ELECTROtec II O&M Manual Rev 2.0a

Hamworthy Combustion ELECTROtec II Burner Manual No/ HC 401 O&M / rev 2.
0 Page 1
HAMWORTHY COMBUSTION
ELECTROtec II
Gas, Oil
and Dual Fuel
Burner.
Operating and Maintenance Manual

Hamworthy Combustion
Fleets Corner, Poole, Dorset.
England. BH17 0LA
Telephone U.K. + 44 (0) 1202 662700
Manual Number HC 401 O&M / rev 2.0
26/11/10
K.J.Bailey
Hamworthy Combustion ELECTROtec II Burner Manual No/ HC 401 O&M / rev 2.0 Page 2
Section Index
ELECTROtec II Burner
Section Contents Page

Revisions List 3
Copyright 4
Contract Specification 5
1.0 Health & Safety Considerations 6
2.0 General Information 9
3.0 General Description 12
4.0 Combustion Control 16
5.0 Burner Management description 18
6.0 Gas Supply System Description 22
7.0 Automatic Controls Description 24
8.0 Light up sequence Description 26
9.0 Operator Guidance Notes 29
10.0 Maintenance Guidance Notes 30
11.0 Installation Guidance Notes 34
12.0 Component Identification 37
Igniter Assy. Drg 300028011 (Page 23) 38
Doorplate Assy. Cam & Cable (Gas Only) Drg. 300028010 39
Doorplate Assy. Cam & Cable (Oil Only) Drg. 300028009 40
Doorplate Assy. Cam & Cable (Dual Fuel) Drg. 300028008 41
Doorplate Assy. A/link – E/link – Lamtec (Gas Only) Drg. 300028007 42
Doorplate Assy. A/link - E/link - Lamtec (Oil Only) Drg. 300028006 43
Doorplate Assy. A/link – E/link - Lamtec (Dual Fuel) Drg. 300028005 44
Burner Machine Gas Only Drg. 300028004 45
Burner Machine Dual Fuel / Oil Only Drg. 300028003 46
Windbox Assy. Drg. 300028002 47
Windbox Assy. Drg. 300028001 48
Fancase Assy. Drg. 300028012 49
Notes 50
13.0 Appendices
Kromschroder TC1 details (not fitted with Lamtec controls) 51
Viscosity temperature chart 09:04:08 Iss. 2 (Page 14) 63
Overall dimensions (Page 34) 64
Typical Fuel Oil Ringmain (Residual Fuels) 65
Typical Fuel Oil Ringmain (Diesel Fuels) 66
Burner fuel schematic (Page 13) 67
Note
Page numbers in brackets refer to section in the text.

REVISIONS:
Manual Number HCE 401 Rev 1.0 (Original)

th
Rev 2.0 - Control system references changed to include Lamtec (26 November 2010)
Published by
HAMWORTHY COMBUSTION LIMITED
(“HAMWORTHY”)
OF
FLEETS CORNER, POOLE, DORSET. BH17 OLA
First Published: 10/01/2006
Copyright and Design Right 

Hamworthy Combustion Limited 2006
No part of this manual may be reproduced, stored in a retrieval system or transmitted in any form or by
any other means, electronic, electrostatic, magnetic tape, mechanical, photocopying, recording or
otherwise without the prior written permission of Hamworthy.
This manual may not be lent, sold, hired out or otherwise disposed of
by way of trade in any form whatsoever.
PRINTED IN THE UK.
NOTES:
1/ The information contained in this manual is intended as a guide only for use by suitably
trained and qualified personnel. Hamworthy can provide training. If in doubt about the
interpretation of this guide the user should contact Hamworthy.
2/ Hamworthy has made every effort to ensure that the information contained in this manual is
accurate at the time of publication. Its contents should be used however as guidance material
only and not as a replacement of current regulations or any contractual specifications.
3/ As the application of the subject matter of this manual will differ dependent upon the particular
circumstances Hamworthy accept no liability for any loss of any kind (including consequential
or indirect loss) occasioned by any person relying upon this manual.
Contract Specification Details
CONTRACT NO/ :
BURNER MODEL NO :
APPLICATION DETAILS :
Boiler/appliance manufacturer :
Heat input rating : System Protection: IP

o
Air system : System Operating Temp. Max/Min C
Appliance working pressure/temp :
OIL FUEL DETAILS :
Primary Fuel Oil Type : Secondary Fuel Oil Type:
Specific Gravity: Gross CV:
Maximum Volume :
Min / Max Pump Speed (Hz): / /
Maximum Pressure / Temp: / /
GAS FUEL DETAILS :
Primary Gas Fuel Type : Secondary Gas Fuel Type :
Specific Gravity :
Gross Calorific Value :
Maximum Volume :
Maximum Pressure :
IGNITION SYSTEM DETAILS:
Fuel Type : Maximum Pressure :

CONTROL SYSTEM DETAILS:
Mains Supply Voltage : v hz Control System Voltage : v hz
Control Circuit Diagram Number
CONTRACTS ENGINEER (Name) Date :

Section 1
ELECTROtec II Burner Health and Safety

GENERAL SAFETY -
Read this section before undertaking ANY work on the burner.
Before attempting to assemble, install or commission the burner it is important that this document is
read and understood completely.
It is essential that any maintenance, fault finding or commissioning operations carried out on
this equipment is performed only by a competent Engineer, i.e. one that is adequately trained,
experienced and qualified with this equipment and associated processes, i.e. gas, electricity
and oil requirements and regulations.
It is strongly recommended that Operators and maintenance staff be trained in the correct and safe
use of the burner. Training courses are available from Hamworthy.
It is important that the burner supplied in this contract is used only on the fuels for which it was
designed and at flows and pressures which are suitable for both the burner and the appliance on
which the burner is fitted.
It is also imperative that the burner geometry, design and ratings are not altered or modified in any
way other than by a Hamworthy Engineer or under the specific direction of Hamworthy.
No responsibility can be accepted by Hamworthy for the outcome of unauthorised tampering with
these crucial parts.
The ‘Health and Safety at work Act’ requires both the Manufacturer and the end user of the equipment
ensure that the equipment supplied can be, and is, operated safely. If the burner is fitted to a boiler or
appliance not manufactured by Hamworthy, then due regard MUST also be given to the operating
instructions supplied with the appliance.
Hamworthy Combustion cannot be held responsible for any consequential damage, loss or injury
resulting from improper commissioning or the failure to follow these instructions.
At all times the equipment should be installed and operated with due regard to good engineering and
safety principles. This cannot be over emphasised when dealing with inflammable or explosive fuels.
Due attention must also be given to any regulations applicable to the storage and handling of fuels.
The equipment has been designed to operate with the fuels and at the conditions detailed in the
contract specification sheet. Proposed changes to any part of this specification must be referred to this
company for prior approval, as must any other questions relating to the safe operation of the supplied
equipment. When reading these instructions always make reference to instructions given by
manufacturers of any associated plant, or appliance.
Hand protection must be worn if contact with the fuel oil is expected, e.g. during servicing work. Clean
up any spillage’s immediately.
Keep the area surrounding the combustion equipment and its associated equipment clear of debris.
Never remove any guards whilst the burner is operating.
It is recommended that adequate lighting and access is available around the burners, especially
during commissioning and servicing activities.
All subsequent settings must progress from a fuel lean condition.
If the plant is operating at in an environment with noise levels in excess of 80dBA it is recommended
that the operators use suitable ear defenders.
If the burner is under repair or being serviced, ensure that warning notices are placed on the burner,
e.g. “Do not operate, machine being serviced”.
Attend to fuel leaks as they are reported. Do not delay.
Make no attempt to operate the associated plant whilst fuel is escaping, since this is dangerous.
Burner machine must not be run with the belt guards removed.
Regular maintenance of the flue ductwork is essential to provide a safe environment within the plant
room.
Ensure that hot pipes, such as those containing steam or water are lagged. Restrict access to any
area where hot metalwork or gases may be encountered.
Always adhere to the rigors of any site Permit-To-Work system.
Never stand directly in front of a burner whilst it is lighting-up.
COMBUSTION AND CONTROLS:
Setting or adjusting the fuel/air ratio must only be carried out by Hamworthy or other competent
personnel.
Do not make repeated attempts to light the burner. If a flame cannot be established after two
consecutive attempts, carry out an investigation into the cause. A succession of abortive attempts to
fire the burner, may result in the build up of a combustible or explosive mixture within the boiler or
appliance.
Pre-purge and post purge settings are set during commissioning and must not be subsequently
altered.
It is essential to ensure that, prior to initial light up during the commissioning phase, all fuel control
valves, proportioning valves, and similar devices are set to their minimum flow positions before any
source of ignition is introduced into the combustion space.
The initial fuel flow adjustments necessary to provide light-up conditions must only be made whilst the
burner is switched OFF.
Subsequent light up attempts being made each time progressing from a fuel lean condition until a
good light up is achieved. Once adequate fuel flow exists to enable the burner to light, then the fuel
flow to the flame may be optimised whilst the burner is lit.
ELECTRICAL
Do not leave control panels or junction boxes open whilst power is on. Should it become necessary to
do so, in the interest of rectifying faults, then only competent personnel should be involved and they
MUST adhere to the requirements of the local Electricity at Work Regulations.
Warning notices must be posted and the covers must be replaced as soon as possible.
Safety interlocks are mandatory. Once a fault on any interlock has been detected, then the fault(s)
must be corrected before the unit is operated.
DO NOT BY PASS INTERLOCKS.
Isolate electrical supplies and fuel lines before attempting to work on the combustion equipment. Post
warning notices as necessary and ensure plant is sufficiently cooled and ventilated, etc.
Ensure that the protective earth bonding of the complete burner machine and gas train and associated
gas pipework remains intact and continuous at all times.
Continuity of the bonding must be maintained when a part, e.g. a gas valve, is removed from the gas
train. Jumper cables of adequate size, (no smaller cross section than the existing bonding cable), must
be connected across the gap.
Whilst the burner is under repair, ensure that the power cannot be reinstated by locking-off electrical
isolators.
High voltages, up to 14,000 volts, may exist around the ignitor plug caps.
This equipment must be earthed via the protected earth terminal.
! CAUTION !
The installation and commissioning of electronic equipment, must be carried out correctly to avoid
damage to plant. Ensure full Electrostatic discharge, (ESD) protection equipment is used during all
phases of handling and installation of this equipment.
SECTION - 2
ELECTROtec II Burner GENERAL INFORMATION
GENERAL INFORMATION
The correct installation of a Hamworthy burner is as important as the design of the burner itself.
Each installation must be carefully planned to ensure a complete system in every detail. Reference must
be made to all the relevant standards and regulations regarding the installation and use of this burner
equipment.
The installer must be familiar with local regulations and insurance requirements, which will serve as a
valuable guide to a safe installation.
FUEL OIL SYSTEM
The system of storing and handling fuel oils, must be designed to ensure the transfer of oil at the correct
pressure and temperature from the storage system to the burner under all conditions of service. All fuel
systems for the Electrotec II burner must be designed and installed in accordance with the Hamworthy
Combustion data sheets.
See Oil ring main data sheets in Section 13.
MATERIALS
The use of correct materials and the highest standards of installation and workmanship will always pay
dividends when installing a burner. The burner operating conditions are often severe, reliability and
performance depends on good installation, commissioning, maintenance and general performance
monitoring.
PLANT IDENTIFICATION
Installation
A “Contract Number” identifies every installation. This is displayed on identification plates mounted on:
1. The burner machine

2. The windbox
3. The control panel
BURNER MACHINES
Each burner is fitted with a plate stating:
1. Contract number
2. Product number
3. Burner serial number
4. Burner designation.
5. Date of manufacture.
CONTROL PANEL
Each control panel is identified by a plate stating:
1. Contract number
2. Panel serial number
PLANT CAPACITY
A plate is attached in a prominent position stating;
1. Burner size.
2. Burner serial number.
3. Gas firing - Maximum gas flow rate.

- Gas type.
- Specific gravity.
- Gross calorific value.
- Nominal manifold pressure at maximum rate.
4. Oil firing - Maximum oil flow rate.

- Oil class type.
- Oil flow setting at maximum rate.
SPARE PARTS
On all orders for replacement parts and on all correspondence regarding individual burners, the burner
serial number, designation and contract number must be given. The information appears on the burner
nameplate. When ordering replacement panel parts the panel serial number must be quoted.
UNITS OF MEASUREMENT
The units quoted in this manual are generally SI.

Electrotec II Burner Range Specifications

GENERAL DATA 5 7 8 10 11 12 15 17 20 22 25 30 35 40 45 50
Model 1.9 2.5 3.1 3.7 4.1 4.5 5.4 6.3 7.2 8.1 9.0 10.9 12.7 14.5 16.4 18.2
OIL DATA
Oil Input Litres/hr $ 170 227 284 341 375 414 496 577 659 741 827 996 1155 1318 1491 1659
Oil Input kg/hr Class “G” Fuel $ 159 211 264 317 349 385 461 537 613 689 769 926 1074 1226 1387 1543
Supply Pressure 0.2 – 4.0 Bar.g.
Fuel Type Class “D2 to Class “G” Fuel Oils
Nominal Turndown 3:1 3.5:1 4:1 4:1 4.5:1 4:1 4.5:1 5:1 5:1 5:1 5:1 6:1 6:1 6:1 6:1 6:1
Pump Type (Hamworthy Ref) A A A A A A B B B B B C C D D D
Typical Pump rpm @ MCR 1275 1702 2130 2560 2812 3105 1880 2189 2500 2800 3140 2470 2870 2610 2950 3288
Pump Motor Absorbed Power kw 0.15 0.15 0.15 0.15 0.16 0.16 0.19 0.22 0.25 0.28 0.31 0.39 0.45 0.5 0.57 0.63
Pump Motor Installed Power kw 0.37 0.55 0.75 1.1
GAS DATA
Natural Gas m³/hr (HCV) # 179 239 298 358 394 434 520 606 692 778 869 1046 1213 1384 1566 1743
Nominal Manifold Loss m.bar.g 24.9 37.4
Nominal Turndown 4:1 4:1 4:1 4:1 4:1 5:1 5:1 5:1 5:1 6:1 6:1 6:1 6:1 7:1 7:1 7:1
NOMINAL BURNER OUTPUT
Burner Output Gross MW 1.87 2.49 3.12 3.74 4.11 4.54 5.44 6.33 7.23 8.13 9.08 10.9 12.7 14.5 16.4 18.2
Burner Output Gcal/hr (Net) ~~ 1.61 2.14 2.68 3.22 3.54 3.90 4.68 5.45 6.22 6.99 7.81 9.39 10.9 12.4 14.1 15.7
BOILER OUTPUT
Steam f & a 100 ºC kg/hr ~~ 2476 3301 4126 4951 5446 6007 7196 8384 9572 10760 12015 14457 16768 19144 21653 24095
Hot Water Gcal/hr (Net) ~~ 1.33 1.78 2.22 2.67 2.94 3.24 3.88 4.52 5.16 5.8 6.48 7.8 9.04 10.32 11.68 12.99
Hot Water MW (Gross) ~~ 1.55 2.07 2.59 3.1 3.42 3.77 4.51 5.26 6.0 6.75 7.53 9.07 10.52 12.01 13.58 15.11
GENERAL
Igniter Input 30KW
Modulation Control High / Low – Fully Modulating – Alpha Link / Electrolink - Lamtec
Atomiser Shaft Motor rpm 5500 4897 5748 5669 5828
Atomiser M’tor Installed Power kw 0.37 0.37 0.37 0.55
$ Table based on residual fuel oil, gross CV 10167 kcal/kg (oil) S.G. 0.93 @ atomising temperature.
# Gas based on std. Conditions 1093 m.bar & 15 ºC. Gross CV 9731 kcal/Nm³ (Gas) Gas corrected for lower efficiency of 79%.
~~ Boiler efficiency 83%.
SECTION - 3
ELECTROtec II Burner GENERAL DESCRIPTION
GENERAL DESCRIPTION
The Electrotec burner model range consists of 16 burner sizes. Individual burners are prefixed with “ER”
(representing Electrotec Rotary cup)
The Electrotec burner is available in three forms -
ERO - Oil only.

ERG - Gas only.
ERD - Dual fuel.
Following the burner model reference, e.g. ERD there will be a number that relates to the burner frame
size e.g. ERD 22. Following this will be another number that relates to the burner output in MW, therefore
an ERD 22 / 8.1 is a frame size 22 dual fuel Electrotec Rotary cup burner with a heat output of 8.1 MW.
The data sheet in this manual gives specific ratings (Page 11).
The Electrotec II burner is of the rotary cup type. The atomising cup is driven by a burner-mounted electric
motor via a belt drive.
Fuel oil is delivered to the burner cup from a variable speed pump mounted under the burner windbox.
Primary and secondary air is normally supplied by a compound fancase containing two separate fan
impellers contained within a single fancase (some applications with high system resistance require the
use of two independent fans each with their own motor drive and silencing equipment as required). These
fans are direct driven by an electric motor sized for the specific burner and boiler duty. Primary air for
atomisation of the fuel oil is ducted via a control damper contained within the burner hinge to the primary
air nozzle. High pressure air discharging from the primary air nozzle “shears” the oil film as it leaves the
atomising cup and breaks it into fine droplets. Secondary air at low pressure is delivered to the air register
through a modulating control damper.
A multi ported gas nozzle (nozzle shield), of the nozzle mix type, is mounted within the burner air register.
The complete burner assembly comprising air register (windbox) and compound fancase can be
turned in any direction to suit the particular application, the burner machine remains in it’s original
orientation.
AIR SYSTEM
Air is drawn into the secondary fan impeller either directly or through an air inlet silencer (if required).
In both cases a simple baffle plate is fitted to act as a coarse damper for purposes of airflow control.
This impeller delivers the main combustion air requirement to the burner through the twin bladed
contra-rotating damper blades, from here it passes into the air register (windbox) and through the
secondary air discharge cone to the furnace.
A small amount of the secondary air passes through ports in the side of the nozzle shield, this airflow
is further sub divided such that some exits through the tertiary air space, the remainder exits through
the refractory face of the nozzle shield.
The primary air fan impeller takes approximately 7% percent of the secondary airflow from the
upstream side of the secondary damper. The primary fan elevates the pressure to the level required
for atomisation of the fuel this is delivered to the primary air nozzle via a separate discharge pipe and
control damper.
It is possible to operate the Electrotec II burner compound fan arrangement with a variable speed
motor drive subject to some special considerations. For details please contact your nearest
Hamworthy Combustion sales contact or our head office at Poole Tel + 44 (0) 1202 662700.
SILENCER AND FAN MOTOR EQUIPMENT
This equipment is designed to reduce the sound pressure level of the combustion equipment only. The
presence of other noise sources such as pumps, I.D. fans, gas boosters, etc. can have a considerable
influence on overall plant noise measurements. Sound pressure levels will also vary according to the
acoustic properties of the plant room.
Compound Fan Intake Silencer
The silencer is designed to reduce the noise level at the inlet to the secondary air fan. The silencer
construction incorporates an outer shell of galvanised steel with an inner manufactured from perforated
plate the void between the two skins is filled with dense fibre. A wire guard and baffle plate is fitted at the
inlet end of the silencer. The baffle can be used as part of the airflow control as described in the “Air
System” section above.
Fan Motor Muffler
A motor muffler can be fitted if required for further noise attenuation.
BURNER OIL SYSTEM
Fuel oil is drawn from the ringmain into the burner machine by the burner oil pump (maximum fuel inlet
pressure 4.0 Bar.g).
The pump, which is of the positive displacement type delivers fuel oil to the burner valve block. The pump
motor is driven by a variable speed drive, this increases and decreases the fuel oil flow in response to
appliance heat demand, pump flow being proportional to speed.
During periods of re-circulation such as during the warm up time for heavy fuel applications or at other
times when the fuel shut off solenoid valves are closed such as during burner pre and post purge. The
fuel oil spills back to the oil ring main via the re-circulation valve (Factory set at 6.0 Bar.g. at maximum
burner flow rate). See fuel flow schematic diagram on Page 67.
During periods of normal operation when the fuel shut off solenoid valves are open the fuel flow takes
the easier route through the back pressure valve to the burner atomising cup. For this to take place it
is necessary for the back pressure valve to be set lower than the re-circulation valve (Factory set at
5.0 Bar.g.).
Heavy fuel oil burners are quipped with low wattage heaters to maintain the valve block in a warm
condition when in standby.
Burner fuel oil meters are available as an optional extra.
BURNER GAS TRAIN
Gas is supplied to the burner gas manifold via the gas valve train. The gas valve train consists of an inlet
isolating valve, two main gas shut off valves, a pressure control device (possibly combined with one of the
shut off valves), high and low gas pressure monitoring switches and a gas flow control valve. The pilot gas
valve train will consist of an isolating valve, two shut off valves and a pressure control device.
Note :
Diesel electric igniters are also available if required as an option on oil only burners.
Dependent upon the incoming gas pressure the gas valve train could also contain a gas booster, high-
pressure govenor and slamshut valve and or relief valves as well as additional interlocks. These devices
are project / application dependent.
Attached to the gas train is a leak test unit that will perform the automatic gas tightness tests of the main
gas shut-off valves prior to each burner light up. Burners that fire heavier than air gases, e.g. propane,
may well employ alternative tests subsequent to every burner shut down (project / application dependent).
In all cases the gas train should be positioned as close to the burner gas nozzle as possible. A distance of
3.0m between the burner gas manifold and the main gas valves is normally considered to be the
maximum for reliable and efficient burner operation.
The burner is capable (with project specific changes) of burning a range of gases including Natural Gas,
Butane, Propane, Methane and Bio Gas. When firing gas the burner machine, i.e. atomiser and pump
motors are stationary, however, the secondary and primary air fans remain operational supplying
secondary air for combustion and primary air for optimum gas/air mixing and performance
COMBUSTION (Fuel Oil)
Fuel oil has to be delivered to the burner atomising cup in carefully controlled quantities and at the
correct viscosity to ensure good atomisation. Residual fuel oils will require pre-heating before the
burner to achieve the correct viscosity for atomisation. Distillate fuels will normally be used at ambient
temperature.
See Data Sheet 09:04:08 Issue 2 in Section 13 for details of viscosity and temperature requirements.
Fuel flow is controlled by varying the speed of the burner fuel pump motor, there are two separate air
streams to the burner (Secondary air and Primary air) controlled by dampers which are used to match
air flow to fuel flow throughout the burner modulating range.
Fuel oil is delivered to the rear of the atomising cup by the pump, the atomiser is rotating at a speed in
excess of 4500 rpm, centrifugal force holds the oil to the side of the atomiser where it is formed into a
uniform film. The design of the atomiser allows this film of oil to move forward toward the discharge
end where it exits from the atomiser lip as a solid sheet of oil. Primary air shears the oil film into small
droplets, which are then propelled into the furnace under the influence of the air mass. Primary air flow
will increase with firing rate on the basis that more primary is required to atomise an increasing fuel
flow. At the ignition stage a pilot gas flame is projected from the tertiary air space the oil droplets pass
through this flame and are ignited. At a point in front of the burner nozzle shield the oil droplets meet
the secondary air, this is discharging from the windbox via the secondary air discharge cone, the flame
stabilises in this zone.
Throughout the length of the furnace the fuel oil mixes with the secondary air to ensure complete
combustion. There is a theoretical amount of air required to ensure complete combustion of any fuel,
in reality slightly more than the theoretical amount is required as mixing can never be 100% efficient,
this additional amount of air is referred to as “excess air”. Typically a heavy fuel oil burner firing into a
firetube boiler furnace will require excess air in the region of 15 – 17%, this is entirely dependent on
furnace size and is subject to selection on a project by project basis. As burner output reduces the
excess air will increase.
COMBUSTION (Gas)
Fuel flow is controlled by means of a Gas Control Valve (GCV), this valve is of the butterfly type, and
the degree of opening is dictated by the appliance heat demand. The gas is discharged from the
burner nozzle shield directly into the secondary air stream where mixing takes place takes place
immediately. A flow of primary air is still maintained whilst gas firing although the total quantity of
primary air can be reduced if required for the control of emissions performance. A portion of the gas /
air mixture is drawn across the refractory face of the nozzle shield by the aerodynamic effect of the air
register design, this allows the mixture to enter the ignition flame which emits from the tertiary air
space as described in the previous section.
As with fuel oil the gas / air mixture burns throughout the length of the furnace to ensure complete
combustion. There is a theoretical amount of air required to ensure complete combustion of any fuel,
in reality slightly more than the theoretical amount is required as mixing can never be 100% efficient,
this additional amount of air is referred to as “excess air”. Typically for a burner operating on Natural
Gas the amount of excess air required at maximum burner output will be in the region of 10 – 15%,
this is entirely dependent on furnace size and is subject to selection on a project by project basis. As
burner output reduces the excess air will increase.
SECTION - 4
ELECTROtec II Burner Combustion Control

COMBUSTION CONTROL
There are four different combustion control options available on the ELECTROtec II burner, these are
Standard, Electrolink, Alpha Link and Lamtec.
STANDARD
This comprises of an Electronic modulation motor commanded by appliance demand either directly
from a potentiometer to give proportional only control through an in built balance relay or in response
to a command signal from a three term controller in the burner control panel.
This motor is mechanically linked directly to the input of a cam assembly mounted on the burner
secondary air damper. The servo motor will be set to travel through 90 degrees via the link rod this will
stroke the damper from fully closed to the maximum required, intermediate settings are set on the cam
profile (set at commissioning).
On oil only burners a single drive cable is connected to the auxiliary end of the modulation motor, the
other end connects to the primary air damper contained within the hinge of the burner machine. The
stroke of the cable can be adjusted as required to deliver the correct amount of primary air to the burner.
This air flow is not characterised throughout the range as a special trailing blade on the damper acts to
make the flow linear throughout the operating range.
An auxiliary potentiometer within the modulation servo motor provides the command signal to the oil pump
variable speed drive.
The maximum and minimum pump speeds are set within the oil pump variable speed drive unit during
commissioning (see the burner specification sheet for details of the speeds required to match the
appliance duty).
ELECTROLINK
An electronic unit (Electrolink) is fascia mounted in the burner control panel. The Electrolink unit positions
via digital output channels individual precision servo motors connected to the various burner control
devices, one each for the Secondary Air Damper, Primary Air Damper and Gas Control Valve. The fuel
oil pump variable speed drive is connected directly to one of the Electrolink analogue output channels.
Each control device provides a feedback signal to the Electrolink unit to confirm correct operation.
The Electrolink controller controls the relative position of each servo to the other. This relationship is set
during commissioning (Refer to the appropriate manual for details of how to commission).
The Electrolink controller can control up to four output devices at any one time and be programmed for up
to four different fuel curves. When applications involve the use of other burner inputs such as Re-
circulated Flue Gas for emission control purposes it is possible to re-assign via a selector switch any un-
used output. In cases such as this reference should be made to the particular circuit drawings for the
burner as these will give details of servo drives actually in use.
ALPHALINK
The functionality of the Alphalink controller is identical to the Electrolink in every respect plus it has the
facility to operate with a flue gas oxygen probe to provide an “oxygen trim” function (Refer to the
appropriate manual for details of how to commission).
LAMTEC
The Lamtec controller contains the functionality of the Alphalink controller with the addition that it also
manages the sequential control of the burner light up and normal run functions.
SECTION - 5
ELECTROtec II Burner Management Description

GENERAL DESCRIPTION
Whether based on Electro-mechanical sequence timing or digital technology the function of the Burner
Management System (BMS) is to monitor the status of the burner safety interlocks during standby, start
up and normal operation. Often other safety devices are monitored from the BMS panel such as boiler or
heater interlocks.
National legislation in most countries of the world dictate the nature and type of safety monitoring devices
that are required, it is therefore important that these safety devices are set and maintained correctly.
During the light up sequence the BMS commands the modulation system into the purge and light up
positions. If the burner is dual fuel or gas only, additional controls for the automatic gas leak testing of the
gas valve train will also be monitored.
The particular circuit drawing issued with the burner will detail the exact method of operation of the burner
to which they apply. The following description is therefore generic in nature, your burner will contain some
or all of the following control functions. The general sequence of operation will be the same in all cases.
BURNER MODULATION
Once the burner is operating and main flame has been established by the BMS, the Normal Run relay is
energised permitting the modulating system to operate. Modulation of the burner can be controlled
manually or automatically through the appliance demand circuit.
Standard Modulation
In the case the Standard system there is a switch on the burner panel that can select “Manual” or “Auto”,
when switched to “manual” the burner firing rate can be determined directly by the operator by turning a
hand potentiometer up or down as required. In “Auto” the burner firing rate is dictated by the appliance
demand signal. Occasionally this switch may have a third position “Remote” this would normally signify
that a demand signal is coming from another system such as a load sharing device (Sequence Control) or
building management system.
Electrolink Modulation
The operator can switch between “Manual” and “Auto” on the key pad at the front of the Electrolink unit.
Using the left and right arrow keys on the keypad the burner firing rate can be taken up or down as
required.
Alpha link Modulation
As Electrolink.
LAMTEC
The modulation mode can be changed via the display.
Reference should be made to the Lamtec operating manual for the specific model being utilised.
BMS SAFETY INTERLOCKS
Gas Pressure Switches (Gas and dual fuel burners only)
Two pressure switches, one for high gas pressure and one for low gas pressure, monitor the gas supply
pressure and will cause an immediate shut down should they be activated.
Burner Hinge Microswitch (All burners)
This prevents the light up sequence starting, or causes immediate shut down if the burner is firing when
not fully closed to the windbox front. The switch is mounted adjacent to the closing handle to the left side
of the burner machine.
Gas Train Isolated Interlock.
A closed position indicator switch within the upstream main gas valve is used to prove isolating of the gas
supply before enabling oil firing.
Power Supply Failure
In the event of supply failure a relay is de-energised which causes the burner to lockout and remain
locked out when the supply is re-instated. This can only be re-set by manual intervention, the “reset”
button should be pressed.
Exit Damper and Flue Draught Switches, (if fitted)
These switches ensure that any manual exit damper is wide open and that a normal flue draught is
present before allowing ignition of the pilot flame.
Gas Leak Test System
This system performs an automatic pressure test to check the integrity of the two main gas valves before
allowing the light-up sequence to commence. On burner panels equipped with Electro Mechanical
sequence timers this test will be performed by a Kromschroder TCI system connected between the two
shut off valves. On burners controlled by Lamtec the valve leakage test is an integral function of the unit,
pressure switches installed on the gas valve trains are used to provide the required monitoring function.
Primary Air Pressure Switch
This pressure switch ensures that correct primary air flow is present during pre-purge and firing periods.
Failure causes the burner to lockout. The primary air switch is mounted on the burner lid of the burner
junction box and connected to the burner primary air plenum by plastic tubing.
Secondary Air Pressure Switch
This pressure switch initially has to be proved in the “no air” position prior to permitting a light up sequence
to commence. One the burner light up sequence has started this switch ensures that the correct
secondary air flow is present during pre-purge and firing periods. Failure causes the burner to lockout.
The secondary air damper switch is mounted on the burner junction box and is connected to the windbox
upstream of the damper by plastic tubing.
Low Fire Air Proving Switches
This microswitch is on the air damper and proves that the damper is at the required low fire, (light up)
position before the burner ignition sequence can commence. Electrolink equipped burners also utilise a
signal provided from the Electrolink when the relevant servos are at the light up position.
Air Purge Pressure Proving Switch
This pressure switch monitors the pressure within the burner windbox during the light up sequence. This
switch must be made for the pre-purge to commence. Electrolink / Alphalink / Lamtec equipped
burners also utilise a signal provided from the controller when the relevant servos are at the purge
position.
Low Fire Gas Proving Switch
This microswitch is located on the gas flow control valve (butterfly valve) and is used to prove that the
valve is in the required low fire, (light up) position before the burner ignition sequence can commence.
Low Fire Oil Proving Interlock.
Monitoring the pump drive motor speed proves oil flow at the light up position. A signal from a sensing
device fitted to the motor is taken to an amplifier within the burner control panel. Provided the speed is at
light up or below the burner light up sequence is permitted to proceed (On Lamtec equipped burners this
function is integral to the controller).
Flame Proving
An ultra violet cell is fitted to the burner igniter to view both pilot flame and main flame. During the pre-
purge period a high voltage check of the cell is made to ensure correct operation. Should a “false” signal
be present at this time a lockout will occur and the burner light up sequence will stop. Once normal
operation is established the U.V. detector is used to continuously monitor the flame, locking out the burner
in the event of flame failure.
As an option it is possible to fit a variety of “self checking” flame detectors to the same position.
Low Boiler Water (Boiler Mounted Switch - Steam Boilers only)
Two low water levels are used.

st
1 Low water alarm will cause the water level alarm and indicator lamp to activate. The burner will initiate
a normal safety shut-down and will automatically re-start when the condition has cleared.
nd
2 low water level, if reached, will shut-down the burner immediately and the burner will remain
shut-down. The alarm will cause the water level alarm and indicator lamp to activate. When the condition
clears the burner is at a locked out condition. Restoration can only be achieved by pressing the Reset
button.
Water level alarms may be muted with the Mute button to silence the alarm, however, the fault condition
will remain.
High Water Level (Boiler Mounted Switch - Steam Boilers only)
High water alarm initiate the alarm and indicator lamp, the burner remains alight. Water level alarms may
be muted with the Mute button to silence the alarm, however, the fault condition will remain.
Boiler Limit Switch (Boiler or Panel mounted - electro-mechanical modulation)
This may be a pressure or temperature operated device which is set to switch the burner on and off.
Boiler Modulation Switch (Boiler or Panel mounted - electro-mechanical modulation)
This may be a boiler pressure or temperature operated device, which is used in conjunction with the
modulation system to adjust the burner firing rate to match the boiler load.
Boiler Pressure Transmitter (Boiler or Panel mounted - Electrolink/Alphalink or Lamtec modulation)
The Transmitter is normally a 4-20mA device and is used in conjunction with the controller to provide
the primary input to the PID loop.
Gas Booster Inlet pressure (If fitted)
This is a manual reset pressure switch mounted on the inlet pipework to the gas booster.
The switch contact will open, and immediately shut down the burner if the booster inlet gas pressure falls
below set point. The set pressure being specified by the local gas supplier.
Oil check thermostat (Heavy oil only)
This thermostat monitors the fuel oil temperature at the burner. Should the fuel temperature be below
the set point the burner is prevented from firing. If the burner is selected “on” and the fuel temperature
is below set point the burner pump will circulate fuel until the thermostat is satisfied at which time the
ignition cycle will commence.
Atomiser shaft rotation sensor
The burner is equipped with a sensor to monitor the rotation of the burner atomiser shaft when firing
fuel oil. This sensor ensures that the atomiser shaft is rotating at the correct speed to atomise the fuel
correctly. The sensor is connected to an amplifier housed in the control panel, should the speed fall
below set point the sensor relay (amplifier) contact will open and inhibit the burner from firing.
Pump motor rotation sensor
The burner fuel oil pump is driven at varying speeds dependant on appliance demand. A rotation
sensor and amplifier / relay is used to monitor the pump speed and ensure that speed is correct for
burner light up. Should the pump speed be greater than the set point the burner will be inhibited from
lighting.
SECTION - 6
ELECTROtec II GAS SUPPLY SYSTEM DESCRIPTION

GAS TRAIN ISOLATING VALVE
A manual isolating valve is fitted to the inlet of the gas train.
AUTOMATIC GAS SHUT-OFF VALVES.
Two automatic gas shut off valves are fitted in series into the system to provide isolation of the fuel,
these valves are approved to EN 161. Proof of isolation of the gas train is provided via a Closed Position
Indicator switch, (CPI switch), fitted inside the first main gas valve.
st
1 GAS SHUT OFF VALVE WITH INTEGRAL GOVERNOR
This valve, when energised, regulates the main gas supply pressure over the burner operating range to
give a constant pressure at the inlet of the gas flow control valve. When de-energised it provides isolation.
It is situated immediately downstream of the isolating valve and contains a CPI, (Closed Position
Indicator) microswitch to prove isolation of the gas train.
nd
2 GAS SHUT-OFF VALVE
When energised this valves opens fully, when de-energised it provides isolation.
GAS FLOW CONTROL VALVE
The flow control valve, (butterfly valve), is fitted downstream of the two shut-off valves usually just below
the burner.
The butterfly valve is operated either by a mechanical cable drive from the burner modulation motor or
from the Electrolink / Alphalink or Lamtec controller via a directly coupled servo.
GAS PRESSURE SWITCHES
Low and high pressure switches, piped directly onto test points on the gas train, monitor the gas supply.
Pressure switch settings are entered into the burner log sheet at commissioning.
LOW FIRE GAS PROVING SWITCH
This microswitch is on the gas flow control valve, (butterfly valve), to prove that the valve is in the required
light up position before the burner ignition sequence can commence. For Electrolink / Alphalink and
Lamtec controlled burners the butterfly valve is operated by a servo motor, on mechanical linked burners
the valve is operated by a cam and cable from the main modulation motor.
GAS BOOSTER INLET PRESSURE
This is a manual reset pressure switch mounted on the inlet pipework to the gas booster.
It will break, and immediately shut down the burner if the booster inlet gas pressure falls below set point.
The set pressure being specified by the gas supplier.
GAS VALVE PROVING SYSTEM
Primary safety of the gas shut off system stems from the fitting of two safety shut off valves in both the
main and ignition gas supplies lines to the burner.
The main gas shut off valves are subject to an automatic leak test, performed by a self contained test unit
mounted to the gas train. The test is carried out during every burner light up, during the pre purge
sequence. If this test is not satisfied, the light p sequence is inhibited and the burner locks out.
KROM SCHRODER Tightness Control – TC1
See Section 13 for details.
GAS FILTERS
Current gas regulations, applicable to gas burners, call for gas filtration upstream of the automatic shut off
valves unless they are positioned within 20 metres of the gas meter filter.
The standard range of valves selected for the burner incorporates an integral filter and it is not
necessary for an additional filter to be installed. When valves not incorporating a filter are selected, it
may be necessary for a separate upstream filter to be installed.
IGNITION
The Electrotec II burner utilises as standard a gas electric igniter with ignition flame proving provided
by a UV detector mounted on the main igniter body. As an option it is possible to utilise a diesel
electric igniter on oil only burners.
The igniter has a centrally mounted spark electrode secured in the igniter body by a hand tightened
retaining nut. Gas is supplied to the igniter via a regulated supply and two solenoid operated shut off
valves. Air for the igniter is supplied from the burner primary air supply downstream of the control
damper via a nylon tube.
Natural Gas or Propane can be used with this igniter. For details of flow and pressures of gas electric
igniter see Section 13.
The igniter head contains two simple needle valves which are used to control air and gas flow to the
igniter. These are adjusted to produce a small blue flame, which is stabilised on the end of the spark
electrode within the venturi section of the igniter. This small stable flame then ignites the main gas flow
that is provided by the 3mm boost tube that runs alongside the main igniter tube.
As a rough guide for setting of the igniter ensure that a supply pressure of 3.5 m.bar. is available at
the inlet, fully close both needle valves. Open the gas needle valve ½ turn from it’s fully closed
position, open the air needle valve two full turns from it’s fully closed position. Tighten the lock nuts,
the igniter should be very close to the ideal setting.
SECTION - 7
ELECTROtec II AUTOMATIC CONTROLS
GENERAL DESCRIPTION
The burner control system may be considered in two separate parts, the burner management system
(BMS), and modulation system, either may take differing forms dependant upon customer specification.
BMS Options include:
Electro-mechanical (cam timer),

Electro-mechanical (cam timer) with a PLC for the diagnostic display system,
Lamtec microprocessor based combined BMS and Modulation system.
Modulation System Options;

Electro-mechanical control,
Electrolink air/fuel ratio control, or upgrade to Alphalink if O2 trim is required.
Lamtec combined BMS and Modulation system.
BMS SYSTEM
Whether Electro-mechanical or Microprocessor based the function of the BMS is to monitor the status of
the burner and boiler safety interlocks all the time the panel isolator is energised so as to ensure that any
unsafe situation will result in immediate burner shut down. Also monitored are the normal operational
interlocks that are responsible for starting and stopping the burner whilst under normal operation.
During the light up sequence the BMS commands the modulation system into the purge and light up
positions. If the burner is dual fuel or gas only, additional controls for the automatic gas leak test will also
be monitored.
MODULATION SYSTEM
Once the light up main flame has been established by the BMS, the Normal Run relay is energised
permitting the modulating system to operate. Modulation may be controlled by an electro-mechanical
system. Automatically tracking appliance demand or under manual control, or by the Electrolink /
Alphalink air/fuel processor system. Again either automatically tracking appliance demand or locally
manual or from a remote external control.
Automatic Modulation:
The modulation is controlled to continually balance the burner heat input to the appliance demand. The
burner will perform a normal shut down if the pressure / temperature set point is exceeded. Upon pressure
/ temperature drop the burner will initiate a normal light up.
Local Manual Modulation:
Upon achieving Normal Run the modulation will drive to a position set on the manual control knob, or
firing rate % on the Electrolink / Alphalink / Lamtec. The burner will remain at that setting regardless of the
boiler load. When the pressure / temperature set point is achieved the burner will shut down. Upon
pressure / temperature drop the burner will initiate a normal re-light and at Normal run return to the
previously set firing rate. Manual control does not balance heat input to boiler load.
Remote External Modulation:
This facility is only available with the Electrolink / Alphalink / Lamtec system. The burner modulation is
controlled by an external source, i.e. Master/Slave Electrolink / Alphalink systems, boiler sequencer etc.
The burner will still shut down upon reaching the appliance set point. Upon pressure / temperature drop
the burner will initiate a normal re-light and resume modulating under the external source.
BMS SAFETY INTERLOCKS
Whilst every burner application has a requirement for safety interlocks to meet certain statutory obligations
a variety of other customer or application specific interlocks will be fitted. Details of these are always
shown on the circuit diagrams supplied with the burner. Interlocks are important to pro9tect the plant and
operator and should always be kept in operation.
ELECTROLINK / ALPHALINK / LAMTEC
Refer to the relevant manual for details of operation.

SECTION - 8
ELECTROtec II LIGHT UP SEQUENCE

This is a typical description of the burner light up sequence, the basic process will be the same
whether electro-mechanical sequence timer, Microprocessor controlled or whether Electrolink,
Alphalink or mechanical modulation is fitted.
Apply power to the burner panel.
The control panel will now be in the Standby mode.
The main safety interlocks are being monitored and, if activated, will cause a lockout, the power being
withdrawn from the sequence timer or Microprocessor inputs/outputs.
Some interlocks will be relevant to Oil, some Gas and others Common to both fuels.
Typical Standby Interlocks include:
• High gas pressure switch G

• Low gas pressure switch G
• Second low water level (steam boilers) C
• Water level/pressurisation (hot water boilers) C
• Burner hinge microswitch C
• Power supply failure relay C
• Excess pressure/temperature switch C
• Gas detectors C
• Fire detectors C
• Emergency Stops C
The Burner management System, (BMS) will be awaiting the Burner On/Off switch activation, (or a
remote start signal from an external source if fitted).
Upon receiving the start signal the BMS will initiate the start loop.
Typical start loop interlocks include:
• Secondary air pressure absent. C

• Local or remote Burner start signal. C
• Gas isolated interlock closed. O
• Oil check thermostat -hot oil Heavy oil burners only). O
• First low water. C
• Pressure/temperature limit switch. C
Note :- On a cold start up situation the oil check thermostat will be showing cold. In this instance the
burner will begin recirculation of the oil, (burner pump runs at 50% speed). Gradually hot oil will be
drawn into the burner, the thermostat will register the presence of the hot oil and show hot. The
recirculation will cease and the burner will await the completion of the loop before commencing).
Oil burners - the start loop is now complete and the BMS is ready to issue the “go to pre-purge
position”.
Gas burners - the start loop is now complete, the gas tightness test of the main automatic gas valves
is now initiated.
• Gas booster started, (if fitted). G

• Gas tightness test executed and completed. G

*(Some specifications perform the gas test before the purge commences, others during the drive to
pre-purge period).
The start loop and gas test is now complete and the BMS is ready to start the pre-purge.
The modulation system is signalled to go to the pre-purge position.
• Gas test initiated *. G

• Fan motor started. G
• Fan and burner motors started. O
• Exit dampers signalled to open, (if fitted). C
Interlocks to prove pre-purge position:

(differing specifications require the pre-purge to take place at either 50% or 100% of the
modulation range).
• Secondary air damper at pre-purge position. C

• Electrolink pre-purge position relay. C (if Electrolink or Alphalink fitted).
• Secondary air pressure proved. C
• Exit dampers open. (if fitted). C
Pre-purge commences - 60 seconds.
At the end of the pre-purge the BMS will signal the modulation to drive to the light up/low fire position.
Interlocks to prove light up/low fire position:
• Secondary air damper at Low fire. C

• Secondary air pressure present. C
• Electrolink light up position relay. C (if Electrolink or Alphalink fitted).
• Primary air pressure present. C
• Gas butterfly valve at low fire position. G
• Oil pump speed equates to low fire light up rate. O
• Atomiser cup rotation. O
• Atomiser cup no rotation. G
• Exit dampers open. C
When all the light up/low fire interlocks are secure the BMS will initiate the ignition sequence
Ignition sequence:
• H.T spark initiated.

• Pilot gas valves opened. (or pilot diesel oil valves in the case of diesel fired ignition).
• Pilot flame proved.
• H.T. spark off.
• Pilot flame still proved.
• Main fuel valves opened.
• Main flame proved.
• Pilot flame off.
• Main flame still proved.
• Normal Run.
Normal Run:
Once at normal run the burner, if selected to automatic or external modulation signal, will modulate
and stop/start in order to match the appliance load. If selected to manual modulation the burner will
drive to the set firing rate and remain there. Stopping and restarting the burner will still be performed
by the BMS.
Lock out conditions:
From the normal run condition the failure of certain units/interlocks will cause a lock out:
• Failure of associated BMS units:

• Electrolink/Alphalink – (Internal fault) C
• Failure of interlocks:
• Lockout and post purge takes place;
• Photo cell - loss of flame signal. C
• Secondary air loss. C
• Primary air loss. C
• Cup rotation loss. O
• Exit damper not open. C
Immediate shut down, lockout on re- instatement;
• Second low water. C

• High gas pressure. G
• Low gas pressure. G
• Burner hinge open. C
• Gas detectors/fire systems. C
• Gas booster inlet pressure. G
SECTION - 9
ELECTROtec OPERATING GUIDANCE NOTES
FUEL CHANGEOVER
If the fuel is heavy or medium oil, ensure that the fuel is circulating within the ringmain and at the required
temperature and pressure. If the oil has not been used for some time take this opportunity to clean the line
filters according to the manufacturers instructions (Fuel change over can only be undertaken with the
burner turned off).
The transfer from one fuel to another is accomplished by a fuel selection switch on the electrical control
panel, marked typically “OIL / GAS”
To change from gas to oil firing;
Select LOCAL/MANUAL modulation control and reduce the firing rate to minimum.
When the burner is at minimum fire, switch off the burner.
Allow the Post Purge to complete.
Close the gas train isolating valve and lock in position with the attached locking screw.
Open the oil isolating valve on the feed pipe to the burner, (if a lock-shield or plain valve is fitted to the
return pipe ensure that this is also opened).
On the burner control panel, select OIL FIRING on the fuel selector switch - this will produce a lockout
alarm.
Press the Reset button to clear the lockout alarm.
Switch the burner ON.
Distillate oils - The burner will now begin its light up sequence and establish a flame.
Residual oils - The burner metering pump operates at low speed in order to pump out the cold oil and
draw in the hot ringmain oil until the temperature at the burner inlet port reaches the Oil Check thermostat
o
setting (approximately 10 C below the specified atomising temperature). Once the oil is at the required
temperature the burner machine stops.
A light up sequence then begins.
To change from oil to gas firing;
Select MANUAL modulation control and reduce the firing rate to minimum.
When the burner is at minimum fire, switch off the burner.
Allow the Post Purge to complete.
Fully open and lock in position the manual isolating valve fitted to the gas train inlet.
Close the oil feed isolating valve to the burner.
On the burner control panel, select GAS FIRING on the fuel selector switch this will produce a lockout
alarm.
Press the Reset button to clear the lockout alarm.
Switch the burner ON.
A light up sequence then begins.
It is the preference of the customer whether to stop the fuel oil ring main oil circulation pumps.
SECTION - 10
ELECTROtec II MAINTENANCE GUIDANCE NOTES
GENERAL
Before commencing static maintenance always ensure that all electrical supplies are isolated and fuel
valves are closed.
When re-assembling any dismantled components, ensure they are clean and undamaged. Renew as
necessary.
Assembly is generally a reversal of dismantling instructions unless otherwise stated. When re-assembling
components always fit new “O” rings, joints and gaskets.
After the completion of any maintenance operations, the re-commissioning procedure must be followed to
ensure the safety of the installation.
LUBRICATION
The bearings utilised on the burner machine are generally of the sealed type and require no routine
lubrication. On occasion fan motors will be of the larger type equipped with external means of greasing,
on these occasions the motor manufacturers guidelines should be followed.
Mechanical linkage burners - Keep all linkage joints, cams and associated bearings clean and lubricate as
necessary. In particular keep the characterising cam adjusters and cam follower strip clean and lightly
lubricated with a general purpose grease.
The burner hinge contains two grease nipples, ensure that these points are kept well greased with a
general purpose grease.
The main atomiser cup shaft runs in sealed bearings and does not require further lubrication.
Note :
Fitted on the main bearing housing is an air vent, this looks a little like a lubrication point do not apply
lubrication to this point.
CLEANING
Maintain the burner and it’s associated equipment in a clean condition.
Due to the nature of residual fuel oil it is important that frequent, regular cleaning and inspection of all
filters and strainers on the burner and fuel supply system is carried out, the frequency of cleaning will be
determined by operational experience.
Atomiser cup cleaning –
Regular cleaning of the atomiser cup is required when firing any fuel oil, minimum frequency is daily.
Routine cleaning of the atomiser may be carried out in situ as this will only require the use of cotton waste.
WARNING
If the cup is to be cleaned in-situ exercise great caution do not use a volatile cleaning liquid as
this could ignite on the hot surfaces exposed when the burner is open.
If the atomiser is damaged or does not run true, a new one must be fitted.
ATOMISER CUP REMOVAL / REFITTING
Note: The atomiser cup must remain fitted when firing gas. When firing gas the atomiser is
stationary but it forms the primary air annulus around the atomiser cup.
The atomiser may be hot.
In the case of an atomiser cup that is heavily fouled. The cup should be removed from the burner
immersed in a suitable solvent and left to soak until the deposits are sufficiently softened to be removed
by light brushing.
Note; Do not use metal scrapers as these could damage the inner surface or edge of the atomiser.
The atomiser must be removed only as detailed below in order to prevent damaging the atomiser boss
and retaining bolt thread in the burner shaft.
The correct box spanner, extracting screw and Allen key are available from Spares department -
Hamworthy Combustion Limited.
If the cup is damaged do not attempt to machine it, the balance of the cup will be upset and damage to
the shaft bearings will occur.
A special box spanner, allen key and extractor bolt are available from Hamworthy Combustion Ltd to aid
atomiser removal and fitting.
To remove apply the box spanner to the atomiser retaining bolt, to break the “hold” of the bolt apply a
sharp tap to the handle of the box spanner remembering that this bolt has a “left hand thread”. When
loosened the bolt can be fully removed, the atomiser will remain in position as it is still “locked” to the taper
of the burner shaft. Apply the socket headed screw to the “jacking” thread on the inside of the atomiser
hub, this is a standard right hand thread. Wind this screw in until it is in contact with the end of the burner
shaft, fit the allen key to the screw and a sharp tap to the allen key to break the grip of the cup onto the
burner shaft. At this time a degree of care is required as when the cup breaks free from the taper it could
fall.
To re-fit ensure that both the taper on the end of the burner shaft and within the rear of the atomiser are
clean. Offer the cup onto the shaft ensuring, apply the left hand retaining bolt and tighten by hand. Apply
the box spanner and “lock” the atomiser onto the burner shaft by giving the end of the spanner a light tap
with a hammer. Now tighten the bolt using the box spanner by hand until resistance is felt. Finally give the
handle of the box spanner a light tap with the hammer to allow the retaining bolt to “bight” and fully lock
the atomiser in position.
CLEANING AND CHECKING THE ALIGNMENT OF THE PRIMARY AIR NOZZLE.
The Primary Air Nozzle and shroud assembly may be removed with or without the cup in
position.
The complete Primary Air Nozzle and shroud may be removed by extracting the 3 off M6 screws around
the shroud.
Mark the 12 o’clock position of the shroud to assist in re-assembling. Take care when releasing the last
(top) screw that the shroud does not fall and hit the male cup taper.
Ensure that the inside lip of the primary air nozzle is free from carbon or oil deposits.
Check that the outside lip of the nozzle is free of damage or heat erosion.
When the cup has been refitted check for the correct alignment of the primary air nozzle.
The nozzle must be concentric with the atomiser cup, and there must be approximately 1.0 mm of cup
protruding concentrically from the lip of the primary air nozzle.
To adjust the 1mm dimension, release the 2 off M4 cap head screws and move the primary air nozzle
forwards or backwards as required, retighten the M4 screws.
DRIVE BELT
Ensure all power is isolated before working on the burner motor and drive belt.
The burner utilises a single “poly vee” type belt to drive the burner atomiser shaft. This can be accessed
by removing the burner glass fibre cover and removing the inner mounting plate.
The glass fibre burner machine cover can be removed by turning of the 2 off ¼ turn screws on the front of
the cover.
No special tools or techniques are required to remove the inner mounting plate, remove the four fixing
bolts and set the inner mounting plate to one side.
Under no circumstances must the motors be activated whilst this cover is removed.
MAINTENANCE PROGRAMME
Routine checks.
Description Operation Frequency
Atomiser Remove deposits from surface Daily

and distributor holes at rear.
(when oil firing).
Inspect for damage and
concentricity.
Refractory Quarls Inspect for condition. Daily observation.
Photocell Remove any dust from cell face. Weekly (Unless very dirty
environment).
Oil Filters Remove baskets and clean. Once per month.
Fuel/Air Ratios Check settings and combustion Monthly.

performance.
Atomiser cup belt Inspect condition and tensioning. 3 Monthly.
Igniter Remove deposits check Weekly.

electrode.
Linkage Inspect screws for tightness and 6 Monthly.

lightly lubricate.
Burner Hinge Inspect for ease of opening and 6 Monthly

grease if necessary.
Silencers Check integrity and security of 6 Monthly.

materials.
Air passages Clean out any deposits. 12 Monthly.
Pressure switches Check operation and accuracy 12 Monthly

and compliance with the
commissioning log.
Photocell Test signal values 12 Monthly
Motor Windings Inspect condition and check 12 Monthly

resistance to earth.
Electrical Terminations Check for tightness 12 Monthly
Panel Relays Ensure that relays are located 12 Monthly

correctly in their bases.
Burner Bearings Replace housing Every 5 years.

SECTION – 11
ELECTROtec II Burner INSTALLATION GUIDANCE NOTES
GENERAL
Burners should be installed by competent staff only, in accordance with the contract
installation drawings. All lifting equipment must be of an approved type - refer to contract
specification sheets for weights of main components. If installing the burner onto existing
plant it is possible that old seals could contain asbestos, if in doubt ask and comply with
relevant safety codes. Many burners appear to be of the same physical size, their
capacities will, however, vary dramatically. Therefore, on multiple burner installations,
ensure that the correct sized burner and air system is fitted to the correct boiler!
See application data sheet in Section 13 for overall dimensions.
COMBUSTION AIR SYSTEM AND REFRACTORY
The windbox, secondary air damper and compound fancase assembly is all sized to suit
the individual installation and must be installed strictly in accordance with the drawings
provided. Refractory is required to protect any un-wetted or un-insulated surfaces of the
boiler or appliance to prevent overheating and damage. If in doubt or if in need of advise
call Hamworthy Combustion, Customer Service on + 44 (0) 1202 662700.
FLANGED BOILER FLUE
Check that the ring of studs on the boiler flange matches the ring of holes in the quarl
backring.
NON-FLANGED BOILER FLUE
Weld the lugs into the furnace mouth, followed by the backring as shown on the contract
drawing supplied. Fix, in position, using the hook bolts provided. Seal between the parts
by applying a ring of 'P' type ceramic fibre tape. It is essential that the plate is concentric,
and steel packing must be placed under two of the plate-lugs in order to achieve this. It
is also important that the plate is “square” and reference marks on the vertical centre line
of the plate have been provided for this purpose.
ALL BOILERS
Fit the quarl assembly to the backring or boiler flange making a joint with a ring of 50mm
x 6mm thick ceramic ladder tape. Check the orientation of quarl assembly with contract
drawing supplied. Backfill between quarl brick and boiler flue using correct grade of
mouldable refractory to secondary quarl contract detail drawing.
Fit the windbox to the quarl, making a joint with a ring of 50mm x 6mm thick ceramic
ladder tape either side of the windbox/quarl ring bolts. Fully tighten the bolts. Fill the gap
between the windbox assembly and the quarl segments with a ring of 19mm soft ceramic
rope soaked in alumina cement.
Assemble the fancase and silencers (if fitted) to the windbox, to the correct orientation
(see contract drawing), making a joint of 6mm (¼ in) soft ceramic rope.
BURNER FUEL OIL METERING SYSTEM
The burner machine is supplied mounted on its windbox and pre-wired to the burner
mounted junction box. Flexible hoses connect between the windbox mounted burner
pump and the burner valve block.
The burner has been designed to operate on a variety of fuel systems. The pressure at
the burner inlet should be in the range 0.2 – 4.0 Bar.g. in the case of burners firing
residual fuel oil the temperature should be controlled to give a viscosity of between 55 –
70 Cst at the burner (There are no heaters on the burner other than those required to
keep the system warm at standby).
Refer to the Data Sheets in Section 13 for acceptable ring main systems.
LINKAGE CONTROL CABLES (mechanical linkage burners)
The control cables are designed to transmit linear push and pull forces and must not be
subjected to twisting or excessive bending forces.
Correct installation of the control cables is important to backlash-free control, long life of
the cable, and to prevent overloading of the modulation motor.
Fit each cable to the required positions and check stroke, ease of operation and swivel
abutments etc. Make final adjustments where necessary, then tighten all locking nuts
holding the threaded sleeve and sliding rods by the spanner flats provided.
Ensure that the stroke of the cables as determined by the modulation motor can be freely
accommodated by the cam assemblies. If fouling, over or under travel exists, adjust the
sweep of the linkage arms - never reduce the travel of the modulation motor. The
0
modulation motor is always set to 90 rotation.
MOTOR ROTATION CHECKS.
Note: If the control panel is to be powered up for rotation checks etc. before the
commissioning engineer has checked and set the modulation linkage travels, then the
modulation motor /Electrolink unit must be electrically inhibited otherwise severe damage
may occur to the linkages/servos. Motors must be checked for free rotation by hand
before being electrically driven to ensure that all rotating parts are not fouling, e.g. rotary
cup, shaft rotation sensors, fans etc.
FUEL OIL SYSTEMS
The fuel oil system must be installed to the appropriate Hamworthy Combustion
Engineering data sheets or contract specific drawings. For heavy oil the ideal system
should include: a steam/electric or hot water/electric tank outflow heater, steam/electric
or hot water/electric line heater and suitably lagged and traced oil flow and return pipes
arranged to provide a true ring main system. Ensure that the feed connection from the
ringmain to the burner comes from the underside of the ringmain pipe.
ELECTRICAL CONNECTIONS
The internal wiring of the burner and its controls are completed at the factory and in
accordance with the wiring diagram supplied.
External wiring must be made strictly in accordance with the diagram supplied, using size
of cables, switches and fuses in accordance with requirements of the load to be handled.
Signal wires used for the installation and interconnection of electronic units must be of
the type specified within the contract documentation, i.e. screened or twisted pair etc.
Signal cable screens must be terminated strictly in accordance with the contract
drawings.
Items detailed within the contract drawings as being connected to the instrument earth
point must be connected to that point.
The earth bonding must be connected to the protected earth point. The earth bonding
must remain intact.
The complete burner package is “CE” compliant. In order to retain this status no
modifications must be performed that compromise the EMC, (Electro Magnetic
Compatibility), or LVD, (Low Voltage Directive) elements of the system.
Any parts that fail must be replaced with identical components.

Any wiring added by the customer providing auxiliary signals to or from remote panels
must be fed through auxiliary contact blocks added to the panel isolator. Such signals
must not feed live supplies into the burner panel when its isolator is in the off position.
GAS TRAIN
The gas train should be mounted at the front or side of the boiler, as close as possible to
the burner. Adequate clearance must be allowed to facilitate maintenance of the gas
shut-off valves. A maximum of 3.0 m from the down stream ignition and main gas valves
to the burner must be adhered to. Ignitor gas pipework must be sized to ensure that
required pressure is available at the ignitor under flow conditions. Vent pipes must be
terminated at a point clear of the boilerhouse. Vent pipework must comply with the
relevant gas regulations. A final check must be made to ensure gas tightness throughout
the system. The gas train must be supported along its full length to ensure that no strain
is placed on the valves, flanges or the burner gas manifold casting.
CONTROL PANEL
The control panel must ideally be situated local to the burner so that the panel indicators
are easily visible from the burner firing position, preferably to the side of the boiler centre
line. Ensure that the panel is not placed under any water containing devices, (gauge
glasses or level controls). Ensure that the panel is not positioned such that the operator
is required to stand directly in front of the burner.
Do not place the control panel in direct sunlight as this could cause the internal
temperature of the panel to exceed the design limit.
AIR SUPPLY TO BOILER ROOM
Where the boiler room is ventilated by natural means the air necessary for combustion
and ventilation must be admitted by permanent openings at low level from the open air
2
having a free area of not less than 0.2 m for each 300 kW of installed boiler capacity. In
addition, permanent openings to the open air having a total free area of not less than 0.1
m² per 300 kW of installed boiler capacity, with a minimum of 0.012 m² should be
provided at high level to effect general ventilation.
In boiler rooms below ground level, special ducts may be necessary to admit the air and
these ducts must be enclosed and separated from the rest of the building by
non-combustible construction having the same standard of fire-resistance as that
required for the enclosure of the boiler room, or for the remainder of the building through
which ducts pass, whichever is the greater.
If in doubt take advice concerning local regulations.

Section 12.0
ELECTROtec Burner Component Identification
The following exploded view drawings will help with component identification. When ordering spare
parts please quote the Contract Reference Number which can be found either on the burner, control
panel or in the specification sheet at the front of this manual. In the case where burners of differing
sizes have been purchased at the same time it would also assist if the Burner Serial Number is
quoted.
See exploded views of burner, windbox and fancase for details.

NOTES
SECTION – 13
APPENDICES
OIL VISCOSITY vs TEMPERATURE CHART 09 : 04 : 08
ISSUE: 2
200.00
195.00 50 60 80 90 100 120 140 150
30 40 70 110 130
190.00
Kinematic
185.00 33 DEGREESC
cStokes
180.00 REDWOOD
3 No 1 seconds
175.00
170.00 35
3.5
165.00
160.00 4
155.00
150.00 5
145.00 40
140.00 6
135.00 7
130.00 45
8
125.00 9 50
120.00 10
115.00 55
110.00 12.5 60
105.00 15 70
100.00
80
95.00 20 90
90.00 70
25
85.00
30 125
80.00 35 150
75.00 40
175
70.00 50 200
65.00 250 ATOMISINGRANGE
60.00 75 300
55.00
100 400
50.00
500
45.00 150
40.00 200 750
35.00 250 1000
30.00 300
1500
25.00 400
500 2000
20.00
3000
15.00 750
1000 4000
10.00 5000
5.00 1500 7500
2000
0.00 10000
-5.0050 70 90 110 130 150 170 190 210 230 250 270 290 310
-10.00
OIL TEMPERATURE °F
TOUSE THE CHART. The viscosity of the oil at one temperature The vertical line which intersects with the black graph line
according to Redwood No.1, Kinematic (Engler or Saybolt) units at the required viscosity indicates the temperature to which
must be known. Thus, if it is known that the oil has a viscosity the oil should be preheated.
Redwood 1 at 100°F, of 1000 seconds, the point on t he 100°F, NOTE: Any number of additional graph lines may be added
vertical opposite 1000 seconds Redwood 1 is found and provided that they are drawn parallel to those existing.
the black graph line passing through this point is followed until The graph lines are a compromise on all the different types
it enters the area of the graph which defines the normal of oil which may be encountered but their accuracy is sufficient
range of burner viscosities. for the practical purposes for which they are provided.
Prepared by: I.J.H-B. Distribution: B.C.E.G.H.
IIIIIIIIIIIII Approved by: C.J.M.
Date: 30:6:89
HAMWORTHY
Combustion Systems
Electrotec II Overall Burner Dimensions (All dimensions in mm)
Burner A B C D E F G H J K L M
Frame Rad. Rad. Dia. Dia.
ER 5-11 355 70 412 1302 408 635 181 200 1068 480 800 810
ER 12-20 355 70 478 1436 478 730 198 220 1366 480 800 945
ER 22-30 355 70 563 1645 565 857 221 220 1366 555 1080 1125
ER 35-50 355 70 563 1830 580 972 288 220 1668 675 1080 1290
RESIDUAL FUEL OIL RING MAIN (TYPICAL)
Please refer to the following guidance notes before installing burner equipment.
1. Refer to Data Sheet 09:04:08 Iss 2 for fuel temperature requirements.

2. Ensure fuel oil ring main pipework is adequately sized for the grade of oil to be used. Maximum
suction lift at ring main pump must not normally exceed 2m head.
3. It is recommended that any electric heater is sized sufficient for one burner low fire capacity as a
minimum. Additional plant interlocks may be required to limit operation during warm up.
4. A minimum pressure head at the burner inlet of 0.2 bar.g. should be maintained under all flow
conditions. Maximum pressure at the inlet to the burner should not exceed 4.0 Bar.g.
5. Ensure all pipework is traced and lagged in accordance with industry norms.
6. Inlet and return lines to individual burners should be of minimum 25mm bore.
7. An isolating valve can be installed in the return line from the burner provided that it is of the
“lockshield” type.
8. The burner return line hose should be trace heated.
9. Inlet and return connections on the burner should be a minimum 300mm apart.
When designing a fuel oil system the following points should be taken into consideration :-
Position of tank outflow relative to fuel pump.

Pressure losses through pipework.
Pressure loss through strainers.
Pressure loss through heaters.
Total system flow requirements.
Temperature loss through system.
Key :-
LV = Lockshield Valve V = Valve NRV = Non return valve F = Filter T = Temperature Gauge
P = Pressure Gauge CH = Check thermostat

DIESEL OIL RING MAIN (TYPICAL)
Please refer to the following guidance notes before installing burner equipment.
1. Ensure fuel oil ring main pipework is adequately sized for the grade of oil to be used. Maximum
suction lift at ring main pump must not normally exceed 2m head.
2. A minimum pressure head at the burner inlet of 0.2 bar.g. should be maintained under all flow
conditions. Maximum pressure at the inlet to the burner should not exceed 4.0 Bar.g.
3. Supply pipework should be a minimum of 25mm bore.
4. An isolating valve can be installed in the return line from the burner provided that it is of the
“lockshield” type.
5. A “lockshield” valve should be fitted at the highest point of the supply pipework to facilitate venting.
When designing a fuel oil system the following points should be taken into consideration :-
Position of tank outlet relative to fuel pump.

Pressure losses through pipework.
Pressure loss through strainers.
Total system flow requirements.
A single pipe system can be used provided that means of priming and venting are addressed. The
supply pipe must also be of sufficient size to prevent fuel starvation at the burner inlet.
Key :-
LV = Lockshield Valve V = Valve NRV = Non return valve F = Filter P = Pressure Gauge
Electrotec II Burner Oil Valve Block
As described in Section 3 (Page 13) the burner oil valve block contains two fuel shut off solenoid
valves as well as a back pressure valve and re-circulation valve. These latter two valves comprise a
simple adjustable spring loaded bullet with a rubber seat, both valves are pre-set at the factory prior to
delivery.
Oil solenoids
Oil inlet from pump at rear
Pencil heater (HFO only)
Re-circulation connection
Re-circulation valve
Feed to atomiser
Back pressure valve
Fuel flow schematic

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Hamworthy Combustion ELECTROtec II Burner Manual No/ HC 401 O&M / rev 2.

Operating and Maintenance Manual

Section Contents Page

Page numbers in brackets refer to section in the text.

Manual Number HCE 401 Rev 1.0 (Original)

HAMWORTHY COMBUSTION LIMITED

FLEETS CORNER, POOLE, DORSET. BH17 OLA

First Published: 10/01/2006

Copyright and Design Right 

PRINTED IN THE UK.

Contract Specification Details

Heat input rating : System Protection: IP

Appliance working pressure/temp :

OIL FUEL DETAILS :

Primary Fuel Oil Type : Secondary Fuel Oil Type:

Specific Gravity: Gross CV:

Min / Max Pump Speed (Hz): / /

Maximum Pressure / Temp: / /

GAS FUEL DETAILS :

Primary Gas Fuel Type : Secondary Gas Fuel Type :

Gross Calorific Value :

IGNITION SYSTEM DETAILS:

Fuel Type : Maximum Pressure :

Mains Supply Voltage : v hz Control System Voltage : v hz

Control Circuit Diagram Number

CONTRACTS ENGINEER (Name) Date :

ELECTROtec II Burner Health and Safety

Read this section before undertaking ANY work on the burner.

All subsequent settings must progress from a fuel lean condition.

Attend to fuel leaks as they are reported. Do not delay.

Always adhere to the rigors of any site Permit-To-Work system.

Never stand directly in front of a burner whilst it is lighting-up.

COMBUSTION AND CONTROLS:

DO NOT BY PASS INTERLOCKS.

This equipment must be earthed via the protected earth terminal.

ELECTROtec II Burner GENERAL INFORMATION

FUEL OIL SYSTEM

See Oil ring main data sheets in Section 13.

1. The burner machine

Each burner is fitted with a plate stating:

Each control panel is identified by a plate stating:

A plate is attached in a prominent position stating;

2. Burner serial number.

3. Gas firing - Maximum gas flow rate.

4. Oil firing - Maximum oil flow rate.

The units quoted in this manual are generally SI.

Electrotec II Burner Range Specifications

ELECTROtec II Burner GENERAL DESCRIPTION

The Electrotec burner is available in three forms -

ERO - Oil only.

SILENCER AND FAN MOTOR EQUIPMENT

Compound Fan Intake Silencer

Fan Motor Muffler

A motor muffler can be fitted if required for further noise attenuation.

BURNER OIL SYSTEM

Burner fuel oil meters are available as an optional extra.

BURNER GAS TRAIN

COMBUSTION (Fuel Oil)

ELECTROtec II Burner Combustion Control

ELECTROtec II Burner Management Description