TD5 R04 Manual Eng

_________________________________________________________________________________________
DUAL FUEL BURNERS
TD5
GENERAL INFORMATION
AND
OPERATING MANUAL
June 13
1 of 129
TD5 Manual Rev 4
Revision Table
Rev No.
1
2
3
4
June 13
Description
emergency stop information added - section 5.9,

exploded drawings revised section 11
2 of 129
Date
By
6.6.13
R.S
TD5 Manual Rev 4
`TD` SERIES DUAL FUEL BURNERS

GENERAL INFORMATION AND OPERATING MANUAL
IMPORTANT
Throughout this publication Dunphy Combustion Limited are referred to as `The Company`.
The manual, which is supplied with every burner should be read prior to the installation of the unit.
While giving information on the site work involved and on the burner commissioning procedure,
the content cannot include all of the data which may be necessary to achieve the design output of a
burner to a particular appliance because of the wide variety of heating and process plant for which
the burner is suitable precludes this.
The Company strongly advises that the commissioning of the burners is carried out by Dunphy
trained engineers and points out that it may be impossible to impart all the necessary information to
enable others to do so.
Under all circumstances the provisions of The Health and Safety at Work Act 1974 are the most
important consideration and if any doubts exist concerning the safe operation of the burner, The
Company should be contacted for advice. This provision also applies to the legislation of countries
to which the burners may be exported.
Where equipment, not of The Company`s supply, is used in conjunction with the burners, reference
should be made to specific instructions or regulations governing the installation and use of such
equipment.
The Company gratefully acknowledges the permission of component suppliers and others to
reproduce data sheets and technical information in this manual.
For reliable and efficient operation of the burner, it is essential that regular maintenance is carried
out in accordance with the instructions contained in the text of this manual. The fact that a burner
may be under warranty does not absolve the user from the responsibility for this and inadequate
maintenance may lead to claims, made under guarantees of materials or performance being denied
IF IN DOUBT - ASK!
Information contained in this manual is given without any responsibility on the part of the company
for the consequences of the actions of persons making use of such information.
Equipment is supplied strictly under the terms of The Companys current `Conditions of Supply`
which are printed on the reverse of order acknowledgements and delivery notes.
Copies are available on request.
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Contents
General Information ...................................................................................................................................... 7

1.1 General ............................................................................................................................................................ 7
1.2 Working parameters ................................................................................................................................... 7
1.3 Fuels ................................................................................................................................................................. 7
1.3.1 Fuel Tanks .............................................................................................................................................. 8
1.3.2 Filtration .................................................................................................................................................. 8
1.3.3 Ring Main Pumps.................................................................................................................................. 8
1.3.4 Pipe Runs ................................................................................................................................................ 8
1.3.5 Burner Connection ............................................................................................................................... 8
1.3.6 Burner Filtration ................................................................................................................................... 8
1.3.7 Pressure Regulation ............................................................................................................................ 8
1.3.8 Oil Line Connections ........................................................................................................................... 9
1.4 Burner construction .................................................................................................................................... 9
1.5 Burner details and power curve ........................................................................................................... 12
1.6 General arrangement detail ................................................................................................................... 13
1.6.1 Electronic modulation burners (M RT) ....................................................................................... 13
1.6.2 TD5 Multi Fuel Low Nox Burner General Arrangement .................................................... 14
2 Installation ........................................................................................................................................................ 15
2.1 Burner Mounting......................................................................................................................................... 15
2.2 Gas Valve mounting .................................................................................................................................. 16
2.2.1 Burner fitted with Unibloc ............................................................................................................... 16
2.2.2 Burner fitted with Siemens VGD40 gas valve ......................................................................... 18
2.3 Fuel oil installations .................................................................................................................................. 19
2.3.1 Pump Connections ............................................................................................................................. 19
2.4 Pump Priming .............................................................................................................................................. 19
2.5 Gas installation ........................................................................................................................................... 20
2.6 Electrical connections ............................................................................................................................... 20
2.7 Inverter Connection .................................................................................................................................. 20
2.8 Ventilation requirements......................................................................................................................... 20
3 Combustion Head Settings ....................................................................................................................... 22
3.1 Modulating Burners ................................................................................................................................... 22
3.2 Modulating TD525 Burners Fitted With Low NOx Multi-Pipe Gas Head ................................. 23
3.3 Modulating TD530 Burners Fitted With Low NOx Multi-Pipe Gas Head ................................. 25
3.4 Modulating TD525 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil .......... 27
3.5 Modulating TD530 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil .......... 29
3.6 Modulating Burners Fitted With Bio - Gas Head ............................................................................ 31
3.7 Nozzle Adjustment .................................................................................................................................... 32
3.7.1 Gas Head ............................................................................................................................................... 32
3.7.2 Multipipe Gas Nozzle adjustment ................................................................................................ 32
4 Adjustments and Operating Principles ............................................................................................. 33
4.1 Electronic Modulation burners (M RT) ................................................................................................ 33
4.1.1 Oil Operating System Modulating Burners ART 114 and ART 1400 Nozzles ............... 34
4.1.2 ART114 Burner Gun .......................................................................................................................... 35
4.1.3 ART 1400 Burner Gun ...................................................................................................................... 35
4.1.4 Oil Operating System Modulating Burners ART 106 Nozzle .............................................. 37
4.1.5 Oil Operating System Modulating Burners Multi-Oil Nozzles ............................................ 39
4.1.6 Fuel Pumps and Motors ................................................................................................................... 39
5 Operation & User Interface ..................................................................................................................... 40
5.1 The Display / Keypad ............................................................................................................................... 40
5.2 Start -up Sequence ................................................................................................................................... 40
5.3 Modulation .................................................................................................................................................... 43
5.4 Normal mode ............................................................................................................................................... 43
5.5 Local mode ................................................................................................................................................... 43
5.6 Non-volatile lockout .................................................................................................................................. 44
5.7 Ratiotronic 6000 Inverter interface additional information ....................................................... 44
5.8 Post Purge Operation................................................................................................................................ 44
5.9 Emergency Stop ......................................................................................................................................... 45
6 Component Setup Parameters ............................................................................................................... 46
6.1 Ratiotronic 6000 ......................................................................................................................................... 46
6.2 Danfoss VLT FC 102 .................................................................................................................................. 52
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6.2.1 RWF 40.000A97 Default Burner Settings ................................................................................. 54

Commissioning ................................................................................................................................................ 55
7.1 Basic settings .............................................................................................................................................. 55
7.2 Start Gas Heat Input ................................................................................................................................ 56
7.3 Pre-commissioning .................................................................................................................................... 57
7.4 Commissioning High Low and Pneumatic Modulation burners - Firing on Gas .............. 58
7.4.1 Dry run ................................................................................................................................................... 58
7.4.2 Check for leaks through the automatic gas valve. ............................................................... 58
7.4.3 Check rotation of burner fan motor ............................................................................................ 58
7.4.4 Check for correct control sequence. ........................................................................................... 58
7.4.5 Firing the burner ................................................................................................................................ 59
7.4.6 Combustion values and results..................................................................................................... 59
7.4.7 Adjustment of Gas Proving Pressure Switch ........................................................................... 60
7.5 Oil Firing ........................................................................................................................................................ 60
7.5.1 Setting the Firing Rate, High / Low Oil Burners ..................................................................... 60
7.6 Electronic Modulating Burners .............................................................................................................. 63
7.6.1 Gas Butterfly Valve ........................................................................................................................... 63
7.6.2 Oil Metering Valve ............................................................................................................................. 63
7.6.3 Adjustment of air pressure proving switch .............................................................................. 63
7.6.4 Ratiotronic programming ................................................................................................................ 64
7.6.5 Setting the servo motors ................................................................................................................ 64
7.6.6 Burner Commissioning ..................................................................................................................... 64
7.6.7 Combustion values and results..................................................................................................... 65
8 Burner Maintenance Schedule ............................................................................................................... 66
8.1 Opening the Burner................................................................................................................................... 66
8.2 Minor Maintenance .................................................................................................................................... 67
8.3 Major Maintenance .................................................................................................................................... 67
8.4 Dismantling and Re-assembly of Burners ........................................................................................ 67
9 Faults and fault finding .............................................................................................................................. 71
9.1 Ratiotronic 6000/6006 ............................................................................................................................. 71
10 Useful Information ....................................................................................................................................... 72
11 Exploded Diagram & Spare Parts List ................................................................................................ 74
11.1 Standard TD5 Assembly .......................................................................................................................... 74
11.2 TD5 Multi-Oil Multi-Gas Assembly ....................................................................................................... 78
11.3 TD525 Low NOx Multipipe Combustion Head Assembly ............................................................. 83
11.4 TD530 Low NOx Multipipe Combustion head Assembly .............................................................. 83
11.5 TD525 Combustion Head Assembly .................................................................................................... 84
11.6 TD530 Combustion Head Assembly .................................................................................................... 84
11.7 DN80 Unibloc Assembly .......................................................................................................................... 85
11.8 DN100 Unibloc Assembly ........................................................................................................................ 85
11.9 DN125 Unibloc Assembly ........................................................................................................................ 85
11.10 VGD40.80 Assembly for Electronic Modulating Burners ......................................................... 86
11.11 VGD40.100 Assembly for Electronic Modulating Burners ....................................................... 86
11.12 VGD40.125 Assembly for Electronic Modulating Burners ....................................................... 87
12 Component Information ............................................................................................................................ 88
12.1 Unibloc ........................................................................................................................................................... 88
12.1.1 Unibloc General Arrangements ..................................................................................................... 88
12.1.2 80mm Ratiotronic Unibloc exploded diagrams and parts list ........................................... 91
12.1.3 80mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ........................ 92
12.1.4 100mm Ratiotronic Unibloc exploded diagrams and parts list ......................................... 94
12.1.5 100mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ..................... 95
12.1.6 100mm Ratiotronic Unibloc with pilot & ETC 1021 exploded diagrams and parts list
97
12.1.7 125mm Ratiotronic Unibloc exploded diagrams and parts list ......................................... 99
12.1.8 125mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ................... 101
12.2 Butterfly Gas Valve ................................................................................................................................. 103
12.2.1 General Arrangement ..................................................................................................................... 103
12.2.2 Exploded Diagram ........................................................................................................................... 104
12.3 Siemens VGD20 and VGD40 Gas Valve Blocks ............................................................................ 105
12.3.1 Siemens SKP actuators .................................................................................................................. 109
12.4 VPS 504 Valve Proving System .......................................................................................................... 115
12.5 Variotronic VT Oil Metering Valve ...................................................................................................... 118
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12.5.1
12.5.2
12.5.3
12.5.4
12.5.5
12.5.6
12.5.7
12.5.8
12.6 DH
12.6.1
12.6.2
12.6.3
12.6.4
12.6.5
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General Description......................................................................................................................... 118

Construction ....................................................................................................................................... 118
Valve Maintenance .......................................................................................................................... 118
Changing Seals ................................................................................................................................. 118
Adjustment of the valve ................................................................................................................ 119
Installation of the valve................................................................................................................. 119
Valve Drive ......................................................................................................................................... 119
Exploded Diagram ........................................................................................................................... 120
Series Pump ....................................................................................................................................... 121
Pressure Regulation ........................................................................................................................ 122
Technical Data Summary .............................................................................................................. 123
Installation Operation Maintenance .......................................................................................... 124
Fault Finding ...................................................................................................................................... 125
Oil Flow Diagrams ............................................................................................................................ 126
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1 General Information
BOILER EFFICIENCY DIRECTIVE

( HOT WATER BOILERS ONLY )
In compliance with the Boiler Efficiency Directive, during commissioning, all adjustments to the
burner must be made in accordance with the boiler manufacturer's instructions and these must include
checking of flue gas temperature, average water temperature and CO2 or CO concentration.
1.1 General
Burners must be checked at the time of delivery and any deficiencies or damage immediately
reported to the carrier or supplier. The company will make good any defects or replace missing
items strictly in accordance with their current conditions of supply.
The company has a policy of continuous development and therefore reserve the right to make
changes, without notice, in burner or other specifications.
Burners carrying the same model number may have major differences in their detailed
specification, such as draught tube lengths to suit the dimensions of a particular appliance, which
makes it impossible to give, in a single publication, precise information on the whole range of
applications. Data is readily available from the company and can be supplied on application.
Please give the burner serial number when requesting information.

All TD series burners are manufactured and tested to European Standards EN676: 2003 & A2: 2008
Automatic forced draught burners for gaseous fuels, Definitions, requirements, testing, marking and
EN 267 Forced draught oil burners Definitions, requirements, testing, marking
It is essential that appliance and burner combinations are correctly matched.

If any doubt exists about the suitability of a particular combination the installer
must check with the manufacturers.
If a burner is to be fitted to an existing boiler, maximum combustion efficiency can only be
achieved if all heat transfer surfaces are cleaned prior to the installation. Generally `TD` series
burners are not suitable for use in areas of high humidity or in explosive atmospheres, but special
units suitable for use in adverse situations can be manufactured to a customer's specific
requirements. Details of special units are available, on request, from the Dunphy sales department.
1.2
Working parameters
Temperature
0 to +50C
Relative Humidity
60 - 90% non-condensing
Atmospheric Air Pressure will generally be in the range of 950 to 1100mbar, but this will change
with altitude, if there are any queries please consult the Dunphy technical department.
1.3
Fuels
'TD' Series of burner must only be used with the fuels specified on the burner data plate and in the
case of gas, the pressure must not, under any circumstances, drop below the stated minimum
operating level.
The burner is also optimised for use with 35 sec diesel oil.
B100 Bio-diesel must not be used on a standard burner. When using B100, it must be specified at
time of order. Special pumps, valves and seals are used when burning B100.
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1.3.1
Fuel Tanks
Fuel storage tanks must be positioned to maintain a positive head to burners or ring main pumps,
regardless of the oil level in the tank.
Vertical and horizontal storage tanks should be mounted on concrete plinths in accordance with
local, national or any environmental standards that may apply.
The fuel lines and fuel filtration system must be sized to prevent any possibility of vacuum
occurring in the pump suction ports.
If a positive head of oil is not maintained, there is a possibility that cavitations will occur within the
fuel pump.
As a general guide, the fuel storage tanks must be mounted at least one meter above the ring main
fuel pumps which should be sited as close as possible to the tank discharge.
1.3.2
Filtration
Duplex fuel filtration is recommended to the ring main pumps, this will allow for maintenance
without shutdown of the ring main system, during normal operation of the plant.
1.3.3
Ring Main Pumps
The ring main pumps should be sized to give 100 to 150% over the burner pumps fuel
requirements.
Pumps must be fitted with an internal relief valve set at a maximum of 3 bar for pump protection.
Manual isolation valves should be fitted to the pump inlet and outlet pipework to allow for
maintenance. It is recommended that the valves have electric switch packs fitted to them so that
they can be interlocked with oil operation.
It is always preferable to use duplex pumping where practical, particularly on multi-burner
installations.
1.3.4
Pipe Runs
Pipework should be run in a manner that allows it to be self venting and, in sections that require
venting, a suitable vent or de-gassing section should be fitted.
Where overhead ring mains are to be installed particular care and attention should be taken that the
system can be adequately vented. Welded construction is preferable to screwed connections.
1.3.5
Burner Connection
Burner connections should be provided in the ring main pipework adjacent to the boiler and close
enough to allow the burner to be opened without the need to disconnect the flexible oil lines.
Note: - Manual isolation valves should not be fitted on the return lines.
1.3.6
Burner Filtration
Burner filtration will depend on the size of burners in question and the quality/grade of the fuel oil
to be used, but good quality fuel filters, preferably of the self-clean type are recommended.
1.3.7
Pressure Regulation
The Pressure regulating valve of the ring main must be of the low, or zero, hysteresis type and
capable of maintaining a stable ring main pressure through the minimum and maximum flow
conditions of the supply system irrespective of any change in flow volume or viscosity.
A number of suppliers manufacture valves suitable for this purpose and further details are available
from the Dunphy technical department.
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1.3.8
Oil Line Connections
It is essential that the final connections between the main oil supply lines and the burner fuel pump
are made with flexible oil lines that are long enough to allow the burner to be swung open on its
hinges without having to be disconnected. Care should be taken to ensure that the flexible oil lines
do not become `kinked` as this will cause damage to the flexible and result in leakage.
1.4
Burner construction
Each T series burner is constructed from 5 separate castings described as follows:

Hinge
In common with all other body castings, the mounting casting is manufactured from aluminium
grade LM6 with the front face drilled to the dimensions given in section 1.5 of this manual suitable
for mounting studs. The rear face has two external lugs which form part of the burner hinge and is
drilled to accept the studs that are used to lock the burner closed.
Note: The fuel pipework enters this casting and it is essential that all joints and connections on the
combustion head are checked for security before the burner is hinged to the closed position. See the
maintenance section for details.
This casting houses the burner draught tube and combustion head along with the appropriate
ignition cables and flame detection equipment.
Fan case assembly
This consists of two aluminium castings with machined faces, bolted together and enclosing
the fan (which is sized to suit the particular burner model according to output and combustion
chamber resistance).
Integral with and inside the front half of the fan cases are the compressor blades; on the outside,
external lugs are attached with pins and thrust bearings to the burner mounting casting to form the
hinges.
The rear half is tapped to take the burner lifting eye and pads are used for the attachment of the
components on various models of the burner. The rear face is machined to match the air shutter
assembly, which is attached to it.
A differential air pressure switch, piped across the air inlet and pressure outlet of the combustion air
fan is mounted on the front section. Its function is to prevent the burner from firing if a supply of
combustion air is not available or to lock out the burner if the air supply is interrupted during
normal running.
Air shutter
Combustion air is introduced through two concentric castings, one rotating about the other on a
PTFE bearing surface, regulating the combustion air supply through characterised slots to
accurately maintain the fuel air ratio. Close machining tolerances ensure almost zero leakage when
the damper is fully closed. The characterisation of the slots also ensures very high control of the air
supply at the important low fire end typically 30 degrees of movement accounts for only 10% of
air throughput thus ensuring very high turndown capability.
The operation of the air shutter is activated by a reversible, mains voltage, synchronous motor (on
high/low burners) or a 240 (or 24V) motor with potentiometer control for fully modulating units.
Adjustable rigid linkage is used and the limits of travel are set by micro switches. Final adjustments
are made during commissioning.
On burners fitted with electronic modulation systems the air shutter and the fuel valves will all be
manufactured with individual drive motors controlled by the modulation system.
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On burners which have air inlet silencers as standard a 0-10 scale is fitted to indicate the opening of
the air shutter (not the firing rate) and nylon support bearings ensure that the travel is as smooth as
possible.
Burner Motor
The burner (fan) motor is a continuously rated 2-pole unit with class 'F' insulation, sized according
to the application. The motor is mounted the inside of the inner shutter thus allowing 100% heat
recovery from the motor into the combustion air offering efficiency ratings greater than EFF1. This
also ensures inherently quiet operation from the burner.
Combustion Air Fan
Mounted directly onto the motor shaft and positioned within the fan case assembly, the fan supplies
combustion air via the compressor vanes and mounting casting to the combustion head.
Due to the 'T' burner requirement for extremely low vibration and noise levels the fans are
manufactured and balanced to the very highest standards (ISO 1940-2003).
All fans are colour coded according to size.
Combustion Head
The air for combustion passes from the burner fan at a pressure related to the resistance of the
boiler, down the draught tube to the combustion head. The latter is an assembly of components
which cause the gas to be discharged into the air flow in such a way that optimum mixing takes
place.
Many types of combustion head are available depending on appliance geometry, gas type, available
gas pressure, NOx level requirement etc
Note: On any burner, an almost infinite combination of combustion head components may be used
to achieve optimum efficiency and a flame shape to suit a very wide range of heat-raising
appliances.
Burner Control Cabinet
Standard burners are supplied with a dust resistant damp-proof cabinet mounted on the side of the
burner. In many cases all the burner controls are fitted within the burner control cabinet (figure 1).
In more complicated installations, this cabinet would house a terminal strip (figure 2) which would
then interface to a control desk via flying leads.
Figure 2
Figure 1
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Control desks are available in wardrobe type style (figure 3) or desk type style (figure 4). These
can vary in complexity and are able to house a whole host of burner/boiler controllers, water levels
controls, inverters, plc etc...
Figure 4
Figure 3
Air Inlet Silencer

Because of their design characteristics, 'T' series burners operate at very low noise levels, however,
further reduction of these levels can be made by fitting air inlet silencers which are designed to
cover the air shutter castings. The standard foam lined silencer typically offers sound levels in the
region of 80dBA. An optional Snorkel type silencer is available which will reduce sound levels to
below 75dBA. Silencers can also be tailored to suit ducted air supplies, filters or additional acoustic
attenuation. For extremely sensitive installations, 'Acoustic Shrouds' which cover the entire burner
can be individually designed to suit most applications. Quotations are available on request.
Typical Acoustic Shroud
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Burner fitted with 'Snorkel' Silencer
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1.5
Burner details and power curve

BURNER
Gas Volume
(m3/hr)*1
Firing Rate kW
Mechanical
Mod
TYPE
MIN
MAX
MIN
MAX
TD525Z
1250
8000
120
769
TD530Y
1500
9800
144
942
*1 Based on Nat Gas C.V 10.4kW/m3

*2 - Fitted with a Ratiotronic 6000 System
June 13
Fan Motor
KW
Pump
Motor kW
Voltage
Hz
Ph
Running
Current
Starting
Current
(without
Inverter)
20.5
3.0
380-420
50
51 Amp
107 Amp
24.0
3.0
380-420
50
61 Amp
136 Amp
FIRING MODE OPTIONS
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Electronic
Mod*2
TD5 Manual Rev 4
1.6
1.6.1
General arrangement detail
Electronic modulation burners (M RT)
Electronic modulation burners are fitted with on/off gas valves

and electronically controlled butterfly valves for the gas
regulation. The gas valve is generally a Unibloc (see
component section for details) however other valves can also be
used depending on site details or customer preference. An
additional electronically controlled oil metering valve is fitted
for oil regulation see principle of operation section for more
details.
TD 525 - 530 Burners
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1.6.2
TD5 Multi Fuel Low Nox Burner General Arrangement
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Installation
2.1
Burner Mounting
Care must be taken when mounting the burner not to damage the mounting gasket. The furnace
pipe (where fitted) is generally positioned at 12 oclock on the mounting flange and care must be
taken not to damage it during the mounting process.
Note: - Ensure that the burner mounting gasket is correctly fitted when fixing the burner to
the appliance. This gasket creates a gas-tight seal between the boiler and burner and also
insulates the burner mounting casting.
It is important to check that the burner draught tube projection into the combustion chamber
conforms to the appliance manufacturers instructions.
Non standard draught tube projections are available on request; - please consult the Dunphy sales
dept.
In general, for reverse flame boilers the draught tube projection into the combustion chamber
should be between 50 and 100mm. For other boilers the burner draught tube should finish flush or
slightly proud of any boiler refractory or insulation. Low NOx heads should be projected into the
furnace by at least 100 - 150mm.
If there is any doubt about the correct projection into the combustion chamber, the appliance
manufacturer must be consulted.
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2.2
2.2.1
Gas Valve mounting

Burner fitted with Unibloc
The Unibloc gas valve is

a heavy item and will
require two persons to lift
it into position and secure
in place using bolts
provided.
The Unibloc is shipped
pre - connected. Please
consult electrical wiring
diagram for electrical
connections.
Governor shown is
supplied with every
burner using a Unibloc
gas valve and should be
installed according to
guidelines illustrated
below and approximately
10 pipe diameters
upstream of the gas valve.
Pipe work and isolating valve are supplied by others.
Important:
The installer must install a 90 turn type isolation ball valve next to or in close proximity to
the burner and capable of rapid operation.
The manual valve must be capable of operating at a pressure equal to 1.5 times the maximum
supply pressure and where possible must be orientated in such a way that when the valve closes the
handle must fall from the vertical to the horizontal. The valve must have mechanical end stops to
prevent the ball valve from going below the 0 point or above the 90 point.
The gas supply pipework
must be adequately
supported to prevent undue
stress on the burner casing or
the gas train components.
Typical Gas train installation
Gas supplies greater than
is shown on the right
500mbar must be governed
down to a suitable gas
pressure below 500mbar
using a CE approved high
pressure gas governor. The
gas governor or should be
fitted as per manufactures
instructions, copies available
on request.
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VGD Gas Valve Orientation
Unibloc Orientation
Governor Orientation
Fit governor in accordance with manufactures instructions.

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With the gas isolation valve next to the burner closed, a pressure test should be carried out on the
main gas supply pipe work and all connections checked with a suitable, non corrosive leak
detection fluid.
If the installation is supplied with a gas pressure above 1 bar (14.5p.s.i.g.) and contains plant with a
heat input of more than 2MW, local authorities will generally ask for the fitting of remotely
operable fire valves. The national or other standards in countries to which the burners may be
exported must be identified and met.
2.2.2
Burner fitted with Siemens VGD40 gas valve
The Siemens gas valve is a heavy item

and will require two persons to lift it into
position and secure in place using bolts
provided.
8mm blue and black PVC pipes plus
fitting are supplied with the burner. The
blue line must be connected between the
Air connection on the SKP75 actuator
and the air pulse line situated on the top
flat of the burner hinge section. The black
line must be connected between the
Combustion Chamber connection on the
SKP75 and the furnace line connection
protruding through the mounting flange of
the burner.
Important:
The installer must install a 90 turn type
isolation ball valve next to or in close proximity
to the burner and capable of rapid operation.
The manual valve must be capable of operating at
a pressure equal to 1.5 times the maximum supply
pressure and where possible must be orientated in
such a way that when the valve closes the handle
must fall from the vertical to the horizontal. The
valve must have mechanical end stops to prevent
the ball valve from going below the 0 point or
above the 90 point.
The gas supply pipework must be adequately
supported to prevent undue stress on the burner
casing or the gas train components.
The Siemens gas valve has a built-in governor and
is suitable for gas pressures up to 500mBar.
Gas supplies greater than 500mbar must be
governed down to a suitable gas pressure below
500mbar using a CE approved high pressure gas governor. The gas governor or should be fitted as
per manufactures instructions, copies available on request.
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2.3
Fuel oil installations
Fuel oil installations must comply with the following British Standards or equivalent local, national
or international standards.
BS799
BS5410
BS2869
Oil burning equipment

Code of practice for oil firing
Fuel oils for non marine use
Installations must conform to local Bye-laws and regulations which should be identified by
application to the local planning authority.
2.3.1
Pump Connections
The burner is supplied with two flexible hose lines and is connected as shown in illustration below.
OIL INLET FLEXIBLE

CONNECTION 1 BSP
OIL INLET FLEXIBLE

CONNECTION 1 BSP
OIL RETURN FLEXIBLE

CONNECTION 1 BSP
OIL RETURN FLEXIBLE

CONNECTION 1 BSP
2.4
Pump Priming
In order to ensure correct start-up for DH series oil pumps, the following guidelines should be
adhered to.
1. Ensure that the oil supply to the pump has been properly bled through and that no air is
present in the oil supply. The flexible oil lines should be fully flooded before connection to
the pump.
2. Check that all isolating valves are open and that the oil supply temperature and pressure are
correct.
3. Lubricate the pump by removing the pressure gauge plug and filling the pump with suitable
thin lubricating oil.
4. Check pumps rotation.
5. Turn pump slow until all air has been vented both from the pump itself and the burner
pipework, and the system is fully flooded.
6. The pump can now be put into operation.
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2.5
Gas installation
In all cases, gas installation work must be carried out by approved members of
Gas Safe
All relevant standards of The British Standards Institute, IGEM Standard's
and the equivalent European Standards must be adhered to.
Note: The national or other standards in countries to which the burner may be exported to must be
identified and adhered to.
2.6
Electrical connections
All electrical installation work must be carried out in accordance with the I.E.E. wiring regulations
17th Edition 2008, with further reference to the Health and Safety Executives `Memorandum of
Guidance on the Electricity at Work Regulations 1989 ( H.S.E. Booklet HS[R]25 )
Take note of the I.E.E. requirement for bonding main gas supply pipework to earth.
Connections to all terminals and the appliance should be made in accordance with the wiring
diagram supplied with each burner.
The final part of the electrical cable run must be made in flexible conduit, long enough to enable
the appliance door to be opened.
Ensure that the mains electrical supply to the burner is protected by a suitably sized fuse.
Connections to all terminals and the appliance should be made in accordance with the wiring
diagram supplied with each burner, using suitable fixed wiring installation (incorporating means of
disconnection) in accordance with local and national wiring regulations.
2.7
Inverter Connection
Burner motor connections can be found in dedicated aluminium enclosure situated on the side of
the burner control panel. Wiring diagram shows how to connect the inverter to this enclosure. The
earth leakage current from the frequency converter exceeds 3.5mA. To ensure excessive leakage
current conforms to EN/IEC 61800-5-1, an earth wire of at least 10mm2 or two separate earth
ground wires are used.
Warning:
Touching the electrical parts may be fatal even after the equipment has been
disconnected from mains.
Also make sure that other voltage inputs have been disconnected, such as
load-sharing (linkage of DC intermediate circuit), as well as the motor
connection for kinetic back-up.
Before touching any electrical parts, wait at least: please consult the inverter
manual.
2.8
Ventilation requirements
Provision must be made for an adequate supply of combustion and ventilating air to be available
when all access doors, fire doors and windows are closed. Air supply fans or flue dilution systems
must be interlocked to prevent operation of the burner(s) in the event of fan failure or shutdown.
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To ensure an adequate supply of combustion air, the room in which the burner(s) are installed
should have permanent ventilation according to local or national standards.
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Combustion Head Settings
On burners fitted with standard 'Z' and 'Y' type nose cones, the dimension 'A' between the end of
the burner nose cone and the front face of the flame plate, can be altered by releasing the three, M6
locking nuts inside the draught tube, and sliding the cone forwards / backwards, along its
adjustment slots until the required setting is obtained.
3.1
Modulating Burners
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3.2
Modulating TD525 Burners Fitted With Low NOx Multi-Pipe Gas Head
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3.3
Modulating TD530 Burners Fitted With Low NOx Multi-Pipe Gas Head
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3.4
Modulating TD525 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil
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3.5
Modulating TD530 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil
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3.6
Modulating Burners Fitted With Bio - Gas Head
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3.7
Nozzle Adjustment
3.7.1
Gas Head
The Combustion head is attached to the gas inlet on the body. The gas flows through the gas annulus
and through the 4 holes in the gas nozzle.
The gas flow can be altered by adjusting the restrictor band, shown below. Undo the four M5 screws,
rotate the band to open or close the nozzle holes.
3.7.2 Multipipe Gas Nozzle adjustment

The Combustion head is attached to the gas inlet on the body. The gas flows through the 6 gas pipes and
through the holes in the gas nozzles.
The gas flow can be altered by rotating the nozzles to direct the gas either towards or away from the
centre of the burner.
The gas nozzles can also be adjusted along the multipipe head, this will either move the gas holes closer
or further away from the flameplate.
To carry out the above adjustments, loosen the 2x M4 grub screws on each nozzle securing the nozzle
to the pipe.
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Adjustments and Operating Principles

4.1
Electronic Modulation burners (M RT)
ME burners are fitted with electronic control systems

which have direct control over the air damper and gas
butterfly valve using high precision digital servo motors.
The Air / Gas or Air / Oil ratio is defined by a profile
curve which is programmed into the controller during the
commissioning phase.
Ratiotronic 6000 series controllers are generally fitted to
these burners however Siemens LMV2.. series and
LMV5.. series controllers may also be offered as an
alternative.
ME burners are relatively complex products and it is

recommend that they are commissioned by qualified
Dunphy personnel.
Documentation on these controllers is too lengthy to
incorporate into this document and therefore is supplied as
a separate manual. Both manuals must be used in
conjunction with each other when commissioning and
operating the burner.
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4.1.1
Oil Operating System Modulating Burners ART 114 and ART 1400 Nozzles
Atomisation of the oil is by means of a single nozzle which works on the spill-back principle. The
nozzle fits into a hydraulic nozzle line assembly that allows oil from the pump outlet to circulate
through the nozzle and back through the metering valve to the pump return when the burner is
ready to fire, N.C. solenoid valves 4 & 5 open allowing oil to flow through the nozzle. the return
path from the nozzle line flows through a metering valve and back to the return of the pump
through a safety shut off valve.
The oil volume is controlled by a metering valve 6, in the spill line restricting the amount of spilled
oil and therefore increasing the volume that passes through the nozzle for combustion.
Control of both the metering valve and the air shutter is achieved by means of independent servo
motors which are positioned by the electronic control system.
Key
1) Nozzle Line Assembly
2) Nozzle
3) Oil Pump (Dunphy)
4) Pump Discharge Valve - Normally Closed
5) Pump Discharge Valve - Normally Closed
6) Oil Metering Valve (Dunphy)
7) Pressure Gauge - 0-40 Bar
8) Gauge Clock
9) Non - Return Valve
10) Test Point
11) Flexible Oil Line (Supplied Loose)
12) Low Oil Pressure Switch (Optional)
13) High Oil Pressure Switch
14) Manual Isolation Valve with Switch Packs (when fitted), interlocked with oil select on
burner.
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Operating Instructions For TD5 Dual Fuel Burner
4.1.2
ART114 Burner Gun
To set the spring tension of the piston, the spring tension screw is set 20mm from the back chamber
as shown above. The piston stroke is setup using the piston limit screw. The screw is first fully
screwed in so that the piston cannot move; the screw is then moved out by 10mm to set the stroke.
The nozzle has a vent on the back chamber to allow the piston to move, DO NOT BLOCK THE
VENT.
4.1.3
ART 1400 Burner Gun
The ART1400 nozzle has a set spring tension and piston stroke; no adjustments can be made to the
operation of the burner gun.
The nozzle has a vent on the back chamber to allow the piston to move, DO NOT BLOCK THE
VENT.
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CAPACITY TABLES FOR

TYPE ART114/1400 RETURN FLOW NOZZLES
Supply pressure - 30 bar Viscosity - 5cSt (35 secs Redwood) Maximum output with return closed.
ATOMIZER
RETURN PRESSURES IN BAR
RECOMMENDED
NUMBER
OUTPUTS IN KILOGRAMS/hr
PUMP
MAXIMUM
6
10
14
18
21
24
MAX OUTPUT TURN-DOWN RATIO
40
50
60
70
80
90
100
112
125
140
160
180
200
225
275
300
330
360
400
450
500
550
625
700
June 13
16
18
20
22
24
27
31
35
40
44
48
58
62
67
73
79
89
98
108
124
138
7
9
11
22
24
27
30
33
36
42
48
54
60
67
80
88
96
106
117
133
148
162
184
209
11
14
17
30
34
37
42
46
52
59
67
76
86
96
118
130
145
160
180
198
220
248
281
315
18
22
27
43
48
54
60
67
76
86
98
112
126
143
175
195
220
240
266
296
333
367
417
464
26
33
40
56
64
72
80
90
103
117
132
150
170
192
240
270
300
335
375
420
467
514
584
648
36 of 129
37
47
58
72
83
94
105
118
135
152
175
195
220
250
310
350
395
-
49
61
74
86
98
110
122
137
153
172
196
220
245
276
337
368
405
440
490
557
612
673
765
857
150
180
200
210
230
254
270
290
320
380
430
460
550
600
700
750
800
870
900
960
1025
1100
1200
1300
2.5
2.85
3.15
3.2
3.2
3.2
3.2
3.2
3.3
3.35
3.5
3.6
4
4
4
4
4
4
4
4
4
4
4
4
TD5 Manual Rev 4
4.1.4
Oil Operating System Modulating Burners ART 106 Nozzle
Atomisation of the oil is by means of a single nozzle which works on the spill-back principle.
From the schematic diagram below it can be seen that when the oil supply is admitted to the
nozzle by the two main oil valves, the flow can either pass through the nozzle into the furnace or
can return down the spill line to the pump return.
The control of the oil volume is achieved by a metering valve in the spill line restricting the amount
of `spilled` oil and therefore increasing the volume that passes through the nozzle for combustion.
Control of both the metering valve and the air shutter is achieved by means of a modulating
motor which is positioned by potentiometer according to the control signal.
On burner shutdown both the main safety shut off valves and the return safety shut off valves
close simultaneously to isolate the nozzle and reduce any possibility of oil spillage into the furnace.
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CAPACITY TABLES FOR

TYPE ART 106 RETURN FLOW NOZZLES
Supply pressure - 20 bar
NOZZLE
NUMBER
1.25
1.5
1.75
2.0
2.25
2.5
2.75
3.0
3.25
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
10.0
11.0
12.0
14.0
16.0
18.0
20.0
Viscosity - 5 cSt ( 35 secs Redwood )
NOZZLE OUTPUT Kg/hr
RETURN PRESSURE
@ 3 bar
CLOSED
RETURN
1.9
2.15
2.6
3.05
3.4
3.8
4.1
4.2
4.75
5.0
5.7
6.5
7.3
7.7
8.5
9.0
9.8
10.2
11.0
11.5
12.2
13.5
15.2
17.0
18.7
21.5
23.8
26.5
5.3
6.4
7.5
8.5
9.6
10.8
11.0
13.0
14.0
15.0
17.0
19.5
22.0
24.0
26.0
28.0
30.0
32.5
35.0
37.0
39.5
44.0
48.0
53.0
62.0
71.0
80.0
88.0
TURN-DOWN
RATIO
2.8
3.0
2.9
2.8
2.8
2.8
2.7
3.1
2.9
3.0
3.0
3.0
3.0
3.1
3.1
3.1
3.1
3.2
3.2
3.2
3.2
3.3
3.2
3.2
3.3
3.3
3.4
3.3
Note:- Turn-down ratio will increase with supply pressures
ART 106
SPILL-BACK NOZZLE BLOCK
ART 106
SPILL-BACK OIL NOZZLE
OIL RETURN
OIL SUPPLY
ART 106 SPILL-BACK NOZZLE BLOCK AND NOZZLE
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4.1.5
Oil Operating System Modulating Burners Multi-Oil Nozzles
Atomisation of the oil is by means of three nozzles which work on the spill-back principle. The
nozzle fits into the hydraulic nozzle line assemblies that allow oil from the pump outlet to circulate
through the nozzles and back through the metering valves to the pump return when the burner is
ready to fire, two PDV N/C solenoid valves open allowing oil to flow through the nozzles. The
return path from the centre nozzle flows through metering valve MV1, while the three outer nozzle
flows through MV2, they then join a common oil line, passing through two N/C safety shut off
valves, and back to the return of the pump.
The oil volume is controlled by the metering valves (MV1 and MV2) in the spill line restricting the
amount of spilled oil and therefore increasing the volume that passes through the nozzle for
combustion.
Control of both metering valves and the air shutter is achieved by means of independent servo
motors which are positioned by the electronic control system.
4.1.6
Fuel Pumps and Motors
All `TD` series burners are supplied with a separate, directly coupled fuel pump and drive motor.
Details of the various sizes of pumps and motors are given in the table below.
BURNER TYPE
PUMP TYPE
MOTOR SIZE
(kW)
RPM
DRIVE
COUPLING
OIL LINE
CONNECTIONS
TD525Z
DH2-1-30
3.0
2800
Fig 71
1 BSP
TD530Y
DH2-1-30
3.0
2800
Fig 71
1 BSP
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Operation & User Interface

5.1
The Display / Keypad
The display is a 2 line, 20 characters per line, dot matrix vacuum fluorescent type allowing the use
of plain text messages for display parameters. The keypad is a membrane construction with tactile
keys to give a positive feedback of the actuation.
The SCROLL keys are used to
view boiler and burner status
data during normal running
conditions.
In commission mode, these
keys select option parameters,
which are adjusted by the
UP/DOWN keys.
The UP/DOWN keys are

used to adjust the fire rate in
manual modulation mode.
In commission mode, they
are used for data value
selection.
Alternate key functions

when in commission
mode.
Key
EK
LOW FIRE
FUEL SELECT
BURNER O-I
MUTE / RESET
AUTO / HAND
DATA
COM
5.2
Function
Selects Engineers Key mode.
Pressing this key will force the burner to Low fire until the key is pressed
again to release the burner to modulate.
Changes Fuel/Profile. If the fuel is changed when the burner is firing, the
burner will go off then restart firing the new fuel selection.
Sets the burner On or Off and enables changes between normal and local
operation. Note: Terminal PE9 must be ON for this switch to start the burner.
Press this key to mute (open) the alarm relays, and then hold the key down
for approximately three seconds to reset the cleared faults.
Selects auto or manual burner modulation. In manual mode the UP/DOWN
keys are used to alter the fire rate.
Selects different data types on the display window.
Changes operation to commission mode via a pass-code.
Start -up Sequence
When a fuel selection is made and the burner select signal is given to start up the burner, the
controller performs the sequence described below. If a gas profile is selected and the safety valve
proving function is selected, the controller will perform safety valve pressure proving concurrently
with the start-up sequence.
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State
no.
State name
Description
0.
Non-volatile
lockout
All fuel valve outputs are OFF and the Alarm output is ON until
muted. The burner is held in this state until all faults are
removed.
1.
Burner off
The burner is checked to make sure that it has switched off

completely. Testing includes - main fuel safety valves closed, no
flame signal and no air pressure signal. The controller will
remain in this state until there is a call for heat from the PID
system.
2.
Wait for purge
The controller waits for both a burner select (PE9 ON) and a
fuel/air profile to be selected. Progression to stage 3 or 5 maybe
held off by external influences, e.g. Digital Communications
control or digital input controlled by an external circuit.
3.
Open fuel valve
If gas firing and safety valve proving are selected, the gas valve
servo motor is moved open for five seconds to allow any gas
in the test section to be vented easily during the proving
sequence.
4.
Hold fuel valve
The fuel motor is held in position until step 1 of the safety valve
proving sequence (open main valve 2, or vent valve) is
completed.
5.
Prove closed
positions
If gas is selected, the gas valve proving sequence begins. The

fuel and air motors are moved to closed position until they stop.
The final positions are compared with the closed positions
stored in memory when the profile is commissioned.
6.
Prove air
pressure
The burner motor output is set ON and air pressure prove time
(t1) is initiated. The selected motors are moved open towards
the purge position. If the fan start early option parameter has
been set then the motors will not move until the option time has
expired.
7.
Prove purge
positions
When the air pressure prove time has elapsed, the air pressure
switch must give a pressure signal or the controller will
lockout the burner and move to stage 0. If primary air is
selected, then both primary and secondary air pressure signals
must be ON to prove air pressure. The selected motors are
driven open until they reach their commissioned purge
position.
8.
Pre-purge
Once the servo motors are at their purge positions the controller
starts the pre-purge (t2) timer.
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State
no.
9.
State name
Description
Move to ignition
positions
When t2 has elapsed, the fuel and the air motors are moved to
the ignition position for the selected profile. The controller will
wait at the ignition positions while the gas valve proving
sequence finishes before progressing to stage 10
10.
Pre-ignition
Once the fuel and air motors are at their ignition positions, the
ignition transformer output is energized and pre-ignition time
(t3) is starts.
11.
Pilot ignition
Once t3 has elapsed the ignition transformer remains on, first

main valve if required for pilot flame gas, and pilot valve
outputs are energised and the first safety time (t4) is started.
If firing on oil and ignition selected to be with both pilot and
main valve, use timing in the start-up sequence table for main
valve 1.
If firing on oil and ignition with main valve is not selected the
pilot ignition will occur with only the pilot valve, use timing in
the start-up sequence table for main valve 2.
12.
Pilot ignition
interval
When t4 is complete, a flame must be detected or the controller

will lockout the burner and move to stage 0. The ignition
transformer may optionally be on or off (See option parameter
14.6).
13.
Main ignition
Once the pilot interval time (t5) has elapsed, the second (and
first if not already open) main valve output(s) for gas, or main
oil valve output for oil is energized and the second safety time
(t6) is started.
If firing on oil and ignition with main valve was selected the
main oil valve will have already opened for pilot ignition. The
ignition transformer may optionally be on or off (See option
parameter 14.6). A flame and air pressure signal must be
detected or the controller will lockout the burner and move to
stage 0.
14.
Wait for Main

flame established
When t6 has expired, the pilot valve output is turned off. If

permanent pilot is selected and the burner is firing on gas, then
the pilot will remain open with the main valves.
Main flame interval time (t7) is started. A flame and air pressure
signal must be detected or the controller will lockout the burner
and move to stage 0.
15.
Moving to low
fire
When t7 has elapsed, the flame is considered established and the

fuel and air motors are moved from their ignition positions to
their low fire positions and held at those positions for the
duration of the Low Fire Hold Time (t8). A flame and air
pressure signal must be detected or the controller will lockout
the burner and move to stage 0.
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State
no.
16.
State name
Description
Modulation
When t8 has elapsed the fuel and air motors are modulated
according to the demand placed on the burner. If the fuel
selection is changed or the burner on signal (PE9) is removed,
the main valve output(s) are turned off. A flame and air
pressure signal must be detected or the controller will lockout
the burner and move to stage 0.
17.
Move to postpurge
If Post Purge is not selected then the controller returns to state 1

to wait for another start-up.
If Post Purge has been selected then the fuel servo motor is
moved to its closed position, and the selected air motor(s) are
moved to their post purge position(s).
18.
Post-purge
When the air drive(s) have reached their post purge positions
then the Post Purge Time (t9) is started. When t9 has elapsed,
the burner motor is turned off and the controller returns to state
1 to wait for another start-up.
5.3
Modulation
During stage 16 (modulation), the controller will position the fuel and air motors within the
programmed profile appropriate to the requirement for heat. The controller has 2 modes of
operation using the standard RATIOTRONIC modulation function, Normal and Local. The mode
of operation is set via the keypad by pushing the Burner ON/OFF key and selecting the mode.
Using the programmable block function (option) within the controller it is possible for the
modulation control to be generated with customised options, these are not covered in the standard
manual.
5.4
Normal mode
In Normal mode, the modulation rate is determined by the internal PID control settings, Manual
modulation from the keypad, or by one of the following remote influences:
Auxiliary modulation input,
Digital set point selection
Serial communications Comview or Lead/Lag.
5.5
Local mode
In Local mode, the modulation rate is determined by either the internal PID settings or Manual
modulation via the UP/DOWN keys. External modulation inputs and set point selection inputs are
ignored.
When Local1 is displayed the burner is running using the Set point 1 PID settings.
When Local2 is displayed the burner is running using the Set point 2 PID settings.
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5.6
Non-volatile lockout
Non-Volatile lockouts cannot be cleared without operator intervention and are remembered in the
event of power being removed from the controller.
A non-volatile lockout will occur under the following conditions:
If any step of the gas proving sequence fails
In stages 1-9 (inclusive) if a flame is detected
In stages 11-16 (inclusive) if a flame is not detected
In stage 4 if the air pressure switch goes high (air pressure present)
In stages 7-18 (inclusive) if the air pressure switch goes low (air pressure not present)
In stages 5, 7 and 8, stages 10-16 (inclusive) and stage 18 if a motor is not in the correct
position
In any stage, if an internal or external fault not previously mentioned occurs which may
affect the safe operation of the burner
5.7
Ratiotronic 6000 Inverter interface additional information
The Ratiotronic 6000 may have an optional daughter board within the main enclosure to allow
control of 1 or 2 inverter drives (daughter board dependent). Optionally the daughter board is also
available to allow feedback to be taken from directly from encoders measuring the speed of the
relevant motor, fan or pump shaft. There is also an option to allow the speed of an additional rotary
device to be monitored as an encoder input.
When not configured to control an inverter, the 4-20mA outputs may be configured to transmit
system variables as current outputs.
There are special wiring requirements for inverter feedback.
5.8
Post Purge Operation
If a post combustion purge is selected (with option parameter 7.9), a normal shutdown post purge
will be performed at low fire. The drives will move to the low fire position (if not already there)
and the post-purge time will then start. If the burner has turned off because the fuel profile selection
has been removed (i.e. set to NONE), no post-purge will be performed.
If the burner locks out at or after ignition, and a post-purge time has been entered, the controller
will also attempt a post purge. For a flame failure fault, the controller will attempt to post purge at
high fire. For all other faults, the drives will stay at the positions they were in when the lockout
occurred. In both cases, the post-purge time starts at the moment the lockout occurs the controller
does not wait for drives to position before starting the post-purge time.
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5.9
Emergency Stop
The emergency stop or e-stop is a safety mechanism used to shut off the burner in an emergency
situation in which it cannot be shut down in the usual manner. Unlike a normal shut-down
switch/procedure, which shuts down the burner in an orderly fashion and turns it off without
damaging it, an e-stop is designed and configured to a) completely abort the operation at all costs
and b) be operable in a manner that is quick, simple (so that even a panicking user with
impaired executive function can operate it), and, usually, c) be obvious even to an untrained
operator or a bystander. The e-stop features a removable barrier to provide protection against
accidental activation.
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Component Setup Parameters
Before the commissioning process of the burner can take place, there are certain components like
the Ratiotronic 6000, inverter (when fitted), etc, which will need to be setup. The burner should be
factory set; however, if the parameters have been erased for whatever reason, then this section can
be used as a starting point. Please note that a fuel / air profile will not have been setup. Please also
note that this parameter set should be used in conjunction with the manual.
6.1
Ratiotronic 6000
Option
0.1
0.2
0.3
0.5
0.7
0.8
Value
xxx
0
0
0
1
2
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
5
1
0
0
0
0
0
0
0
0
2
3
10
11
0
0
0
0
0
0
xxxx
xxxx
xxxx
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
4.2
4.3
4.4
VSD1
0
0
0
0
0
0
1
2
3
3
June 13
Description
Site passcode
Serial communications control address
Reset hours run
Language Select
IsoComsAddress
IsoComsSetting
Power up option
Keyboard auto/manual enable
Fault mute input enable
External profile select enable
Gas valve proof of closure select
Oil valve proof of closure
Second airflow switch (primary air) enable
Safety time configuration set
Force Mode Input
Drive 0 name
Drive 1 name
Drive 2 name
Drive 3 name
Drive 4 name
Drive 5 name
Drive 6 name
Drive 7 name
Drive 8 name
Drive 9 name
Drive 0 serial number
Drive 1 serial number - Gas Servo
Drive 2 serial number - Oil Servo
Drive 3 serial number - Air Servo
Drive 0 profile assignment
46 of 129
Comments
last 3 digits of burner serial number
5=ignore alarms for 5 seconds at

power up
not used
gas servo motor
oil servo motor
air servo motor
VSD drive
not used
1st 4 Digits of Ser No
Found on side of servo motor
not used
profile 1
profile 2
profiles 1 + 2 = 3
profiles 1 + 2 = 3
TD5 Manual Rev 4
4.5
4.6
4.7
4.8
4.9
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6.1
6.2
6.3
6.4
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
8.0
8.1
8.2
9.0
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
10.0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
0
15
30
1
3
3
3
3
5
30
0
1
0
0
1
100
30
30
0
0
0
0
0

Drive 0 rotation
Drive 1 rotation
Drive 2 rotation
Drive 3 rotation
Drive 4 rotation
Drive 5 rotation
Drive 6 rotation
Drive 7 rotation
Drive 8 rotation
Drive 9 rotation
Fuel train for profile 1
Fan on early time
Air Proving time
Pre-purge time
Pre-ignition time
Pilot ignition time
Pilot hold time
Main ignition time
Ignition hold time
Low fire hold time
Post purge time
Ignition spark output check
Flame failure response time
Extend false flame response time
Inverter control accuracy
Inverter error tolerance
Inverter closed loop gain
Inverter stop time
Inverter acceleration time
VSD1 speed encoder scaler
VSD2 speed encoder scaler
Low speed cup limit
Oil warning speed
Gas pressure sensor select
10.1
10.2
0
70
Gas pressure sensor span

Gas pressure nominal
10.3
10.4
10.5
0
0
1
Gas pressure low limit

Gas pressure high limit
Test volume
June 13
47 of 129
0 = anti-clockwise / 1 = clockwise
gas
oil
Do not reduce this timing

Do not extend this timing
Do not reduce this timing
0 = low / 1 = high
0 = low / 1 = high
1 valve proving via sensor,

0 valve proving via pressure
switches
Parameters 10.2, 10.5 and 10.6 will
give a valve proving time of approx
40secs. This is an optimised set of
figures do not alter
TD5 Manual Rev 4
10.6
10.7
7.5
0
Maximum permissible leakage rate

Vent valve select
10.8
10.9
12.0
12.1
12.2
12.3
12.4
13.0
13.1
1
3
0
0
0
0
0
x
x
Valve proving select

VPS Power Time
Photocell / IR flame detection select
Pilot flame threshold photocell
Main flame threshold photocell
Centre frequency photocell
Frequency pass ban photocell
UV/Ionisation flame detection
Pilot flame threshold
13.2
14.0
14.1
14.2
14.3
14.4
14.5
14.6
14.7
14.8
15.0
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
16.1
16.2
16.3
16.4
16.5
20
6
0
0
0
1
1
0
1
0
2
x
0
xx
x
0
20
0
1
0
0
011
012
xx
Main flame threshold

Primary fault relay
Limit relay
Oxygen + fuel temperature limit relay
Permanent gas pilot select
Pilot with/without main valve select
Direct ignition on oil
Spark termination
Oil pump relay function
Extended oil pilot
Modulation input sensor type
Modulation input decimal places
Modulation input zero value
Modulation input span value
Set-point display units
Boiler high safety limit
Modulation time
Bumpless transfer
Low fire before off
Go back to pilot
Allow profile swap online
HV input 12 alarm/lockout function
HV input 13 alarm/lockout function
HV input 12 display message
16.6
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
18.1
18.2
18.3
18.4
18.5
18.6
17
0
20
19
20
19
0
26
0
0
0
0
0
22
21
HV input 13 display message

Relay 1 output function
LV input 1 function
LV input 2 function
LV input 3 function
LV input 4 function
LV input 5 function
LV input 6 function
June 13
48 of 129
1 VPS enabled, DO NOT DISABLE
1=non-shuttered/2=shuttered
non-shuttered = 20, shuttered = 10
0 = without / 1 = with
1 = light oil / 2 = heavy oil

2 = 4-20mA
0 = temp / 1 = pressure
default: temp = 150, pressure = 16.0
1 = bar / 3 = deg c
0 = no / 1 = yes
Boiler high limit stat, on PE7

Fan trip, on PE8
11 high temp, 13 high pressure,
on PE7
Fan interlock, on PE8
(display unit) PR1,PR2,PR3
(controller) PD6,PD7,PD8
(26 = VSD1 start circuit) PZ17-PZ18
PZ15-PZ16
PB9-PB10
PB9-PB11
PB9-PB12
PB9-PB13
Low Gas Pressure
PB14-PB15
High Gas Pressure
PB14-PB16
TD5 Manual Rev 4
18.7
18.8
18.9
19.1
19.2
19.3
19.4
19.5
19.6
19.7
19.8
19.9
20.0
20.1
20.2
20.3
20.4
20.5
20.6
20.7
20.8
21.0
21.1
21.2
21.3
21.4
21.5
21.6
0
0
0
0
0
0
0
5
4
0
0
0
0
0
0
0
0
0
0
0
0
0
x
0.5
1
0
2
0.5
LV input 7 function
LV input 8 function
LV input 9 function
LV input 1 message
LV input 2 message
LV input 3 message
LV input 4 message
LV input 5 message
LV input 6 message
LV input 7 message
LV input 8 message
LV input 9 message
Set-point select input
Boiler shutdown input
Low fire hold input
Oxygen trim disable input
Ignition wait input
Purge hold input
Purge time start input
Analogue input 5 option
Lead boiler select
Set-point 1 enable
Set-point 1 control value
Set-point 1 proportional value
Set-point 1 integral time
Set-point 1 derivative time
Set-point 1 control limit type
Set-point 1 low limit control value
21.7
0.5
Set-point 1 high limit control value
21.8
21.9
22.0
22.1
22.2
22.3
22.4
22.5
22.6
22.7
22.8
22.9
23.0
23.1
23.2
24.0
24.1
24.2
24.3
24.5
24.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
June 13
Remote set-point 1 zero (4mA) value

Remote set-point 1 span (20mA) value
Set-point 2 enable
Set-point 2 control value
Set-point 2 proportional value
Set-point 2 integral time
Set-point 2 derivative time
Set-point 2 control limit type
Set-point 2 low limit control value
Set-point 2 high limit control value
Mod Max Enable Input
Mod Max Value
Warming enable
Warming limit
Warming time
Number of sequence lag boilers
1st lag boiler address
2nd lag boiler address
3rd lag boiler address
Lead assign type
Lag on rate
49 of 129
Low Gas
High Gas
PB14-PB17
PB5-PB6
PB5-PB7
PB9-PB10
PB9-PB11
PB9-PB12
PB9-PB13
PB14-PB15
PB14-PB16
PB14-PB17
PB5-PB6
PB5-PB7
1-7 or 12-13
1-7 or 12-13
1-7 or 12-13
1-7 or 12-13
1-7 or 12-13
1-7 or 12-13
1-7 or 12-13
aux mod input
1-7 or 12-13

Deviation
Burner On 0.5 below SP
Burner Off 0.5 above SP
enables into sequencing
TD5 Manual Rev 4
24.7
24.8
24.9
29.0
29.1
29.2
29.3
29.4
29.5
29.6
29.7
29.8
30.0
30.1
30.2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
30.3
30.4
30.5
30.6
30.7
30.8
30.9
31.0
31.131.4
32.0
32.132.4
33.133.4
34.0
34.134.4
35.0
35.135.4
35.535.8
35.9
36.0
36.136.4
37.137.4
38.0
38.138.4
39.139.4
40.140.4
41.141.3
42.0
0
0
0
0
0
0
0
0
Lag on delay
Lag off rate
Lag off delay
Analogue output 1 function
Analogue output 1 zero (4mA) value
Analogue output 1 span (20mA) value
Oxygen probe interface serial number
Oxygen probe calibration offset value
Oxygen probe calibration gain value
Oxygen probe calibration gas
concentration
Flue & inlet temp sensor units
Oxygen input function
Oxygen probe calibrate enable
Boiler transport delay
Reset oxygen trim profile
Automatic trim commissioning
Limit modulation range
0
0
Trim type for profiles

Trim limit default
Trim limits
0
0
Trim integral gain

Trim proportional gain default
0
0
0
0
0
Trim proportional gain

Inlet temp sensor serial number
Hydrocarbon ratios for each fuel
respectively
Calorific values of fuels / profiles 1-4
respectively
Boiler radiated heat loss
Flue temperature alarm select
Flue temperature low alarm value
0
0
Flue temperature high alarm value

Oxygen alarm select
Oxygen low alarm value at low fire
Oxygen low alarm value at high fire
Oxygen high alarm at low fire
0
0
Oxygen high alarm at high fire

Second oxygen probe select
June 13
50 of 129
VSD1 overrides if selected
VSD2 overrides if selected
TD5 Manual Rev 4
42.1
42.2
42.4
42.5
42.6
44.0
44.1
44.2
44.3
44.4
44.5
44.6
44.7
44.9
45.0
45.1
45.2
June 13
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Second oxygen probe calibration offset

Second oxygen probe calibration gain
Maximum oxygen variation
Maximum flue temp variation
Second oxygen probe calibration enable
Set real time clock
Set year
Set month
Set day of month
Set day of week
Set hours
Set minutes
Set seconds
Clear fault history
Erase/Restore enable
Erase command
Restore command
51 of 129
TD5 Manual Rev 4
6.2
Danfoss VLT FC 102
PNU
0-20
0-21
0-22
0-23
0-24
0-40
0-41
0-42
0-43
1-00
1-03
1-20
1-22
1-23
1-24
1-25
1-29
1-90
1-93
3-02
3-03
3-13
3-15
3-41
3-42
NAME
DISPLAY LINE 1.1
DISPLAY LINE 1.2
DISPLAY LINE 1.2
DISPLAY LINE 2
DISPLAY LINE 3
LCP HAND START
LCP STOP
LCP AUTO START
LCP RESET
CONFIG MODE
VT CHARACTER
MOTOR POWER
MOTOR VOLTAGE
MOTOR FREQUENCY
MOTOR CURRENT
MOTOR NOM SPEED
AUTO MOTOR ADAPT
MOTOR THERM PROTECTION
THERMISTOR SOURCE
MIN REFERENCE
MAX REFERENCE
REFERENCE SITE
REFERENCE 1 SOURCE
RAMP UP TIME
RAMP DOWN TIME
FACTORY DEFAULT
REF %
MOTOR AMPS
POWER KW
FREQUENCY HZ
KW/H COUNTER
ENABLE
ENABLE
ENABLE
ENABLE
OPEN LOOP
AEO FUNCTION
xxxKW
400 V
50 HZ
xxx A
xxxx RPM
NO AMA
ETR TRIP 1
NONE
0.0 HZ
50.0 HZ
HAND / AUTO
ANALOG INPUT 53
45.0 SEC
90.0 SEC
DCL SETTING
ANALOG INPUT 53
PNU
4-10
4-12
4-14
4-16
4-18
4-19
4-50
4-51
4-52
4-53
5-01
5-10
5-11
5-12
5-13
5-14
5-15
5-40
5-41
NAME
MOTOR SPEED DIRECTION
MOTOR SPEED LOW LIMIT
MOTOR SPEED HIGH LIMIT
TORQUE LIMIT MOTOR MODE
CURRENT LIMIT
MAX OUTPUT FREQUENCY
WARNING LOW CURRENT
WARNING HIGH CURRENT
WARNING LOW SPEED
WARNING HIGH SPEED
TERMINAL 27 MODE
TERMINAL 18 DIGITAL INPUT
RELAY 1 FUNCTION
RELAY 1 ON DELAY
FACTORY DEFAULT
BOTH DIRECTIONS
0.0 HZ
50.0 HZ
110 %
110 %
100 HZ
0.0 A
99.0 A
0.0 RPM
3000 RPM
INPUT
START
NO OPERATION
COAST INVERSE
JOG
NO OPERATION
NO OPERATION
ALARM
0.01 SEC
DCL DEFAULT
CLOCKWISE
June 13
52 of 129
SPEED RPM
DISABLE
DISABLE
DISABLE
Use Motor Dataplate Info

ENABLE COMPLETE
THERMISTOR TRIP
ANALOG INPUT 54
REMOTE
30 SEC
30 SEC
150 %
150 %
NO OPERATION
RUNNING
TD5 Manual Rev 4
5-42
5-40
5-41
5-42
6-12
6-13
6.14
6.15
6-20
6-21
6-50
6.51
6.52
RELAY 1 OFF DELAY

RELAY 2 FUNCTION
RELAY 2 ON DELAY
RELAY 2 OFF DELAY
TERMINAL 53 MIN SCALING
TERMINAL 53 MAX SCALING
TERMINAL 53 LOW
REF/FEEDBACK VALUE
TERMINAL 53 HIGH
REF/FEEDBACK VALUE
TERMINAL 42 ANALOG OUT
June 13
0.01 SEC
RUNNING
0.01 SEC
0.01 SEC
4.00 mA
20.00 mA
0.00
ALARM
50.00
0.07 V
10.0 V
SPEED 0 HIGH LIMIT
0%
100 %
53 of 129
SPEED 4-20mA
TD5 Manual Rev 4
6.2.1
RWF 40.000A97 Default Burner Settings
SETTING
FACTORY
DEFAULT
DCL SETTING
REMARKS
C111
9030
F000
0000
PRESSURE
TEMP
C112
0010
0000
C113
0110
0110
SCL
0.0
0.0
SCH
100.0
16.0
100
SCL2
0.0
0.0
SCH2
100.0
100.0
SPL
0.0
0.0
SPH
100
16.0
100.0
OFF1
0.0
0.0
OFF2
0.0
0.0
OFF3
0.0
0.0
DF1
1.0
1.0
DF3
1278
1278
OLLO
-199.9
-199.9
OLH1
999.9
999.9
DTT
30
30
AL
0.0
0.0
HYST
1.0
1.0
PB.1
10.0
1.0
10.0
DT
80.0
25.0
RT
350
100.0
DB
1.0
1.0
TT
15.0
15.0
HYS.1
-5.0
-1.0
-5.0
PRESSURE
TEMP
HYS.2
3.0
0.5
3.0
PRESSURE
TEMP
HYS.3
5.0
1.0
5.0
PRESSURE
TEMP
0.0
0.0
1.0
1.0
0.0
0.0
SP1
60.0
8.0
80.0
June 13
54 of 129
PRESSURE
TEMP
PRESSURE
TEMP
PRESSURE
TEMP
PRESSURE
TEMP
User definable
TD5 Manual Rev 4
Commissioning
7.1
Basic settings
It is essential that heat output of the appliance is known in order that the correct fuel input can be
calculated and set. If there is any doubt at all with regard to the appliance rating, the manufacturer
should be consulted before the burner is fired. The calorific value of the fuel must be known and
measurement of the fuel input should be by meter wherever possible.
Do not leave the burner firing at a rate which is known to be or which may be excessive, this will
result in damage to the appliance.
The nett flue gas temperature should be taken throughout the process of setting combustion. The
figure will vary according to the construction of the appliance but will normally be in the range
of 180 to 250C gross. if in doubt what this figure should be, please consult the boiler/appliance
manufacturer.
Calculation of burner firing rate ( output ).
Qf
Qn
[ kW ]
k
Qf = Burner Firing Rate ( Output ) kW

Qn = Boiler nominal thermal output ( kW )
k = Boiler Efficiency
Calculation of Gas Throughput at Nominal Boiler Output
Vb
Qn
[ m 3 h]
HU * k
Vb = Gas Throughput ( Fuel Input ) m3h.

Qn = Boiler nominal thermal output ( kW )
k = Boiler Efficiency
HU = Calorific Value of Fuel under Normal Conditions ( kWh/m3 )
Calculation of Gas Throughput for Boiler Firing Rate
Vb
Qf
[ m 3 h]
HU
Vb = Gas Throughput ( Fuel Input ) m3h.

Qf = Burner Firing Rate ( Output ) kW
HU = Calorific Value of Fuel under Normal Conditions ( kWh/m3 )
Burner output ( kW ) = Boiler output ( kW )

Boiler efficiency
The indicating scale on the air damper motor is calibrated so that zero represents the fully closed
position for the air damper. The indicated low fire and high fire positions will be the result of the
June 13
55 of 129
TD5 Manual Rev 4
adjustments described below, there are no pre-determined positions applicable to a particular

burner. The scale reading only represents the air damper opening and not the firing rate!
Adjustments to the burner combustion head (for example the position of the flame ring in the nose
cone) may be necessary during the `setting up` of a burner.
Details of the settings for a particular burner , firing a given make of boiler, cannot be given in a
manual of a realistic size, however, standard basic settings are given in section 3 of this manual.
The size and relative position of the flame ring to the cone will have an appreciable effect on the
volume and velocity of air passing over the flame ring and this must be taken into consideration
when setting the combustion efficiency, with adjustments made as necessary. Adjustment of the
flame plate in relation to the nose cone can be made by loosening the screws holding the nose cone
in place and moving the nose cone backwards or forwards. After adjustments have been made,
ensure that screws are retightened and sealed in place.
NOTE:
ON ANY BURNER, AN ALMOST INFINITE COMBINATION OF COMBUSTION
HEAD COMPONENTS AND SETTINGS MAY BE USED TO ACHIEVE OPTIMUM
EFFICIENCY AND A FLAME SHAPE TO SUIT A VERY WIDE RANGE OF HEATRAISING APPLIANCES. THE MOST SUITABLE COMBINATION/SETTINGS
MUST BE DETERMINED DURING THE COMMISSIONING PROCEDURE.
7.2
Start Gas Heat Input
The table below summarises the ignition gas rates for different burner configurations.
The start gas heat input must not exceed 120kW or the value given by the equation :
ts x Qs 100
where:
June 13
56 of 129
TD5 Manual Rev 4
ts is the safety time in seconds (s):

Qs is the maximum start gas heat input expressed as a percentage of the main gas rate
This approximates to an ignition rate of less than one third of the maximum firing rate.
If the burner is fitted with a separate pilot, the start gas heat input of the ignition burner must not
exceed the value given by the equation:
ts x Qs 150
where:
ts is the safety time in seconds (s):
Qs is the maximum start gas heat input expressed as a percentage of the main gas rate
7.3
Pre-commissioning
Note: The following tests must be carried out before commissioning is started.
Check that the appliance has been filled to the correct level
Check that the appliance isolating valves are fully open.
Where fitted, check that the flue damper is locked in the open position.
Check that the flue-draught stabiliser moves freely
Check that the gas supply is guaranteed and is at the correct pressure.
Check that the gas meter is the correct size.
Ensure that a manual gas isolation valve is positioned as close as possible to the burner and
that all gas pipe work is adequately supported.
Check that the external electrical connections are in accordance with the appliance
manufacturers wiring instructions.
Make certain that both fuel supplies and electrical supplies have been isolated.
Ensure that all gas, oil and electrical connections are tight as connections may come loose
during transportation.
Check the electrode gap to be 3mm at the narrowest point of the ignition electrode (twin)
and the tip of gas ignition electrode is 3mm away from the gas nozzle outlet.
Set the firing rate control switch to `low fire` to ensure that the burner will remain at low
fire after light-up.
Hot water boilers - check operation of the control and limit thermostats and that the boiler
has been filled with water.
Steam boilers - confirm the operation of the boiler feed pump and switch, and check that
the water level controls are working.
After the initial firing of the boiler, do not leave the unit operating in an unmanned boiler
house unless the boiler on/off control has been operated and set at a suitable figure and the
flame failure system on the burner has been checked.
June 13
57 of 129
TD5 Manual Rev 4
7.4
7.4.1
Commissioning High Low and Pneumatic Modulation burners - Firing on Gas

Dry run
Note: Gas leak checks must be carried out using a suitable non-corrosive leak detection fluid.
Check for gas leaks on meters, governors and all mains gas supply pipe work.
Ensure all pipework leading up to the burner main gas valve has been purged according to
IGE/UP/1 Soundness testing and Purging of Industrial & Commercial Gas Installations
Ensure that the burner manual isolation valve is closed.
Check that all isolation valves in the main gas supply pipe work are open.
Remove or loosen the gas inlet pressure test point on the inlet side of the gas valve and open
the burner isolation valve until all air has been purged between the isolation valve and the
burner gas valve.
When this has been done, close the isolation valve.
Note: For the following tests a digital manometer will be required.

7.4.2
Check for leaks through the automatic gas valve.
Connect the manometer to the gas inlet test point on the automatic gas valve, open the manual gas
isolation valve for two seconds and then close it again.
The pressure shown on the manometer should remain constant.
7.4.3
Check rotation of burner fan motor
Switch on mains electrical supply. Momentarily 'blip' the burner fan connector and check rotation
of fan against direction of rotation sticker fixed to the rear of the burner. If motor rotates in the
wrong direction, changeover two of the incoming 3 phase supply. Repeat test to ensure rotation is
now correct.
7.4.4
Check for correct control sequence.

Open manual gas isolation valve for two seconds and then close it again, sealing the gas
between the automatic gas valve and the isolation valve.
Check that all time switches, room thermostats etc are in the òn` position and that the boiler
thermostat is set to the required temperature.
Switch on the mains electrical supply.
Select 'Gas' on the control system
The control box will commence the starting sequence which, depending on the control box,
will average:Prepurge time
Pre-ignition time
Pilot proving time
30 seconds
3 seconds
3 seconds
When the pilot proving time is reached, the automatic gas valve is energised and will
release the gas trapped between the valve and the closed isolation valve.
The burner will then stop because the pressure acting upon the gas pressure proving switch
will be reduced due to the isolation valve being closed.
Switch off the electrical supply on completion of this test.
June 13
58 of 129
TD5 Manual Rev 4
7.4.5
Firing the burner

Ensure that the heat demand will allow an extended run, otherwise the burner may not
continue to fire throughout the time required for throughput measurement or commissioning
procedure.
Unscrew or loosen the outlet gas pressure test point on the gas valve and connect a
manometer.
Open the manual gas isolation valve.
Switch on the mains electrical supply and, if the control box is locked out (indicated by the
reset button being illuminated) press the lockout reset button. For electrical modulation
systems, please consult relevant manual.
Provided all control devices, thermostats etc are in the òn` position the burner control box
will start the operating sequence. For information relating to sequence of operation please
refer to section 5.
If the control sequence fails to start, check for correct setting of the gas pressure proving
switch.
The amount of gas flowing through the valve can be adjusted by using the
and
and is proportional to the amount of combustion air set by the air damper
motor. Cam setting for the air damper have been described in section 3.1.
is used to set the Low Fire rate and

is used to adjust the high fire
rate. A combination of the two settings will define an operating line between high fire and
low fire and the valve will maintain the air/gas ratio across this range. Full information on
the gas multiblock may be found in section 5.
Adjustment of
will have an effect on the setting of
and viceversa. It may take 3 or 4 fine adjustments at both high fire and low fire to ensure good
combustion at both ends.
ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS.

7.4.6
Combustion values and results
All combustion readings must be taken with an approved and correctly calibrated test kit.
The following combustion values should be reached:Low Fire
CO content
CO2 content
O2 content
0 - 20 ppm
9 - 11 %
5.4 - 2%
High Fire
CO content
CO2 content
O2 content
0 - 20 ppm
10 - 11%
3.6 - 2%
In all cases the CO figure should not exceed 100mg/m3 maximum.

The nett flue gas exit temperatures should be taken throughout the process of setting the
combustion.
The figures will vary according to the type of appliance but for shell and sectional boilers will be in
the range of 180 - 250C gross.
Always keep the exhaust flue gas temperatures within the manufacturers recommended
range and ensure that the appliance is not over or under fired. Warm up the boiler, or raise
steam in accordance with appliance manufacturers instructions.
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7.4.7
Adjustment of Gas Proving Pressure Switch
Loosen the screw in the gas inlet measuring point, connect a manometer and remove the clear
plastic cover from the gas pressure detector.
Switch on the burner and allow to fire.
Close the burner manual gas isolation valve slowly until the gas pressure is reduced to 50%.
Adjust the numbered black plastic ring on the gas pressure detector until the burner switches off.
Switch off the mains electrical supply to the burner, remove the manometer and seal the test point
screw.
Open the manual gas isolation valve and switch on the burner.
7.5
Oil Firing
All burners using oil as a fuel are fired before despatch as part of the standard test programme. This
does not mean that the pump pressure or any other adjustment applying to the oil system is
necessarily correct for the application.
Commissioning of the burner must include confirming that the nozzle size and characteristics are
suitable, calculating the fuel pressure required to give boiler M.C.R. and ensuring that, subject to
the requirements given below, the firing rate is correctly set.
The following text in included on the basis that the burner has been commissioned on gas and that
the boiler or appliance controls have been set.
The change - over of fuels is made by operation of the selector switch on the burner control cabinet.
This selector switch controls two contactors which electrically isolate one fuel from the other. On
electronic modulating burners, fuel selection can be made via the keypad.
For change-over to either fuel the switch selection is made through the 'off' position which causes
the burner control box to extinguish the flame before recycling.
The starting cycle will not immediately commence because it will be necessary for the burner
motor to slow down, reducing the air flow to a level which allows the air pressure switch to return
to the 'no' air position.
Note: Even on oil firing the leak detection cycle will be activated.
Before changing to oil firing, ensure that the oil pump has been properly vented and flooded.
No mechanical changes or re-adjustment of components are required for the burner to be changed
from one fuel to another.
Before the first firing on oil, it is always advisable for the availability of fuel, fire valves open etc,
to be confirmed.
Check that the burner will remain at low fire.
7.5.1
Setting the Firing Rate, High / Low Oil Burners
Step 1
Set the Low Fire air damper motor setting to between 1 and 2 on the scale and the high fire
air damper setting to between 5 and 6 on the scale. Set O2 to approx 3 on the scale.
Ensure that the High / Low switch is in the low fire position and switch on the burner.
Momentarily 'blip' the oil pump contactor to check for correct rotation of pump - ensure it
rotates according to rotation sticker fixed to rear of the motor. If rotation is incorrect, swap
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over two pluses on the pump motor. Do not swap the mains electrical feed as this will also
reverse the burner fan motor rotation.
Start the burner and allow to go through pre-purge cycle. When the burner reaches its
ignition position, the ignition transformer is switched on, followed by the fuel pump motor,
and then the two solenoid valves, which should result in the burner lighting.
Set the pump pressure to approx 25 bar.
Adjust the low fire air position to give the following figures:
Carbon Dioxide: 11 - 14%
Smoke Number: 0 - 1 (
Excess Oxygen: 3 - 6%
Nett Flue Gas Temperature: 180 - 220c
Step 2
Allow burner to move to High Fire position. On its way to High Fire, the V2 Oil Valve will
energise, thus passing oil into the second nozzle.
Once at High Fire, adjust air damper to give combustion figures similar to above.
Switch between Low and high Fire, checking the firing rate and combustion, ensuring that
consistent figures and smooth, reliable light-up are being obtained.
Listen for signs of flame instability.
With the burner firing, remove and cover the photocell, ensuring that the burner goes
immediately to lockout.
Warm up the boiler or raise steam slowly, and in accordance with the manufacturer's
instructions.
After running for a reasonable amount of time, remove the combustion head and check for
any oil impingement, oil leaks, or fouling at the flame plate.
If necessary, make adjustments to the combustion head to cure this.
Check the flame ring for indications of overheating or impingement by the oil spray.
The basic, relative positions of the combustion head components are given in section 3 of this
manual, but the principles to be followed are that:1. The ignition electrodes must be positioned so that the spark, which `strikes` at the narrowest
point is blown forward by the combustion airflow on to the widest point of the `horns`. This
will ensure that the arcing takes place within the cone of atomised fuel, with a consequent
immediate ignition of the fuel.
Note that if the electrodes are set too far forward, they will be subjected to continuous
impingement by un-burnt fuel, some of which will carbonise, quickly reducing the intensity
of the spark and leading to poor ignition.
2. The relative position of the flame ring must give a flame which is ànchored` on to the front
face of the ring. The slotted vanes must be opened enough to allow the passage of an
adequate amount of air, which because of the swirl effect imparted, will be a major
stabilising factor. If the vane gap is irregular, the flame shape will be affected and soot will
build up at the points which restrict the air flow.
If the nozzle is too near to the flame ring, the flame will tend to `lift off`, giving very
unreliable ignition and a degree of instability which will make reliable operation, especially
when modulating from high to low fire.
3. The combustion head as an assembly, must be central in the draught tube, otherwise the air
velocity round the outside of the flame ring ( and therefore of the flame ) will vary in
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relation to the gap through which the air is passing, causing poor flame shape and
impingement on the furnace structure.
4. Where divergent ( expanded ) nose cones are used, the cone itself should be positioned
relative to the flame ring and allow an adequate volume of air for combustion, but at the
same time, give a velocity which is high enough to assist in shaping the flame to give
optimum combustion.
While the design of the combustion head is the major factor in obtaining maximum
combustion efficiency, careful setting of the various component parts is also important.
When a burner has been in service for a period long enough for its performance to be
confirmed and before the settings have been disturbed, the relative dimensions of the
combustion head components should be recorded, so that after dismantling for maintenance,
correct reassembly can be assured.
Set the high/low thermostat or pressure switch to a lower figure than the on/off control. The
difference should take account of demand, bringing the burner back to low fire early enough
to slow down any boiler pressure or temperature rise if the heat demand is less than the
boiler M.C.R. and reduce the on/off cycling of the burner. Equally the burner must revert to
its high fire rate in time to maintain the pressure or temperature above a figure which is
determined by site conditions.
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7.6
Electronic Modulating Burners
IMPORTANT!
When commissioning burners fitted with Electronic Modulating Control Systems, the
respective operating manuals must be followed. Only competent and trained personnel are
permitted to commission burners fitted with these controls.
7.6.1
Gas Butterfly Valve
Control of the gas supply to the burner is performed using a butterfly valve.
material specification of blade and spindle can be altered depending on gas
type, E.G. Stainless Steel can be specified for Bio-gas.
Check the butterfly valve has been correctly set to zero - Please consult
manual for details. More details on the butterfly valve can be found in the
component section.
7.6.2
Oil Metering Valve
The oil metering valve is used to control the amount of oil returning from the
spill back oil nozzle line. On spill back systems, the witness mark on the
inner spool piece must be set to 'B'.
Set the pointer to zero - Please consult manual for details. With the pointer set to zero, this
represents maximum flow through the metering valve. As the valve modulates up to 90, the valve
closes off, also closing off the return spill line from the oil nozzle line and
therefore increasing the firing rate. More details on the oil metering valve can be
found in the component section.
7.6.3
Adjustment of air pressure proving switch
Check the air pressure proving switch and, if necessary, set to 50% of
differential pressure.
Example of adjustment:Negative pressure ( ) measured
Positive pressure ( + ) measured
Differential pressure is Switch off point of pressure switch is
4 mbar
5 mbar
9 mbar
4.5mbar
From this point all commissioning procedures are dictated by the Ratiotronic 6000 manual.
ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS
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7.6.4
Ratiotronic programming
The Ratiotronic 6000 burner control system is generally pre-programmed in the factory prior to
despatch. However it is important that the parameters are checked against the lists supplied with the
test data supplied with the burner.
The combustion engineer must be competent with such a controller and be fully trained in burner
commissioning before proceeding any further.
This manual must be used in conjunction with the Ratiotronic 6000 manual at all times.
7.6.5
Setting the servo motors
Please refer to section 5 of the Ratiotronic manual.

In general the drive servo motors are allocated as follows:
Drive 1: Gas Butterfly valve
Drive 2: Oil Metering Valve
Drive 3: Air damper servo motor
Drive 4: Inverter
7.6.6
Burner Commissioning
Important:
It is recommended for T5 burners, that a variable speed drive should be fitted to avoid
excessive axial forces on motor bearings when commissioning. Initially set the inverter speed
to approximately 30-35 Hz and use all available stroke on air damper first. Once the air
damper is fully open, any additional air required can be achieved by increasing the inverter
speed.
See table below as an example setup.
GAS PROFILE
P0
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
GAS (degree)
AIR (degree)
INVERTER
10
20
30
40
50
60
70
80
90
10
25
40
55
70
85
90*
90
90
600 (30Hz)
600 (30Hz)
700 (35Hz)
700 (35Hz)
700 (35Hz)
700 (35Hz)
800 (40Hz)*
900 (45Hz)
999 (50Hz)
*NOTE AIR DAMPER IS MECHANICALLY FULLY OPEN BEFORE INVERTER

FREQUENCY IS RAMPED UP.
Please now refer to Section 6.6 Commission Ratio Mode of the Ratiotronic 6000 manual for
details on how to commission the burner.
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7.6.7
Combustion values and results
All combustion readings must be taken with an approved and correctly calibrated test kit.
The following combustion values should be reached:Low Fire
CO content
CO2 content
O2 content
0 - 20 ppm
9 - 11 %
5 - 2%
High Fire
CO content
CO2 content
O2 content
0 - 20 ppm
10 - 11%
3.6 - 2%
In all cases the CO figure should not exceed 100mg/m3 maximum.

The nett flue gas exit temperatures should be taken throughout the process of setting the
combustion.
The figures will vary according to the type of appliance but for shell and sectional boilers will be in
the range of 180 - 250C gross.
Always keep the exhaust flue gas temperatures within the manufacturers recommended
range and ensure that the appliance is not over or under fired. Warm up the boiler, or raise
steam in accordance with appliance manufacturers instructions.
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Burner Maintenance Schedule

REMEMBER!
ELECTRICAL AND FUEL SUPPLIES MUST BE ISOLATED BEFORE ANY
MAINTENANCE WORK IS CARRIED OUT ON THE BURNER.
The following schedules are only to be taken as a guide to those persons responsible for day to day
maintenance of the burners. Details of a service agreement covering the major items of routine
servicing are available on request.
An annual check by factory trained technicians is strongly advised.
All control circuit components, fire valves and other safety devices should have a functional check
at not greater than annual intervals.
Maintenance and inspection of boilers or other appliances must meet the requirements of the
manufacturers' schedules and of the insurers. It is usually more convenient to carry out burner
maintenance after the completion of the boiler inspection or cleaning, so that the burner can be fired
and the combustion reset to optimum figures.
The measurements given in the various combustion head drawings in this manual are to be regarded
as datum figures only. During commissioning, alterations may be made to the relative positions, or
to the components themselves, to suit the particular application.
Therefore, before dismantling the combustion head, take note of the measurements concerned and
record them on the manual's drawings. It is important that where possible components of the same
type and size are fitted as replacements.
The commissioning certificate for the burner should be available, to be used as a reference for the
fuel input and combustion figures which will give boiler MCR and the highest efficiency level.
8.1
Opening the Burner
To open the burner, the two nuts securing the hinge section to the fan section must be removed. The
burner will swing open on its hinge offering full access to all combustion head components.
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When necessary checks/repairs have been carried out, close up in reverse order ensuring that the
locking nuts are fully tightened.
8.2
Minor Maintenance
(a) Check the operation of the flame failure system daily by deliberately locking out the burner.
This can be achieved by either removing the UV cell, or on burners fitted with ionisation
probes isolating the gas supply to the burner.
(b) Where fitted, check and regularly clean the UV cell window with a soft cloth.
(c) Inspect the burner control cabinet to ensure that all indicator lamps are serviceable.
(d) Make a general check for cleanliness and security.
(e) As convenient, make an inspection of the combustion head components for cleanliness,
security and serviceability.
(f) Check the main gas valves for external hydraulic fluid leaks.
(g) Confirm the security of all linkages, locking nuts and any component parts fitted to the
burner
(h) Where a micro-ammeter is fitted make regular checks to confirm that the UV cell output
does not significantly deteriorate.
8.3
Major Maintenance
Take adequate safety precautions against the small amount of gas which escapes when gas train
components are removed.
Carry out all of the maintenance tasks listed above, plus the following:
(a) Remove the upstream pilot valve and determine the amount of dust etc. which is present. If
a substantial quantity is found, remove the upstream main gas valves from the burner and
clean the seats (Unibloc only, see 'Unibloc' section of this manual for actuator removal).
The Siemens valve is a sealed unit any unauthorised opening will invalidate warranty.
(b) Check and clean any gas filters in the site pipework if significant quantities of dust or scale
are found. Make a request to the gas region for similar work on the service filter which
protects the meter
(c) Confirm correct operation of electrical components, e.g. control boxes, motor starters etc
and check tighten all electrical terminals.
(d) The nominal life of a U/V cell is 10,000 hours, subject to regular checks of the cell output
as registered on the micro-ammeter (which might indicate an earlier deterioration) the cell
should be changed every third year.
(e) Disconnect the air shutter linkage at the shutter spigot. Move the shutter by hand to confirm
freedom of movement. Clean as necessary (the PTFE bearing surfaces need no lubrication
but will require replacement when worn)
(f) Inspect the refractory of the burner mounting plate. Make good any defects in refractory or
sealing
(g) Ensure that boiler furnace sight glasses are clean and that their sealing is flue gas-tight.
(h) When the inspection and any rectification work has been completed on the burner/boiler,
bring the unit up to working temperature (slowly).
(i) With the boiler on line, confirm that the fuel throughput and combustion efficiency are
equal to the 'commissioned' figures.
8.4
Dismantling and Re-assembly of Burners
Combustion Head Removal
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The combustion head can be removed, as a unit, for maintenance purposes. Before commencing
refer to the combustion head drawings in the exploded diagram section at rear of this manual for
relevant positions of the various components.
(a) Open the burner, as described in the burner maintenance schedule.
(b) Disconnect the probe/HT lead and, where a UV cell is fitted, remove this from its retaining
clip and move to a safe place.
(c) Loosen the jacking screw in the mounting hinge section opposite the gas entry, as shown in
the illustration below.
(d) Pull the nozzle line spigot out of the gas entry.
(e) Withdraw the nozzle line complete, out of the blast tube.
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(f) Re-assemble in reverse order, ensuring that a new gas head seal is fitted.
(g) Check the combustion head is correctly aligned in the blast tube and that the seal is gas
tight.
(h) Close and lock-up the burner
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Burner Motor Replacement

(a) Disconnect the probe and ignition leads from the combustion head and withdraw them and,
where necessary the UV cell from the mounting casting.
(b) Disconnect air pressure switch and hinge switch cables. Ensuring that all cables are properly
marked for ease of re-connection.
(c) Ensure that the burner door locking nuts are fully tightened.
(d) Disconnect all mains power connections and other electrical wiring between the burner
panel and the boiler or other electrical panels again ensuring cables are marked.
(e) Disconnect the motor wiring at the panel end (ensure that all cables are identified and that
the wiring connections on the replacement motor are the same as on the original).
(f) Remove the air damper drive linkage.
(g) On the TD3, TD4 and TD5 burners it will be necessary to electrically disconnect the air
damper modulation motor.
(h) Take out the four fixing bolts and remove the modulation motor mounting bracket .
(i) Using suitable lifting gear take the weight of the burner by its lifting eye.
(j) Remove the ring of screws which secure the two halves of the fan case.
(k) Remove the rear half of the burner (half fan case, motor, fan, panel) and place on a bench or
clean floor area.
(l) Remove the fan retaining bolt from the end of the motor shaft and carefully remove the fan
taking care not to misplace the drive key.
(m) Remove the motor by releasing the four retaining bolts at the rear of the main air shutter
casting.
(n) Re-assemble in reverse order, ensuring that the motor shaft is properly greased before the
fan is fitted.
Gas Valve Actuator -Removal/Replacement
Removal of gas valve actuators must only be carried out by suitably qualified personnel. Full
details of removal/replacement procedures for all standard actuators fitted by Dunphy Combustion
are given in the 'Unibloc' section of this manual.
NOTE: THE FAN AND BOSS MUST BE
REMOVED COMPLETE AS A SINGLE UNIT
UND
ER NO CIRCUMSTANCES MUST THE
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9
9.1
Faults and fault finding

Ratiotronic 6000/6006
Faults relating to electronic modulation burners must refer to the Ratiotronic 6000 controller
manual Section 9.
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10 Useful Information
Common Conversion Tables

To Convert
Into
Multiply by
Bars
kg/m2
1.020 x 104
Bars
p.s.i.
14.5
Bars
kg/cm2
1.01972
Btu
1054.8
Btu
kg.cal
0.2520
Btu/hr
kW
2.928 x 104
Btu/lb
MJ/Kg
2.326 x 10-3
C.
f.
(C x 9/5) + 32
cm.Hg.
ft. of H20
0.4451
cm.Hg.
p.s.i.
0.1928
ft.
metres
0.3048
gallons (US)
litres
3.785
gallons (Imperial)
litres
4.546
gallons (US)
gallons (Imperial)
0.83267
Hp
kW
0.7457
hp (boiler)
kW
9.803
Inches
cm.
2.54
Inches of H2O
mb.
2.54
Btu
9.48 x 10-4
kg.Cal.
Btu
3.968
kg/cm
p.s.i.
14.2233
kW
Btu/hr.
3412
kW
kg.cal/min.
14.34
Litres
gallons (Imperial)
0.21997
Litres/minute
gallons(Imp.)/second
3.669 x 10-3
Metres
ft.
3.281
p.s.i.
bars
6.895 x 10-2
p.s.i.
mbars
69
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RECORD OF COMMISSIONING VALUES

SITE:
ADDRESS:
BURNER TYPE:
SERIAL NUMBER:
BOILER TYPE:
SERIAL NUMBER:
BOILER OUTPUT:
OPERATING TEMP/PRESS:
DATE OF COMMISSIONING:
ENGINEERS NAME:
FUEL:
PUMPED RING MAIN/GRAVITY SUPPLY?
NOZZLE TYPE & SIZE
OIL PUMP
WIRING DIAGRAM NO
Firing Rate Position
Low Fire
1
High Fire
10
Burner Output
CO2
CO
O2
NOX
Nett Flue Gas Temperature C
Smoke Number
Ambient Temperature
Efficiency
Electronic
Channel 1 - Fuel
Modulation
Channel 2 - Air
Furnace Pressure
Fan Pressure
Pump Outlet Pressure bar
Oil Return Pressure ( Spill ) bar
Boiler Temperature C
Boiler Pressure
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11 Exploded Diagram & Spare Parts List

11.1 Standard TD5 Assembly
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ITEM
TD525
TD530
QTY
DESCRIPTION
TD5 LOW NOx COMBUSION HEAD ASSEMBLY

TD5 COMBUSTION HEAD ASSEMBLY
T5 VANE CASTING
GA14933
GA14933
T5 IMPELLOR
IMPELL00320
IMPEL00300
T5 FAN MOTOR
MOTORF01270
MOTORF01280
T5 PLAIN CASTING
GA14932
GA14932
T5 INNER SHUTTER
GA17211
GA17211
T5 OUTER SHUTTER
GA17290
GA17290
NYLON ROLLER FOR AIR SHUTTER (OUTER)
GA5761
GA5761
NYLON ROLLER FOR AIR SHUTTER (INNER)
GA5761
GA5761
10A
T5 SNORKEL SILENCER
GA21376
GA21376
10B
T5 ACOUSTIC SILENCER
GA6437
GA6437
11
MOD PLATE SPACER
GA7961
GA7961
12
MOD PLATE
GA17188
GA17188
13
SERVO CONNECTING ROD BEARINGS
BEAROS00250
BEAROS00250
14
SERVO LINK ARM
GA18765
GA18765
15
RATIOTRONIC 6027 SERVO MOTOR
ETCRAT00745
ETCRAT00745
16
BRIDGE HANDLE
CONTOL02285
CONTOL02285
17
CABINET HANGER BRACKET
GA6433
GA6433
18
UNIVERSAL HANDED BURNER CABINET
CABUN00140
CABUN00140
19
BURNER CABINET DOOR
CABCPD00160
CABCPD00160
20
M16 EYE BOLT
EYEBLT00100
EYEBLT00100
21
T5 BURNER MOUNTING GASKET
GASKET00150
GASKET00160
3B
T5 INPELLOR HUB
GA15360
GA15360
23A
T5 UNIBLOC SIDE ENTRY ASSEMBLY (DN80)

GA23519A
GA23519B
GA23519C
GA23519A
GA23519B
GA23519C
23B
T5 VGD.40 SIDE ENTRY FOR ELECTRONIC MODULATING BURNERS (DN80)

GA23530A
GA23530B
GA23530C
GA23530A
GA23530B
GA23530C
24
100NB PN6 BUTTERFLY GAS VALVE C/W 6026 MOTOR
BUTFLY02141
BUTFLY02141
25
100NB PN6 GASKET (FULL FACE)
GASKET00975
GASKET00975
26
T5 SIDE ENTRY PLATE (100NB PN6)
SIDENT00130
SIDENT00130
27
QRA53 FLAME DETECTOR (230V)

QRA53 FLAME DETECTOR (110V)
PHOTOL00152
110VLG00365
PHOTOL00152
110VLG00365)
28
SANDWICH BLOCK - PART A
BLOCK00215
BLOCK00215
29
ORING, BS211 VITON
ORINGS00675
ORINGS00675
30
ORING, BS236 VITON
ORINGS00445
ORINGS00445
31
SANDWICH BLOCK - PART B
BLOCK00215
BLOCK00215
32
1/4"BSP DOWTY BONDED SEAL
SEADOW00105
SEADOW00105
33
1/4"BSP x 10mm MALE STUD COUPLING
COMPAD00485
COMPAD00485
34
n 10mm BUNDI TUBE
BUNDIT00090
BUNDIT00090
35
1/4" COPPER WASHER
COPWAS00075
COPWAS00075
36
LGW50 A2P AIR PRESSURE SWITCH

KROMSCHRODER DG50U6
PRESWI00245
PRESWI00450
PRESWI00245
PRESWI00450
37
OIL IGNITION ELECTRODE n14 x 68MM LONG
IGELEC00110
IGELEC00110
38
SPLIT ELECTRODE BUSH FOR n14 ELECTRODES
ELBUSH00100
ELBUSH00100
39
TD5 DUAL FUEL SPIDER
SPIDER00145
SPIDER00145
40
ART1400 BURNER GUN
BRNGUN00215
BRNGUN00215
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PART No.
PART No.
GA23631
GA23630
GA23634
GA23633
TD5 Manual Rev 4

41
1/4"BSP x 10mm ELBOW
COMPAD00550
COMPAD00550
42
1/2" BSP YORKSHIRE FITTING
YORFIT00510
YORFIT00510
43
n12mm BUNDI TUBE
BUNSIT00100
BUNSIT00100
44
1/2" BSP x 12mm MALE STUD COUPLING
COMPAD00425
COMPAD00425
45
14
1/2" BSP DOWTY SEAL
SEADOW00110
SEADOW00110
46
12mm x 1/2" STANDPIPE ADAPTOR
COMPAD00480
COMPAD00480
47
12mm SWIVEL RUN TEE
COMPAD00465
COMPAD00465
48
1/4" BSP x 12mm STANDPIPE ADAPTOR
COMPAD00470
COMPAD00470
49
3/4" BSP DOWTY SEAL
SEADOW00050
SEADOW00050
50
1/4" BSP MINI BALL VALVE
VALOIL00110
VALOIL00110
51
M5 FLAT COPPER WASHER
COPWAS00025
COPWAS00025
52
0-41 BAR (0-600 PSI) PRESSURE GAUGE
PRESGA00155
PRESGA00155
53
VARIOTRONIC OIL VALVE MOUNTING BRACKET
OILMET00630
OILMET00630
54
VT2 OIL METERING VALVE ASSEMBLY
GA16090
GA16090
55
3/8" BSP DOWTY SEAL
SEADOW00100
SEADOW00100
56
3/8"BSP x 12mm MALE STUD COUPLING
COMPAD00420
COMPAD00420
57
PRESSURE SWITCH ADAPTOR
BANMAN00170
BANDMAN00170
58
1/4" COPPER WASHER
COPWAS00075
COPWAS00075
59
BAILEY & MACKAY 1381R - 1/2" BSP OIL PRESSURE SWITCH (0.7 - 14 BAR)
PRESWI00700
PRESWI00700
61
No.8 BANJO BOLT - 1/2" BSP x 72mm LONG
BANMAN00100
BANDMAN00100
62
BANDMAN00330
BANMAN00330
63
3/4" BSP x 1" BSP POSITIONAL ELBOW
CONELB00135
CONELB00135
64
OIL MANIFOLD BLOCK No 6U
GA16771
GA16771
65
1/2" COPPER WASHER
COPWAS00110
COPWAS00110
66
3/4" COPPER WASHER
COPWAS00115
COPWAS00115
67
DH SERIES OIL PUMP
PUMDUN02017
PUMDUN02017
68
1/2" BSP N/C LUCIFER OIL SOLENOID VALVE (230V)

1/2" BSP N/C LUCIFER OIL SOLENOID VALVE (110V)
SOLOIL00240
110VLS00131
SOLOIL00240
110VLS00131
69
OIL MANIFOLD BLOCK No.1
BANMAN00380
BANDMAN00380
70
BANMAN00290
BANMAN00290
71
12mm x 1/4" BSP STUD COUPLING
COMPAD00430
COMPAD00430
72
MOUNTING FLANGE
PUMFLA00120
PUMFLA00120
73
VALVE BRACKET
CLUSVL00100
CLUSVL00100
74
BELL HOUSING
PUMBEL00140
PUMBEL00140
75
HRC 70 B SOLID HUB COUPLING
PUMZCP00700
PUMZCP00700
76
HUB COUPLING RUBBER INSERT
PUMZCP00705
PUMZCP00705
77
OIL PUMP MOTOR
MOTPUM00310
MOTPUM00310
78
OIL PUMP HANGER BRACKET
GA9562
GA9562
79
MOD PLATE & HANGER PLATE SPACER
GA22422
GA22422
80
BERGER LAHR STM30 B3.37 SERVO MOTOR
30039
30039
81
REDUCING NIPPLE, 1.0"-3/4"
PIPNIP01450
PIPNIP01450
82
D100 TOP HAT COVER
GA6707
GA6707
83
n 12mm BUNDI TUBE
GA23632A
GA23632A
84
n 12mm BUNDI TUBE
GA23632B
GA23632B
85
n 12mm BUNDI TUBE
GA23632C
GA23632C
86
COMPAD00495
COMPAD00495
87
15-40 Bar SAUTER PRESSURE SWITCH

2-28 Bar BAILEY & MACKEY PRESSURE SWITCH
PRESWI00400
PRESWI00705
PRESWI00400
PRESWI00705
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TD525
TD530
PART No.
PART No.
GA12981
GA12981
ITEM
QTY.
DESCRIPTION
T5 HINGE CASTING
T5 VANE CASTING
GA14933
GA14933
T5 IMPELLOR
IMPELL00235
IMPELL00300
T5 FAN MOTOR
MOTORF01270
MOTORF01280
T5 PLAIN CASTING
GA14932
GA14932
T5 INNER SHUTTER
GA17211
GA17211
T5 OUTER SHUTTER
GA17290
GA17290
8A
T5 SILENCER
GA6437
GA6437
8B
T5 CHAMFERED SNORKEL SILENCER
GA21376
GA21376
MOD PLATE SPACER
GA7961
GA7961
10
T5 MOD PLATE
GA17188
GA17188
11
ETCRAT00745
ETCRAT00745
12
CABINET HANGER BRACKET
GA6433
GA6433
13
UNIVERSAL HANDED BURNER CABINET
CABUN00150
CABUN00150
14
BURNER CABINET DOOR
CABCPD00200
CABCPD00200
15
T5 EYEBOLT
EYEBLT00100
EYEBLT00100
16
n10mm BUNDI TUBE
BUNDIT00090
BUNDIT00090
17
COMPAD00485
COMPAD00485
18
LGW50 A2P AIR PRESSURE SWITCH
PRESWI00245
PRESWI00245
19
T5 GAS BLANKING PLATE
GA22420A
GA22420A
20
T5 BURNER MOUNTING GASKET
GASKET00150
GASKET00160
21
T5 MULTI-FLAME MOUNTING SECTION
GA21751
GA19596
22
T5 MULTI-FLAME MOUNTING SECTION NOSE CONE
GA21750
GA19598
23
T5 AIR GUIDE (WHEN FITTED)
GA18046
GA22353
24
QRA2 PHOTO CELL
PHOTOL00115
PHOTOL00115
25
T5 MULTI-FLAME SPILT BLOCK - BOTTOM PIECE
BLOCK00272
BLOCK00273
26
22
1/8" BSP DOWTY SEAL
SEADOW00050
SEADOW00050
27
14
COMPAD00105
COMPAD00105
28
n6mm BUNDI TUBE
BUNDIT00070
BUNDIT00070
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29
1/8" BSP NON - RETURN VALVE
VALVCH00220
VALVCH00220
30
COMPAD00280
COMPAD00280
31
ART106 BURNER GUN NOZZLE BLOCK ASSEMBLY - OUTER NOZZLES
GA19508
GA19599
32
T5 MULTI-PIPE HEAD GAS NOZZLES
GA19806
GA19806
33
TD5 MULTI-FLAME FLAMEPLATE
GA22350
GA22352
34
SHELL HEAD FOR T5 MULTI-PIPE HEAD
GA19146
GA22299
35
T5 MULTI-PIPE LOW NOx DUAL FUEL HEAD
GA21749
GA19600
36
ART106 BURNER GUN NOZZLE BLOCK ASSEMBLY - CENTRE NOZZLE
GA6867
GA6867
37
6 - 10mm REDUCING ADAPTOR
COMPAD00650
COMPAD00650
38
COMPAD00495
COMPAD00495
39
19
1/2" BSP DOWTY SEAL
SEADOW00110
SEADOW00110
40
SANDWICH BLOCK - PART A
BLOCK00215
BLOCK00215
41
SANDWICH BLOCK - PART B
BLOCK00215
BLOCK00215
42
PUMP HOUSING COVER PLATE
GA6707
GA6707
43
MOD PLATE & HANGER PLATE SPACER
GA22422
GA22422
44
MOTOR BRACKET
MOTBRA00100
MOTBRA00100
45
OIL PUMP MOTOR
MOTPUM00310
MOTPUM00310
46
BELL HOUSING
PUMBEL00140
PUMBEL00140
47
VALVE BRACKET
CLUSVL00100
CLUSVL00100
48
MOUNTING FLANGE
PUMFLA00120
PUMFLA00120
49
DH SERIES OIL PUMP
PUMDUN02017
PUMDUN02017
50
1/2" COPPER WASHER
COPWAS00110
COPWAS00110
51
3/4" COPPER WASHER
COPWAS00115
COPWAS00115
52
OIL MANIFOLD BLOCK
BANMAN00370
BANMAN00370
53
No.8 BANJO BOLT - 1/2"BSP x 72mm LONG
BANMAN00100
BANMAN00100
54
BANMAN00330
BANMAN00330
55
3/4" BSP DOWTY SEAL
SEADOW00120
SEADOW00120
56
1" BSP - 3/4" BSP REDUCING NIPPLE
PIPNIP01450
PIPNIP01450
57
COMPAD00160
COMPAD00160
58
COMPAD00480
COMPAD00480
59
1/2" BSP SRV OIL SOLENOID VALVE
SOLOIL00360
SOLOIL00360
60
n12mm BUNDI TUBE
BUNDIT00100
BUNDIT00100
61
12mm EQUAL TEE PIECE
COMPAD00455
COMPAD00455
62
3/4" BSP x 1" BSP POSITIONABLE ELBOW
CONELB00135
CONELB00135
63
BANMAN00290
BANMAN00290
64
OIL MANIFOLD BLOCK No.1
BANMAN00380
BANMAN00380
65
1/2" BSP N/C LUCIFER OIL SOLENOID VALVE
SOLOIL00240
SOLOIL00240
66
COMPAD00768
COMPAD00768
67
3/8" BSP DOWTY SEAL
SEADOW00100
SEADOW00100
68
VT2 OIL METERING VALVE ASSEMBLY
GA16090
GA16090
69
TWIN VT2 METERING VALVE MOUNTING BRACKET
OILMET00753
OILMET00753
70
COMPAD00420
COMPAD00420
71
COMPAD00470
COMPAD00470
72
1/4" BSP MINI BALL VALVE
VALOIL00110
VALOIL00110
73
0 - 41 BAR (0-600 PSI) PRESSURE GAUGE
PRESGA00155
PRESGA00155
74
PRESSURE SWITCH ADAPTOR
BANMAN00170
BANMAN00170
75
SAUTER PRESSURE SWITCH DSF152

BAILEY & MACKEY 1381R - 1/2" BSP OIL PRESSURE SWITCH (0.7 - 14
Bar)
PRESW00570
PRESWI00700
PRESW00570
PRESWI00700
76
12mm EQUAL ELBOW
COMPAD00435
COMPAD00435
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77
ETCRAT00720
ETCRAT00720
78
1/4" COPPER WASHER
COPWAS00075
COPWAS00075
79
M5 COPPER WASHER
COPWAS00025
COPWAS00025
80
NYLON ROLLER FOR AIR SHUTTER
GA5761A
GA5761A
81
STEEL BUSH FOR AIR SHUTTER
GA5761B
GA5761B
82
BRIDGE HANDLE
CONTOL02285
CONTOL02285
83
SAUTER DSF 170 PRESSURE SWITCH

BAILEY OIL PRESSURE SWITCH
PRESWI00400
PRESWI00700
PRESWI00400
PRESWI00700
84
12mm SWIVEL RUN TEE
COMPAD00465
COMPAD00465
85
1/2" MINI BALL VALVE
VALOIL00115
VALOIL00115
86
n12mm BUNDI TUBE
GA23760A
GA23760A
87
n12mm BUNDI TUBE
GA23760B
GA23760B
88
n12mm BUNDI TUBE
GA23760C
GA23760C
89
n12mm BUNDI TUBE
GA23760D
GA23760D
90
n12mm BUNDI TUBE
GA23760E
GA23760E
91
n12mm BUNDI TUBE
GA23760F
GA23760F
92
12
COMPAD00430
COMPAD00430
93
T5 ZINC CLEAR GAS SIDE ENTRY PLATE
PLCSIDENT00130
PLCSIDENT00130
94
10mm Mk2 BUTTERFLY VALVE ASSEMBLY WITH STM 30 SERVO

MOTOR
BUTFLY02140
BUTFLY02140
95A
T5 UNIBLOC SIDE ENTRY ASSEMBLY - DN80T5 UNIBLOC SIDE ENTRY

ASSEMBLY - DN100 T5 UNIBLOC SIDE ENTRY ASSEMBLY - DN125
GA23519A
GA23519B
GA23519C
GA23519A
GA23519B
GA23519C
95B
T5 UNIBLOC SIDE ENTRY ASSEMBLY - DN80

GA23530A
GA23530B
GA23530C
GA23530A
GA23530B
GA23530C
96
AIR DAMPER LINK ARM
GA18765
GA18765
97
10mm ROD END BEARING
BEAROS00250
BEAROS00250
98
IGNITION ELECTRODE
IGELEC00130
IGELEC00130
99
ART 106 NOZZLE BLOCK HOLDER
GA9150A
GA9150A
100
18
1/4" BSP DOWTY SEAL
SEADOW00105
SEADOW00105
101
1/4" BSP YORKSHIRE FITTING
YORFIT00510
YORFIT00510
102
CONE PILOT ASSEMBLY
GA21712
GA21712
103
TD5 JACKING SCREW
FASHEX00170
FASHEX00170
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11.3 TD525 Low NOx Multipipe Combustion Head Assembly
11.4 TD530 Low NOx Multipipe Combustion head Assembly
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11.5 TD525 Combustion Head Assembly
11.6 TD530 Combustion Head Assembly
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11.7 DN80 Unibloc Assembly
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11.10 VGD40.80 Assembly for Electronic Modulating Burners
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12 Component Information
12.1 Unibloc
12.1.1 Unibloc General Arrangements
All Unibloc gas trains are manufactured and tested in accordance with EN 161 : 1991 'Automatic
Shut-off Valves for Gas Burners and Gas Appliances'
The Unibloc body is cast iron to BS 1452 grade 220 (the 100 N.B. body conforming to EN161 is
S.G. cast iron to BS 2789 grade 2712). All bodies are manufactured in one piece and are precision
machined to accept the various gas valve actuators that are described in section 2.
The standard unit is designed for use with 2nd and 3rd family gases and is fitted with plated carbon
steel valve seating rings. For other gas applications, e.g. bio or producer gas, the valve seating rings
are manufactured out of grade 321 stainless steel, because of the corrosive nature of these gases.
Where hydrogen sulphide (H2 S) is present in the gas advice must be sought from Dunphy
Technical Department.
A gas filter is fitted around the seating of the first stage valve to prevent foreign bodies entering the
Unibloc and causing valve seating problems. Gas filters are available to suit the various
specifications as required.
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Valve actuators are supplied as standard with plated carbon steel seat assemblies fitted with nitrile
rubber seating discs.
If valves are required to be used on bio, producer or other corrosive gases, the valve seat assemblies
will be manufactured in 321 stainless steel with viton seating discs.
Installation
Select a location where the ambient temperature will be within the range of 0C to +50C, ensure
that the gas supply pipework is clean and contains no loose particles, fit valve to pipework so that
the gas flow travels in the direction of the arrows on the valve casing.
Please note that the 40, 50, 65, 80 and 100 mm N.B. valve bodies should be mounted with the inlet
flange facing vertically downwards. The 125 mm. N.B. valve body has an adjustable inlet flange
section that can be rotated to face in various directions
Due to the size and weight of the 100mm N.B. Unibloc, it is recommended that after installation
in the gas pipework the valve body is supported using the hole drilled in the valve body rib.
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12.1.2 80mm Ratiotronic Unibloc exploded diagrams and parts list
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12.1.3 80mm Ratiotronic Unibloc with pilot exploded diagrams and parts list
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12.1.6 100mm Ratiotronic Unibloc with pilot & ETC 1021 exploded diagrams and parts list
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12.2 Butterfly Gas Valve

12.2.1 General Arrangement
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12.2.2 Exploded Diagram
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12.3 Siemens VGD20 and VGD40 Gas Valve Blocks

Double gas valves for use on gas trains, consisting of 2 class A
safety shutoff valves.
Suited for use in connection with gases of the gas families I...III.
The double gas valve is to be combined with 2 actuators of the
SKP series (e.g. to provide the functions of 2 safety shutoff
valves connected in series, with different types of gas pressure
governor if required).
Supplementary data sheets on the actuators is located at the end
of this section.
VGD20
To avoid injury to persons, damage to property
or the environment, the following warning notes
should be observed!
Do not open, interfere with or modify the double gas valve,
except when fitting the service replacement set! _ When used in
connection with gas, the valves constitute part of the entire safety
system. Fall or shock can adversely affect the safety functions.
Such valves may not be put into operation, even if they do not
exhibit any damage.
VGD40
Protect the actuator against excessive temperatures (caused by radiation, for example), to ensure the
maximum permissible ambient temperatures will not be exceeded.
Mounting notes
Ensure that the relevant national safety regulations are complied with. To mount the double gas
valve VGD20..., 2 flanges type AGA41... / AGA51... are required.
To prevent cuttings from falling inside the valve, first mount the flanges to the piping and then
clean the associated parts. On the gas train, the valve can be mounted in any position, but the
permissible mounting positions of the associated actuator must be observed (refer to the relevant
Data Sheet)
The direction of gas flow must be in accordance with the arrow on the valve body.
When used in combination with the SKP10..., SKP15..., SKP25... or SKP75...,
the minimum gas pressure switch must always be mounted upstream of the double gas valve!
The electro hydraulic SKP15... actuator, which is used for shutoff functions, must always be
mounted on the inlet side while the actuators with integrated governor (SKP25..., SKP75...,) must
always be fitted on the outlet side of the valve (with a contoured disk).
Check to ensure the bolts on the flanges are properly tightened . Check to ensure the connections
with all components are tight. Mounting and replacement of the actuator can take place while the
valve is under pressure. Sealing materials are not required. Ensure that the O-rings are fitted
between the flanges and the valve body.
Installation notes
Installation work must be carried out by qualified staff.
If the available gas pressure exceeds the valves maximum permissible operating pressure, the gas
pressure must be reduced by a pressure regulator upstream of the valve.
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Commissioning notes
Commissioning work must be carried out by qualified staff.
If environmental conditions produce corrosion (e.g. sea climate), apply protective coating.
Check wiring carefully prior to commissioning.
Standards
CE conformity in accordance with the directives of the European Union
- Directive for pressure equipment 97/23 EEC
- Directive for gas appliances 90/396 EEC
Service notes
Check the correct functioning and the internal and external tightness of the VGD... each time a
valve has been replaced. The valve may only be replaced by qualified staff.
VGD20
The double gas valves VGD20... are of the normally closed type and have 2 disks, one noncontoured disk on the inlet side and one contoured disk on the outlet side. The stems are guided on
both sides of the disks, thus ensuring precise alignment and tight shutoff. The high closing force of
the return spring is supported by the prevailing gas pressure (class A to EN 161). A strainer on
the inlet side protects the valve and downstream controls against dirt. Valve body and connecting
flanges are made of die-cast aluminium, the seals of nitril rubber, and the stems of stainless steel.
The double gas valves feature a pilot gas connection Rp" . Gas valve, flanges and actuators are
supplied as separate
items. The 4 screws
required to fit the SKP...
to the valve are contained
in
the
terminal
compartment. No special
tools are required for
assembly.
The
connecting flanges have
a test point. They are
internally threaded and
supplied as separate
items, together with the
necessary accessories, such as bolts, nuts, seals, etc. The overall flange dimensions and bore-holes
are identical, so that all types of flanges can be fitted to the double gas valve, irrespective of
nominal size. This means that a 1" flange can be fitted to a 2" VGD... valve, and vice versa. Each
double gas valve requires 2 connecting flanges, which are to be ordered as separate items.
General Data
Class
Group
Types of gases
Built-in strainer, mesh size
Perm. medium temperature
Mounting
Flanges for VGD40...
Materials
- VGD20...
- VGD40...
VGD40
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A (EN 161)
2 (EN 161)
gas families I, II, III (to G260 of DVGW) air
0.9 mm
-15...+60 C
spring housing horizontal or vertical, pointing downward
to ISO 7005; PN16
die-cast aluminium
sand-cast aluminium
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The double gas valves VGD40... are double seat disk valves of the normally closed type. The stems
are guided on both sides of the disks, thus ensuring a precise stroke and tight shutoff. To improve
the control performance, the disks at the bottom are pro-filed.
The patented double seats are closed by 2 springs. The high closing force of the return spring is
supported by the prevailing gas pressure (class A to EN 161). The spring of each stem exerts a
pressure on the disk so that there is a
defined closing force acting on each disk.
The surface area proportions of the 2 valve
disks per stem
are such that the closing force increases as
the inlet pressure increases (class A valve
to EN 161). A strainer on the inlet side
protects the valve and downstream controls
against dirt. The 4 screws required to fit the
SKP... to the valve are contained in the
terminal compartment. The double gas
valves DN40150 correspond to the
standard valve sizes of single valves (EN
558).
The VGD40... are supplied with a pilot gas
flange having a connection for the pilot
gas line and a connection for an impulse line. This impulse line connection between the 2 valves
and another impulse line connection on the outlet flange can be connected directly to the constant
pressure governor SKP20... fitted to V1 or V2.
A universal mounting plate facilitates attachment of a number of commercially available pressure
switches or valves proving devices. Both the pilot gas flange and the universal mounting plate are
exchangeable and can be fitted on either side of the valve.
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Power Output Curves
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12.3.1 Siemens SKP actuators
The combination of actuator and valve provides the following functions:

- Safety shutoff valve (SKP15...)
- Safety shutoff valve with gas pressure governor / controller (SKP25..., SKP55..., and SKP75...)
The electrohydraulic SKP... actuators together with the valves are designed for use with gases of
gas families I...III and air. They are used primarily on gas-fired combustion plant. The actuators
open slowly and close rapidly. They can be combined with any of the above mentioned valve types
and nominal sizes. The actuator can be supplied with end switch (for indicating the fully closed
position).
The SKP25... operates as a constant pressure governor with a setpoint spring.
Its field of use are primarily forced draft gas burners
- with mechanical fuel / air ratio control
- with electronic fuel / air ratio control
The SKP55... operates as a differential pressure
governor. Its field of use are primarily
- combustion plant with combined heat recovery
systems
- plant where pressure conditions in the burner and
in the combustion chamber do not change in
proportion to load changes - burners with adjustable
fuel / air mixing devices in the burner head - plant
with negative pressure levels on the gas or air side.
The SKP75... operates as a ratio controller and
provides control of the gas pressure
depending on the pressure of the combustion air,
ensuring that the gas / air ratio remains
constant across the entire load range. Its field of use are primarily modulating forced draft gas
burners.
To prevent injury to persons, damage to property or the environment, the following warning notes
should be observed! Do not open, interfere with or modify the actuators!
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All activities (mounting, installation and service work, etc.) must be performed by qualified staff
Check to ensure that the impulse pipes are properly fitted and tight
Fall or shock can adversely affect the safety functions. Such actuators must not be put into
operation, even if they do not exhibit any damage.
If mains voltage is fed to the end switch via the second plug-in space, protective earth must be
connected to the actuator via the same plug.
Use of connectors conforming to DIN EN 175301-803-A is mandatory
The connectors used must have cable strain relief
The pumps stem must not be pulled out using the overstroke element since that part could
become loose.
If the available gas pressure exceeds the maximum permissible operating pressure of the valve /
SKP..., it must be lowered by an upstream pressure controller. The pressure switch for lack of gas
must always be fitted upstream of the gas valve when used in connection with the SKP The
inside diameter of the impulse pipes must be a minimum of 6 mm. The impulse pipes must be
installed such that the differential pressure can be acquired with no disturbance (unfavourable flow
conditions). Pressure test points must not protrude and be flush with the inside diameter of the pipe
or duct wall. The impulse lines to the governor / controller should be as short as possible, enabling
the governor / controller to respond quickly should sudden load changes occur.
Installation of impulse pipes
In the case of unsafe combustion chamber pressure pipes (e.g. resulting from potential leaks), the
setting must also be checked during operation without having the combustion chamber pipe
connected, especially with respect to maximum burner capacity. The impulse pipes must be fitted
such that the differential pressure can be acquired with no disturbance. With gas / air ratios > 3, the
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impulse pipes for the combustion air and the combustion chamber pressure must have an inside
diameter of at least 8 mm. The impulse pipe for the combustion chamber pressure must be fitted
such that the gases will cool down in the vicinity of the impulse pipe and condensing gases cannot
enter the controller but will return to the combustion chamber.
Recommendations:
The gas pressure should be acquired at a distance of 5 times the nominal pipe size downstream
from the valve.
Do not use the lateral test points on the VG... valve body for picking up the pressure
Considering the combustion chamber pressure
If the resistance value of the combustion chamber / heat exchanger / stack system is constant, the
combustion chamber pressure changes in proportion to the gas and combustion air pressure as the
burners output changes. In that case, the combustion chamber pressure need not be fed to the
SKP75... as a disturbance variable. However, if the combustion chamber pressure does not change
to the same extent as the gas and air pressure as this is the case in plants with flue gas fan or
modulating flue gas damper the combustion chamber pressure must be fed to the SKP75... as a
disturbance variable, enabling the controller to counteract.
Ensure that the relevant national safety regulations are complied with
The quadratic arrangement of the fixing holes allows the actuator to be fitted in 4 different
positions, each step being 90
The actuator can be mounted or replaced while the system is under pressure; sealing
materials are not required
Electrical commissioning may only be performed when the SKP is fitted to the valve;
otherwise, the SKP can be damaged.
Power is supplied and connection of the end switch is made directly via a connecting cable
(conforming to DIN EN 175301-803-A)
The end switch is factory set.
When power is applied, the pump will be activated and the control valve closed. Oil is now pumped
from the chamber below the piston to the pressure chamber above the piston. The oil pressure
causes the piston to move downward, thereby opening the valve against the pressure of the
closing spring. The pump remains energized until the closing command is given. When power is
removed, or in the event of a power failure, the pump will be deactivated and the control valve
opened so that the closing spring pushes the piston back. The return flow system is sized such that
the counterstroke required for reaching the fully closed position is completed within about 0.6
seconds.
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12.4 VPS 504 Valve Proving System

The VPS 504 is the valve proving system used for double
block gas valves. The valve proving system complies
with EN 1643:
Equipment operates independent of residual
pressure in the range of the permissible operating
range
Test volume 4 l
Setting work not necessary on site
Short test period: min. 10 s, max. 26 s
Tightness or leaks are displayed by an LED
External fault display possible for series 02, series
04 and series 05.
Group fault alarm optional for series 01 (SSM)
Suitable for TRD systems
Electrical connection possible by plug connection
series 01, 02, 03. No rewiring is required for
contact allocation as per DIN 4791.
Series 04 and series 05: electrical connection at screw terminals via PG 13.5 cable entry.
Suitable for gases of gas families 1, 2, 3 and other neutral gaseous media.
Not suitable for use with hydrogen VDK 200 H2 to be used for hydrogen.
Approvals
EC type test approval as per EC Gas Appliance Directive:
VPS 504 CE-0085 AP 0168
EC type test approval as per EC Pressure Equipment Directive: VPS 504 CE0036
1 Hall switch
2 Solenoid
3 Pressure switch diaphragms
4 Compression spring
5 Filter
6 Solenoid valve anchor
7 Solenoid valve coil
8 Pressure pump
9 Unlock switch
10 Fault lamp
11 Operating lamp
12 Test nipple
13 Volume restrictor
14 Pump diaphragm
15 Pump linkage
16 PCB
17 Plug connection
18 Equipment fuse
19 Spare fuse
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Specifications
Operating pressure
max. 500 mbar (50 kPa)
Test volume
4.0 l
Pressure increase by motor pump
20 mbar
Nominal voltage
(Permissible voltage range)
230 V AC (-15%) to -240 V (+6%), VPS 504 series 05: 24 VDC

For further voltages, refer to type overview
Frequency
VPS series 01-04: 50 Hz or 60 Hz

Series 05: DC
Rating requirement
During pumping time approx. 6 VA, in operation 17 VA
Prefuse (provided by customer)
10 A quick-acting or 6.3 A slow-acting fuse
Fuse installed in housing cover,

replaceable
Switching current
Microfuse 6.3 slow-blow L 250 V; IEC-127-2/III (DIN 41 662)
Degree of protection
VPS 504 Series 01, 02, 03: IP 40

VPS 504 Series 04, 05: IP 54
50 Hz 230 VAC -15C to +70C
others: -15C to +60C
Approx. 10 - 26 s, depending on test volume and input pressure
Ambient temperature
Release time
Sensitivity limit
Switch-on duration of control
Operating output VPS 504 Series 01, 02, 03, 04, 05: max. 4 A
Interference output VPS 504 Series 02, 04, 05: max.1A
Refer to motor startup current!
max. 50 l/h
At inlet pressures of < 50 mbar, limit pressure rates well below 50 l of
air
per hour occur due to the mode of operation. This allows for
applications
involving low inlet pressures.
100 % ED
Max. number of test cycles
20/h. Wait for at least 2 minutes after carrying out more than 3
consecutive
test cycles.
Installation position
vertical, horizontal, not upside down
Media
Standard model
Liquefied gas model
Gas families 1, 2, 3 and other gaseous media.

Not suitable for butane.
Gas family 3 and butane
The VPS 504 operates depending on pressure

build-up.
The program module starts to function when
heat is requested.
Test is performed depending on the
burner functional procedure:
Check prior to burner start or
Check during pre-purge period or
Check after burner shut-down
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Electrical Connections
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12.5 Variotronic VT Oil Metering Valve

12.5.1 General Description
The Variotronic oil valve has been designed to work primarily in conjunction with electronic
positioning motors for the accurate control of fluids, fuel oils and liquids as defined in the
specification of recommended applications.
The design of the valve incorporates an adjustable linear characterising spool which enables the
valve to operate to a virtually linear characteristic. the characterising spool adjusts the output of the
valve in relation to the metering valve spindle. This changes the flow rate of the valve - thus
ensuring that the maximum angular rotation is utilised to optimise the flow accurately.
12.5.2 Construction
The valve construction consists of a carbon steel body which is
drilled at each end to accommodate the valve output port and the
valve retaining cap. The output port is secured by 6 screws with an
oil seal 'O' ring sealing the face of the end cap and valve body. An
identical construction is on the drive end of the valve.
The end cap has a duel function in retaining the spool sleeve and
providing a clamp for adjustment. The valve control flow spindle is
mounted directly through the spool and retained by the output port
plate. This also has a duel function acting as a surface thrust plate
for the valve control. When the valve is used in conjunction with an
electronic servo motor, there are mounting pillar locations provided
at 52mm hole centres (which is the European standard for the 4Nm
required torque for operating this type of valve.)
12.5.3 Valve Maintenance
All rotating valves do eventually require maintenance, but maintenance is only generally necessary
as a result of wear on oil seals or 'O' rings. as a general guide we recommend that 'O' rings are
normally re-placed every 2 years or 20,000 hours, but this could vary on the type of fuel being
used, generally when operating on heavy fuel oils the service frequency should be reduced to 12
months. The normal grade of 'O' ring seals fitted within the valve is Viton.
Special materials are available for corrosive or fuels that contain corrosive substances. The
general service and maintenance of the valve is a very simple operation and all the seals could be
changed within a matter of minutes. It is essential to ensure that all replacement seals are of the
correct specification, any deviation from the specification could lead to premature seal failure and
even leakage from either the valve spindle or retaining faces.
12.5.4 Changing Seals
It is recommended that a spare set of seals is always retained for service and maintenance of the
valve. Changing the seals is a relatively simple task.
A.
B.
C.
D.
Isolate all electrical and fuel supplies

Ensure that the valve is cold and that there is zero pressure within the hydraulic circuit
Disconnect the valve drain mechanism, either mechanically or via electric servomotor
Before dismantling the valve, ensure that the positions are appropriately marked so that the
re-assembly, particularly of the spool ring can be repeated to the original settings. Remove
the 2 pillars securing the index plate. this will then expose the 4 countersunk retaining
screws on the valve retaining cap. The valve can then be de-assembled.
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E. The entire metering spindle and spool sleeve can be removed from the top plate. The
spindle has a Viton 'O' ring and there is a Viton 'O' ring between the cap and the valve body.
the shaft sealing is via 2 x 'O' rings which are submersed inside the spool sleeve.
There should not be any need to remove the bottom plate, although as a precautionary measure if
'O' rings are being replaced, it is good practice to replace all of the seals with the correct
specification for the valve.
12.5.5 Adjustment of the valve
Since the valve can operate either for spill back
nozzles or for direct metering of fuel, the
configuration can be changed by indexing the
pool witness mark to change the opening and
closed characteristic of the valve. In other words,
when the witness plate is indexed to position 'A'
the valve operates from closed to open over the
90 degree scale.
When the witness plate is indexed to position
'B', the valve operates from fully open to closed over a 90 degree movement. It is also possible to
change the flow characteristic of the valve by changing the position of the spool in accordance with
the details on the flow graph and scale plate indicators.
Valve adjustment is extremely simple. The design of the valve allows maximum travel from 0 to
90 degrees to control the modulating range of the burner. Depending upon the flow rate required
across the valve, this could control fuel flows in excess of 20:1 over the valve spindle angular
movement.
It is possible to adjust the output of the valve whilst still maintaining the large amount of
linearization by adjusting the spool ring on the inner scale plate. This is adjusted by loosening the
retaining cap and rotating the spool with a peg spanner. The index mark on the spool indicates the
spool position which can be read in conjunction with the flow charts on the opposite page.
12.5.6 Installation of the valve
The Variotronic valve can be mounted in any access. it is however,
essential that there is no pipe stress from either the inlet or discharge
port of the valve. Any external pressure caused from pipe stress could
distort or cause the valve to malfunction. Fixing of the valve is via a
pad with 2 off tapped holes, 5MM tapped directly into the valve body.
12.5.7 Valve Drive
While the Variotronic valve has primarily been designed to be driven
by an electronic positioning motor, it is possible to use the valve via
mechanical linkage. It is essential that there is zero play on any
connection between the valve spindle and the drive to the valve. This
is particularly important with electronic positioning since the valve is
normally controlled by a sensor or potentiometer mounted directly on
the servo motor shaft.
Zero hysteresis drive couplings must be used or, alternatively, a solid
coupling between the servo motor and valve spindle. Before commencing operation of the valve,
please ensure that there is oil or lubrication within the valve.
Do not run the valve dry as this could affect the long term accuracy. If the valve has to be operated
before the oil system has been fully primed, it is prudent to put lubricating oil in the valve ports.
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12.5.8 Exploded Diagram
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12.6 DH Series Pump
`DH` SERIES GENERAL DESCRIPTION

The oil pump is a vital part of any oil fired heating plant, whether
being used as a transfer pump for pumping oil at low pressures or on
an oil burner delivering oil at 35 bar.
The Dunphy DH series pump has been specifically designed to
overcome the problems associated with current grades of fuel oils in a
variety of different situations, giving accurate pressure control
combined with reliability and performance.
The pump housing is Grade 14 cast iron that is precision machined to
accept the various combinations of gear sets that are available to suit a
wide variety of applications.
Exhaustive work on test rig and field trials that internal leakages in a
gear pump are most severe through the lateral running clearances.
They are less severe through the radial clearances, here, the leakage
path is long and the rotation of the gears opposes the pressure gradient.
Based on these observations a `Sandwich` construction of the gear-set
and the pumping chamber has been designed from first principles.
Calculations and computer modelling gave clear figures for the very
high bearing loads resulting from high liquid pressure acting on the
projected area of the gears. As a result, the design has catered for
bearings of large surface area. This must result in minimal rubbing
speed. They must also provide rigid shaft support with no appreciable
deflection.
The final design provides all DH series with gear-sets of nitrogen
hardened steel supported by an extremely strong bearing assembly.
It enables the standard unit to handle fuels with viscosities from 2 up to
2000 centistokes at pressures up to 35 bar and temperatures of up to
140C.
Single or tandem gear-sets can be offered as standard. Pumps with
special series gear-sets can be offered for specific applications.
The most characteristic and frequent failure of oil pumps is that of
pump seizure. In operation, a gear pump is required to deliver the
maximum possible volume for a given centre distance and face-width
of the gears. Losses due to internal leakage must be minimal and
sufficient only to provide adequate lubrication of the rotating parts.
However, the capacity of the gear-set depends on the depth of the gear
tooth. Design must therefore cater for a minimum number of teeth and
for minimum peripheral rubbing speeds
These parameters were used in making a choice between an internal
pinion and rotor format and an external gear-set employing straight
spur gear teeth of corrected involute form.
Dunphy engineers chose the external gear-set because it provides
maximum capacity for minimum peripheral rubbing speeds.
This factor is of vital importance in the elimination of pump seizure.
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12.6.1 Pressure Regulation

A pressure regulating valve is provided as a
standard feature of the pump.
It is located within the pump body and
consists of a steel piston with P.T.F.E. wipers
that slides in a honed steel bore.
Pressure is exerted on the piston itself by a
spring, the loading of which is adjustable by
the user.
The pressure of the oil bears on the cross
sectional area of the piston.
The Dunphy DH Series of oil pumps has been

purposefully designed, in-house, to a
demanding brief, by experienced engineers
who have learned, at plant level, what
qualities the user demands of an oil pump.
When oil pressure and spring force balance,

the piston lifts and permits by-passed oil to
return to the suction port.
The accuracy of the machining and honing
ensures that the close fitting piston is kept in
contact with the cylinder bore by the pressure
of oil acting on its annular area
This combination of material selection and
fine tolerance eliminates edge filtration,
prevents sticking in operation and reduces
hysteresis effects to an absolute minimum.
This facility eliminates the need to insulate

the pump and the flexible's and ensures that
both are kept at the correct temperature.
As a result the DH oil pump has been

designed up to an extremely high quality
standard.
For heavy oil installations, the DH pump can
be fitted with a restrictor which will allow oil
from the ring main system to circulate
through the flexible oil lines and also the
pump body when the burner is not running.
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TD5 Manual Rev 4
12.6.2 Technical Data Summary

Pump Model Code
DHO-1
DH1-1
Gearwheel Capacity litres/hr

Gearwheel Capacity gall/hr
Weight - kg
Shaft Diameter - mm
Fuel Types
Speed
Operating Pressures
Capacity Range
Inlet Pressure
Pump Fixing
Maximum Operating Temperature ( Fuel Oil )
290
750
1500
2250
4500
65
165
330
495
990
6.3
6.7
8.1
17.5
20.9
10
10
10
16
16
1.3 cSt. @ 40C up to 130 cSt. @ 80C
3600 Revolutions per minute ( maximum )
35 bar on standard units, maximum of 60 bar on tandem units
145 to 4500 litres/hour ( 32 to 1000 imp gallons/hour approx )
2 bar ( maximum ) ( 30 lbs. sq. inch )
Flange or Boss
140C
NOTES
DH2-1
DH2-2
Because running clearances in the pump

are at an absolute minimum, the
Volumetric Efficiency of the gear-set
becomes a function of the viscosity of the
liquid being pumped.
( See diagram below ).
1. PUMP CAPACITY
A number of variants can be offered. There are
two basic gear-sets available in the range, these
cover swept volumes from 290 to 4500 litres/hour
at 2 pole ( 2850 rpm and 3400 rpm ) speed.
95%
VOLUMETRIC
EFFICIENCY
The further variants arise from the potential of

using the pumps as SINGLE, SERIES
or TANDEM sets as described in the diagrams
below.
DH1-2
SINGLE
70%
VISCOSITY
2. CAPACITIES
Capacities are given for pumps running
at 2 pole speed ( 2850 rpm ) and a 50 Hz
electric supply.
SINGLE gear-set
SERIES
The SERIES arrangement provides a similar CAPACITY

to the SINGLE but the PRESSURE can be doubled
without any increase on the bearing load.
3. GEARWHEEL CAPACITIES
As stated, these give the full swept
volume of the pump.
TANDEM
The TANDEM arrangement DOUBLES the capacity

of the SINGLE gear-set
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TD5 Manual Rev 4
12.6.3 Installation Operation Maintenance

12.6.3.1 Installation
The DH Series can be supplied for either
flange or boss mounting to suit most
applications.
Pumps should be mounted with the shaft
horizontal, but the pump body may be turned
on its axis to allow easier access for pipe
connections etc.
It is essential that the pump and the motor
drive shafts are correctly aligned, that there is
no `play` in the drive connector and that there
is no end pressure on either drive shaft.
See the pump and motor arrangement
drawing at the bottom of the page.
Check that all joints on the oil supply pipes,
flexible oil lines etc. are properly sealed and
that the oil supply temperature and pressure
are correct ( see the relevant burner manual
for guidance notes on oil installation,
remembering that the maximum permissible
oil supply pressure to DH series pumps is 2
bar.
Residual fuel oils should be supplied to the
inlet port of oil burner pumps at temperatures
of:
40C for 200 secs R1 ( 13.5 cSt at 80C )
65C for 960 secs R1 ( 35 cSt at 80C )
When DH series pumps are used with
air/steam atomised burners burning residual
fuel oils the oil supply temperatures can be
reduced to:
10C for 200 secs R1 ( 13.5 cSt at 80C )
H O U S IN G C O V E R
AND SCREW S
PARALLEL KEY
Distillate fuel oils should be supplied to the

pump inlet port at a slight positive pressure.
Where suction lift is required, the Dunphy
technical department should be consulted.
Residual fuel oils should be supplied to the
pump inlet port at a pressure between 1 and 2
bar.
12.6.3.2 Filtration
Filters must be fitted in the oil supply system
to prevent foreign matter entering the pumps
and possibly affecting performance or
causing physical damage.
All DH1 fuel are supplied with internal
filters, however, when pumps are used with
residual fuel oils, it is recommended that this
filter is removed after approximately one
weeks running when it is certain that any
swarf or other foreign matter has been
thoroughly flushed out of the oil supply lines.
DH2 pumps do not have an integral filter.
12.6.3.3 Oil Re-Circulation
When supplied for use on heavy oil
installations all `DH` series pumps are fitted
with a restrictor with a 4mm diameter orifice
fitted between the oil inlet and ring main
return ports.
This allows the flow of oil to circulate from
the ring main system, through the flexible oil
lines and pump and into the ring main return,
effectively keeping both the pump and the
flexible oil lines warm, eliminating the need
for lagging and trace heating.
The pumps can be fitted with restrictors with
a larger orifice size, but care must be taken
when fitting these that the re-circulation does
not depress the ring main capacity as this is a
direct bleed between the flow and return.
D R IV E M O T O R
PUMP
12.6.3.4 DH (P) Fuel Pumps ( Light oil)
H O U S IN G
PUMP FLANGE ADAP TOR
AND SCREW S
C O U P L IN G A N D S E T S C R E W S
C O U P L IN G IN S E T
TYPICAL ARRANGEMENT OF PUMP, MOTOR AND DRIVE COUPLING
June 13
All `DH` series pumps with the prefix `P` are

fitted with a manifold on the oil return port
that allows a flow of oil back into the return
while the burner is `purging`.
This allows the pump to automatically prime
itself every time the burner goes through its
starting cycle and eliminates the need for
mechanical
venting.
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TD5 Manual Rev 4
12.6.4 Fault Finding

Symptom or Fault
Probable Cause
Pump motor runs, but no oil delivered.
Pump coupling loose on either pump side or motor side.
Fuel starvation.
Oil system air locked.
Pump seized.
Pump shaft broken.
Burner solenoid valves not opening.
Blocked atomising nozzle.
Fuel starvation.
Gas or air in pump
Pump worn.
Blocked line filters.
Insufficient pressure in pumped ring main to suppress

gas formation in the suction side of the pump.
Dirt in regulating valve.
High vacuum at pump suction.
Fuel starvation.
Worn pump.
Pump drive slipping.
Air leakage into the system.
Pump undersized.
Pump worn.
Defective solenoid valve.
Oil starvation/defective metering system.
Regulating valve stuck.
Pump oversized.
Miss-alignment of pump drive.
Dirt in oil.
Pump rotates but no oil passing from nozzle.
Pump noisy.
Fluctuating Oil Pressures.
Low Oil Pressures.
Pump Overheats.
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12.6.5 Oil Flow Diagrams
ROTATION
ROTATION
OIL RETURN
OIL UNDER PRESSURE
OIL UNDER SUCTION
PLAN VIEW
PLUG OR VACUUM GAUGE
PLAN VIEW
PLUG OR PRESSURE GAUGE
PRESSURE REGULATOR
OIL OUTLET TO NOZZLE

PLUG OR SUCTION RETURN
PLUG OR SUCTION RETURN
OIL INLET
" B.S.P.P.
ALTERNATIVE OIL INLET
OIL INLET
" B.S.P.P.
OIL FLOW DIAGRAM FOR TYPE DH1 FUEL PUMPS
ROTATION
ROTATION
OIL RETURN
OIL UNDER PRESSURE
OIL UNDER SUCTION
PLAN VIEW
PLAN VIEW
RETURN FROM BURNER

SHOWN OUT OF POSITION
FOR CLARITY
RETURN FROM BURNER

FOR CLARITY
PRESSURE REGULATOR
PLUG
OIL RETURN
PLUG
OIL INLET
OIL INLET
OIL RETURN
OIL FLOW DIAGRAM FOR TYPE DH1 (P) FUEL PUMPS
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TD5 Manual Rev 4
ROTATION
ROTATION
OIL RETURN
OIL UNDER PRESSURE
OIL UNDER SUCTION
PLAN VIEW
PLAN VIEW
PRESSURE REGULATOR

PLUG OR
SUCTION RETURN
PLUG OR
SUCTION RETURN
OIL INLET
" B.S.P.P.
OIL INLET
" B.S.P.P.
OIL FLOW DIAGRAM FOR TYPE DH2 FUEL PUMPS
ROTATION
ROTATION
OIL RETURN
OIL UNDER PRESSURE
OIL UNDER SUCTION
PLAN VIEW
PLAN VIEW
RETURN FROM BURNER

FOR CLARITY
RETURN FROM BURNER

FOR CLARITY
PRESSURE REGULATOR
PLUG
OIL OUTLET
PLUG
OIL INLET
OIL INLET
OIL OUTLET
OIL FLOW DIAGRAM FOR TYPE DH2 (P) FUEL PUMPS
June 13
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TD5 Manual Rev 4

litres/Hr
3000
kW 4
DH2-2
NOTES
DHO-1
3
2000
DH2-2
DH2-1
1000
DH1-1
DH2-1
0
0
DH1-2
DHO-1
10
20
30
DH1-1
DHO-1
40 bar
NOZZLE CAPACITY
SINGLE STAGE PUMPS 2850 RPM
0
0
10
15
20
25
30
35
40
bar
TYPICAL POWER CONSUMPTION 1425 RPM
litres/Hr
2500
kW
8
DH2-2
2000
DH2-2
7
1500
DH2-2
DH2-1
1000
DH1-2
500
DH1-1
4
DH2-1
DHO-1
0
0
10
20
30
40 bar
DH1-2
NOZZLE CAPACITY
SINGLE AND TWO STAGE PUMPS 1425 RPM
DH2-1
2
DH1-1
litres/Hr
5000
DHO-1
1
DH2-2
4000
0
0
10
15
20
25
30
35
40
bar
TYPICAL POWER CONSUMPTION 2850 RPM
3000
2000
DH1-2
LEGEND
1000
10 cSt at 80C
3.5 cSt at 40C
0
0
10
20
30
40 bar
1-2 cSt at 40C

NOZZLE CAPACITY
TWO STAGE PUMPS 2850 RPM
June 13
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TD5 Manual Rev 4
DUNPHY COMBUSTION LTD

QUEENSWAY ROCHDALE ENGLAND OL11 2SL
Tel +44 (0) 1706 649217
Fax: +44 (0) 1706 655512
Internet http://www.dunphy.co.uk
June 13
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DUAL FUEL BURNERS

TD5 Manual Rev 4

emergency stop information added - section 5.9,

TD5 Manual Rev 4

`TD` SERIES DUAL FUEL BURNERS

TD5 Manual Rev 4

General Information ...................................................................................................................................... 7

TD5 Manual Rev 4

6.2.1 RWF 40.000A97 Default Burner Settings ................................................................................. 54

TD5 Manual Rev 4

General Description......................................................................................................................... 118

TD5 Manual Rev 4

BOILER EFFICIENCY DIRECTIVE

Please give the burner serial number when requesting information.

It is essential that appliance and burner combinations are correctly matched.

TD5 Manual Rev 4

Ring Main Pumps

TD5 Manual Rev 4

Oil Line Connections

Each T series burner is constructed from 5 separate castings described as follows:

TD5 Manual Rev 4

TD5 Manual Rev 4

Air Inlet Silencer

Typical Acoustic Shroud

Burner fitted with 'Snorkel' Silencer

TD5 Manual Rev 4

Burner details and power curve

*1 Based on Nat Gas C.V 10.4kW/m3

FIRING MODE OPTIONS

TD5 Manual Rev 4

General arrangement detail

Electronic modulation burners (M RT)

Electronic modulation burners are fitted with on/off gas valves

TD5 Manual Rev 4

TD5 Multi Fuel Low Nox Burner General Arrangement

TD5 Manual Rev 4

TD5 Manual Rev 4

Gas Valve mounting

The Unibloc gas valve is

TD5 Manual Rev 4

VGD Gas Valve Orientation

Fit governor in accordance with manufactures instructions.

TD5 Manual Rev 4

Burner fitted with Siemens VGD40 gas valve

The Siemens gas valve is a heavy item

TD5 Manual Rev 4

Fuel oil installations

Oil burning equipment

OIL INLET FLEXIBLE

OIL INLET FLEXIBLE

OIL RETURN FLEXIBLE

OIL RETURN FLEXIBLE

TD5 Manual Rev 4

TD5 Manual Rev 4

TD5 Manual Rev 4

Combustion Head Settings

TD5 Manual Rev 4

TD5 Manual Rev 4

TD5 Manual Rev 4

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