Issue 003/March 2000
CHILTERN TECHNICAL SYSTEMS
PROPAMISER BURNER CONTROL SYSTEM
identification: Mk 1 - pre October 2000
identification : Mk 2 - post October 2000
identification : Propamiser special build
There are no significant alterations to user serviceable components between the types.
??? click here for problem solving guide ???
THE CTS PROPAMISER IS SUITABLE FOR MANY DIFFERENT USES, AND ACCORDINGLY THESE INSTRUCTIONS CAN ONLY BE OF A GENERAL NATURE. THEY RELATE TO THE STANDARD CONTROL SYSTEM AND NOT THE INSTALLATION TO WHICH IT IS FITTED, THIS BOOKLET MUST BE READ IN CONJUNCTION WITH O.E.M. SAFETY AND OPERATING MANUALS RELATING TO YOUR SPECIFIC INSTALLATION. IF THERE IS ANYTHING THAT IS UNCLEAR OR NOT ACCORDANCE WITH THE SUPPLIED INFORMATION PLEASE CLARIFY THIS WITH THE APPLIANCE MANUFACTURER BEFORE COMMISSIONING.
CHILTERN TECHNICAL SYSTEMS, BRISTOL, ENGLAND ISSUE 03
THIS UNIT DOES NOT ABSOLVE THE OPERATOR FROM NORMAL SAFETY PRECAUTIONS, USE OF PROTECTIVE CLOTHING, REGULAR FUNCTION AND SAFETY CHECKS ON THE EQUIPMENT, CONTROL SYSTEM AND TEMPERATURE MEASURING DEVICES
IF YOU LOOK AFTER THIS UNIT, IT WILL LAST MANY YEARS. IF YOU ABUSE IT YOU WILL WRECK IT ON THE FIRST MORNING.
DO NOT OPEN THE BOX OR BREAK THE SEALS . THERE ARE NO USER SERVICEABLE PARTS IN THE BOX AND OPENING IT OR CAUSING OTHER PHYSICAL DAMAGE WILL IMMEDIATELY VOID THE WARRANTY.
IN THE EVENT OF A PROBLEM, PLEASE CONTACT THE MANUFACTURER OF YOUR APPLIANCE, NOT CTS. WE MAKE THE CONTROL SYSTEM BUT WE DO NOT INSTALL IT AND HAVE NO CONTROL OVER THE INSTALLATION, BURNER, EXTERNAL PIPEWORK, HEATSHIELDING OR OTHER ASPECTS OF THE APPLIANCE!
INFORMATION ON THERMOSTAT CONTROL
Any system designed for use on site can only measure the temperature at a single point in the container. While the Propamiser is we believe the best system available, it is still limited in how it can operate. As bitumen heats up, the temperature in the melting pot will vary widely. The sides of the pot will be extremely hot, while in some cases, the centre of a solid block of material can be cold. This is important to remember because if you are heating a 'solid' pot of bitumen or sealant, the temperature at the edge can be well above danger point while the part surrounding the thermostat sensor might be solid. The control unit will be trying to warm up the solid bit and other parts of the boiler can be dangerously hot. For this reason it is important to monitor the temperature and control the boiler manually during first heating, reducing the gas pressure by adjusting the burner control valve on the Propamiser until all the material is liquid. After use drain down so that no solid material is left surrounding the sensor probe to give problems during the next heat up.
When feeding material into the unit it is important to break up large lumps. This increases the surface area so that it will melt faster and also enables the control system to respond more effectively. If you put in large blocks of solid material the surrounding sealant will remain hot and the burners will reduce power, resulting in a longer melt down time. Break it into small pieces and the temperature in the pilot will drop, the burner power will increase and the material will be ready for use much sooner.
It is most important to monitor the effectiveness of the control system using a separate thermometer to ensure that the calibration is correct. While the inside of the unit is robust, and is set up accurately during manufacture, any control equipment used on site can be subject to unintended impacts and damage and it will be far cheaper to return the unit for recalibration and service than press on regardless until it fails to work!
Please remember that the burners are under automatic control and will start and stop with little warning, so DON'T work on the burner when the pilot is alight.
,...... and finally a note for the impatient! The control knob alters the temperature cut out point. It has absolutely no effect at all on the speed of heating or the output power of the burners. We have seen users force the knob and in one case try to rotate it with a pair of grips. This will have one effect - a repair bill. Do NOT open the box or break the seals as this will invalidate the warranty and calibration.
IF IN ANY DOUBT, IF THERE IS ANYTHING THAT YOU DON'T UNDERSTAND, IF YOU ARE UNSURE, ASK!
ALL EQUIPMENT SUPPLIED IS FOR INDUSTRIAL USE ONLY.
BASIC
INSTRUCTIONS FOR USE
THIS DOES NOT FORM A FULL STATEMENT OF USE RELATING TO THE
APPLIANCE
For industrial use with high
pressure propane only.
Maximum supply pressure 30psi/2bar.
1) Connect an approved 0-30
psig regulator and hose to the
inlet of the Propamiser control box
2) Connect to a 47kg propane cylinder and turn on.
3) Check for leaks. DO NOT USE A NAKED FLAME.
4) Set the regulator to suit the appliance ( MAX 30 PSI). See separate information.
5) Check that the burner
control valve is closed by
turning
fully clockwise or tap handle in horizontal position. Ensure
bypass tap is closed ( if fitted ).
6) Depress and hold fully in the push button of the flame
failure valve and ignite the pilot burner or light with a
taper.
7) Slowly open the burner valve and check that the burner
lights. Keep hands and face clear of burner and exhaust
openings.
8) Set temperature control knob to the maximum position and
when the required temperature is reached on the indicator turn
the knob back slowly until the flame reduces to a
very low setting. The burner will modulate at this. It may
be necessary to adjust the knob slightly.
9) Turn the main burner off at the burner valve when not
required, leaving the pilot alight.
10) For further charges simply open the burner valve. Once
set the temperature control knob will only need checking
occasionally.
11) For bitumen or any solidifying material ALWAYS drain down
after use.
12) The temperature sensor pocket must always be covered with
material when in use.
13) The burner assembly may be withdrawn to light the pilot
with a match. Replace the burner assembly before turning on
the main burner.
14) After use turn off the gas at the cylinder.
READ AND UNDERSTAND
THE MAIN INSTRUCTION BOOKLET AND ANY
O.E.M. INSTRUCTIONS THAT CAME WITH THE APPLIANCE.
This MUST be done by a competent person.
If in doubt, DON'T FIDDLE!
PROBLEM: The pilot burner will not light.
a) There is air in the line. Try to ignite with a match. The gas/air mixture will blow the match flame away from the pilot, and then ignite when the propane comes through.
b) There is a blockage in the gas line. In this case the gas flame will not be blown away from the pilot. Strip and clean the copper pipe and pilot assembly taking great care with the pilot burner jet and pressure drop unit if fitted.
c) The optional spark ignitor will not work. Turn off the gas. Check that the spark gap is not too big. The gap between the end of the brass thread inside the pilot burner and the electrode tip should be no more than 3/16" (5mm). If this does not work, check that there is no spark jumping to earth between the control box and the electrode. Check that the electrode is undamaged. If there is still no spark, ignite the pilot burner with a match and continue operation. Contact your supplier when convenient.
PROBLEM: The pilot burner lights but will not stay alight when button is released.
a) The thermocouple tip is dirty - clean with wire wool or fine abrasive paper.
b) The thermocouple tip is not in the hottest part of the flame - readjust positions using the two nuts securing the electrode to the bracket. (See below)
c) the connection into the back of the box is damp, loose or dirty - undo split nut and remove thermocouple from control box - clean and dry thermocouple connection and socket in the flame failure valve. Reassemble and tighten. DO NOT USE WD40 or similar cleaning fluid due to fire risk.
d) If none of the above work, replace the thermocouple with a new one.
f) If this does not result in correct operation, the control box needs servicing - please contact your main supplier.
PROBLEM - System does not reach temperature.
a) Thermostat knob set too low.
b) Too rapid offtake of heated liquid, allowing insufficient time for recovery of temperature. Whilst solid bitumen is melting, the system may appear to be controlling at a lower temperature, but will regain the set temperature when melting is completed.
c) Burner incorrectly sized for application.
d) Gas cylinder running out. ( Obvious but it happens ! )
e) Damaged thermal sensors - contact your supplier.
PROBLEM: System exceeds temperature.
a) Thermostat knob set too high.
b) Insufficient offtake of heated liquid. In this case the heat supplied by the pilot burner alone may be enough to overheat the liquid, event though the main burner may be at a very low rate, or even turned off. This can be checked by turning the main gas off completely at the main burner shut off valve and seeing whether the temperature still rises.
c) Damaged thermal sensor - contact your supplier.
TO CHANGE THERMOCOUPLE
to view illustrations click here
This is the only user serviceable item and does NOT require entry into the control box.
1) The thermocouple is attached to the pilot burner by means of brass back nuts. Undo the back nuts of the faulty thermocouple and remove it from the pilot burner bracket.
2) Place the new thermocouple in the bracket with one brass nut either side of the bracket and adjust brass back nuts so that the thermocouple tip is just in the edge of the pilot flame.
3) Undo the 11/32" diameter split nut or extended nut on the rear of the control box and remove the old thermocouple completely.
4) Check the socket of the flame failure valve protruding through the control box and the junction of the thermocouple for cleanliness and then connect the new thermocouple into the socket using a new 11/32" diameter split nut provided. Later versions have a recessed flam fail unit with a blue button and extended nut - in this case the thermocouple needs to be fed into the back of the box with the nut. Take care not to cross thread or snag the thermocouple tube on the extended nut. Avoid twisting the thermocouple when the split nut is tightened.
5) Bend the thermocouple copper conductor to suit and clip in place using the boiler manufacturers original fittings.
Correct positioning of thermocouple head in pilot flame. The tip should be in just far enough to glow a dull red. If the entire thermocouple head is red or worse, glows orange, the thermocouple will have a very short life. Wait until cool before adjusting! In this picture the thermocouple head is in the top left section of the pilot flame and the flame guides show up as a red cross. The tip is just visible against the blue flame. It is normal for the pilot burner 'cross' to be red hot.