There are many methods for repairing burners, including inquiry repair method, program repair method, intuitive repair method, replacement repair method, comparison repair method, simulation repair method, sequential repair method, experience repair method, emergency repair method, association repair method, addition and subtraction repair method, etc. The following examples illustrate several special repair methods:
I. Sequential repair method for burner faults
Repair model: Italian Riello GW type
Fault phenomenon: After turning on, the burner does not start.
Fault analysis:
1. No power supply
2. The temperature control limit switch on the electrical cabinet is open
3. The RIELLO 503 SE controller is in a locked state or the controller fuse is disconnected or the controller is damaged
4. The motor or the starting capacitor of the motor is damaged
5. The photosensitive tube is short-circuited or the furnace leaks light or simulated flames appear
6. The oil pump is stuck
Repair process:
1. Use the multimeter AC 250 volt gear to measure the burner terminal BM 1 (L) and 2 (N) pins. The multimeter shows 220 volts, which is normal. (You can also use an electric pen to measure)
2. Use the multimeter resistance × 10 gear to measure the burner terminal BM 3 and 5 pins. The temperature limit switch is connected normally.
3. Use AC 220V to test the motor alone. The motor starts normally. Since the motor can start normally, it means that the oil pump is not stuck.
4. Use the multimeter resistance × 1K gear to measure the photosensitive tube. Normally, the resistance value of the photosensitive tube should be greater than 20K when there is no light, and the resistance value when there is light should be less than or equal to 1K. The measurement result is 1K with or without light, indicating that the photosensitive tube is damaged and needs to be replaced.
5. After the power is turned on for testing, the burner still cannot start normally, and even the motor does not rotate, but the 503SE controller has been activated (to determine whether the controller is activated, just put your hand on the controller. If there is a slight vibration, it means that the controller has been activated)
6. Because the motor does not rotate, and the motor is good when tested alone, this means that there is a problem with the connecting wire inside the burner that provides power to the motor. So where is the problem?
7. Pull out the 503 SE controller and check the connecting wire of the control motor power supply in the controller base. It is found that the N line of the control motor (connected to the 17th pin of the controller base) is not connected to the BM 2 (N) pin of the burner terminal, while the 15th pin of the controller base is connected to the BM 2 (N) pin of the burner terminal. Because the 15th, 16th, 17th, and 18th pins of the controller base are connected with brass, they are all N, how can they not be connected? At this time, use a wire to short-circuit the 15th and 17th pins, connect the power supply to test the machine, the burner starts, and the motor works. After it is normal, remove the copper sheet for inspection. It turns out that the copper sheet is corroded and cracked, causing the N line to be open and blocked. It was not discovered at the time because the crack was pressed by the wire, which is generally not easy to find.
8. After the burner is started, it does not ignite, and the controller alarms soon.
9. Use AC 220 volts to test the ignition transformer alone. Sparks between the ignition rods can be observed from the fire viewing hole. This shows that the ignition transformer is good, but the power provided by the 503 SE controller to the ignition transformer is faulty, and the power of the ignition transformer is provided through the contacts inside the 503 SE controller. This analysis can determine that the 503 SE controller is faulty. Because I didn't bring a new controller at the time, I had to open the outer shell of the controller and carefully observe the contact that provided power to the ignition transformer. Sure enough, the contacts were seriously blackened and the contact was poor. After gently polishing with fine sandpaper, the power was turned on and the burner started to ignite. The large and small fires worked normally.
Summary:
It is very difficult for people who lack maintenance experience to have multiple faults in a burner. I hope this real maintenance example will serve as a starting point for discussion.
2. Experience-based repair method for burner failure
One day, I received a strange call from Tangshan, Hebei. The other party claimed to be the stationmaster of the mixing station. He heard from an insider and asked me to help him. He said that his Weishaupt 70/2 burner had a strange problem. He started to ignite at more than four o'clock in the morning, but it couldn't be ignited. But at more than ten o'clock, the burner ignited at once, and there was no problem in production until the evening. He said that he had invited many people to repair it, but they couldn't eliminate it. The stationmaster was very anxious because I couldn't start work early in the morning, which affected the production process. He asked me to take a plane immediately and he would reimburse all the expenses. After arriving at the construction site, the situation was indeed like this. I had never encountered such a strange problem before, but based on my experience, it took three hours to eliminate the fault.
3. Emergency repair method for burner failure
An Italian Energy EB8N heavy oil burner at the Xinjiang Karamay Asphalt Mixing Station was normal from installation to commissioning and ignition. When the stone was sent to the test machine, it was found that the material temperature rose too fast and reached more than 200 degrees in a short time. Obviously, such a high material temperature cannot be produced. So, the machine was stopped to check the settings of the thermocouple and the ratio table parameters, and the inspection results were normal. Considering that the construction site is located in a large desert, the temperature is high and the stone is dry, if the normal oil pressure is used for debugging, the temperature will definitely be high. So I had to lower the oil pressure while watching the stone temperature. As a result, when it was lowered to 3 kg, it was found that the combustion was a little abnormal, and the stone temperature was still higher than the normal value. After debugging the machine, the burner failed to ignite due to low oil pressure and poor atomization. It seems that only by replacing the 1200 kg/h nozzle equipped on the machine with a 900/h nozzle can the problem be solved. For this reason, the construction site professional was very anxious, because this time the production cycle was only three weeks, and it would take at least a week to ask the burner company to send a small nozzle to the construction site. If the plan was not completed, there would be a fine. He asked if we could produce immediately without changing the nozzle and complete the task with quality and quantity! I agreed to try it, and finally I applied the method of emergency repair of burner failure to solve this problem.
4. Burner Failure Association Repair Method
A GI510 burner at a construction site in Guangzhou had a failure to ignite. After inspection, it was found that the main solenoid valve coil was open. So the user was asked to replace the new original parts. The user said it was too expensive and asked if there were any other solutions? In order to meet the user's requirements and eliminate the burner failure, I adopted the burner association repair method, which solved this problem in an economical, affordable and reliable way.
5. Burner Failure Addition and Subtraction Repair Method
An aluminum factory in Suzhou needs to change the five 260,000 kcal diesel burners in the factory to natural gas, with a natural gas pressure of 50mbar. After the burner was installed in place, the four gas machines on the drying channel were debugged first, which was very smooth, ignited successfully at one time, and the output was normal. When debugging a gas machine installed on the hot air furnace, it failed to ignite. Adjust the gas valve and reduce the natural gas flow. The burner works normally, but the temperature cannot be raised. Increase the natural gas flow, the burner immediately goes out, and then reduce the natural gas flow, and the burner can work normally again. It seems that the fault may be caused by the high back pressure in the furnace, so why does this problem not exist when burning diesel? Since the problem already exists, we must solve it. Later, I used the burner addition and subtraction repair method to solve this problem.
A friend who is in the burner business called to ask about a fault that no one would believe existed. He said: The two Baide gas burners equipped with the thermal oil furnace were tested in the company's test workshop and sent to Taiwan after being recognized by the equipment manufacturer. After arriving in Taiwan, one of them was returned to the company because it could not ignite. The technician immediately connected the gas to ignite, and the burner worked normally without the phenomenon of not igniting. So the machine was sent to the equipment manufacturer and connected to the gas provided by the manufacturer for ignition. As a result, the burner was abnormal and an alarm was issued when it was ignited. It was the same after many attempts. Is there a problem with the gas source provided by the manufacturer? The company's gas cylinder was pulled to the factory for another test, but the fault still existed. This is strange. The machine ignited normally in the company, but why did it not work after it arrived at the factory and Taiwan? The power supply voltage was normal. Considering that the company used civilian electricity, the factory also used civilian electricity for testing. At the same time, the burner was placed in different positions and angles for testing, but none of them worked. He had consulted many people in the industry about this matter, but none of them gave a clear answer. The factory told him that if it still didn't work, he had to return the product! Wouldn't the loss be huge if he returned the product? He asked what the reason was? How to eliminate it? Since he had never encountered such a difficult fault, he could only say that he would consider it and give an answer in half an hour. Later, I called him and told him to use the burner addition and subtraction repair method, and the problem was actually solved.
There are many methods for repairing burners, including inquiry repair method, program repair method, intuitive repair method, replacement repair method, comparison repair method, simulation repair method, sequential repair method, experience repair method, emergency repair method, association repair method, addition and subtraction repair method, etc. The following examples illustrate several special repair methods:
I. Sequential repair method for burner faults
Repair model: Italian Riello GW type
Fault phenomenon: After turning on, the burner does not start.
Fault analysis:
1. No power supply
2. The temperature control limit switch on the electrical cabinet is open
3. The RIELLO 503 SE controller is in a locked state or the controller fuse is disconnected or the controller is damaged
4. The motor or the starting capacitor of the motor is damaged
5. The photosensitive tube is short-circuited or the furnace leaks light or simulated flames appear
6. The oil pump is stuck
Repair process:
1. Use the multimeter AC 250 volt gear to measure the burner terminal BM 1 (L) and 2 (N) pins. The multimeter shows 220 volts, which is normal. (You can also use an electric pen to measure)
2. Use the multimeter resistance × 10 gear to measure the burner terminal BM 3 and 5 pins. The temperature limit switch is connected normally.
3. Use AC 220V to test the motor alone. The motor starts normally. Since the motor can start normally, it means that the oil pump is not stuck.
4. Use the multimeter resistance × 1K gear to measure the photosensitive tube. Normally, the resistance value of the photosensitive tube should be greater than 20K when there is no light, and the resistance value when there is light should be less than or equal to 1K. The measurement result is 1K with or without light, indicating that the photosensitive tube is damaged and needs to be replaced.
5. After the power is turned on for testing, the burner still cannot start normally, and even the motor does not rotate, but the 503SE controller has been activated (to determine whether the controller is activated, just put your hand on the controller. If there is a slight vibration, it means that the controller has been activated)
6. Because the motor does not rotate, and the motor is good when tested alone, this means that there is a problem with the connecting wire inside the burner that provides power to the motor. So where is the problem?
7. Pull out the 503 SE controller and check the connecting wire of the control motor power supply in the controller base. It is found that the N line of the control motor (connected to the 17th pin of the controller base) is not connected to the BM 2 (N) pin of the burner terminal, while the 15th pin of the controller base is connected to the BM 2 (N) pin of the burner terminal. Because the 15th, 16th, 17th, and 18th pins of the controller base are connected with brass, they are all N, how can they not be connected? At this time, use a wire to short-circuit the 15th and 17th pins, connect the power supply to test the machine, the burner starts, and the motor works. After it is normal, remove the copper sheet for inspection. It turns out that the copper sheet is corroded and cracked, causing the N line to be open and blocked. It was not discovered at the time because the crack was pressed by the wire, which is generally not easy to find.
8. After the burner is started, it does not ignite, and the controller alarms soon.
9. Use AC 220 volts to test the ignition transformer alone. Sparks between the ignition rods can be observed from the fire viewing hole. This shows that the ignition transformer is good, but the power provided by the 503 SE controller to the ignition transformer is faulty, and the power of the ignition transformer is provided through the contacts inside the 503 SE controller. This analysis can determine that the 503 SE controller is faulty. Because I didn't bring a new controller at the time, I had to open the outer shell of the controller and carefully observe the contact that provided power to the ignition transformer. Sure enough, the contacts were seriously blackened and the contact was poor. After gently polishing with fine sandpaper, the power was turned on and the burner started to ignite. The large and small fires worked normally.
Summary:
It is very difficult for people who lack maintenance experience to have multiple faults in a burner. I hope this real maintenance example will serve as a starting point for discussion.
2. Experience-based repair method for burner failure
One day, I received a strange call from Tangshan, Hebei. The other party claimed to be the stationmaster of the mixing station. He heard from an insider and asked me to help him. He said that his Weishaupt 70/2 burner had a strange problem. He started to ignite at more than four o'clock in the morning, but it couldn't be ignited. But at more than ten o'clock, the burner ignited at once, and there was no problem in production until the evening. He said that he had invited many people to repair it, but they couldn't eliminate it. The stationmaster was very anxious because I couldn't start work early in the morning, which affected the production process. He asked me to take a plane immediately and he would reimburse all the expenses. After arriving at the construction site, the situation was indeed like this. I had never encountered such a strange problem before, but based on my experience, it took three hours to eliminate the fault.
3. Emergency repair method for burner failure
An Italian Energy EB8N heavy oil burner at the Xinjiang Karamay Asphalt Mixing Station was normal from installation to commissioning and ignition. When the stone was sent to the test machine, it was found that the material temperature rose too fast and reached more than 200 degrees in a short time. Obviously, such a high material temperature cannot be produced. So, the machine was stopped to check the settings of the thermocouple and the ratio table parameters, and the inspection results were normal. Considering that the construction site is located in a large desert, the temperature is high and the stone is dry, if the normal oil pressure is used for debugging, the temperature will definitely be high. So I had to lower the oil pressure while watching the stone temperature. As a result, when it was lowered to 3 kg, it was found that the combustion was a little abnormal, and the stone temperature was still higher than the normal value. After debugging the machine, the burner failed to ignite due to low oil pressure and poor atomization. It seems that only by replacing the 1200 kg/h nozzle equipped on the machine with a 900/h nozzle can the problem be solved. For this reason, the construction site professional was very anxious, because this time the production cycle was only three weeks, and it would take at least a week to ask the burner company to send a small nozzle to the construction site. If the plan was not completed, there would be a fine. He asked if we could produce immediately without changing the nozzle and complete the task with quality and quantity! I agreed to try it, and finally I applied the method of emergency repair of burner failure to solve this problem.
4. Burner Failure Association Repair Method
A GI510 burner at a construction site in Guangzhou had a failure to ignite. After inspection, it was found that the main solenoid valve coil was open. So the user was asked to replace the new original parts. The user said it was too expensive and asked if there were any other solutions? In order to meet the user's requirements and eliminate the burner failure, I adopted the burner association repair method, which solved this problem in an economical, affordable and reliable way.
5. Burner Failure Addition and Subtraction Repair Method
An aluminum factory in Suzhou needs to change the five 260,000 kcal diesel burners in the factory to natural gas, with a natural gas pressure of 50mbar. After the burner was installed in place, the four gas machines on the drying channel were debugged first, which was very smooth, ignited successfully at one time, and the output was normal. When debugging a gas machine installed on the hot air furnace, it failed to ignite. Adjust the gas valve and reduce the natural gas flow. The burner works normally, but the temperature cannot be raised. Increase the natural gas flow, the burner immediately goes out, and then reduce the natural gas flow, and the burner can work normally again. It seems that the fault may be caused by the high back pressure in the furnace, so why does this problem not exist when burning diesel? Since the problem already exists, we must solve it. Later, I used the burner addition and subtraction repair method to solve this problem.
A friend who is in the burner business called to ask about a fault that no one would believe existed. He said: The two Baide gas burners equipped with the thermal oil furnace were tested in the company's test workshop and sent to Taiwan after being recognized by the equipment manufacturer. After arriving in Taiwan, one of them was returned to the company because it could not ignite. The technician immediately connected the gas to ignite, and the burner worked normally without the phenomenon of not igniting. So the machine was sent to the equipment manufacturer and connected to the gas provided by the manufacturer for ignition. As a result, the burner was abnormal and an alarm was issued when it was ignited. It was the same after many attempts. Is there a problem with the gas source provided by the manufacturer? The company's gas cylinder was pulled to the factory for another test, but the fault still existed. This is strange. The machine ignited normally in the company, but why did it not work after it arrived at the factory and Taiwan? The power supply voltage was normal. Considering that the company used civilian electricity, the factory also used civilian electricity for testing. At the same time, the burner was placed in different positions and angles for testing, but none of them worked. He had consulted many people in the industry about this matter, but none of them gave a clear answer. The factory told him that if it still didn't work, he had to return the product! Wouldn't the loss be huge if he returned the product? He asked what the reason was? How to eliminate it? Since he had never encountered such a difficult fault, he could only say that he would consider it and give an answer in half an hour. Later, I called him and told him to use the burner addition and subtraction repair method, and the problem was actually solved.