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Service Manual
Revised October 26, 2016
1
15 PSI
Pressure Relief Valve
Low Water
Cut Off
Water Level
Sensor
Steam Valves
Steam Pressure
Sensor 1
Operating Pressure
Limit Switch
Steam Pressure
Gauge
High Pressure
Limit Switch
Steam Pressure
Sensor 2
Steam Purge Valve
Boiler Water
Temp. Sensor
Water Purge Valve
Flue Temp. Sensor
Boiler Door
Temp. Sensor
Furnace Sight Glass
Circulation Water Pump
Boiler Water
Sight Glass
Feed Water Pump
Feed Water
Temp. Sensor
Feed Water Valve
Boiler Drain Valve
2
Air Flow Switch
Gun Assembly
Burner Cone
Fuel Nozzles
Fuel Pump
Fuel Pressure Gauge
Louver Actuator
Fuel Pressure Sensor
3
IR Flame Sensor
Ignition Transformer
Control Switch
Fan Motor
Ignition Electrode
Propane Regulator
Fuel Valves
Propane Valve
Propane Pressure Sensor
4
6210
Panel 1
5
6210 Panel 2 & 3
6
24 VDC to C-more Touch
24 VDC to Discrete Outputs, all
Analog Sensors, Safety Relays
24 VDC to all PLC Input and
Output Cards
24 VDC to Ethernet Switch
24 VDC Power to PLC
12 VDC to 24 VDC Power
Converter
24 VDC to fuse 6
(1.5) C-More Touch Screen
12 VDC to ON/OFF Switch on
(0.5) Position Switches
24 VDC to Louver Actuator
(1.5) Screen
(2)
(2)
(2)
(1.5)
(5)
(15)
(2)
Work Lights
12 VDC to 12 VDC Power
(15)
Converter
12 VDC Generator Start/Stop
(15) 12 VDC to all Valves and
(5) Louver Actuator
(5) Feed Water Valve
(5) Blow Down Valve
(5) Steam Purge/Manifold Drain
(5) Steam Valve 4
(5) Steam Valve 3
(5) Steam Valve 1
(5) Steam Valve 2
Note: All fuses are Buss Type
AGC-5-R
Fuse Labels
F1 F2 F3 F4 F5 F6 F7 F8
Note: All fuses are Buss Type AGC-(Amp Rating)-R
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
7
8
C-More Touch Screen Power Diagram
9
Safety Circuit Diagram 1
This 24 VDC provides the safety relays with
the 24 VDC power for the signal to the PLC.
It is jumpered from Air Flow Switch through
Control Power.
2
9
A1
A2
9
A1
A2
9
24 VDC Signal to PLC X6
A1
A2
9
A1
A2
9
A1
A2
9
24 VDC Signal to PLC X7
24 VDC Signal to PLC X5
5
Burner
Relay
5
A1
A2
9
Air Flow
Switch
5
Fan VFD
24 VDC Signal to PLC X3
24Signal
VDC Signal
to PLC
to PLC
X0X4
24 VDC Signal to PLC X2
A1
A2
5
OPLS
24 VDC Signal to PLC X1
5
HPLS
5
Control
Power
5
Low Water
2
120 VAC to Safety Relays
Low Water
1
Burner Control
Switch
24 VDC Signal to PLC X0
24 VDC to Safety Relays
1
The safety relays are used to tell
the PLC the state of each safety
device. Each device recieves its
power at (A1) on the relay before
it. When the switch inside a safety
device closes it provides
120 VAC to the safety relay which
closes the relay sending a 24 VDC
to the PLC to indicate the safety
switch is closed. It also provides the
Power supply to the next safety
device.
3
When the "Burner On/Off" switch on the control panel
door (Above) is turned on, it introduces 120 VAC power
into the safety circuit.
5
OPLS and HPLS are normall closed. they
open when steam pressure reaches their
set point. OPLS=14 PSI, HPLS=15 PSI.
Power cascades down the chain through each safety
device through the Black, Grey, Blue, and Orange circuits
to the right.
LWCO 1
LWCO 2
4
LWCO 1 and LWCO 2 are normally open.
They close when probes contact water
in the boiler. (See "Low Water Cut Off"
diagram for more detail.)
12 VDC Power
24 VDC to all 24 VDC Components
+12 VDC power from Battery
-12 VDC from Battery
24 VDC Power
12 VDC to 24VDC Power Converter
_
+
Ground
+12 VDC from Relay
+12 VDC Supply to Relay
When 12 VDC
power is applied
to (86) The
contacts close
between (30)
and (87) to
provide 12 VDC
power to the
system
+12 VDC from Battery
-12 VDC from Battery
24 VDC to Safety Relays
<1 1<
<2 2<
<3 3<
<4 4<
10
Safety Circuit Diagram 2
This 24 VDC provides the safety relays with
the 24 VDC power for the signal to the PLC.
It is jumpered from Air Flow Switch Relay
through the Control Power Relay.
2
24 VDC to Safety Relays
13
9
24 VDC Signal to PLC X5
24 VDC Signal to PLC X6
5
5
5
5
24 VDC Signal to PLC X7
24 VDC Signal to PLC X3
24 VDC Signal to PLC X2
5
24Signal
VDC Signal
to PLC
to PLC
X0X4
24 VDC Signal to PLC X1
5
A1
A2
9
A1
A2
9
A1
A2
9
A1
A2
9
A1
A2
9
A1
A2
9
9
A1
A2
9
Air Flow
Switch
Burner
Relay
A1
A2
Fan VFD
OPLS
HPLS
Low Water
2
Control
Power
CR 1
14
CR 2
5
12
5
5
Low Water
1
8
24 VDC Signal to PLC X0
120 VAC from Burner Relay to Safety Relay Chain
120 VAC from OPLS to Burner Relay
When CR 1 receives a 120 VAC
signal from the Honeywell
Burner Controller on (14),
Contacts close between (12)-(8)
and (9)-(5) on CR1. (12)-(8)
sends a 12 VDC signal to (2) on
the VFD to start the fan. (9)-(5)
sends 120 VAC to the Air Flow
Switch and to the VFD relay in
the safety chain to tell the PLC
that the VFD has been started.
1
The safety relays are used to tell
the PLC the state of each safety
device. Each device recieves its
power at (A1) on the relay before
it. When the switch inside a safety
device closes it provides
120 VAC to the safety relay which
closes the relay sending a 24 VDC
to the PLC to indicate the safety
switch is closed. It also provides the
Power supply to the next safety
device.
Honeywell
Burner Control
Air Flow Switch
3
Once power has progressed
to the OPLS, the PLC turns
on the burner relay which sends
a 120 VAC signal to (6) on the
Honeywell that it is safe to start
the burner. The Honeywell sends
a 120 VAC signal out to the CR1
to start the fan on (5).
1 1 1 1 2 2 2 2 2 2 3 5 5 6 6 7 7 8 9 10 11 12 13 14 14 14 15 16 17 18 19 20 21 22 23 24
Once the fan starts and the Air
Flow Switch closes the Honeywell
receives a 120 VAC signal on (7)
that it is safe to procede.
6
120 VAC from Air Flow Switch
120 VAC to Air Flow Switch
12 VDC
Common Ground
12 VDC to CR1
12 VDC From CR1
120 VAC from OPLS (See Safety Ciruit Dagram 1)
VFD
1
2
5
6
11
12
2
14
13A
13B
13C
15
25
2
30
31
TXA
TXB
LWCO 1
LWCO 2
12 VDC Power
24 VDC to all 24 VDC Components
+12 VDC power from Battery
24 VDC Power
12 VDC to 24VDC Power Converter
_
+
-12 VDC from Battery
Burner Control
Switch
5
Whenever the VFD is supplied
with 240 VAC current, which
is any time the generator is
running, the Blu/Blk wire from
(14) on the VFD should be
supplied with 12 VDC power.
this closes the contacts
between (9) and (5) on CR 2
wich provides 120 VAC, through
the Blue wire, to (9) on CR 1
Ground
+12 VDC from Relay
+12 VDC Supply to Relay
When 12 VDC
power is applied
to (86) The
contacts close
between (30)
and (87) to
provide 12 VDC
power to the
system
+12 VDC from Battery
-12 VDC from Battery
24 VDC to Safety Relays
<1 1<
<2 2<
<3 3<
<4 4<
4
11
LWCO Diagram
2
The red wire below provides the safety relays with the
24 VDC power for the signal to the PLC.It is jumpered
from Air Flow Switch through Control Power.
The yellow wires below are the 24 VDC signal from the
PLC to the Low Water 1 Test and Low Water 1 Reset
7
24 VDC to Low Water 2 Reset
24 VDC to Low Water 1 Test
Ground
24 VDC to Safety Relays
11
5
5
5
5
5
5
A1
A2
9
A1
A2
9
9
A1
A2
9
A1
A2
9
9
A1
A2
Low Water
2 Reset
Air Flow
Switch
Fan VFD
A1
A2
Low Water
1 Test
HPLS
A1
A2
OPLS
1
Burner
Relay
3
5
Low Water
2
Control
Power
120 VAC to Safety Relays
When the "Burner On/Off" switch on the control panel
door is turned on, it introduces 120 VAC power into
the safety circuit.
5
Low Water
1
The safety relays are used to tell
the PLC the state of each safety
5
device. Each device recieves its
power at (A1) on the relay before
it. When the switch inside a safety
device closes it provides
120 VAC to the safety relay which
closes the relay sending a 24 VDC
A1
A2
to the PLC to indicate the safety
switch is closed. It also provides the 9
Power supply to the next safety
device.
Burner Control
Switch
A1
A2
9
A1
A2
9
9
6
Low Water 1 Test is
normally open. when it
receives 24 VDC from
the PLC on (A1),
contacts close between
(9) and (5) to simulate
a Low Water 1 fault.
Low Water 2 Reset is
normally closed. When
it receives 24 VDC from
the PLC on (A1),
contacts open between
(9) and (1) to reset
LWCO 2.
Power cascades down the chain through each safety
device beginning with Low Water 1 and Low Water 2
4
Black and Grey wires
carry 120 VAC to and
from LWCO relays
3
4
5
_
+
The LWCO sensor relays detect
water in the boiler by sensing
resistance between the probe
which is connected to (6) and
ground which is connected at
(5). When resistance is detected,
contacts close between (1) and
(10). This closes the circuit for
this link in the safety chain and
sends 120 VAC power to the
safety relay in the safety chain.
(See #1 above)
(See "Safety Circuit Diagram
1" & "Safety Circuit Diagram 2")
2
1 11
10
LWCO 1
5
6
7
9
3
8
4
2
1 11
10
LWCO 2
5
6
7
9
8
8
(7) and (8) on LWCO 1 are connected to
Low Water 1 Test relay which is a normally
open relay. Since this is a normally open
circuit LWCO 1 will automatically reset once
water is detected after a Low Water 1 fault
If the relay is closed it will cause the
contacts between (1) and (10) to open
simulating a Low Water 1 fault.
12 VDC Power
e
-12 VDC from Battery
+12 VDC power from Battery
24 VDC Power
24 VDC to all 24 VDC Components
(See relays above for more details.)
12 VDC to 24VDC Power Converter
(7) and (8) on LWCO 2 are connected to
Low Water 2 Reset relay which is a normally
closed relay. If there is a Low Water 2 fault,
the circuit between (7) and (8) must be
broken to reset the relay. Water must be
detected when the relay is reset, otherwise
the Low Water 2 fault will return immediately
Ground
+12 VDC from Relay
+12 VDC Supply to Relay
When 12 VDC
power is applied
to (86) The
contacts close
between (30)
and (87) to
provide 12 VDC
power to the
system
+12 VDC from Battery
-12 VDC from Battery
24 VDC to Safety Relays
<1
<2
<3
<4
1<
2<
3<
4<
12
Louver Actuator Diagram
Mod-Bus Connection from Honeywell to PLC
120 VAC power supply to high fire and low fire switch relays
Normal Opera�on
120 VAC from low fire switch relay
120 VAC from high fire switch relay
The “Louver Actuator”controls how far the air louver will open which controls the amount of air flow
through the burner. The Louver Actuator works in connec�on with two separate control systems in the
burner,the “PLC”and the “Honyewell Burner Controller”. The PLC controls the ac�on of the Louver Actuator.
The Honeywell Burner Controller is a safety device which confirms that all func�ons are being carried
out safely and correctly. There are two separate systems inside the Louver Actuator which interact with
these two control systems. The 4-20 mA signal and the 12 VDC power work together with the PLC to
open and close the louver to the correct posi�on. The 24 VDC power runs through posi�on switches
which communicate with the Honeywell Burner Controller to verify that the purge cycle was completed
correctly.
During normal opera�on, when the burner state is “Run,”the PLC controls the opening and closing of
the actuator for low and high fire. This is determined by the steam pressure in the boiler which is sensed
by the two pressure transducers on the top front of the boiler. The 4-20 mA signal from the PLC tells the
Louver Actuator how far it should be open. The 12 VDC motor inside the Louver Actuator drives the
Louver open to the posi�on called for by the 4-20 mA signal. The Honeywell Burner Controller does not
care what the Louver Actuator is doing when the burner state is “Run.”
120 VAC Power from control relay
see 120 VAC control power
For the burner to ignite safely,an effec�ve purge cycle must be completed. For an effec�ve purge cycle
to take place the air louver must open completely and the fan must move air through the completely
open louver for 30 seconds. The Honeywell Burner controller uses the 24 VDC posi�on switches in the
“Louver Actuator” to confirm that an effec�ve purge has taken place. When the burner ini�ates the
Honeywell Burner Controller will call for a purge cycle, it will start the fan, it will send a signal to the PLC
through the Mod-Bus connec�on that it wants to purge,it will go into a “Purge Hold”state and wait
un�l it receives a signal that the louver is open. The PLC will tell the Louver Actuator to open completely.
Once the actuator has opened beyond the “High Fire Switch,”the “High Fire Switch”will close, sending
24 VDC power to the “High Fire Switch Relay”which will close the relay sending a 120 VAC signal to the
Honeywell Burner Controller, telling it that the louver has opened. The Honeywell Burner Controller will
then go to the “purge”state. The burner will purge for 30 seconds. A�er the purge is complete, the Honeywell
Burner Controller will tell the PLC, through the Mod-Bus connec�on, that the purge is complete it will go into
a “Purge Hold”state again and wait un�l it receives a signal that the louver is closed. The PLC will tell the
Louver Actuator to close. Once the actuator has closed beyond the “Low Fire Switch,”the “Low Fire
Switch”will close sending 24 VDC power to the “LowFire Switch Relay”which will close the relay
sending a 120 VAC signal to the Honeywell Burner Controller, telling it that the louver has closed.The
Honeywell Burner Controller will then progress to “Pilot Igni�on.”
_
+
+12 VDC Power
+24 VDC to Position Switches
+24 VDC From High Fire Switch (when louver is open)
+24 VDC From Low Fire Switch (when louver is closed)
24 VDC to Analog Output Card
12 VDC Power
When 12 VDC
power is applied
to (86) The
contacts close
between (30)
and (87) to
provide 12 VDC
power to the
system
<1
<2
<3
<4
<5
<6
<7
<8
1<
2<
3<
4<
5<
6<
7<
8<
24 VDC
Power Converter
+12 VDC to Louver Actuator
<3 3<
<4 4<
-12 VDC (Ground)
24 VDC to Louver Position Switches
Ground
+12 VDC from Relay
+12 VDC Supply to Relay
<1 1<
<2 2<
4-20 mA common
Ground
CH8>
COM>
COM>
+24V>
0V>
+12 VDC from Battery
-12 VDC from Battery
4-20 mA signal from PLC
24 VDC to all 24 VDC Components
9
12 VDC power to Actuator
A1 A2
9
12 VDC to 24VDC Power Converter
A1 A2
When position switches
in actuator close, 24
VDC is applied to (A2),
contacts close between
(9) and (5) sending
120 VAC to the
Honeywell Burner
Controller which
confirms that the
louver is in the
correct position
120 VAC to Relays
5
12 VDC Power
-12 VDC from Battery
+12 VDC power from Battery
120 VAC from Relay
120 VAC from Relay
5
13
Pump Wiring
Pump Wiring
Yellow/Black
Black
Brown
Cap
Orange
White
Yellow
White
Ground
Green
14
Safety Circuit
The safety circuit is a chain of switches that determine whether the burner may be
operated safely. The circuit is designed so that each switch, when closed, provides the
power for the next switch in the chain. In order for the fire to run, power must reach the
end of the chain.
120 VAC power is introduced into the chain when the “Burner On/Off” switch, on the
control panel door, is turned on. Power flows down the chain as each switch closes. Each
component in the system will be discussed in more detail later.
15
Safety Relays
In order for the PLC to know the state of the safety circuit, a 24 VDC signal must be sent from
each component in the circuit to the PLC. To accomplish this we use a series of relays that is
supplied with 24 VDC power and is switched by the 120 VAC as it flows through the safety
device circuit.
The safety relays are normally open. (A2) is a common neutral 120 VAC for all
relays, (9) is always supplied with 24 VDC power, When a safety switch in the
system closes it allows 120 VAC power to flow to (A1). When (A1) receives 120
VAC from the switch, contacts close between (9) and (5) sending the 24 VDC signal
to the PLC that the safety switch is closed. The 120 VAC supply for the next safety
switch in the chain is also connected to (A1). Therefore, when (A1) receives power
it tells the PLC that the switch is closed and it provides power to the next switch in
the chain. In this way the power cascades down the safety circuit sending
information to the PLC along the way. (See “Safety Circuit Diagram 1” & “Safety
Circuit Diagram 2” for details.)
16
Sequence
17
Sequence
As each safety device engages and the signal is
sent to the PLC, indicators on the “Systems Start”
screen will turn green to indicate that the device
is engaged.
Remember: The Safety Relays send this signal to
the PLC. If the device is engaged but the PLC is
not receiving the signal that it is engaged, check
the relay.
18
Burner Relay
The Burner Relay is the switch the PLC uses to turn the burner on and
off. It is located in the safety chain after the safeties for water level
and pressure. Therefore if for any reason a safety trips for water level
or pressure it will cut off the power to the relay and shut off the
burner regardless of what the PLC is telling it to do.
The Burner Relay is located in the bottom right corner of panel 2. It
receives a 24 VDC signal to the coil from the PLC which switches the
120 VAC power in the safety circuit. (See “Safety Circuit Diagram 2.”)
19
Burner Relay
Certain conditions must be met before the PLC will turn on the Burner Relay:
1.
2.
3.
4.
5.
Low Water Cut Off 1 and Low Water Cut Off 2 must be engaged. (See “Low Water Cut Off.”)
High Pressure Limit Switch must be engaged (See “High Pressure Limit Switch (HPLS).”)
Operating Pressure Limit Switch must be engaged (See “Operating Pressure Limit Switch (OPLS).”)
Water level in the boiler must reach the “Boiler Water Level Target”(See “Water Level Control.”)
Steam pressure must be below operating set point (See “Steam Pressure Control.”)
20
Burner Relay
Once all the conditions for start-up are met, the
PLC sends a 24 VDC signal here to close the relay
When the coil receives 24 VDC from the PLC,
Contacts close supplying this wire with 120 VAC
(See “Safety Circuit Diagram 1”)
If water level and steam pressure are within normal
limits for operation, this terminal will be supplied with
120 VAC (See “Safety Circuit Diagram 1”)
21
High Pressure Limit Switch (HPLS)
The HPLS is a safety device which shuts off the fire if the steam pressure in the boiler gets too high.
The HPLS is normally closed as long as the steam pressure is below the set point. If the steam
pressure exceeds the set point, the switch trips and breaks the safety circuit which shuts down the
fire. The HPLS should only trip if the OPLS fails to shut off the flame (See Operating Pressure Limit
Switch). When steam pressure drop back below the set point, The HPLS requires a manual reset to
let the burner restart. (see Safety “Circuit Diagram 1” and “Safety Circuit Daigram 2”)
To reset the HPLS pressure in the boiler must drop below the set point and the switch
must be reset manually by pressing firmly on reset button on top of the sensor.
22
High Pressure Limit Switch (HPLS)
The HPLS set point may be adjusted by turning this nut.
Since the HPLS is a backup to the OPLS it is normally set
1 PSI higher than the OPLS
• Clockwise increases set point.
• Counter clockwise decreases set point
Operating Range
Recommended Set Point
0-15 PSI
15 PSI
23
Low Water Cut Off
(LWCO)
The Low Water Cut Off (LWCO) is a safety device designed to ensure that the water level in the boiler never drops below a safe level during operation. The LWCO consists of two probes. One is slightly longer than the other. Each probe is a totally separate sensor from the other. The tip of the probes sit at the lowest safe level in the boiler. When the water level in the boiler rises enough that it touches the tip of the probe, the LWCO knows that the water is high enough to safely operate. If the water level in the boiler drops so that the water is no longer touching the probe, the LWCO knows that the water is below the safe operating level and shuts off the burner. The Low Water Cut Off has only two Functions:
1. Shut off the burner if water level drops below safe level
2. Tells the PLC to start the Circulation Pump when the LWCO is engaged.
See “LWCO Diagram” for more detail on the Low Water Cut Off.
24
Operating Pressure Limit Switch (OPLS)
The OPLS is a safety device uses to shut off the fire if the steam pressure
in the boiler gets too high. The OPLS is normally closed as long as the
steam pressure is below the set point. If the steam pressure exceeds the
set point, the switch trips and breaks the safety circuit which shuts down
the fire. When steam pressure drop back below the set point, The OPLS
will automatically reset. (see Safety “Circuit Diagram 1” and “Safety
Circuit Daigram 2”)
25
Operating Pressure Limit Switch (OPLS)
The OPLS set point may be adjusted by turning this nut.
• Clockwise increases set point.
• Counter clockwise decreases set point
Operating Range
Recommended Set Point
0-15 psi
14 psi
26
Water System
The purpose of the water system is to provide the boiler with
water and maintain the proper water level during operation. It is
essential for both function and safety that the water inside the
boiler is maintained at an appropriate level. Outlet
The Water System can be broken down into 4 main parts:
1.
2.
3.
4.
Controls and Safeties
Supply Water (Blue)
Feed Water (Purple)
Circulation (Red)
Inlet
27
Water System
Boiler Water Temp. Sensor
Y-Strainer
Feed Water Temp. Sensor
Outlet
Circulation Pump
Feed Water Valve
Feed Water Pump
T-Strainer
Supply Water Shut-Off Valve
Inlet
28
Water System
Circulation
Hot water is pulled out of the boiler. It passes
through the Y-strainer to the circulation pump.
It is then pumped to the feed water pipe where it
mixes with the cold supply water as it enters the
boiler.
Outlet
Feed Water
The warm mixed water from the
supply water and circulation water
enters the boiler.
Supply Water
Cold water is pulled in through the bulk head fittings
in the water tanks. It passes through the supply water
shut off valve and T-strainer to the feed water pump.
It is then pumped through the feed water valve and
mixed with the hot circulation water as it Inlet
enters the
boiler
29
Water Level Control
There are 2 main factors that will affect the water level in the boiler, the supply water system and the feed water control system. In order
for the water level in the boiler to be controlled properly both of these systems must be functioning correctly.
Feed Water Control System
Supply Water System
30
Supply Water System
The supply water system contains the water tanks, the supply water shut off valve, the T-strainer and the feed water pump.
Water tanks are the source of water
to fill the boiler. They must have
water in them
The feed water pump pumps the water
into the boiler. It should be running any
time the water system is active.
The supply water shut off valve
stops the flow of water to the Tstrainer so that is can be cleaned
without spilling water all over the
ground. It must be open to allow
water supply to the feed water
pump
The T-strainer stops particles in the supply water from being
pumped into the boiler. It should be cleaned every time the
water tanks are filled. If it is not cleaned frequently it will
plug and stop the water flow into the boiler.
31
Water Level Control
This consists of three components, the boiler water level sensor, the PLC, and the feed water valve.
The feed water valve opens to allow water to flow
into the boiler to raise the water level. When the
water has reached the correct level inside the
boiler the valve closes to stop the flow of water
into the boiler.
The boiler water level sensor measures the level of
the water in the boiler and sends a signal to the
PLC to indicate what the water level is. The water
level in the boiler is measured in inches
and should correspond to the level in the
sight glass on the upper right side of the
boiler.
The PLC is programmed to maintain the boiler water level at a set point (Default 5 in.). When the
boiler water level sensor indicates that the water level has dropped below the set point, the PLC tells
the feed water valve to open to allow water to flow into the boiler. When the water level reaches the
set point the PLC tells the valve to close which stops the flow of water into the boiler.
32
Water System Safeties
(Low Water Cut Off)
The Low Water Cut Off (LWCO) is a safety device designed to ensure that the
water level in the boiler never drops below a safe level during operation. The
LWCO consists of two probes. One is slightly longer than the other. Each probe is
a totally separate sensor from the other. The tip of the probes sit at the lowest
safe level in the boiler. When the water level in the boiler rises enough that it
touches the tip of the probe, the LWCO knows that the water is high enough to
safely operate. If the water level in the boiler drops so that the water is no
longer touching the probe, the LWCO knows that the water is below the safe
operating level. The only function of the LWCO is to shut off the flame if the
boiler water level drops below the safe operating level. It does not have any
effect on water level control.
See “Safety Circuit” for more detail on the Low Water Cut Off.
33
Feed Water Pump
The Feed Water Pump is used to pump the supply water from the water tanks
to the boiler. The Feed Water Pump runs anytime the water system is active.
The flow of water from the Feed Water Pump to the boiler is controlled by
the Feed Water Valve (See “Feed Water Valve”).
34
Circulation Pump
The Circulation Pump is used to pull hot water out of the boiler and circulate
it back through the feed water pipe. The circulation pump will not run until
the water system is active and Low Water 1 is closed (water is above Low
Water 1).
35
Feed Water Valve
The Feed Water Valve controls the flow of supply water into the boiler to
maintain the proper water level.
36
Boiler Water Temp. and Feed Water Temp.
Sensors
Circulation Water
Temp.
Boiler Water
Temp.
The Boiler Water and Circulation Water Temp. sensors are both critical for boiler
operation. When the boiler is heating up the burner will not go to high fire until the
Outlet
boiler water temp. reaches 180 degrees F. During operation the PLC is always
comparing the readings from both sensors.
Both sensors are exactly the same and can be
interchangeable if needed.
Inlet
37
Boiler Water Temp. and Feed Water Temp.
Sensors
Field Work
The readings from the Boiler Water Temp. and Feed Water Temp. sensors can be
seen on the touch screen controller on the two screens to the right. The feed
water will normally be cooler than the boiler water when the Feed Water Valve is
open. When the Feed Water Valve is closed the two sensors will normally read
very close to the same.
Outlet
(Menu)(Diagnostics)(Inputs/Outputs)
(Analog Inputs)
Sensor
Normal Operating Range
Boiler Water
220-250 deg. F
Feed Water
120-250 deg. F
Default temp differential set point = 150 deg. F
Inl
et
38
Boiler Water Temp. and Feed Water Temp.
Alarm Settings
Outlet
If the feed water is too much
cooler than the boiler water,
(150 deg. F) it indicates a failure
in the circulation system and
gives an alarm to the operator.
The temperature differential set point can
be adjusted by going to
(Menu)(Settings)(Alarm Settings) on
the touch screen controller and adjusting
the set point here.
The temperature differential alarm can be
disabled by going to
(Menu)(Settings)(Alarm Status) on the
touch screen controller and disable alarm
here. Make sure to read warningInlet
to the
right when disabling alarm.
39
Electrical path of the Boiler Water Level Sensor:
Troubleshooting Guide
Boiler Water Level Sensor
DewPoint 6210
40
Staheli West Inc. • 600 N. Airport Road • Cedar City, Utah • 435.586.8002 • [email protected]
Staheli West Inc. • 600 N. Airport Road • Cedar City, Utah • 435.586.8002 • [email protected]
41
Staheli West Inc. • 600 N. Airport Road • Cedar City, Utah • 435.586.8002 • [email protected]
Staheli West Inc. • 600 N. Airport Road • Cedar City, Utah • 435.586.8002 • [email protected]
4-20 mA VRO Trouble Shooting
Test individual components of system to isolate problem.
1. Test Sensor Output
a. Turn off power
b. Disconnect sensor wires from signal conditioner.
c. Sensor is now a potentiometer with the
i. Black wire being the wiper and
ii. Red & Yellow wires the ends of the potentiometer.
d. With an ohmmeter connect between Red & Black wires. The closer the float is to
full the higher the resistance typically 500 to 750 ohms. Move the float toward the
empty end of the sensor and the resistance will decrease.
e. With an ohmmeter connect between Black & Yellow wires. The closer the float is
to full the lower the resistance typically will be less than 100 ohms. Move the float
toward the empty end of the sensor and the resistance will increase.
f. With an ohmmeter connect between Red & Yellow wires the resistance will not
change with float movement. The resistance will be 600-750 ohms.
g. The resistance tests above must never be above 900 ohms.
h. If the sensor output changes as described above the sensor is good.
i. Reconnect sensor wires to signal conditioner.
2. Test Signal Conditioner
a. Turn off power.
b. Disconnect any wires from the two position terminal block.
c. Measure the incoming power voltage this must be 10-28 VDC.
d. With an amp meter set to measure milliamps DC.
i. Connect a 250 ohm resistor to the signal terminal on the signal
conditioner.
ii. Connect meter positive lead to loose end of 250 ohm resistor.
iii. Connect meter negative lead to power supply GROUND.
iv. Connect power to plus terminal on the signal conditioner terminal block.
e. If the float on the sensor cannot be moved (i.e. remote location or installed in
tank), verify signal conditioner output is between 4-20 mA.
f. If the float on the sensor can be moved, slide the float to the empty position and
verify 4 mA output.
g. Adjust zero pot. on signal conditioner if required to get 4 mA when float is at
empty position.
h. Next slide the float to the full position and verify 20 mA output.
i. Adjust gain pot. on signal conditioner if required to get 20 mA when float is at the
full point.
j. Finally slowly move the float up and down the full length of the stem, watching
the meter for abnormal output readings.
k. Now the sensor and signal conditioner test good. Any errors in readings when
connected in your application may be the result of:
i. How the signal conditioner wires are routed
ii. Grounding of sensor and tank
iii. Or other application & installation issues.
Staheli West Inc. • 600 N. Airport Road • Cedar City, Utah • 435.586.8002 • [email protected]
Signal Conditioners
Continuous Output Sensor to 4-20 mA
4-20 mA Output Loop Powered:
• 24 Vdc powered from loop
• Adjustable Zero, 4 ma output by 25 turn sealed pot.
• Adjustable Gain, 20 ma output by 25 turn sealed pot.
• Two piece terminal blocks, plug-in for easy wiring
• Load resistor typically 250 ohms
• Epoxy sealed electronics for industrial applications
• Reverse polarity protected
• Voltage spike and surge protected
Ordering Information: Part number: SCL-BM0BB
Staheli West Inc. • 600 N. Airport Road • Cedar City, Utah • 435.586.8002 • [email protected]
42
Feed Water Valve
The Feed Water Valve controls the flow of supply water into
the boiler to maintain the proper water level (See “Water Level
Control” for more detail). The valve is a 1 in. STD port brass ball
valve. It is driven by an EH2 4-20 mA actuator.
The Feed Water Valve is located inside the back door here.
43
Feed Water Pump
The Feed Water Pump is used to pump the supply water from the water tanks
to the boiler. The Feed Water Pump runs anytime the water system is active.
The flow of water from the Feed Water Pump to the boiler is controlled by
the Feed Water Valve (See “Feed Water Valve”).
This pump requires little or no service other than reasonable care and periodic cleaning. Occasionally, however, a shaft seal
may become damaged and must be replaced. The procedure as outlined on the next page will enable you to replace the seal.
44
Circulation Pump
The Circulation Pump is used to pull hot water out of the boiler and circulate
it back through the feed water pipe. The circulation pump runs any time the
water system is active and Low Water 1 is closed (water is above Low Water
1).
This pump requires little or no service other than reasonable care and periodic cleaning. Occasionally, however, a shaft seal
may become damaged and must be replaced. The procedure as outlined on the next page will enable you to replace the seal.
45
Pump Service
NOTICE: The highly polished and lapped faces of this seal are easily damaged. Read instructions and handle the seal with care. Some
models are equipped with an impeller screw, which has a left hand thread. Before unscrewing the impeller, remove the impeller screw.
REMOVAL OF OLD SEAL
1. After unscrewing impeller, carefully remove rotating part
of seal by prying up on sealing washer, using two screw drivers (see Figure 5A). Use care not to scratch motor
shaft.
2. Remove seal plate from motor and place on flat surface,
face down. Use a screwdriver to push ceramic seat out
from seal cavity (see Figure 5B).
INSTALLATION OF FLOATING SEAT (Figure 5C)
1. Clean polished surface of floating seat with clean cloth.
2. Turn seal plate over so seal cavity is up, clean cavity
thoroughly.
3. Lubricate outside rubber surface of ceramic seat with
soapy water and press firmly into seal cavity with finger
pressure. If seat will not locate properly in this manner,
place cardboard washer over polished face of seat and
press into seal cavity using a 3/4" socket or 3/4" piece of
standard pipe.
4. DISPOSE OF CARDBOARD WASHER. Be sure polished
surface of seat is free of dirt and has not been damaged
by insertion. Remove excess soapy water.
INSTALLATION OF ROTATING
PART OF SEAL UNIT (Figure 5D)
1. Reinstall seal plate using extreme caution not to hit ceramic
portion of seal on motor shaft.
2. Inspect shaft to make sure that it is clean.
3. Clean face of sealing washer with clean cloth.
4. Lubricate inside diameter and outer face of rubber drive
ring with soapy water and slide assembly on motor shaft
(sealing face first) until rubber drive ring hits shaft shoulder.
5. Screw impeller on shaft until impeller hub hits shaft shoulder.
This will automatically locate seal in place and move
the sealing washer face up against seat facing. Reinstall
impeller screw (if used).
46
Pump Service
47
Y-Strainer
The Y-strainer will catch any large particles as the boiler water is pulled out and
recirculated. The Y-strainer should be flushed at the end of each day by
opening the hand valve on the front for several seconds. If the Y-strainer is not
flushed often it will cause malfunction of the circulation system.
If the screen inside the Y-strainer becomes damaged
or permanently plugged, the screen can be easily
replaced.
Y-Strainer
Flush
48
Steam Pressure Control
This system consists of three components, the Steam Pressure Transducers, the PLC and the Burner. The Burner provides the fire which increases the pressure inside the boiler. The burner alternates between Low Fire, High Fire and Off depending on the steam pressure demand.
The two pressure transducers sense the pressure inside the boiler and send that information to the PLC. The PLC receives the signal from the Steam Pressure Transducers and switches the burner between Low Fire, High Fire and Off to maintain the correct steam pressure.
49
Steam Pressure Control Logic
Because steam pressure is such a critical measurement, the two Steam Pressure Transducers both measure the steam pressure inside the boiler. The PLC compares the readings from each sensor and calculates the average for the actual steam pressure reading. The steam pressure reading from the pressure transducers is displayed here on the field work screen.
50
Steam Pressure Control Logic
If the readings from the two pressure transducers are ever more than 2 psi different from each other, an error message will appear that will require the operator to select which transducer matches the reading on the mechanical gauge. The selection can be made by selecting the sensor that matches, directly from the error message…
or by going to MenuàSettingsàBoiler
PressureàPressure Sensor Selectionà
and select the matching sensor.
The DewPoint may be operated on one sensor for a short period of time until the bad sensor can be replaced. All pressure safety devices will still function normally. However, to ensure accurate steam pressure control the DewPoint should never be operated for an extended time with one Steam Pressure Transducer.
51
Steam Pressure Control Logic
The PLC automatically adjusts the flame between Low Fire, High Fire and Off to keep the steam pressure within 1 psi of the “Boiler Steam Pressure Operating Target.” The logic for this is:
• High Fire: When steam pressure is more than 1 psi below the Operating Target and the boiler water is more than 180 deg., the Burner goes to “High Fire”
• Low Fire: When steam pressure is within 1 psi (+ or -­‐) and/or the boiler water is below 180 degrees of the Operating Target, the Burner goes to “Low Fire”
• Off: When the steam pressure is more than 1 psi greater than the Operating Target, the burner goes to off.
The “Boiler Steam Pressure Operating Target” can be found by going to MenuàSettingsàBoiler Pressure.
52
Actuators
The EH2 4-20 mA actuator is used in several locations on the machine. It receives an analog signal from the PLC
which can range from Closed to 100% open and anywhere in between. It has a four pin plug and a red position
indicator. It can be interchanged with any actuator that has the same plug
EH2 4-20 mA
The EH2 On/Off actuator is used on the steam purge valve. It receives a discrete signal from the PLC which tells the
actuator to open or close completely. It has a three pin plug and a yellow position indicator. It can be interchanged
with any actuator that has the same plug.
EH2 On/Off
The EH3 4-20 mA actuator with position switches is a very specialized actuator that is used to control the airflow to
the burner. It receives an analog signal from the PLC which can range from Closed to 100% open and anywhere in
between. It has an eight pin plug and a red position indicator. (For more detail see “Louver Actuator”)
EH3 4-20 mA with
Position Switches
The EH3 On/Off actuator is used on the manifold drain valve. It receives a discrete signal from the PLC which tells
the actuator to open or close completely. It has a three pin plug and a yellow position indicator. It can be
interchanged with any actuator that has the same plug.
EH3 On/Off
53
Blow Down Valve
The Blow Down Valve opens to let concentrated water out of
the boiler to maintain good water quality inside the boiler (See
“Automatic Blow Down System” for more detail). The valve is a
1 in. STD port brass ball valve. It is driven by an EH2 4-20 mA
actuator.
The Blow Down Valve is located inside the back door here.
54
Manifold Drain Valve
The Manifold Drain Valve opens to drain any water that has accumulated in the bottom of the steam manifold. It normally opens for 30 seconds and closes for 30 seconds. The open time can be changed in settings. The valve is a 0.5 in. standard port brass ball valve. It is driven by an EH3 On/Off actuator.
The Manifold Drain Valve is located on the bottom of the steam manifold here.
55
Steam Purge Valve
The Purpose of the steam purge valve is to keep the steam
pressure low enough that the burner will not shut off when
turning around or using low steam rates. This prevents big
drops in steam pressure because of the burner shutting off
during operation. The steam purge valve uses a 1 in. full port
valve with an EH2 On/Off actuator.
The steam purge valve is located in the middle of the steam
manifold.
56
Steam Valve
The steam valves control the steam rate to the corresponding
steam manifold in the baler. They are a 1.5 in. standard port
brass ball valve with an EH2 4-20 mA actuator.
The steam purge valve is located in the middle of the steam
manifold.
57
Valve Repair
 Before you begin turn the valve to the fully closed position
 Be careful not to damage the surfaces on the valve where
the seats will need to seal.
1.
Remove the retainer nut from the end of the valve and
remove the outer seat and the ball. (the ball must be in
the closed position before it can be removed)
2.
Remove the retainer nut on the stud at the top of the
valve.
3.
Remove the stud and the inner seal by pressing the stud
down into the valve and out the end.
4.
Remove the outer seal
5.
Remove the inner seat

To re-assemble do these steps in reverse with the new
parts.
58
DewPoint 6210 Startup Timeline
DewPoint 6210 Start-Up Timeline
1 Generator Starts and Runs
2 Feed Water Pump Turns On and Runs
3 Feed Water Actuator Opens and lets water into the Boiler until Boiler reaches operating level
4 Burner Control Power comes on automatically (unless manually shut off)
5 Low Water Cut Off Probe #2 makes contact with Boiler Water
6 Low Water Cut Off Probe #1 makes contact with Boiler Water and satisfies Both LWCO safeties at this time
7 Circulation Pump Turns On
8 Burner Controller checks for overpressure (over 15 existing Boiler PSI) in the boiler by Checking the "High Pressure Limit" sensor
9 Burner Controller checks for overpressure (over 14.5 existing Boiler PSI) in the boiler by Checking the "Operating Pressure Control" sensor
10 System Waits for the "Burner Relay" to be initiated (done automatically during a "Start All" or done manually if system was started using "Start Fill")
11 Burner Relay is active (After the Target Boiler Water level is satisfied the program sequence to the next step)
12 Burner Initiate (Checks that Voltage and Frequency tolerances are met)
13 Burner Standby (Checks that all safeties are in their correct state)
14 Fan VFD turns On and begins to spin the Fan
15 Pre-purge (Power is sent to the Fan Motor and the Air Louver opens to 100%)
16 Air Flow Switch must confirm the Fan started and air is moving through the Burner
17 Purge goes for 30 seconds
18 Burner Louver goes completely closed at the end of the 30 second Purge cycle
19 Propane solenoid opens and the Ignition Transformer sparks for 10 seconds
20 Pilot Flame is sensed with the IR Flame Detector
21 Main Fuel Valve #1 and the Safety fuel valve (Main Valve #2) open to start Main Oil Ignition
22 Main flame is verified using the IR flame sensor
23 Burner advances to Low Fire
24 Burner heats the Boiler Water on Low Fire until the Boiler Water reaches 180 degrees F
25 Burner goes to High Fire after the Boiler Water Temp gets above 180 degrees F
26 Burner stays on High Fire until the target pressure is reached (Default 12 PSI)
27 Steam Purge Valve opens for 30 seconds to purge oxygen
28 Screen changes from the "Systems Start" to "Liability Release"
29 When the Liability is "agreed" the screen changes to "Field Work"
30 DewPoint 6210 is ready to Steam!
59
DewPoint 6110 Burner Sequence Table
BURNER STATE
INITIATE
STANDBY
SAFETY
START
PURGE HOLD
T19 HI FIRE
SWITCH
30 SECOND
PURGE
PURGE HOLD
T18 LOW FIRE
SWITCH
PROPANE
PILOT
IGNITION
MAIN OIL
IGNITION
RUN: LOW FIRE
(HEATING BOILER ON
LOW TO 180F)
RUN: LOW FIRE/HIGH FIRE
(CONTROLLED BY STEAM
PRESSURE/DEMAND)
15 SECOND
POSTPURGE
STANDBY
BURNER
ALARM
HONEYWELL LED
DISPLAY
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
BURNER SYSTEM
VFD - VARIABLE FREQUENCY DRIVE
STARTS
ON
BURNER COMBUSTION FAN MOTOR
STARTS
ON
COMBUSTION AIR LOUVER ELECT. ACTUATOR
LOW
6 sec TO HIGH
HIGH
6 sec TO LOW
LOW
COMBUSTION AIR LOUVER OIL ACTUATOR
LOW
LOW
HI FIRE (LOUVER OPEN) SWITCH
ON WHEN HIGH
HIGH - LOW - HIGH: BY STEAM PSI
ON
LO FIRE (LOUVER CLOSED) SWITCH
ON WHEN LOW
ON
PILOT IGNITION TRANSFORMER
ON FOR 10 sec THEN 10 sec
PILOT GAS VALVE
ON FOR 10 sec THEN 10 sec
OIL SHUTOFF SAFETY VALVE
ON FOR 15 sec
ON THROUGHOUT "RUN" STATE
MAIN OIL VALVE
ON FOR 15 sec
ON THROUGHOUT "RUN" STATE
LOW FIRE BYPASS OIL VALVE
ON
ON
HIGH FIRE 3-WAY OIL VALVE
PRIMARY SAFETY SYSTEM
OFF - ON - OFF: BY STEAM PSI
ON - OFF - ON: BY STEAM PSI
FLAME SIGNAL DETECTOR
BURNER SWITCH (MANUAL)
LOW
SAFE START CHECK TO BE SURE THERE IS NO FLAME
CHECK TO PROVE FLAME
MUST BE ON
LOW WATER CUT-OFF 1
MAY BE ON
MUST BE ON
LOW WATER CUT-OFF 2
MAY BE ON
MUST BE ON
HIGH PRESS LIMIT CONTROL
MAY BE ON
MUST BE ON
OPERATING PRESS CONTROL
MAY BE ON
MUST BE ON
BURNER RELAY
MUST BE ON
CR-1 CONTROL RELAY VFD
MUST BE ON
CR-2 CONTROL RELAY VFD
MUST BE ON
BLOWER AIR PRESS SWITCH
MUST BE ON
PLC CONTROLS
BURNER ON/OFF CONTROL
DY7 BURNER RELAY
SR RELAY ANNINCIATION TO PLC
SR-1 BURNER SWITCH (MANUAL)
ON - BY PLC "DY7" CONTROL WHEN BURNER IS ACTIVATED FROM SCREEN OR BY "START ALL" FUNCTION
"ON" ANUNCIATION
SR-2 LOW WATER CUT-OFF 1
"ON" ANUNCIATION
SR-3 LOW WATER CUT-OFF 2
"ON" ANUNCIATION
SR-4 HIGH PRESS LIMIT CONTROL
"ON" ANUNCIATION
SR-5 OPERATING PRESS CONTROL
"ON" ANUNCIATION
SR-6 BURNER RELAY
"ON" ANUNCIATION
SR-7 CR-1 CONTROL RELAY VFD
"ON" ANUNCIATION
SR-7 CR-2 CONTROL RELAY VFD
"ON" ANUNCIATION
SR-8 BLOWER AIR PRESS SWITCH
STEAM PSI & FLAME MANAGEMENT
"ON" ANUNCIATION
BOILER WATER TEMP SENSOR
CONSTANT TEMP READING BUT N/A HERE
STEAM PSI 1 SENSOR
CONSTANT PSI READING ALWAYS COMPARES TO "STEAM PSI 2 SENSOR" FOR SAFETY REDUNDANCY
AVERAGE OF STEAM PSI 1 & 2 SENSORS
STEAM PSI 2 SENSOR
HIGH FIRE RELAY
PSI N/A HERE
LOW HOLD BELOW 180F
PSI HERE MUST BE AT LEAST 0.5 PSI BELOW STEAM PSI TARGET TO START BURNER AND OPERATE THROUGH WARM-UP PERIOD
CONSTANT PSI READING ALWAYS COMPARES TO "STEAM PSI 1 SENSOR" FOR SAFETY REDUNDANCY
PSI CONTROL ABOVE 180F
CONSTANT TEMP READING BUT N/A HERE
HI WHEN > 0.5 PSI BELOW TARGET
LO WHEN > 0.5 PSI ABOVE TARGET
OFF WHEN > 1 PSI ABOVE STEAM PSI TARGET
ON - OFF - ON: BY STEAM PSI
60
DewPoint 6210 Burner Sequence Table
BURNER STATE
INITIATE
STANDBY
SAFETY
START
PURGE HOLD
T19 HI FIRE
SWITCH
30 SECOND
PURGE
PURGE HOLD
T18 LOW FIRE
SWITCH
PROPANE
PILOT
IGNITION
MAIN OIL
IGNITION
RUN: LOW FIRE
(HEATING BOILER ON
LOW TO 180F)
RUN: LOW FIRE/HIGH FIRE
(CONTROLLED BY STEAM
PRESSURE/DEMAND)
15 SECOND
POSTPURGE
STANDBY
BURNER
ALARM
HONEYWELL LED
DISPLAY
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
Power
Pilot
Flame
Main
Alarm
BURNER SYSTEM
VFD - VARIABLE FREQUENCY DRIVE
STARTS
ON
BURNER COMBUSTION FAN MOTOR
STARTS
ON
COMBUSTION AIR LOUVER
CLOSED
1.5 sec TO OPEN
HI FIRE (LOUVER OPEN) SWITCH
OPEN
1.5 sec TO CLOSE
CLOSED
OPEN TO LOW
OPEN TO LOW
HI - LOW - HI: BY STEAM PSI
LO FIRE (LOUVER CLOSED) SWITCH
ON FOR 10 sec THEN 10 sec
PILOT GAS VALVE
ON FOR 10 sec THEN 10 sec
OIL SHUTOFF VALVE
ON FOR 15 sec
ON THROUGHOUT "RUN" STATE
1st STAGE OIL VALVE
ON FOR 15 sec
ON THROUGHOUT "RUN" STATE
2nd STAGE OIL VALVE
CLOSED
ON - OFF - ON: BY STEAM PSI
FLAME SIGNAL DETECTOR
PRIMARY SAFETY SYSTEM
1.5 sec TO CLOSE
ON
PILOT IGNITION TRANSFORMER
BURNER SWITCH (MANUAL)
OPEN
ON
SAFE START CHECK TO BE SURE THERE IS NO FLAME
CHECK TO PROVE FLAME
MUST BE ON
LOW WATER CUT-OFF 1
MAY BE ON
MUST BE ON
LOW WATER CUT-OFF 2
MAY BE ON
MUST BE ON
HIGH PRESS LIMIT CONTROL
MAY BE ON
MUST BE ON
OPERATING PRESS CONTROL
MAY BE ON
MUST BE ON
BURNER RELAY
MUST BE ON
CR-1 CONTROL RELAY VFD
MUST BE ON
CR-2 CONTROL RELAY VFD
MUST BE ON
BLOWER AIR PRESS SWITCH
MUST BE ON
PLC CONTROLS
BURNER ON/OFF CONTROL
DY7 BURNER RELAY
SR RELAY ANNINCIATION TO PLC
SR-1 BURNER SWITCH (MANUAL)
ON - BY PLC "DY7" CONTROL WHEN BURNER IS ACTIVATED FROM SCREEN OR BY "START ALL" FUNCTION
"ON" ANUNCIATION
SR-2 LOW WATER CUT-OFF 1
"ON" ANUNCIATION
SR-3 LOW WATER CUT-OFF 2
"ON" ANUNCIATION
SR-4 HIGH PRESS LIMIT CONTROL
"ON" ANUNCIATION
SR-5 OPERATING PRESS CONTROL
"ON" ANUNCIATION
SR-6 BURNER RELAY
"ON" ANUNCIATION
SR-7 CR-1 CONTROL RELAY VFD
"ON" ANUNCIATION
SR-7 CR-2 CONTROL RELAY VFD
"ON" ANUNCIATION
SR-8 BLOWER AIR PRESS SWITCH
STEAM PSI & FLAME MANAGEMENT
"ON" ANUNCIATION
BOILER WATER TEMP SENSOR
CONSTANT TEMP READING BUT N/A HERE
STEAM PSI 1 SENSOR
CONSTANT PSI READING ALWAYS COMPARES TO "STEAM PSI 2 SENSOR" FOR SAFETY REDUNDANCY
AVERAGE OF STEAM PSI 1 & 2 SENSORS
STEAM PSI 2 SENSOR
PSI N/A HERE
LOW HOLD BELOW 180F
PSI HERE MUST BE AT LEAST 0.5 PSI BELOW STEAM PSI TARGET TO START BURNER AND OPERATE THROUGH WARM-UP PERIOD
CONSTANT PSI READING ALWAYS COMPARES TO "STEAM PSI 1 SENSOR" FOR SAFETY REDUNDANCY
HIGH FIRE RELAY
COMBUSTION AIR LOUVER
PSI CONTROL ABOVE 180F
CONSTANT TEMP READING BUT N/A HERE
HI WHEN > 0.5 PSI BELOW TARGET
LO WHEN > 0.5 PSI ABOVE TARGET
OFF WHEN > 1 PSI ABOVE STEAM PSI TARGET
ON - OFF - ON: BY STEAM PSI
CLOSED
1.5 sec TO OPEN
OPEN
1.5 sec TO CLOSE
CLOSED
OPEN TO LOW
OPEN TO LOW
HI - LOW - HI: BY STEAM PSI
OPEN
1.5 sec TO CLOSE
CLOSED
61
DewPoint 6110
Burner Training
62
Complete Burner Overview
Right Side View
63
Complete Burner Overview
Left Side View
64
Air System
Right Rear View
Air Louver
“Purge” Actuator
Airflow Switch
Burner Fan Motor
(opens louver during
“purge” cycles)
Air Louver Upper
Fan Cleaner Tube
Burner Fan
Air Louver
“Run” Actuator
(drives louver
open and closed
for High/Low
firing rates)
Air Louver, Lower
65
Air System
Top, Front Left View
Air Louver
“Purge” Actuator
Air Louver Upper
(opens louver during
“purge” cycles)
Airflow Switch
Air Louver
“Run” Actuator
(drives louver
open and closed
for High/Low
firing rates)
Fan Cleaner Tube
Burner Fan
Air Louver, Lower
Airflow Switch
Burner Fan Motor
Airflow Switch
High Pressure Line
Airflow Switch
Low Pressure Line
66
Fuel System
General View
Burner “Gun” Assembly
Bypass Fuel Nozzle
Assembly
Pilot Propane Tube
Flame Sensor
(Delivers Propane
during Pilot Ignition)
Pilot Ignition Electrode
Nozzle Fuel Press Gauge
(Active spark during Pilot Ignition)
Nozzle Fuel Press Sensor
(sends signal to PLC)
Air Louver
“Run” Actuator
Fuel Pump
Fuel Pump Press Regulator
(also controls High Fire Pressure.
Set to 280-300psi typical)
(drives Air Louver
open and closed
for High/Low
firing rates)
3-Way Fuel Valve
(directs fuel to “Air Louver
Run Actuator” on “High
Fire”)
Bypass Fuel Valve
(Opens on “Low
Fire”,
Closes on “High
Fire”)
Main Oil Valve
(Opens when Burner fires)
Fuel Pump
Press Gauge
Fuel Pump
Press Sensor
(Sends signal to PLC)
Safety Shutoff Oil Valve
(Opens when Burner fires)
Low Fire Press Regulator
(Set to 160-180psi typical
when in “Low Fire”)
67
Fuel System
Color Right Front View
• Red = Oil Pressure from Fuel Pump to
Bypass Nozzle
• Blue = Return Oil from Bypass Nozzle
• Yellow = Final Return Oil on Low Fire
when Bypass Valve is “open” and
3way valve is “closed”
• Green = Final Return Oil on High Fire
when 3way Valve is “open and
Bypass Valve is “closed”
68
Fuel System
Color Right Front View
• Red = Oil Pressure from Fuel Pump to
Bypass Nozzle
• Blue = Return Oil from Bypass Nozzle
• Yellow = Final Return Oil on Low Fire
when Bypass Valve is “open” and
3way valve is “closed”
• Green = Final Return Oil on High Fire
when 3way Valve is “open and
Bypass Valve is “closed”
Air Louver
“Run” Actuator
(Drives Air Louver
open and closed
for High/Low
firing rates)
3-Way Fuel Valve
(Opens to direct fuel
to “Air Louver Run Actuator”
on “High Fire”,
Closes on “Low Fire”)
Bypass Fuel Valve
(Opens on Low Fire to
bypass fuel to Low Fire
Press Regulator. This
decreases fuel pressure at
the Nozzle.
Closes on “High Fire” to
increase fuel pressure at
the Nozzle)
Low Fire Press Regulator
(Controls Bypass Fuel
Pressure to lower Nozzle
pressure for Low Fire
Operation)
69
Fuel System
Color Right Front View
• Red = Oil Pressure from Fuel Pump to
Bypass Nozzle
• Blue = Return Oil from Bypass Nozzle
• Yellow = Final Return Oil on Low Fire
when Bypass Valve is “open” and
3way valve is “closed”
• Green = Final Return Oil on High Fire
when 3way Valve is “open and
Bypass Valve is “closed”
3-Way Fuel Valve
(Opens to direct fuel
to “Air Louver Run Actuator”
on “High Fire”,
Closes on “Low Fire”)
Bypass Fuel Nozzle
Assembly
Low Fire Press Regulator
(Controls Bypass Fuel
Pressure to lower Nozzle
pressure for Low Fire
Operation)
Bypass Fuel Valve
(Delivers atomized fuel to
Burn in Furnace.
Bypass fuel pressure is
regulated through the
Return Fuel System to
increase the Nozzle pressure
on High Fire and decrease
the Nozzle pressure on Low
Fire)
(Opens on Low Fire to
bypass fuel to Low Fire
Press Regulator. This
decreases fuel pressure at
the Nozzle.
Closes on “High Fire” to
increase fuel pressure at
the Nozzle)
70
Ignition System
Pilot Ignition
Transformer
General
(Produces high energy
electrical current for “Spark”
ignition of the Pilot Propane)
Pilot Propane Tube
(Delivers Propane for
Propane Pilot Ignition)
Pilot Ignition Electrode
(Delivers high energy “Spark”
for ignition of the Pilot
Pilot Propane Regulator
Propane)
(Controls Propane pressure
for Pilot Propane Ignition)
Pilot Propane Valve
(Opens to control Propane flow
for Pilot Propane Ignition)
71
Ignition System
Ignition Electrode
Pilot Propane Tube
(Delivers Propane for
Propane Pilot Ignition)
Pilot Ignition Electrode
(Delivers high energy “Spark”
for ignition of the Pilot
Propane.
Tip of Electrode must be
centered in the small hole
and flush with the outside of
the Pilot Propane Tube)
72
Ignition System
Component Location
Pilot Ignition
Transformer
(Produces high energy
electrical current for “Spark”
ignition of the Pilot Propane)
Pilot Propane Regulator
(Controls Propane pressure
for Pilot Propane Ignition)
Pilot Propane Valve
(Opens to control Propane flow
for Pilot Propane Ignition)
73
Air/Fuel Adjustment
PREREQUISITE
The Burner Fan and Burner Gun Assembly
MUST BE COMPLETELY CLEAN before
adjusting the Air/Fuel Ratio to tune the
Burner.
If Flue Temperatures are running high,
above 600 degrees, your Boiler Fire Tubes
are likely sooted-up and will alsorequire
cleaning before tuning the Burner
4.
Check for Smoke on High Fire
With Fuel Pump Pressure set to
280-300psi with Burner running,
this should produce Nozzle
Pressure of 160-180psi on High Fire
Air Louvers should be fully open
There should be no continuous
smoke on High Fire, however it is
normal to see a short “puff” of dark
smoke when the burner transitions
from Low to High Fire
If there is smoke, lower the Pump
Pressure until smoke clears. If you
must lower the Pump Pressure to
less than 250psi you will need to
diagnose the problem and correct
it before operation
DO NOT RUN A SMOKEY BURNER!!!
3.
Low Fire Air Louver
Adjustment Screw
Adjust Air Louver toward
“closed” until Burner just starts
to smoke on Low Fire
Then adjust Air Louver toward
“open” until Burner just clears
smoke on Low Fire
Finally, adjust Air Louver
toward “open” 1 additional
turn on Low Fire
2.
Low Fire Press Regulator
While Burner is in Low Fire
(Air Louvers closed), set
Nozzle pressure to 70-80psi
1.
Fuel Pump Press
Regulator
Set Fuel Pump Pressure to 280300psi with Burner running.
74
Cleaning
1.
3.
Clean Burner Internally every 50 Hours
Remove this front cover and use compressed
air to clean the
• Burner Fan (thoroughly from the top)
• Gun Assembly
• Flame Sensor Sight Tube
• Ignition Electrode
• Propane Pilot Tube
Clean entire Burner Area at
least Daily, but preferably each
time you load with water
• Use Compressed Air to remove
dust and crop debris from around
the Burner and Generator
2.
Clean Burner Fan at least Daily, but preferably
each time you load with water
• Connect your compressed air hose to the small red hose
on this valve
• Open the Valve 4 or 5 times for about 2 seconds each
time to blow dust off the fins of the Burner Fan
• Be sure your compressed air has enough pressure to spin
the Fan
75
Reference Resources
For Complete DewPoint 6110 Burner Training Videos, Go To:
www.staheliwest.com
• Login
• Customer Portal
• User name: customer
• Password: dewpoint
• 6110 Burner Videos
Or go to this link:
https://drive.google.com/folderview?id=0BzP5iQzMFZCaflRXT
3lrUlJoWlN3bVJYcTJvODBIdTVna2FnVnFQWHc5S3JiUk9ieHlhZ
Uk&usp=drive_web
76
DewPoint 6210
Burner Training
77
Complete Burner Overview
Right Side View
78
Complete Burner Overview
Left Side View
79
Air System
Right Rear View
Air Flow Switch
Checks for Airflow
during Buner Start-up
and Operation
Airflow Switch
Burner Fan Motor
Burner Fan
Air Louver
Air Louver Actuator
Drives louver open and closed during
the following stages:
• PRE-PURGE
• RUN, for High/Low firing rates
• POST-PURGE
80
Air System
Airflow Switch
High Pressure
Connection
Right, Front View
Airflow Switch
Burner Fan
Burner Fan Motor
Air Louver Actuator
Drives louver open and closed during
the following stages:
• PRE-PURGE
• RUN, for High/Low firing rates
• POST-PURGE
Air Louver
Airflow Switch
Airflow Switch
Low Pressure Hose
81
Fuel System
General View
2nd stage Fuel Press Sensor
(not shown here but this is
the location when equipped)
•
•
Sends signal to PLC
Reads 2nd Nozzle Pressure on
High Fire
Fuel Pump
Press Gauge
2nd Stage Fuel Line
Fuel Pump
Press Sensor
Sends signal to PLC
Fuel Pump
Fuel Inlet Port
from Fuel Tank
Fuel Pump
Press Regulator
Set to 145-150psi
typical
Combustion Air
Diffuser Cone
1st stage Fuel Press Sensor
(not shown here but this is
the location when equipped)
•
•
Sends signal to PLC
Reads 1st Nozzle Pressure on
Low Fire and High Fire
Fuel Return Port
to Fuel Tank
1st Stage Fuel Line
2nd Stage Oil Valve
Opens when Burner is
in High Fire
Safety Shutoff Oil Valve
Opens when Burner fires on
Low Fire and High Fire.
This is a redundant Safety
Shut-off Valve if the 1st Stage
Oil Valve fails to close on
Burner shut-down
1st and 2nd Stage
Fuel Nozzles
1st Stage Oil Valve
Opens when Burner fires on
Low Fire and High Fire
High Pressure Fuel
Line to Valves
82
Fuel System
Fuel Lines
2nd Stage Fuel Line
Fuel Pump
Fuel Inlet Port
from Fuel Tank
Fuel Return Port
to Fuel Tank
1st Stage Fuel Line
High Pressure Fuel
Line to Valves
83
Fuel System
Fuel Valves and Nozzles
1st Stage Oil Valve
Opens when Burner fires on
Low Fire and High Fire
2nd Stage Oil Valve
Opens when Burner is
in High Fire
Safety Shutoff Oil Valve
Opens when Burner fires on
Low Fire and High Fire.
This is a redundant Safety
Shut-off Valve if the 1st Stage
Oil Valve fails to close on
Burner shut-down
2nd Stage
Fuel Nozzle
1st Stage
Fuel Nozzle
On in both
Low Fire and
High Fire
On when in
High Fire
84
Fuel System
Fuel Pump
Press Sensor
Fuel Pressure Sensors
and Controls
2nd stage Fuel Press Sensor
(not shown here but this is
the location when equipped)
•
•
Sends signal to PLC
Fuel Pump
Press Regulator
Set to 145-150psi
typical
Sends signal to PLC
Reads 2nd Nozzle Pressure on
High Fire
1st stage Fuel Press Sensor
(not shown here but this is
the location when equipped)
•
•
Sends signal to PLC
Reads 1st Nozzle Pressure on
Low Fire and High Fire
85
Fuel System
1st & 2nd Stage Burner Gun Assembly
Exploded View
2nd Stage Fuel Line
On when in High Fire
1st Stage Fuel Nozzle
On in both Low Fire and
High Fire
2nd Stage Fuel
Nozzle
On when in High Fire
1st Stage Fuel Line
On in both Low Fire and
High Fire
86
Ignition System
Flame Sensor
Detects Flame presence in all
stages of boiler operation
General
Pilot Ignition Electrode
Delivers high energy “Spark”
for ignition of the Pilot Propane
Pilot Propane Tube
Delivers Propane for
Propane Pilot Ignition
Pilot Ignition
Transformer
Produces high energy
electrical current for “Spark”
ignition of the Pilot Propane
Pilot Propane Valve
Opens to control Propane flow
for Pilot Propane Ignition
Pilot Propane Hose
Delivers Propane for
Propane Pilot Ignition
Propane Pressure Sensor
Pilot Propane Regulator
Controls Propane pressure
for Pilot Propane Ignition
Monitors Propane Pressure
from Propane Supply Tank.
Sends signal to PLC
87
Ignition System
Ignition Electrode
Pilot Ignition Electrode
Delivers high energy “Spark” for
ignition of the Pilot Propane.
Pilot Propane Tube
Delivers Propane for
Propane Pilot Ignition
Pilot Ignition Electrode
Adjustment
Set gap to 1/8” between tip
of Electrode and edge of Pilot
Propane Tube
88
Ignition System
Component Location
Pilot Ignition
Transformer
Produces high energy
electrical current for “Spark”
ignition of the Pilot Propane
Flame Sensor
Detects Flame presence in all
stages of boiler operation
Pilot Propane
Valve
Opens to control
Propane flow for
Pilot Propane
Ignition
Pilot Propane Tube
Delivers Propane for
Propane Pilot Ignition
Pilot Ignition Electrode
Delivers high energy “Spark”
for ignition of the Pilot Propane
Pilot Propane Hose
Delivers Propane for
Propane Pilot Ignition
Pilot Propane Regulator
Controls Propane pressure
for Pilot Propane Ignition
Propane Pressure Sensor
Monitors Propane Pressure
from Propane Supply Tank.
Sends signal to PLC
89
90
Air/Fuel Adjustment
PREREQUISITE
The Burner Fan and Burner Gun Assembly
SHOULD BE CLEAN before adjusting the
Air/Fuel Ratio to tune the Burner.
If Flue Temperatures are running high,
above 600 degrees, your Boiler Fire Tubes
are likely sooted-up and will also require
cleaning before tuning the Burner
3.
Always watch for Smoke
DO NOT RUN A SMOKEY BURNER!!!
Unless you really enjoy cleaning
soot from your Boiler Fire Tubes
2.
Adjust Air Louver Position from
Touch Screen from the “Tune
Burner” Menu
Follow instructions on the Touch Screen to
tune the Burner for both Low Fire and High
Fire Adjustments.
Remember to re-tune the Burner when
elevation or seasonal temperatures change
1.
Adjust Fuel Pump
Pressure
Set Fuel Pump Pressure
to 145-150psi with
Burner running.
91
Cleaning
Page 1
1.
2.
Clean Burner Internally every 50 Hours
Remove this cover and use compressed air to
clean the
• Burner Fan area
• Gun Assembly
Clean entire Burner Area at
least Daily, but preferably each
time you load with water
•
Use Compressed Air to remove
dust and crop debris from around
the Burner and Generator
92
Cleaning
Page 2
3.
Clean Burner Flame Sensor and Sight Tube
every 50 Hours
Remove Sensor from Tube to clean
4.
Clean Ignition Electrode and Propane Tube
Assembly every 50 Hours
•
•
Use Compressed Air to remove dust and crop debris from
the Ignition Assembly by attaching your air compressor
hose to the short Red Air Hose that is attached to this
port.
Then turn on your air hose 4-5 times for 2-3 seconds each
time.
93
Reference Resources
For Complete DewPoint 6110 Burner Training Videos, Go To:
www.staheliwest.com
• Login
• Customer Portal
• User name: customer
• Password: dewpoint
• 6210 Burner Videos
94
Sensors
Sensor
Function/Range
Normal Range
Supply Water Level
Fuel Supply Level
Ambient Temperature
0-1000 gallons
0-300 gallons
32° - 212° F
Below 200 gal
Below 30 gal
Above 110° F
Low Water Cut-Off 1
Low Water Cut-Off 2
Manual Steam Pressure Gauge
High Pressure Limit Switch
Operating Pressure Limit Switch
Boiler Water Level
Steam PSI 1 Transducer
actuate on contact with water
actuate on contact with water
0 - 30 psi
set at 15.0 psi
set at 14.5 psi
0 - 12 in.
0 - 30 psi
Below about 1 inch in site glass
Below about 1 inch in site glass
4 - 8 in
6 - 13 psi
Opens above 15 psi
Opens above 14.5 psi (auto reset)
Below 4 in. Above 10 in.
More than 2 psi differential
Steam PSI 2 Transducer
0 - 30 psi
6 - 13 psi
More than 2 psi differential
Feed Water Temperature
0 -300° F
100 - 240° F
Above 150° F differential
Boiler Water Temperature
0 -300° F
100 - 240° F
Above 150° F differential
Rear Door Temperature
0 -300° F
100 - 150° F
Above 250° F
Propane Pilot Pressure
0 - 100 psi
10 - 12 psi
Below 5 psi
Fuel Pump Pressure Gauge
Fuel Pump Pressure Transducer
Nozzle 1 pressure
0 - 300 psi
0 - 500 psi
0 - 500 psi
145 - 155 psi
145 - 155 psi
145 - 155 psi
Nozzle 2 pressure
0 - 500 psi
145 - 155 psi
Flue Temperature
0 - 1000° F
300 - 450°F
0 -15v (Screen Reading)
3-15 v (Screen Reading)
Air Flow Sensor
Infrared Flame Detector
Trip/Alarm
if 20 psi less than Fuel Pump High Fire if
30 psi less than Fuel Pump High Fire
if 20 psi less than Fuel Pump High Fire if
30 psi less than Fuel Pump High Fire
Above 600° F
Options
Disable in Settings/Alarm Status Screen
Disable in Settings/Alarm Status Screen
Disable in Settings/Alarm Status Screen Adjust in
Settings/Alarm Settings
Level adjustable in Settings/Water System
Selectable and Differential Limit adjustable in
Setting/Boiler Pressure Screen
Selectable and Differential Limit adjustable in
Setting/Boiler Pressure Screen
Disable in Settings/Alarm Status Screen Adjust in
Settings/Alarm Settings
Disable in Settings/Alarm Status Screen Adjust in
Settings/Alarm Settings
Disable in Settings/Alarm Status Screen Adjust in
Settings/Alarm Settings
Disable in Settings/Pilot Propane
Reset Count etc.
Disable in Settings/Alarm Status Screen
Disable in Settings/Alarm Status Screen
Disable in Settings/Alarm Status Screen Adjust in
Settings/Alarm Settings
Communicates with Honeywell Controller to
indicate airflow in burner.
Works with Honeywell Controller Flame Amplifier
card to detect presence of Flame.
95