YGK-CZJP-Tl

MARINE CONTROL BOX

FOR
BURNING EQUIPMENT
OF
FUEL OIL BOILER
 I. GENERAL

II. PRINCIPLE OF CONTROL SYSTEM

III. GENERAL DESCRIPTION OF AIR DAMPER CONTROLLER

IV. GENERAL DESCRIPTION OF LIQUID LEVEL CONTROLLER

V. CAUTIONS FOR INSTALLATION, OPERATION &

'~
MAINTENANCE

VI. CONFIGURATION & INSTALLATION DIMENSIONS

ATTACHED DRAWING: BLOCK DIAGRAM FOR AUTOMATIC

CONTROLLED BURNING SEQUENCE

This control box adopts three-phase, 380 V / 50 Hz A.C. power supply. Control
circuits adopts 220 V / 50 Hz A.C. power supply. The control system consists of such
circuits as water level control, steam pressure control, burning sequence control,
safety protection and alarming etc. The system can be automatically controlled or
manually controlled.
This control box can be suitable for the control and protection of the marine boiler, of
which its fuel oil is heavy oil (1500 s), and for the dual water level control and the
multi-position burning control of the boiler.
This control box can be normally operated under the following ambient conditions:
(1) Ambient temperature: _5°C '---+55 °C;
(2) There exists humid air, dew, salt mist, oil mist, and fungus etc;
(3) Trim and list being 22.5 0 in each direction;
(4) Rolling being 22.5 0 in each direction;
(5) There exists vibration caused under normal operation in ships.
Designation of model:
YGK-C Z J P- Tl

LSerialNO.

Type of burner:
Mechanical type with double nozzle

1. Control of water level

Water level control device equipped in this control box is of dual level type
device. Change of water level is converted into the change of displacement of the
magnetic probe via the floater of liquid level controller, thus controls the starting and
stopping of water feed pump and fulfils the water level control, and the protection and
alarming of too low water level, low water level and high water level.
This system controls the operation of two water feed pumps. One pump is for
normal running, and the other pump is for stand-by. The pump can be automatically
controlled or manually controlled.
 Manual control of the pump can be carried out as per the follQwing modes:
Set the control switch 2S7 or 2S8 of water pump at the "Manual" position, the pump
will supply water into the boiler. After the water level reaches to ;its normal level, set
the switch at "0" position, the pump stops to supply water.
Automatic control of the pump can be carried out as per the following modes:
Set the control switch 2S7 or 2S8 of water pump at the "Automatic" position and set
the other switch (2S8 or 2S7) at the "Stand-by" position, the water pump will be
operated under the control of liquid level controller. When the water level is lowered
to the starting position of the stand-by pump, then the stand-by pump will be started
and run.
2. Control of steam pressure:
This control system controls the starting and stopping of the burner via pressure
controller 12B8 during the automatic running. Pressure controller 13Bl adjusts the
burning load (big or small of the flame) as per the value of steam pressure.
3. Control of burning sequence
Before running the system, the oil pump should be started at first. When the oil
supply system is in normally running, then the burner can be started.
The controlled burning sequences are:
Starting - Starting fan - Adjust the air damper to its maximum posItIOn-
Pre-purging- Adjust air damper to position for class I load- Ignition- Establish
flame-Flame monitor is put into operation-Normal burning (at class I load or class
II load) -Flame out- Post-purging.
Manual control of burning is controlled as per the following sequences:
Press down the starting pushbutton, and set the operating mode switch 11S4 at the
"Purging" position; start and run the fan (at this moment, the oil pump has been
operated), and at the same time, adjust the air damper to its maximum position, make
pre-purging for approx. 30 s; then set the switch 11S4 at the "Ignition" position; the
ignition transformer begins to ignite; at the same time, adjust the air damper to the
position for the class I load; the system begins to spray oil after time delayed for 2 s;
after established flame, set the switch at the "Small fire (partial load)" position. 20 s
later, the switch can be operated for selecting big fire (full load) or small fire (partial
load) burning; After completed the burning, shut-off the burner after removed the tail
gas by post-purging for 30 s.
To avoid the unintentional accidents by operating personnel, all the protection
and alarming functions provided for "Automatic" operation mode are also valid when
the system is in "Manual" mode. Once the following cases such as too low water level,
high steam pressure, unclosed hinge, low air pressure, flame faults, low inlet oil
pressure, high return oil pressure, high oil temperature and low oil temperature etc are
occurred, the system can give audible and optical alarming signal, and cut-off the
burning.
When the system is to be run in "Manual" operation mode, the operator must
make operation as per the sequence of "Purging" - "Ignition" - "Nozzle I" -
"Nozzle HI1". In addition, when making ignition, set the operation mode switch at the
"Purging" position in case misfire occurred within 8 s, make purging for 30 s; then
make re-ignition or shut down for inspection. After confirmed t.obe normal, manual
operation of the Starting / Stopping of boiler can then be made.
4. Control of oil temperature
When the burner combusts heavy oil, it is necessary to heat the fuel oil by pre-heater
to the temperature required for atomization. The control system controls the on/off of
the pre-heater and the heat-tracing of nozzle holder etc, via thermal resistor 4R4,
temperature regulator 4A4, temperature switch 4R6 and temperature controller
4B5&4A8 in the pre-heater. If the burner is started at cold state, the burning mode
selection switch 11S4 can, after the oil pump is turned on, be changed over to position
"PURGING", to circulate and heat the fuel oil in pipeline. Only after the fuel
temperature reaches the temperature required for normal atomization, can the burning
sequences be run.
5. Safety protections and alarming
(I) High water level
When the water level is raised to the high water level due to some reasons, contact B5
of 13A7 opens; after time delayed for 5 s and acknowledged by PLC, audible and
visual alarm signals are given; the burner continues to run. Alarm signals can be
automatically released after the faults are eliminated.
(2) Low water level
When the water level is lowered to the low water level due to some reason, contact B2
of 13A7 opens; after time delayed and acknowledged by PLC, the standby pump is
started and run; at the same time, audible and visual alarm signals are given. After the
water level has reached the normal water level, operating personnel should timely
switchover the water pump.
(3) Too low water level
When the water level is lowered to the lower limit, contact B1 of 13A7 or 13A2 opens;
after time delayed for 5 s and acknowledged by PLC, the burning circuit is
disconnected, at the same time the audible and visual alarm signals are given and the
system is locked.
(4) Low oil temperature
When heavy oil is burning, if its pressure is too low, then the contact of pressure
regulator 4K7 will open. After PLC confirmation, the burning circuit will be cutoff,
and audible-visual alarming signal will be given and the system will be locked. Then
the system will perform post-purging.
(5) Flame faults
When the burner is misfired or extinguished during the burning process due to some
reasons, the flame monitor 14B2 does not sense the flame; after acknowledged by
PLC, the burning is shut off; audible and visual alarm signals are given and the
system is locked the system carries out post-purging.
(6) Low air pressure
After the burner has been started and run for 5s, if the PLC does not receive the air
pressure signal fed back from 1481, the system will shut off the burning, give audible and
visual alarm signals and the system is locked. The system carries out post-purging.
(7) Network voltage failure protection
In case the network voltage is suddenly decreased when the bqper. is under normal
running, main relay 2K4 of burner will be de-electrified, and main control circuit is
disconnected. When the network voltage is recovered to be normal, the system can be
put into operation only by pressing down the starting pushbutton again.
(8) Unclosed hinges of burner
An interlocking switch 12 B 1 is installed on the housing of the burner. When the
burner is out of its working position due to repair or other causes, a push bet of this
switch is spring out from its pressing position, thus disconnect the main control circuit
of the burner, then the burner cannot be started and run (This function is not provided
when in manual operating mode).
(9) Burner motor overload
When the fan motor is overloaded, IF2 actuates; after acknowledged by PLC, burning is shut off,
the system is locked, and audible and visual alarm signals are given.
(10) Start the stand-by oil pump
When the heavy oil is burning, if the oil pressure is lower then the preset value of
pressure regulator 12B6, then its contact opens, after acknowledged by PLC, the
standing pump is started, the system gives audible and visual alarm signals.
(11) High heavy oil temperature
When heavy oil is burning, if its temperature is too high, then the contact of
intermediate relay 4K5 will open. After PLC confirmation, the burning circuit will be
cutoff, and audible-visual alarming signal will be given and the system will be locked.
Then the system will perform post-purging. Low steam pressure
(12) Low oil pressure in supply line
When the heavy oil is burning, if the oil pressure is too low, then the contact of
pressure regulator 13B8 opens, after acknowledged by PLC. The burning is shut off,
audible and Visual alarm signals are gives. The System is locked. The System carries
out post-purging.
(13) High steam pressure
When the boiler steam pressure is raised to its upper limit due to some reason, 12B5 is
actuated, its normally closed contact opens; after acknowledged by PLC, the burning
is shut off; audible and visual alarm signals are given and the system is locked. The
system enters into post-purging.
(14) Quick action valve closed
When the quick action valve in heavy oil pipes is closed, the burner cannot be started
and run.
In case the boiler is requested to be remote controlled to stop when it is under
normal running, press down the emergency stop pushbutton 2S4a, then the boiler is
suddenly stopped ("Stop" pushbutton on the control box of boiler also has the same
function).
When the system produces audible and optical alarming signal due to the faults,
pressing down the "Silencing" pushbutton can eliminate the audible alarming signal,
but the optical alarming signal is still existed. When the faults occur once again due to
other causes, the system will continue to give both audible and optical alarming
signal.
 After eliminated some locked faults, the locking functions~can be relieved by
pressing down "Starting / Reset" pushbutton; then the system -recovers to normal
running state.

Servomotor controls the opening angle of the air damper of the burner under various
working load condition according to the preset values, make the proportioning ratio of
fuel pipe and air pipe to be the optimum value. Servomotor controls the opening and
closing angle of the air damper by using the rotating of the servomotor and the
location cam etc.
Each cam can be adjusted according to the following table. (IV= 0° < II < I < III)
Cam IV-Closed.
Cam III-Two-stage load (Full load)
Cam II-One-stage load (Partial load)
Cam I-Solenoid valve II, adjusted between III and II.
Liquid level controller consists of housing, floater and magnetic n;lay etc.
Liquid level controller connect the container to be controlled by means of connecting
flange. The floater will be floating up and down as the liquid level fluctuates. When
the liquid level is raised to the working position of a certain magnetic relay, the
magnetic probe on the floater make this relay to change its original state and give
required switching signals, and maintain it in this state. This relay can recover to its
original state only until the liquid level is lowered to the working position of this relay.
We hereby specify that the state in which the magnetic probe is lower than the
position of this relay is the initial state.
Before the liquid level controller is to be installed, the probe should be slowly pulled
several times, make each magnetic relay to be reset. Now we take one magnetic relay
as an example, the following figures will indicate the states of this relay when the
water level is up and down.

NC NO

4j.~.. ~~.
NC NO NC NO

..4j..~.

(h) (el (d) (e)

This relay is actuated ·fhis relay state is This relav is recoveredfhis relay is maintained
when the liquid level is maintained when the to its initi~1 state when the in its·initial state
raised liquid level is continuously liquid level is lowered when the liquid is
raised continuously lowered

1. The control cabinet shall be installed on the vertical plane and fixed with 4 MI2
bolts.
2. The wiring shall be in accordance with the provided external wiring diagram
and the number of lead shall be correct.
3. Inspect the grounding status before connecting with power source.
4. Before operation, check whether the acting values of thermal relays are III
accordance with the motor to be protected.
5. During the installation, screws, washers and lead shall not be dropped inside the
cabinet.
6. During the application, the flue on the flame sensor shall be frequently
eliminated.
 -1

3
D 5 6 7

CS) 0cs)®
10 If 12 1;3 rl 15 16

0CS) @
17 18 19 20 2I2:r
In ::g; (Q90 0 0
0
0 24 i 25 262L 28 29 _
+1 ,.....;
0
0\
,.....;
,.....;
"""'"
,.....;
0000@0
;)(1 31 - ~3:r= _.:13 _

®®
34 :].5 :36
®®
:37 :lfL.

V V V V i,
39
j
I

-1 <D13
V
40
~j
I
___
J
 Turn on the mam power Intermediate relay 2K4 PLC 5A 1 IS put Approx 40s later, the air damper is
supply. Press START ~ IS closed; the system ---. into operation,---. opened to ignition position; approx 3s
pushbutton, set operating starts the automatic performing later, Nozzle I is turned on and
mode selection switch sequences. pre-pur mg. Ignites, and establish flame.
11S4 at position AUTO.

Approx 15s later, it is possible

to run under big fire load (i.e.,
Nozzle I+II)

The temperature of heat transfer oil

decreases; Nozzle II IS put into
operation.

The temperature of heat

The temperature of heat transfer oil The temperature of heat
transfer oil decreases to
continues to increase to preset value; transfer oil increases;
burner's starting value; 4Kl ~
4Kl actuates; the burning stops; the Nozzle II stops working.
actuates; the burner is put into
system perform post-purging.
operation again.