sunflame boiler burner instruction manual sdr-1500

7/16/2019 Sunflame Boiler Burner Instruction Manual SDR-1500

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1 ／ 14株式会社サンフレム式会社サンフレム式会社サンフレム

INSTRUCTION MANUAL

TYPE ； R-9 , R-15 , R-25 , R-40 , SDR-350～700 ,

SDR-1000,SDR-1500 , SSR-3.5～8

SDR-1～2.5

Name ； ROTARY CUP BURNER

Revision history15 JUL.2008 Make doc. Maenishi23 JUN.2011 Grammar and vocabulary check Kagawa



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CONTENT

PREFACE ・・・・・・・・・・・・・・・・・・・・・・・３PAGE

MAINTENANCE ・・・・・・・・・・・・・・・・・・・・・４PAGE

ABOUT ROTARY CUP BURNER ・・・・・・・・・・・・・・・９PAGE

STRUCTURE OF EACH DEVICE ・・・・・・・・・・・・・１４PAGE



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PREFACE

This document describes what engineers of this vessel should understand when they use thesystem.

For also boiler makers and engineers of shipyards, we hope that this book will give usefulinformation.

This user’s manual includes optional functions.For some ships, this book may give information that is notrelevant.Confirm your specification for information of youroptional function.

About Icons

WARNING

This indication gives you a warning when mishandling theproducts, it will lead to serious injuries or result to deathfor the user. It also may result to serious damage for the

products as well.

CAUTION

This indication gives you a warning when mishandling theproducts, it may lead to minor injuries to the users, or

physical damage to the products.



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MAINTENANCE

１． CHECKUP

1.1. DAILY CHECK The 6 topics below are needed to be done every day.

■ Confirm if there is no F.O. leakage out of pipes, pumps, valves and for theconnection part.

■ Inspect the oil pressure, quantity. Inspect the temperature as well whenthe H.F.O. is used.

■ Inspect the furnace pressure and the exhaust gas temperature.

■ Check the combustion condition.

■ Confirm if there is no smoke generation (Be careful of smoke when thetemperature of the engine room is high.)

■ Check if the steam heat tracing is working.

1.2. WEEKLY CHECK

The 7 topics below are needed to be done once a week. (or every 200 hours operation). These topics are also needed to be checked when the system is not operated for overa week.

■ Clean the oil strainer screen.

■ Drain water and air from the oil heater.

■ Clean the inside of the rotary cup.

■ Check if there is no incombustible deposition in the burner tile and thefurnace. If necessary, clean the burner tile and the furnace for removal.

■ Inspect the tension of the burner belt (this is needed for the SSR type andthe R type rotary cup burners)

■ Check and clean the ignition burner (pilot burner)

・ See if there is no crack in the insulator of ignitor.

・ Clean the insulator and the electrodes. Check if the distance of the electrodes is correct.

・ Clean the strainer in the atomizer

・ Clean the disc and the jet nozzle in the atomizer by air blowing.

The electrodes size

↑ Vertical direction

Assembly of atomizer



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■ Inspect the function of the Flame eye and clean it if necessary.Hold the flame eye up to the light and confirm if the flame eye relay is working.Wipe the flame eye’s front glass.

1.3. MONTHLY CHECK The 6 topics below are needed to be checked once a month. (or every 1000 hoursoperation).

These topics are also needed to be inspected when the system is not operated for over

a month.

■ Lubrication for the main shaft

・ For the rotary cup burners with a grease nipple, inject 4～5g

grease to the nipple. (for type R, type SDR-1000 and typeSDR-1500 rotary cup burner)

・ Too much grease will cause damage to the bearing.

・ The equivalent type of the grease for the main shaft should be,Grease heavy (CHEVRON), or Unirex N3 (ESSO).

■ Way of dismantling and cleaning of the rotary cup

・ Open the burner and take out the primary air nozzle.

・ Fix the main shaft, and then loosen the fixation screw in the cupand take out the cup.

・ For the R and SDR-1500 type burner, the tools for fixing the shaftand for taking out the cup are in the spare parts box.

・ The Cup fixation screws for each type of the rotary cup aredescribed below.

Type Cup fixationscrew

Loosening Tightening

R Right screw Counterclockwise Clockwise

SDR－1500 Right screw Counterclockwise Clockwise

SSR Left screw Clockwise Counterclockwise

SDR Left screw Clockwise Counterclockwise

Dismantle and clean the rotary cup and the rotary cup hub.

A diagram example（R-15 Rotary cup burner）



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・ Lightly spread grease on the main shaft（so that the cup will be

removed easily the next time when taking it off ）・ After cleaning, return the cup and the cup hub to the original.

・ Set up the primary air nozzle and create an equal space betweenthe outer circumference of the rotary cup and the innercircumference of the primary air nozzle. Adjust and fix thedistance between the rim of the rotary cup and the rim of the

primary air nozzle to size“A” in length.(A is described in the

following table.)

Type

Distance between the rim of the rotary cup and the rimof the primary air nozzle A[mm]

Standard value Minimum value Maximum value

R9 １．５１．５２．０

R15 １．５１．５２．０

R25 ２．０２．０３．０

R40 ３．０３．０４．０

SDR-350～500 ０．５０１．５

SDR-1000、1500 １．００２．０

SSR3.5 ０．５００．５

SSR5～８０．５００．５

SDR１～２．５０．５００．５

Caution

The rim of the rotary cup is the most important part for theF. O. atomization.Careful treatment is needed when handling the rotary cup.No damage is indispensable.

Caution

1) Confirm if the clearance between the outer circumference of the rotary cup and the inner circumference of the primary airnozzle is even.

2) Confirm if the distance between the rim of the rotary cup andthe rim of the primary air nozzle is as per the table above.

3) These measurements will have major effect on the combustion.



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■ Inspect each connection and each fixation screws, and check if they arenot loose or if there are no backlashes.

■ Check the vibration of the rotating body, backlashes of the bearing and if there is no abnormal noise. Repair if necessary.

■ Inject oil to the rotating part and to the slide part.

■ Confirm the tension of the burner belt and see if there is no crack. (If the

belt is used the first time (renewed or replaced), adjust it again after 50～

100hours operation.)1.4. OTHER CHECKS

■ Check each sensor for the boiler and the burner operation regularly.(pressure switch, thermostat, and e.t.c.)

■ Tighten the fixing screws of each part every 6 month.

■ For the burners that have a piping heater in the flexible pipe, (Type R andSSR) it is better to clean the flexible piping every year.

■ To prevent black smoke that is caused by choking of the gas passage of theboiler, back fire, and oscillating combustion, record the UP-TAKE GAStemperature and the furnace pressure, and clean the boiler regularly.

■ For systems that are using the electric oil heater, it is better to remove the

scale that is on the surface of the heater every year.■ Check if the drain trap, which is in the end of steam heat tracing line, isnot blocked every month.



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２． CHECK LIST

No.ITEM JOB INTERVAL REMARKS

1Piping, Pump, Valve Visual check, Leakage of fuel

Daily

2F.O. pressure andF.O. temperature

Visual check

3

Furnace pressureand up-take gastemperature

Visual check

4Flame condition Visual check

5Black smoke Visual check

6Steam trace Touch with gloves

7Oil strainer Cleaning of the basket

Weekly

8 Oil heater Removal of drain and air

9Rotary cup Cleaning and check

10Burner tile, Furnace Visual check of the soot

11Burner belt Visual check of crack

12Ignition burner Cleaning and check

13Flame eye Cleaning of glass and check

14Main shaft bearing Grease up

Monthly

15 Rotary cup Disassembling and Cleaning

16Air/Oil linkage Visual check

17Each motor Auditory (noise) Check

18Each bearing Oiling

19Burner belt Check of tension



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Rotary cup burner

１． Features of the rotary cup burner

1.1. Principles of the rotary cup burner1) By guiding the fuel oil to the inner surface of the rapidly spinning rotary cup, therotary cup burner sprays fuel oil from the rim of the cup by the centrifugal force of therotation.

2) The F.O. film that is sprayed from the cup will be stroked and converted to oilmist by the primary air pressure and will form a sprayed flame pattern in front of therotary cup burner.

3) Functions of the rotary cup.

■ By the centrifugal force, the F.O. will be formed into a thin oil film in theinner surface of the rotary cup

■ By the centrifugal force, the F.O. will be pushed into the cup.

■ By the centrifugal force, the F.O. will move forward until it is thrown off the cup rim as a very thin uniformed film.

■ The rotary cup will make the primary air pass between the primary airnozzle.

Primary Air(1000mmAq)

Secondary Air

Secondary Air

Fuel Oil Air Rotating parts

Oil Guide PipeDistributor

Rotary Cup

Cup Nut

Air Vanes

The F.O. film formed by the

centrifugal force. The F.O. film atomized and convertedto mist by the primary air



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4) The high-velocity (High pressured) primary air will turn to the opposite direction

of the rotary cup rotation by the air vane, and will strike the F.O. film. In this way,F.O. will break up and will be converted into mist of fine oil particles.

5) This system can be applied to the fuel in wide ranges of viscosity. The F.O. formsa film by the centrifugal force described above, and this F.O. film will be strokedby the primary air and will be sprayed.

1.2. Features of the rotary cup burner1) The advantages of the rotary cup.

■ By sending the F.O. in low pressure (0.3～0.5MPa, depending on the type

of the burner), the pump will last for a long time. In addition to this, thelow pressure pump will decrease the risk of leaking from the connectionparts and other parts of the flanges. (Long lasting pump, safety operation)

■ Oil flow channels of the rotary cup are wide and there are no nozzles inbetween, so it has no possibility from being chocked by foreign particles.(Higher reliability against most obstacles)

■ The F.O. viscosity has very little effect on the burner combustion becausethe thin oil is formed by the centrifugal force.(High stability to the F.O. in a

wide range of viscosity)■ The combustion capacity has very little effect on the burner combustion

because a good combustion can be secured under any oil flow rate due togood atomization with oil film made by the centrifugal power.

■ By striking the F.O. with the primary air, the F.O. will be sprayed, and by this, the F.O. is exposed to the air quickly and will enable a stable

combustion. (Combustion will be possible at a low excess of air ratio）

■ By the large diameter of the oil spray mist, the F.O. will be exposed to thesecondary air quickly, and the flame made by the rotary cup will be widerand shorter.



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2. The composition of the Rotary cup burner

2.1. The F.O. supply and the circulation1) The Oil in the F.O. tank and the D.O. tank will be selected by the valve and will

be supplied to the F.O. circulating line.

2) The supplied oil will join the oil that returned from the air separator, and will beforwarded to the F.O. PUMP by the head pressure.

3) Before the F.O. comes to the F.O. pump, the strainer (R201) removes the largeforeign particles (standard #60), and prevents the pump from getting stuck.

4) The Oil pressure will be increased by the F.O. pump (the standard pressure of the built-in safety valve is; 0.55MPa) and will be delivered to the F.O. Heater.

The capacity of the F.O. pump is 1.5 to 2.5 times larger than the ratedcombustion capacity.

AIR SEPARATOR

RETURN

TO F.O.PUMP



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5) The oil that comes into the F.O. heater will be heated, and then will be guided to

the burner side.

6) The relief valve (Pressure adjustment valve R237), which is installed near theburner, keeps the oil pressure fixed and will supply oil to the burner constantly.

The relief valve will return the amount of oil, which has subtracted the amountof oil supplies to the burner, from the gross volume of the oil from the pump, tothe RETURN pipe.

7) By running the F.O. pump, the temperature of the warm oil will come to thepipe, and will avoid the oil pipe from cooling down.

From F.O. Pump

STEAM FOR HEATING INLET TemperatureControllerSensor

To the burner side

Burner side

From F.O. Heater

RETURN



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2.2. Burner side

1) A thermometer（R812）is equipped at the entrance of the burner side, and will enable

a visual temperature confirmation.

2) Between the FLANGE of the F.O. IN （A FLANGE）and the flexible tube (R255) that is

connected to the burner, the adjusting valve（R231）and the main valve (R608）are

equipped in a line, and is controlling the combustion capacity.

3) Between the flanges of the F.O. IN (A FLANGE）and the flexible tube (R255), the D.O.

MIX. Line (R609 and R247）is connected to send the D.O. from the output line from

the D.O. PUMP to the main burner at each normal stop of the burner.

The D.O. MIX. valve（R609）opens when the burning stoppage is demanded, and

closes when the main valve closes. This system works with the D.O. pump when it isin mode H.F.O. (when the switch of the F.O. TEMP. DETECT is active)

The D.O. MIX. mixes the oil (H.F.O) that is in the burner with the D.O. to prevent theoil from having high viscosity at cooling. It also makes it easy to put fire when using itthe next time.

The D.O. MIX. valve will open for 30 seconds (as standard) for small sized burners.For medium and large sized burners, the time can be instituted by the touch panel.

2.3. THE IGNITIION BURNER

1) The D.O. sent from the D.O. pump is supplied to the ignition burner（R108）by the

IGN. valve (R606).

The structure of each device (exploded diagram etc.)

To IGN.Burner

From D.O. PUMP

RETURN

F.O. IN

From D.O.PUMP



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Read the following diagram and the explanation documents for information about thestructure of each device. The diagrams, which have been overlapping with the submitted diagrams, are omitted.

sunflame boiler burner instruction manual sdr-1500

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