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1
Service Training Course
Mobile Diesel Heaters TOR / MIR
Rev. No. 1 April 1st, 2010
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MIR Indirect-fired Diesel Heaters
• MIR 37 WE MIRAGE 37 H• MIR 55 WE MIRAGE 55 H• MIR 85 WE MIRAGE 85 H
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TOR Direct-fired Diesel Heaters
• TOR 67 WU TORNADO 67• TOR 115 WU TORNADO 115
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MIR General Assembly
Combustion Chamber (closed)
Fuel Tank
Exhaust Duct Burner
Head
Motor
Fuel Pump
Fan
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TORGeneral Assembly
Combustion Chamber (open)
Fuel Tank
Front Flame Shield
Burner Head
Motor
Fuel Pump
Fan
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FAN MOTOR ASSEMBLY
Motors
430W 2800 rpm 2 poles MIR 37 WE - MIR 55 WE - TOR 67 WE750W 1300 rpm 4 poles MIR 85 WE - TOR 115 WE1100W 1300 rpm 4 poles TOR 175 WE
Motor
Capacitor
Fan
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THE FUEL CIRCUIT The fuel circuit is basically composed of : fuel tank suction and return hoses fuel filter (normal or heated) fuel pump fuel solenoid valve high pressure microhose burner head nozzle
Inflow Hose
Backflow Hose
Fittings
Pump
To BurnerValve
Coupling
Filter Cartridge
Filter Glass
Burner Head
Nozzle
Gaskets
To Pump
From Pump
To Tank
From Tank
To Tank
From Tank
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Fuel Tank(with drain cap)
Tank Capacities
51 l MIR 37 WE - MIR 55 WE - TOR 67 WE 100 l MIR 85 WE - TOR 115 WE 139 l TOR 175 WE
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Fuel Filter
Normal Filter Heated Filter
Heating Element
Heating Element Cable
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Fuel Pump (BFPC)
Danfoss BFPCfuel pump
BFPC 21R3 MIR 37BFA 21R3 MIR 55
TOR 67
BFPC 21R5 MIR 85BFA 21R5 TOR 115
TOR 175
Fuel Inlet
Fuel Return
Pump Filter
High Pressure Line (To Burner)
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Fuel Pump (BFA)
Fuel PumpDanfoss BFA
BFA 01R3 MIR 37MIR 55TOR 67
BFA 01R5 MIR 85TOR 115
Inflow
Backflow
Filtro pompa
High pressure line (to burner)
Pump filter!
Pressure gauge port
Pressure adjustment screw
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Fuel Cutoff Valve
Solenoid
Fixing Screw
Valve Stem
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BURNER ASSEMBLY
Nozzle Holder
Ignition electrodes
Swirl disc
Air Shutter
Fuel Nozzle
Flame Sensor
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BURNER ASSEMBLY
The burner assembly includes : nozzle holder air shutter swirl disc fuel nozzle
Air Shutter Combustion Air inlets
Swirl Disc(Distributor)
Graduated Scale (Dial?)
Fuel Spraying Nozzle
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BURNER ASSEMBLY
ignition electrode
air shutter
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BURNER ASSEMBLY
• Burner head easy to remove for maintenance and service
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CHAMBER INLET
• Chamber inlet easy to remove for maintenance/cleaning
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COMBUSTION CHAMBER
Combustion chamber (MIR)
TOR Combustion Chamber Protection Shield (TOR)
Combustion chamber inside (MIR)
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WIRING DIAGRAM (TOR 67/MIR 37/MIR55)
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WIRING DIAGRAM (TOR 115/TOR 175/MIR 85)
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ELECTRICAL BOARD
The electrical board consists of:
Control panel Protection casing (against water/dust) Power cable with strain relief and plug ON/OFF switch Room thermostat receptacle and cap with inner jumper (to
close circuit for operation without thermostat) Reset pushbutton with built-in warning lamp High voltage ignition transformer Fuse with fuseholder Electronic burner control unit (BCU) Power Lamp
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Control Panel and Protecting Cover
ON-OFF Switch
Power Cable
Reset Pushbutton
Room Thermostat Socket
Power LampProtection Casing (water-and dust-proof)
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Electronic Burner Control Unit
Solenoid Valve (line)
Transformer (line)
Motor (line)
NeutralWires
PhotocellContacts
SwitchContacts
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SAFETY DEVICES• Flame Sensor (photoresistor)
Detects false flame signal or anticipated ignitionMonitors flame at ignitionMonitors flame failure during operation
• (Safety Thermostat or Temperature Limit Control, optional)
Prevents unit overheatingRequires manual reset
• Line FuseProtects unit from overcurrents
Flame Sensor
SensorEnclosure
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SAFETY DEVICES
• Air Pressure Switch Monitors fan pressureShuts burner off in case of reduced pressure/airflow
Pressure (+) Sensing Probe Pressure Switch
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TOR-MIROPERATIONAL SEQUENCE
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BASIC SERVICE PROCEDURES
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1. Shut off and unplug heater before service. ELECTRICAL SHOCK RISK!
2. Allow heater cooling before removing guards, panels, enclosures: BURN RISK!
3. Do not remove guards if any parts are moving or rotating. INJURY RISK!
4. Discharge capacitors by grounding before removal. ELECTRICAL SHOCK RISK!
5. Vent exhaust gases outdoors or provide adequate ventilation when heaters are operated indoors. CARBON MONOXIDE POISONING RISK!
Important Safety Warnings for Service Operators
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Line Fuse Check
Fuse
Fuseholder (on power cord inlet)
Check correct fuse rating on heater data plate!
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Fan motor/capacitor check
Fan/Motor Assembly Disassembling motor from support
Replacing capacitorWarning! Capacitors may hold an
electrical charge and cause electrical shocks.
Disassembling fan from motor shaft
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Smoke Index Test (Bacharach-Shell, indirect models only)
IMPORTANT : 10 TIMES EXACTLY
1
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Air Shutter Adjustment
Read air shutter setting HERE
Loosen screw to slide air shutter
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Fuel Filter Maintenance
Unscrew filter glass
Clean or replace filter cartridge
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Burner Nozzle Maintenance
Remove burner head Clean or
replace nozzle
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Burner Head/Chamber MaintenanceRemove burner inlet tube
Access to inner parts of combustion chamber for cleaning Clean burner
tube and distributor
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Fuel Pump ReplacementLoosen fixing screws
Checkcoupling
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Fuel Pressure Adjustment (BFPC)
Pump pressure setting for all TOR/MIR:12 (+0 -0.5 bar)
Remove threaded cap
Connect pressure gauge HERE
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Fuel Pressure Adjustment (BFA)
Standard pressure setting for all TOR/MIR models:12 (+0 / -0.5) bar
Rimuovere tappo filettato
Connect pressure gauge HERE
Adjust pressure HERE
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Ignition Electrode Service
3 1 mm0.12 ± 0.04”
7 1
mm
0.27
±0.
04”
Check and correct electrode gaps
Fix electrode, do not overtighten
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Flame Sensor (Cad Cell) Service
Extract sensor casing
Check and correct electrode gaps
Expose and wipe sensor Replace if needed
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Limit Switch Reset
Fixed SettingsIndirect Heaters: 170°C Direct Heaters: 100°C
Press HERE to reset limit switch
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CORRECT INCORRECT
Installation GuidelinesExhaust Pipe Design
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Installation GuidelinesAir Ducting
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Installation GuidelinesAir Ducting Accessories
MIR 37/55 dia. 315 mm (12.4”) max duct length: 40 ftMIR 85 dia. 457 mm (18”) max duct length: 60 ft
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TROUBLESHOOTING
yes
SWITCHON
THE HEATER STARTSno
See Service ManualReplace burner control unit
If fuse is burnt:Replace, use same type/rating
Check burner control unit
Check mains voltage
If heater is not powered:Check all electrical connectionsCheck warning lamp
Check fuse (burn-outs, damages, etc.)
Check that the green warning lamp on control
panel is alight
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For operation without remote thermostat: check that thermostat socket cap
is correctly inserted
Lock-out from previous operation:Wait 30 seconds and press reset button
Check that lock-out warning lamp (red) is not alight
Check connectionsSet on a temperature higher than room temperature
Check that room thermostat is properly
connected and adjusted
Check electric jumper inside capReinsert and lock cap
Safety thermostat action from previous operation:Open inspection cover and push thermostat reset button
Check that overheat thermostat has not been
activated
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Tighten fuel line fittingsCheck for damages/cracks in fuel hoses
Check - and remove - light reflections due to sunrays, lamps etc. that could reach and disturb the flame sensorLook for flames inside chamber
Check presence of external false flame signals
(sunlight, lamps, etc.) during prepurge time
Clean flame sensor with a soft cloth and ethylic alcoholReplace flame sensor if damaged or burnt
Check that fuel tank is full
Check for air bubbles or leaks
in fuel lines
Check that nozzle is cleanSee Service Manual “Cleaning the combustion head”
Check that swirl disc is clean
See Service Manual “Cleaning the combustion head”
See Setting ChartCheck air shutter
adjustment
Check that flame sensor is not damaged, clean and properly fixed in its seat
THE HEATER STARTS, THE PREPURGE SEQUENCE STARTS BUT THEN THE
HEATER STOPS WITHOUT IGNITION yes
no
Fill tank with proper clean fuel
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See Service Manual chapter 3.12
HEATER STARTS, FLAME IGNITES BUT COMBUSTION
IS NOT GOOD
Check nozzle size
Check that pump filter is clean
Check that fuel filter is clean
Check air shutter adjustment
Check that nozzle is clean
yes
no
See setting chart
Check for correct nozzle size on setting chart. Replace nozzle if necessary
See Service Manual chapter 3.7
Clean or Replace nozzleSee Service Manual chapter 3.8
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Check that there are no air bubbles in the fuel lines
Fuel of incorrect type, dirty, polluted
or containing water
Empty tank and refill with clean fuel of proper type
Measure and adjust fuel pressureReplace pump (see Service Manual chapter 3.12)
Incorrect fuel pressure
Tighten fittingsReplace faulty pipes/hoses
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no
yes
THE BURNER SHUTS OFF DURING OPERATION AND THE FAN CONTINUES TO
ROTATE
Tripping of air pressure switch
Check air inlet/outlet for blockage, restrictions, etc. Check supply voltage, motor fan rpm, fan blades, fan/shaft coupling
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OK
no
yes
Wrong (too large) nozzle size Wrong (too high) fuel pressure Insufficient ventilation air due to motor fault Insufficient ventilation air due to fan failureBlockage of air inlet/outlet due to dirt or foreign objectsExhaust pipe obstructionCombustion chamber clogged by soot (see chapter.3.10)
THE HEATER SUDDENLY STOPS
Excessive overheating of combustion chamber(overheat thermostatcorrectly activated)
Wrong location of overheat thermostat (after incorrect service, repairs etc.)Wrong thermostat setting/type Faulty thermostat
Overheat thermostat incorrectly activated
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MIR WE - SETTING CHART
1.50 60° W
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TOR WE - SETTING CHART
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SERVICE & MAINTENANCE EQUIPMENT
Measuring devicesElectric Multimeter (V, A, )
PC Flame Sensor Tester Kit
Pressure Gauge Kit (incl. hose and fitting)
Smoke Index Tester
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SERVICE & MAINTENANCE EQUIPMENT
Basic handtoolsType Application
17 mm hex key motor fixing screws16 mm hex key nozzle head13 mm hex key fuel hose fittings10 mm hex key upper shell, inspection door, control panel 8 mm hex key burner head fixing screw
2.5 mm Allen key pump fixing screws4 mm Allen key pressure adjustment screw5 mm Allen key air blades fixing screws (MIR 85)
Phillips screwdriver various, different sizes requiredSlotted screwdriver various, different sizes required