISTANCE Y

mm mm

PA-15 60 12
PA-20 65 12
PA-25 90 12
PA-30 100 12
PA-35 120 25
PA-40 130 25
PA-45 160 25
PA-50 180 25