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INSTRUCTIONS
CS BURNER
FOR GK BOILER
998-9908-00
. MIURr:\
ZBOILER
Operation Manual
Introduction
This operation manual contains instructions for sale, proper use of the CS burner for marine use built in the
boiler. Prior to using the system, be sure to appoint an operation supervisor (engineer), then read and under-
stand the manual thoroughly. To carry out all of the operations with the manual at hand is recommended.
This operation manual gives an overview of the CS burner for marine use, its main functions, operating the pro-
cedures, safety inspections and trouble shooting. Consult the, operation manual of the boiler for operating
equipment that is not described in this manual.
The operating methods and the safety precautions included in this manual are to be used for only specified
purposed. Do not operate the system in any other manner. We are not responsible for any consequences due
to misuse of the system.
Because of our continued efforts to improve the design of the GK boiler, some details in this manual may differ
from those of your system. Be advised that the contents are subject to be changed without prior notice.
For any questions on your system or the contents of this operation manual, please feel free to contact us any-
time.
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TABLE OF CONTENTS
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1. Terminology
Follwing guide words and used in this manual for your safe,eflicient operation.
~ WARNING
i Indicates and condition for practice which may cause death
or serious injury to the operator if not observed.
~ CAUTION
i Indicates and condition or practice which may result in
damage or destruction of the property and/or minor per-
sonal injury.
NOTE
i The cautions of prevent the failure of the devices,and the
tips for effective opration are show with the guide word
11
11
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Here is a list of special terms used in this manual. Make sure of the terms and their meanings.
Term Meaning
To periorm ventilation inside the combustion chamber of the boiler before combus-
Pre-purge
lion.
Low combustion
High combustion
Combustion at approximately 50% of maximum combustion capacity.
Water Cleaning To clean the boiler body with water to remove soot.
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2. Warning Labels
,&. WARNING
The following label plates are placed in selected locations of the GK Boiler main unit and its accessories.
2. Catch Warning Plate · · · · · · · · · · · · · · · Placed on moving and spinning parts with openings, where
fingers may get caught if not careful.
3. Electric-Shock Warning Plate · · · · · · · · · · Placed in areas where complete insulation (or coverage)
is not provided, or such surroundings.
4. Crush Warning Plate . . . . . . . . . . . . . . . Placed where moving parts exist; the same definition
applies as with the catch warning plate.
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6 WARNING
When operating the GK Boiler, the safety precautions described in the operation manual must be strictly
observed. Neglecting these items may result in serious bodily injury to an operator.
2-
safety precautions indicated in the manual. Furthermore, he/she should not operate the system or perform
any maintenance procedures until the contents of the manual are completely understood.
Wear appropriate clothes and safety equipment
When operating or maintaining the system, avoid any loose clothing or any tangling of accessories that may
•
be caught by valves and other machine parts. Do not wear oil-stained clothing, since it may catch fire easily.
Depending on the nature of the operation, wear a helmet, goggles, safety shoes and gloves. When operating
around a high-temperature area, wear safety clothing to avoid accidental burns.
Be sure to wear goggles and gloves during chemical injection because chemicals may spatter onto your
hands or eyes.
3· Do not modify the system
Do not modify the system without authorization from us. Be sure to use genuine parts and chemicals of the
manufacture.
4- Use only the specified fuel.
Using fuels other than specified fuel may cause explosion.
5- Keep any combustibles clear of the boiler.
Do not place combustible items in the vicinity of the boiler, since they may catch fire. It is extremely danger-
ous to expose Boiler fuel to fire, since it may ignite. Store combustibles in a safe place where there's no dan-
ger of fire. Also, verify the locations and proper use of fire extinguishers in preparation for an emergency.
•
'
Dispose the fuel and oil-stained properly. Improper storage may cause spontaneous combustion.
Wipe up the spilled fuel and oil immediately.
6- Fire extinguisher and first-aid kit
Install a fire extinguisher in preparation for fire. Be sure to understand its proper use. A first-aid kit must be
kept at a predetermined location. Emergency procedures must be in place for cases of fire or accidents.
7- When re-installing or selling the Boiler
To operate the Boiler properly, the system must be correctly installed and prepared.
Be sure to contact us before reinstallation or selling the system.
Improper installation and preparation may lead to bodily injury.
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1) Nozzle Tip
2) Baffle Plate
3) Shroud
4) Spark Rod
5) Nozzle Pipe
6) Lead Rod
7) Upper Plate
1) Nozzle Tip
This nozzle atomizes and sprays the fuel.
*Handle with care since nozzle tip is a precisely machined. I
2) Baffle Plate
It performs flame maintenance for stable combustion.
3) Shroud
It contains the spark rod and rectifies combustion air.
4) Spark Rod
It performs ignition with high-voltage spark at the end.
5) Nozzle Pipe
It supplies the fuel oil to the nozzle tip, and simultaneously performs heating by circulation oil.
6) Lead Rod
It connects between ignition transformer and spark rod.
7) Upper Plate
Lock a nozzle pipe to the boiler.
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ON-OFF r.nntrnl
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4.4 Blower
The blower which sends air to the burner rotates the impeller with a motor to secure the air pressure and
flow rate.
CD
I
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®®
No. Names
1) Flame Eye
2) Flame Eye Fitting Box
3) Flame Eye Fitting Stand
4) Protection Glass
5) Packing
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Pnmary stde
AC 100V
......
...
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I
fuel oil
(heavy oil grade)
1)
2)
3)
Pilot Solenoid Valve
Pressure Gauge
4)
5)
6)
Low Combustion Solenoid valve
The supplied fuel oil flows into main combustion nozzle after adjustment of combustion flow rate
with the fuel oil flow control valve.
Excessive fuel oil returns to the fuel pump unit through the nozzle pipe.
Fuel oil such as diesel oil grade is independently supplied to the pilot burner for ignition, and is
sprayed from the pilot burner nozzle after passing the pilot solenoid valve.
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NOTE
Time chart may differ depending on the specifications of the boiler. Consult the final drawing of the boiler for
details.
lime Chart
Comb.S.W.
Heater -
F.O. Pump
Circulation S.V.
-
Dfafl Fan
::10 ec. Osee. 35sec. 30sec. 10sec. 35sec.
Ignition Trans
Pilot F.O. Pump
PilotS.V.
" " '" '""· J
Low Comb. S.V.
9sec.
""·
...
I 30sec. b
Damper(High Comb.) r-l ---r_
Flame Eye
Steann Pressure S.W.
(High Comb.)
Stearm Pressure S.W.
(low Comb.) • Above chart shows 3 position step burnner
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Start up I
1. Inspection and preparation are required prior to operation.
Check the following items prior to operation of the burner.
1) Turn ON the main power switch of the boiler.
it WARNING
I
Avoid handling with wet hands, which rnay cause electrical shock resulting injury and/or death.
2) Open the fuel main valve of the oil tank after making sure that there is sufficient fuel oil in the
service oil tank.
3) Check the fuel leakage of the piping
4) Rotate handle of the oil strainer several times to remove stuck dirt from the strainer. The handle can
be rotated in either way.
2. Push the combustion button.
After pre-purge, ignition working is performed and main combustion starts.
(In three-position step control, ignition working is switched to high combustion through low
combustion.)
1) Make sure that no black smoke or no white smoke emits from the chimney.
2) Make sure that there is nothing wrong with the sound of blower and damper.
3) Make sure that no extreme vibration and no abnormal indication of the oil pressure gauge can
be found.
4) Make sure that there is no fuel leaking from fuel pipe.
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I Shut down I
1. Turn OFF the combustion switch.
The combustion lamp will be went off.
Then post-purge will be performed.
6 CAUTION
Operation of the fuel main valve should be performed with only fuel main valve of the oil tank.
Closing valve other than the fuel main valve of the oil tank may cause damage of the machine and fuel leak-
ing since oil in the fuel pipe expands with the heat radiation of the boiler after the boiler stops.
During heavy oil operation, the operation of oil pump and fuel oil heater, and steam trace should be contin-
ued even if combustion is stopped. These equipments can not be re-started with congealed oil in the fuel
pipe if stopped.
Before stopping the boiler, Heavy oil must be changed to Diesel oil completely.
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•
3. Check the set pressure with a pressure gauge mounted on the side of the flow control valve.
4. Remove the adjust screw cover at the top of the flow control valve when the specified pressure is
different from the standard set pressure.
5. Unscrew locknut
6. Adjust the pressure to the standard set pressure by turning adjust screw.
Turn clockwise the screw to increase pressure and combustion flow.
Turn counterclockwise the screw to decrease pressure and combustion flow.
7. Make sure again that pressure is the standard set pressure, and tighten the locknut.
B. Put the cover sr.rP.w_
t
To pump suction side
cap
) I
-l I
-r- 11
I IJ
I
H ~ 1
\ \ pressure adiusling bolt
It
Pressureizd fuel oil from the fuel oil pump
lock nut
& WARNING
Wear safety equipment during operation to avoid burn when fuel oil temperature is high. The defective of
combustion and explosion may occur by malfunction of combustion adjustment. If you decide that combus-
lion adjustment is necessary, contact maintenance staff of our company first, and follow the directions.
NOTE
Field adjustment of the flow control valve is not necessary because the flow control valve is preadjusted at
the factory. However the flow control valve will require readjustment due to parts replacement of flow control
valve. In that case, Previous pressure adjustment by diesel oil is recommended. Changing to heavy oil
after the pressure adjustment by diesel oil operation makes little differences in set pressure.
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2) Damper Adjustment
2. To operate the burner follow the steps as, "Start up" of operation method. See page 10 ~
3. Af1er the combustion gets stable, you should adjust the opening of the damper measuring exhaust
gas oxygen (or C02) con tent, and lock it with locknut tightened in the proper combustion.
Adjust screws for adjustment depends on burner control specification as listed below.
• Setting up the damper adjustment of pilot combustion only is not necessary with the CS burner.
The damper adjustment of main combustion is only needed.
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Do not fail to carry out periodic inspection and cleaning as listed below in order to use the burner for a long
period and to take precautions against possible troubles.
Standard schedule for inspection and cleaning are listed below, however, the number of times of inspection
and cleaning varies with such working conditions as combustion period or properties of fuel oil. Please set
the appropriate number of times by working conditions of the veddel.
(Follow the instructions of person in charge of maintenance in our company.)
Regular Maintenance
dairy
Page Described
19
•
Checking of the combustion conditions dairy 19
•
Cleaning the flame eye-glass monthly 24
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NOTE
Check of the fuel oil pressure should be executed during oil pump operation. Accurate check of the fuel oil
pressure can not be done unless the oil pump is running.
~ WARNING
Do not touch since each part becomes hot while the boiler is running. It may cause burn.
2. Make sure the oil pressure gauge indicates
standard point.
The standard point of fuel oil is 1.BMPa
(1 Bkg/cm'), during the combustion.
~WARNING
In case of know or suspected problem of the oil pres-
sure gauge, stop operation immediately and contact
us.
To continue operation without resolving the problems
of the oil pressure may cause serious accident result- oil pressure gauge
ing in injury or death due to damage of the boiler.
~WARNING
In case of found black or white smoke, stop operation
immediately and contact us.
To continue operation without resolving problems in
combustion may cause accident resulting in injury or
death due to damage of the boiler.
~ CAUTION
There is no problem if white smoke emits during the
pilot burner operation.
Checking of the combustion condition should be done
during main combustion.
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& WARNING
Operation must not be made until the boiler gets cooled completely. Each part of the boiler becomes high
temperature, which may cause a burn.
& WARNING
Avoid handling the main switch with wet hands that
may cause electrical shock, resulting in injury & death.
3. Open the cap of the Y shaped oil strainer with main switch main valve of the oil tank
a wrench.
filter
brush
& WARNING
Packing needs replacing whenever overhaul at every
~cap
maintenance. Seal packing used for CS type burner
is made of special materials; thus genuine parts
should be used.
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Lh WARNING
Operation must not be made until the boiler gets cooled completely. Each part of the boiler becomes high
temperature, which may cause burn.
Lh WARNING
Avoid handling the main switch with wet hands, which
may cause electrical shock resulting in injury and/or
death.
NOTE
Utilizing 2 wrenchs, the copper pipe can be removed
without any damages.
Receive a little amount of oil coming out of the copper
pipe into a vessel.
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NOTE
Keep the burner in upright position to avoid oil leaking
of nozzle pipe until drain the remains of oil out.
nozzle pipe
Receive the oil from nozzle pipe into a vessel during
turning the burner sideways.
NOTE
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NOTE
Care must be taken to clean up the end of nozzle tip
to avoid being covered with soot or dirt.
& WARNING
The nozzle tip should be replaced if any damage is
found. nozzle tip
Usi ng with defective tip may cause fire and explosion
spark rod
due to fuel leaking.
NOTE
Care should be taken to set spark rod. It will be bro-
ken if locked too tightly, and will slip if locked too
loosely when ignition code is pulled.
(mm)
14. Assemble in the reverse procedure of remov-
ing to reassemble all parts.
for three-position
15. Make sure that copper pipe union and flexible for ON-OFF control
step burner
hose joints are tightened completely. circulation outlet
& WARNING
~upper view
•
upper view -
0-;;0
c o :;·
:::!.:JO
(!) c
'!l
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& WARNING
Avoid handling the main switch with wet hands, which
may cause electric shockal resulting in injury or death.
set screw
packing
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& WARNING
Be sure to understand the method thoroughly before cleaning of the wore blower.
& WARNING
Operation must not be made until the boiler gets
cooled completely. Each part of the boiler becomes
high temperature, which may cause a burn.
Avoid handling the main switch with wet hands , which
may cause an electrical shock.
Always disconnect all electrical power at the main cir-
cuit breaker before performing inspection and/or
maintenance.
If failure to disconnect the power so could cause main power
slashing wounds that will result in serious injury or
death.
blower
air suction wire mesh
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8. Trouble Shooting
& WARNING
Always disconnect all electrical power at the main circuit breaker of the Boiler and then observe the speci-
fied procedures of each item for proper operation.
If problems can not be resolved after executing specified repairs, be sure to stop the boiler immediately and
contact our company.
No operation not specified may be attempted. Otherwise an accident resulting in injury or death may occur.
Page
Problem Causes Corrective actions
described
Alarm is given during purge
Flame eye detects a resid- Make sure that flame eye is 11
after pushing the combustion
ual flame. mounted correctly. 24
button.
Fan does not run even after Make sure that combustion starts
Steam pressure rises up to
pushing the combustion but- after steam pressure reaches 13
set pressure.
tom. below set point.
5 Open the fuel main valve of D.O.
::J 12
Pilot fuel is not supplied. tank to check pilot fuel supply
""i5" 14
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c
ro
Speak leaking of ignition
pressure.
Clean the spark rod and make
sure that the spark rod is mounted
21
I
device. 23
in the right dimension.
No firing at all.
Defective pilot solenoid
Replace the pilot solenoid valve. 9
valve.
21
Dose not change to Defective nozzle tip. Replace the nozzle tip. I
main after pilot. 23
.
Page
Problem Causes Corrective action
described
Defective high combustion Replace the high combustion noz- 21
nozzle tip. zle tip.
I
23
Main combustion can not go Defective main high com- Replace the high combustion sole-
9
from low combustion to high bustion solenoid valve. noid valve.
combustion. Too much air in high com-
Adjust the damper. 17
bustier.
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Page
Problem Causes Corrective actions
described
9. Supplement
9-1 Heavy oil heating temperature chart
fuel oil temperature
Heating of the fuel oil depending on the fuel properties for use is necessary to keep proper combustion.
Set point of the heater of our boiler is previously set during commissioning test. Re-set to a proper supply temper-
ature according to the figure below if the fuel oil is changed.
~ CAUTION
CS burner sense the oil temperature at the first combustion after pressing combustion switch, and
combustion will be on the alar! if the oil temperature is low.
If the oil temperature will not increase combustion shift will not occur. Check the fuel oil temperature at
the first combution.
28
--------------------------~ ------------·&----~ .. ..
Heavy oil heating temperature chart
Temperature oF
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170180190200210220230240250260270280290
I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I
100.000
50.000
How to obtain heavy oil heating
30.000
20.000
""'\.
' '"...... temperature
1. Obtain the viscosity of the oil to
~ "'\. pointat50'C.)
5.000
4.000
3.000
2.000
1"'\.
' 1'\.
~
"
2. From the viscosity, draw a line
parallel to the viscosity Item-
perature diagram and obtain the
crossing point with 60 seconds.
3. From the crossing point, draw a
...... ~
1.500
1.000
'" 1\.. l'~
vertical line to obtain the heat-
Ing temperature.
4. Set the temperature 10'C to
~
750
500
"' " 1\.. '\ ~.
20"C higher than the heating
temperature.
(Example) : When the heating
...... ~ '-'· temperature of fuel of 1500 sec
400
' ,,
at RW No.1 100F is obtained
1\)
Redwood
No.1
300
250 '" '
~ according to the dotted line,
around 103'C is the optimum
' ..
......
1"'-
~ L...
~
- tip of the burner end
Optimum atomizing viscosity
~ :
55
:
50
"' N.. "'~
45
40
' I"' _I
I
1\.I"'
~ I
35
~ ...1.
I_ I _I_ I_ I I I I ~ I_
-40 -30 -20 -10
.'.
50
I_
~- I I I I I I I
0 10 20 30 3840 60 70 80 90 100 110 120 130 140
Temperature oc
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/ Tip Orifice
i
Main Body
i
Screw Pin
i
Filter
Distributor
Body
1/Jv
&r;:r - Screw Pin
The nozzle tip is used to atomize fuel oil as neces- rotates in the rotary chamber, increases its velocity,
sary. Oil pressurized by the fuel pump passes and is sprayed into the combustion chamber through
through the fuel heater and solenoid valve and reach- the orifice. Since the nozzle is machined precisely, it
es the nozzle. Pressure is converted to velocity in should be handled carefully. At the same time oil
the tip and oil is brough in contact with air at a suffi- wears the orifice and other parts with its high pres-
cient velocity. Oil sent to the nozzle enters the rotary sure and velocity, and so hard materials are used for
chamber through the strainer (except a large capacity this application. However, replace the orifice approxi-
tip) and fine grooves of the distributor. This rotary mately once every six month or so.
chamber is conical and has an orifice at the tip. Oil
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,-----------------------------------------------------------------=~
Head Office:
.- '
;
1
Miura Co., ltd.
Marine Boler Division 7,HORIE-CHO,MATUYAMA-SHI,
EHIME, 799-2696 JAPAN TEL: ( +81 )89 979 7066
FAX: (+81 )89 979 7067
Authorized Distributors
' N. Y.Co.,Ltd. 1-4-26,Takanawa Minato-ku,Tokyo TEL: (+81)3 3449 3821
FAX: (+81)3 3440 0944
Koyo Co., ltd. 2-27,Minaminakamachi Hyogo-ku,Kobe TEL: (+81)78 681 5411
FAX: (+81)78 681 6567
Chuo machinery Co.,Ltd 22,yata Honmachi,Nakagawa-ku, TEL: (+81 )52 363 4645
Nagoya FAX: (+81)52 383 3607
OVERSEAS NETWORK
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