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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

JDH-STEP CONTROL SYSTEM INSTRUCTION MANUAL

JIANGYIN CHUANGJIE ELECTRICAL EQUIPMENT CO., LTD.

  • 1. The system constitutes

The system is constitute of DHK-step control cabinet , JGD-30 high

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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

power ignition equipment, JZRS400QR vortex burner, JZYQ2000/R HFO gun JZYQ 2000/1550R HFO/LDO gun valves and meters . They can complete step igniting function safely and reliably .And at the same time they supply connecting signal for the DCS distance control .They are good choice for small scaled boilers to ignite.

  • 2. Main control in system logic (basic function)

● Step control the ignition of high power ignition equipment by hand; ● Step control the propulsion device is enter or back by hand; ● Step control the purge ,reliefoil/ gas and stop oil/gas returning valves by hand; ● Can adopt one method among three kinds of fire method : locale step control by hand, distance step panel control , DCS distance program control; ● The shift of the automatic control (remote operation room) or hand step control (at the locale) ● Show the running condition (signal light);

● Flames surveillance; ● Provide for the DCS right on the spot action signal of carrying out the device (with no- source touch).

  • 3. Working condition Working power supply: Control part and Igniting part:

AC240Vvalves and air propulsion deviceDC24VPower Rating: 1.5KW

Working temperature: Not more than 50ºC for step control

box

Not

more

than

80ºC

for

ignition

equipment

and

propulsion device Height over sea :Not higher than 1000ms Working environment: No serious chemistry contaminative, no the large quantity of hanging metals floats .

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4. The principle diagram and ports diagram (See the attached) 5. Operation process

Locale step control igniting method Check circuitClose the general switch in step control box (the signal light of power is bright)Close together the related air switch in the corner to be ignited Make the revolve button to locale ignition Check if the instructions lights of the ignition gun returning ,oil gun returning oil valve closing, purge valve closingatomizing valve closing are bright; Check if the instructions lights of the ignition gun entering, oil gun entering oil valve opening, purge valve opening atomizing valve

closing and flame signal are dark; If satisfied, it is time to ignite.

Igniting process:

A angle use HFO igniting:

Open the main valves first

Make the revolve button to locale ignition Open the main HFO valveIts signal light is brightand returning HFO valveIts signal light is brightOpen steam valve (Its signal light is bright). Then we can ignite all angles (A, B, C), for the example with A angle:

Press the button A enter oil gun(Its signal light is bright) Open the A purge valve(Its signal light is bright), purge the oil pipes for 3minutes,then close the A purge valve(Its signal light is bright)Press the button A enter ignition gun(Its signal light is bright)Press the button A ignition (Its signal light is bright),Press the button open A atomizing valve(Its signal light is bright) and open

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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

A HFO valve (Its signal light is bright) at the same time.When the instructions light of the flames scanner is bright (Or check if the oil gun is lighting through observation port), ignition gun is burning for 10 seconds Press the button A withdraw ignition gun The fire process will be completed when the ignition gun returning the original position and its signal light is bright. If there is no fire after the ignition gun igniting for 10 seconds, it is stated that igniting fails. Close the A HFO valve quickly (The instruction light of A HFO valve is bright). When the oil gun stops working, purge must be carried out, finish purgingclose A purge valve and withdraw A oil gun . And purge should be carried out again before igniting beginning again. A use LDO igniting:

Open the main valve first:

Make the revolve button to locale ignition Open the main HFO valveIts signal light is brightand returning HFO valveIts signal light is bright);Open the main LDO valveIts signal light is bright and returning LDO valve Its signal light is brightOpen the compressed air valve (Its signal light is bright). Then we can ignite every angles (ABC),B angle and C angle are same as above. Introduced emphatically A angle:

Press the button A enter oil gun(Its signal light is bright) Open

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the A purge valve(Its signal light is bright), purge the oil pipes for 3minutes,then close the A purge valve(Its signal light is bright)Press the button A enter ignition gun(Its signal light is bright)Press the button A ignition (Its signal light is bright),Press the button open A atomizing valve(Its signal light is bright) and open A LDO valve (Its signal light is bright) at the same time.When the instructions light of the flames scanner is bright (Or check if the oil gun is lighting through observation port), ignition gun is burning for 10 seconds Press the button A withdraw ignition gun The fire process will be completed when the ignition gun returning the original position and its signal light is bright. If there is no fire after the ignition gun igniting for 10 seconds, it is stated that igniting fails. Close the A LDO valve quickly (The instruction light of A LDO valve is bright). When the oil gun stops working, purge must be carried out, finish purgingclose A purge valve and withdraw A oil gun . And purge should be carried out again before igniting beginning again. NOTE:

1.In this system ,the compressed air valve interlock with the steam valve ,so the steam valve will closed when the compressed air open ; vice versa. 2. In this system, the A LDO valve interlock with the A HFO

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valve, so the A LDO valve will close when the A HFO air open; vice versa.

The igniting method through distance step panel control

Make the button revolving to distance control to ignite. The control

signal lines is connected with the ports for distance panel step control according to igniting system principle diagram , lines diagram and ports diagram. The igniting operation can be carried out through the buttons controlling on distance panel (supplied by customer) or computer. Step control to igniting will be finished through distance step panel control in operation room.

The igniting method through distance DCS program control

Make the button revolving to distance control to ignite. The control signal lines and signal reflecting lines are connected with the ports for distance DCS program control according to igniting system principle diagram, lines diagram and ports diagram. And the program in DCS system should be made according to ignition logic (See the attached). The igniting operation can be carried out automatically through distance DCS program control in operation room.

6. Installment

  • 1. DHK- step control box The cupboard is for the style of waterproof Cupboard in dust palliative design, it is close At hand steady to placed that the better environment, convenient in operation. The shape of cupboard is(High*Breadth*Deep):

1400*750*600, the connecting lines can go Through from the hole at the end of step control Box (how to connect line, please see the attached diagram).

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就地控制柜 (一控三) 1400 750
 
 
就地控制柜 (一控三) 1400 750

就地控制柜

(一控三)

(一控三)

就地控制柜 (一控三) 1400 750
1400

1400

就地控制柜 (一控三) 1400 750
 
750
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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

2. JGD-30 type high -power ignition equipment

The high-power ignition control box and lighter are connected through high power cable (Both ends of high power cable must be screwed tightly), the control box should be hung to install near its lighter. The size of Installment sees the detailed instruction manual of high power ignition equipment.

JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD 2. JGD-30 type high -power ignition equipment The high-power ignition

3JZRS400QR vortex burner

The device is mainly used in boiler warmer and ignition, the main function is to control ignition gunoil gun is adjustable, steady oil gun fire, etc. This device make stable-combustion cover, propulsion system , oil gun and ignition gun is an organic whole repeatedly, improve all system`s performance, make installation operation more convenient and reliable. At the same time, this device also can deserve to choose among components, in order to meet the needs of different users.

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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD 4. JZYQ - 2000/R HFO gun 、 JZYQ - 2000/1550R

4. JZYQ2000/R HFO gun JZYQ2000/1550R HFO/LDO

gun and soft metal tube This oil guns are HFO gun and HFO/LDO gun. Its designed parameter is: The output of oil guns are 2000Kg/h2000/1500Kg/h; the pressure of pipeline is not more than 2.0 Mpa ,The installing method sees the detailed installment diagram. The oil atomizing test should be carried out every time before using. Ignition can not be begun until atomizing well. The size of soft mental tube is M30*1.5, its pressure grade is designed for2.0Mpa; Its length is 2 meters.

JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD 4. JZYQ - 2000/R HFO gun 、 JZYQ - 2000/1550R

5. Valves and pipeline

Distribution of valves and pipeline should be made according to oil

transport system diagram. The circulating oil test and purging pipeline

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JIANGYIN CHUANGJIE ELECTRIC EQUIPMENT CO., LTD

tests must be carried out.

7. Maintenance and Test for Equipment

1) Maintenance and test for step control box

  • 1.1 Lines should be connected rightly and carefully according to ignition principle diagram, line-connecting diagram and port diagram.

  • 1.2 Check connecting lines. The connecting lines between step control box and locale equipment should be checked if it is right. The connecting lines between step control box and DCS control system should be checked if it is right.

  • 1.3 Power should be connected. The revolving button Locale/Distance

should be made to locale station and the related locale light should be bright. Button, Revolving Button, signal light and other parts should be check if they are right. 2) Test for Propulsion Device 2.1 Press the button entering ignition gun to check if the hoop of

propulsion device is moving forward, then the related light is bright

Press the button withdraw ignition gun to check if the hoop of propulsion device is moving backward, then the related light is bright. 2.2 Press the button entering oil gun to check if the hoop of propulsion

device is moving forward, then the related light is brightPress the

button withdraw oil gun to check if the hoop of propulsion device is moving backward, then the related light is bright. 2.3 If into place and out of reach the designated position indicator, back in place and into reach the designated position indicator light that limit switch signals at the opposite position; If clamping claw in place position in place semaphore not all bright, the limit switch signals should be faulty pick up right or fluctuation adjustment limit switch position. 3) Test for High Power Igniting Equipment. 3.1 Screwed the lighter in the hoop. The position of hoop should be determined as follows : When the ignition gun is entered enough ,the ignition gun should be inserted into atomization area of the oil gun) 3.2 The high-power ignition control box and lighter are connected through high power cable. And both ends of high power cable must be screwed tightly. Igniting is forbidden before screwed tightly. 3.3 The time of delay in step control box is set in 10 seconds. 3.4 Press the button igniting and watch there is fire .The bright light should be watched from the watching hole in burner and the sound of fire should be heard when the lighter had been entered in its

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position.

8.Ready for ignition.

1. Clear away welders (Important) It is necessary to clear away welders in pipes by the way of sore washing, water washing and purging when finished installation to prevent the welders blocking valves and flow meters but flow meters must be discharged when carried out the above action in first time.

2Purging Test (Important, Purged for 4-12 hours)

All pipes should be purged and the rust and welding must be cleaned by smoke air or compressed air and all valve should be opened at the same time before igniting. Goal: a. To protect the valves from being blocked and closed loosely. b. To protect the nozzle of oil gun from being blocked.

3Circulating Oil Test and Oil Atomizing Test (Important, for 2-4

hours)

  • 3.1 Oil valves before oil gun should be closed and Returning Oil valve should be opened. Oil pump should be run. Returning Oil valve should be adjusted to watch the change of oil pressure. The oil pressure should be 0-25Kgf.

  • 3.2 Oil atomizing test should be carried out after one hour oil circulating. Oil gun should be put to empty barrel and valves before oil gun should be opened. Then Returning oil valve should be adjusted until the oil pressure of pipe is 0-20Kgf and the atomizing condition of oil gun should be watched.

  • 3.3 Atomizing Test must be carried out every ignition.(The oil pressure atomizing should be about 12-20 Kgf) .Igniting should be carried out until oil atomizing well.

  • 3.4 The output of oil gun can be adjusted through atomizing part in oil gun according to the use of oil gun. The screw of nozzle must be screwed tightly to prevent from the leakage of oil every change of atomizing part .At the same time, atomizing test should be carried out until the oil gun atomized well. Goal: a. To check if the oil pump work well b. To check if the pipe has the leakage of oil c. To check if the nozzle of oil gun is screwed tightly d. To check if the pipe is cleaned. e. To prevent the coal pit from making agglomeration or burning badly or spoiling

9. Formal igniting 1 Igniting (on the basis of atomizing well for oil gun)

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  • a) The oil pump should be run and the entering-oil regulate valve should be adjusted until the oil pressure of pipe is about 12

18Kgf.

  • b) Igniting Process (by locale step igniting): The revolving button locale and distance should be in locale position and its related bulb is bright. Then the lighter should be entered until the bulb lighter returned to its position is brightIgnitingOpen oil valveReturn lighter until the bulb lighter returned to its position is bright after the bulb igniting is dark

  • c) If the igniting fails, please close the oil valve quickly.

Reasons of Fails as follows:

  • a) The matched air is not appropriate

  • b) The atomizing part of oil gun is blocked

  • c) Atomizing test is not good (The atomizing part of oil gun is

blocked or distorted.)

  • d) Pipe is blocked

  • e) The lighter is not in the atomizing position.

2 Burning load regulation (Oil gun’s flux regulation)

  • a) Please lower oil pressure/ Adjust the gas valve position or increase burning wind or change little flux atomizing part if the temperature of the chamber of boiler is risen too quickly;

  • b) Please lower oil pressure if the temperature of the burning room is risen too quickly;

  • c) Please lower oil pressure if the temperature of the first wind room is risen too quickly; at the same time, it mustn’t affect with the oil gun/gas gun burning.

3 When the oil gun stop working, please shut off the oil valve

quickly ,when the gas gun stop working ,please shut off the gas

valve and open the relief valve ,after any time ,close relief valve .Then the oil or gas system all need purge for 3-5 minutes must be carried out. 10. Others

  • 1. Igniting test should be carried out every formal ignition to check if the igniting equipment is working well and guarantee igniting succeeded one time.

  • 2. The nozzle should be cleaned or atomizing part should be changed before used again when the oil gun was unused for a long time.

  • 3. Valves and oil strainer should be cleaned in regular time.

  • 4. Valves and oil strainer should be cleaned in regular time. Power should be broken after unused for a long time.

  • 5. Please according to the instruction manual when operating.

  • 6. Please take right measure to dustproof and waterproof ; examine and repair.

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Jiangyin Chuangjie Electric Equipment Co., Ltd Add:11 Yuedong Road,Yuecheng Town,Jiangyin City

Tel:+86-510-86581652;86584652

Fax:+86-510-86581522

E-Mail:Chuangjiedianqi@sina.com. Post Code:214404