Operating instructions

MIBG burner

MIBG-2.14-FlEL

Translation of the Original Operating Instructions

Ammann retains copyright of these instructions.

Reprinting, translation and duplication, even of excerpts, is not permitted without written
approval.

Subject to modifications.

© Ammann Schweiz AG

0202BRMIBG201512_Gb

Font: Arial, WingDings

Author: CTR Documentation Langenthal

Created on: 12.12.2015

2 Translation of the Original Operating Instructions neutral

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Introduction and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . 13

1 Introduction to operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Symbols used in these operating instructions . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Explanation of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Use with other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Burner residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Use and product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Description of the MIBG type burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Size 1 (without equipment for gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Size 2 and 3 (with equipment for gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 MIBG burner type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Electrical direct ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.5 Ignition gas burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.6 Combined ignition devices (MZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6.1 MZE for NEL/S size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6.2 MZE for NEL/S size 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6.3 Removing OE-DG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Nozzle linkage DG-32/40-ELS-HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.7.2 Installing the nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.8 Nozzle rod DG-32/40-ELS-ND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.8.2 Installing the nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.9 Oil quantity regulator OE-RLV (200-4000 l/h) . . . . . . . . . . . . . . . . . . . . . . 45
3.9.1 Maximum flow rate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.10 Actuators (servo motors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Operating instructions - MIBG burner

3.10.1Actuator for oil delivery regulator, gas valve and air valves . . . . . . 47

Safe working practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Recommended protective and safety equipment . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Coordination and supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Coordination of work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5 Work instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Suitability of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 5 safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8 Working with electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9 Welding, burning and grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10 Working with pneumatic and hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . 69
11 Working in silos, drums, tanks, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
12 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12.1 DIN 18 800 Part 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12.2 ISO 4017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.3 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Overview of technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Output table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Dimensions and weights – burner with fan. . . . . . . . . . . . . . . . . . . . . . . . 80
3 Combustion pressure drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1 Pump pressure / delivery quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.2 Burner oil nozzles / oil quantity regulator . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Oil atomization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.4 Gas pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
1 Hazards during transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3 Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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4 Suspension rings and lifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.1 Suspension of the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2 Dimensions and weights – MIBG burner . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Assembly and commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1 Hazards during assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1.1 Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1.2 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 Preparing for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.1 Inspections before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.2 Power and operating supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.4 Pneumatic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.5 Assembly sequence for MIBV burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4 Initial set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2 Commissioning preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3 Burner commissioning/start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3.1 Start conditions and start procedure without flame . . . . . . . . . . . . 113
4.3.2 Start conditions and start procedure with ignition flame, without main
flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.3.3 Start conditions and start procedure with main flame . . . . . . . . . . 115
4.3.4 Adjusting the basic load flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.3.5 Adjustment at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4 Function check at burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.4.1 Functional check for oil, gas and liquid gas operation . . . . . . . . . . 118
4.4.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.4.3 Final checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1 Hazards during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Dangers during operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1.1 Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.1.2 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2 Notes for the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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3 Notes for operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4 Emergency and safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.1 General notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2 Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5 Special operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.1 Procedure in the event of operating faults . . . . . . . . . . . . . . . . . . . . . . . 136
5.2 Procedure in the event of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.1 Fault causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.2 Action to take if the smell of gas is detected . . . . . . . . . . . . . . . . . . . . . 139

Inspection, maintenance, repairs and troubleshooting . . . . . . . . . . .141

1 Hazards during maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.1 Burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.1.1 Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.1.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2 Inspection and maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3 Burner inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.1 General notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5 Ordering spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.1 Address for spare parts orders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Storage of operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

1 Operator's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2 Plant operative's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Decommissioning and disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .159

1 Hazards during dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.1 Burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.1.1 Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.1.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2 Temporary decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 General notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.2 Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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3 Decommissioning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4 Preparing for dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.1 Checks prior to dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.2 Power and operating supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.2 Disassembly of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Annexe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1 Supplier documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Service schedule tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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 Preface

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Operating instructions - MIBG burner
Preface

As an owner or operator of the machine , please refer to the following notes before
setting up the machine MIBG burnerand use them as a guide to safeguard your
duty of supervision to prevent damages and subsequent costs .

During initial assembly, the plant operative must become familiar with the machine.
This carried out in close cooperation with the Ammann installation supervisor.

After carrying out the approval procedure required for installation and operation,
plant personnel are instructed on the initial setup. During this phase, Ammann
offers advice and support.

The procedure covers the installation and assembly of units and devices, the laying
of supply lines and electrical and control cables (including fuse protection, earthing,
etc.). Protective equipment and hazards must also be addressed.

Check that the entire plant is safely accessible, for example handles, rails, barriers
with safety circuits, etc.

Inspect the access and function of the emergency and fault cutoff devices.

Check that all necessary notices and

prohibiting signs are displayed.

Discuss maintenance points and high-maintenance components with the instal-

lation supervisor or another represenative of Ammann.

After purchasing the plant or a machine, the plant operative /customer must fully
control the process flow and must be familiar with the safety equipment and
switches.

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 In addition to the requirements described in these operating instructions, be sure
to observe the requirements of the operating licence, environmental protection
regulations (TA Luft [German Technical Instructions on Air Quality Control], WHG
[Water Resources Management Act]) and general accident prevention rules.

For safe operation also read and follow the supplier's operating manuals

The operator is responsible for suitable access to temporay work areas, e.g. fixed
platform ladders, scaffolding or lifting platforms. The operator is also responsible
for providing safety gear for work that involves a risk of falling.

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Operating instructions - MIBG burner
Preface

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 Introduction and
explanation of symbols

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Operating instructions - MIBG burner
Introduction and explanation of symbols

1 Introduction to operating instructions

In the following section the MIBG burner machine is referred to as the machine.

These operating instructions contain the notes and codes of conduct required for
the safe operation of the machine. These operating instructions should therefore
be made available to all persons entrusted with various work on the machine.

NOTE
As the operator, read this operating manual before starting any work on the
machine!

These operating instructions describe the mechanical part of the machine.

Electrical wiring is described in separate switching, plugging and connection
diagrams. Separate documentation is also provided on control systems.

Instruct the relevant personnel based on these operating instructions prior to

starting work on the machine.

These operating instructions aim to make it easier for you and your personnel to
become familiar with the machine and to make proper use of its functions.

The operating instructions also include important notes on operating the machine
safely, correctly and efficiently. Observing these instructions helps to avoid
hazards, repair costs and down times and increases the reliability and service life
of the machine.

14 Translation of the Original Operating Instructions neutral

 NOTE
In addition the compulsory rules on accident prevention at the place of use also
apply!

You can add existing instructions relating to local regulations on accident

prevention and environmental protection to these operating instructions.

These operating instructions must be made permanently available at the point of

use of the machine and must be read and observed by all personnel enstrusted
with the operation of the machine.

The images and drawings used may not always correspond to the latest status of
the machine supplied. The design may differ from the illustrations.

NOTE
As the operator, provide a risk assessment for the machine.
(§3 Ordinance on Health and Safety at Work (BetrSichV)

A risk assessment is not included with delivery of the machine. Documents for
carrying out a risk assessment can be ordered separately from Ammann.

neutral Translation of the Original Operating Instructions 15

Operating instructions - MIBG burner
Introduction and explanation of symbols

Operation is understood to include the following:

• Operation of the machine
• Transport
• Assembly
• Set-up
• Troubleshooting in operation
• Elimination of production down times
• Disposal of supplies
• Inspection
• Maintenance
• Repairs
• Dismantling

16 Translation of the Original Operating Instructions neutral

2 Signs and symbols

2.1 Symbols used in these operating instructions

NOTE Important notes!

General notes on hazards and

ATTENTION!
hazardous conduct.

Important for safety, must be observed!

DANGER! Failure to observe creates a
risk of injury.

At the points marked there is a risk of

Danger! ELECTRICAL HAZARD!
electrical shock and electrical waves.

Safety indications must be followed

precisely to ensure the safety of
Safety first!
personnel
at all times.

First aid Note on first aid procedures

Such actions may result in serious

Prohibited
damage and injury.

neutral Translation of the Original Operating Instructions 17

Operating instructions - MIBG burner
Introduction and explanation of symbols

2.2 Signs

General notes on hazards and

ATTENTION!
hazardous conduct.

At the points marked there is a risk of

Danger! Danger of being crushed!
crushing.

Danger! Danger of being pulled in! At the points marked there is a risk of
catching in machine parts or other
Risk of catching in mechanical parts! mechanical risks.

Danger! Danger of falling! Risk of falling at the points marked.

At the points marked the heat is so

Danger! Risk of burning!
intense that burning can occur.

At the points marked there is a risk of

Danger! ELECTRICAL HAZARD!
electrical shock and electrical waves.

At the points marked materials can

Danger! Risk of fire!
ignite.

At the points marked there is a risk of

Danger! Risk of explosion!
explosion.

It is prohibited to remain under overhead

Attention! Suspended load!
loads for an extended period.

18 Translation of the Original Operating Instructions neutral

 There must be no persons at the points
Access prohibited
marked during operation.

These parts of the plant are not suitable

No passenger transportation
for passenger transportation.

Cigarettes, naked flames and fire Fire, naked flames and cigarettes are
prohibited prohibited at the points marked.

Water must not be used here for

Do not extinguish with water
extinguishing.

Safety Instruction on the use of

Fire extinguishing equipment
extinguishing equipment.

neutral Translation of the Original Operating Instructions 19

Operating instructions - MIBG burner
Introduction and explanation of symbols

Wear ear protection!

Helmets must be worn!

Face protection must be worn!

Protective footwear must be worn!

Protective gloves must be worn!

Protective gear must be worn!

20 Translation of the Original Operating Instructions neutral

3 Explanation of terms
Term Explanation
The persons entrusted with the day-to-day operation of
Operating staff the asphalt mixing plant.
These persons are appointed by the operator.
Specially trained personnel from Ammann or
supplier companies.
Qualified personnel
Qualified personnel must only be employed in consul-
tation with Ammann.
A brief inspection, e.g. using sight, hearing or touch.
Inspect
E.g. missing, loose or loosened parts.
An inspection with measurement instruments and
Check tools. E.g. the power supply or temperature of parts of
the plant.
Specially trained personnel entrsuted with mainte-
nance work.
Maintenance staff
Maintenance personnel are generally instructed by
Ammann or authorised in exceptional circumstancest.

neutral Translation of the Original Operating Instructions 21

Operating instructions - MIBG burner
Introduction and explanation of symbols

4 Liability

4.1 Modifications

PROHIBITED
Modifications and customisations/conversions to the machine that impair safety
are not permitted!

Ammann and its suppliers accept not liability for all other modifications and custo-
misations/conversions that are carried out without the approval of Ammann.

This also applies to the installation and the adjustment of safety equipment as well
as to welding on load-bearing parts.

Modifications to the electrical control system that impair the safety of the machine
are equallly not permitted.

If modifications that affect safety are carried out without consultation with the
supplier, this causes a nullification of the Declaration of Conformity and Incorpo-
ration with respect to the Machinery Directive. Ammann shall accept no liability for
damages and accidents that arise as a result of such modifications.

NOTE
The Declaration of Incorporation of the machine covers only the state in which it
was delivered.
Subsequent modifications and attachments which have not been carried out by
Amman are not covered by the Declaration of Incorporation.

22 Translation of the Original Operating Instructions neutral

 The computer is used exclusively for control of the plant and the execution of statis-
tical analyses and other programs that were installed by Ammann.

It is prohibited to make modifications to the programmes (software), programmable

control systems or to the system configuration of the computer.

Any modifications that may be required must only be carried out by Ammann and
by appropriately trained personnel.

Ammann shall accept no liability for damages and accidents that arise as a result
of modifications to the control systems.

4.2 Use with other components

Ammann is not liable for the use of components not forming part of the machine
and faults from the use of such.

Ammann is only liable for interfaces with other components if these have been
designed and manufactured by Ammann.

If the use of the machine changes as a result of components not forming part of the
machine, Ammann shall not be liable for any resulting faults.

neutral Translation of the Original Operating Instructions 23

Operating instructions - MIBG burner
Introduction and explanation of symbols

5 Warranty
The terms of the warranty are set out in the purchase agreement.

If no terms of warranty have been agreed, the relevant statutory warranty shall
apply.

24 Translation of the Original Operating Instructions neutral

6 Declaration of conformity

e
ur
at
gn
si
ut
o
ith
w
y
op
C

MIBG burner
MIBG-2.14-FlEL
neutral

neutral Translation of the Original Operating Instructions 25

Operating instructions - MIBG burner
Introduction and explanation of symbols

6.1 Burner residual risks

Danger source Hazard Measure

Caution!
Risk of burns and fire
hazard! Install the burner in the appropriate
Burner pipe
opening of a drying drum.
During operation of
burner!

Caution!
Risk of burns and fire Close the openings for any unused
Connections for fuel hazard!
fuel supply with blind covers, screw-
supply
During operation of on plugs or other suitable means.
burner!

26 Translation of the Original Operating Instructions neutral

 Use and product
description

neutral Translation of the Original Operating Instructions 27

Operating instructions - MIBG burner
Use and product description

1 Proper use
The machine is built in accordance with the latest developments in technology and
recognised safety regulations. However, improper use can pose a risk to life and
limb.

NOTE
Never operate the machine if it has a technical fault!
Immediately remedy any faults that could impair safety!
Never use the machine parts if they are damaged!

Proper use also includes following the operating instructions and complying with
inspection and maintenance intervals.

NOTE
Only use the machine parts for their intended purpose.
The use of machine parts for any task other than the intended purpose shall be
deemed improper use.

The burner must only be used in combination with a mineral or recycling

dryer. The mineral dryer may only be used for drying and heating round
and broken sand, pebbles and gravel and for manufacturing standard
asphalt mixing material; the recycling drier must only be used for the
drying and heating of broken asphalt.
Any other usage is considered to be inappropriate. The manufacturer/
supplier shall not be liable for any losses or damage arising herefrom.
The user is solely responsible for the risk!

28 Translation of the Original Operating Instructions neutral

2 Improper use

NOTE
Any use that exceeds the proper use shall be deemed improper use and is
therefore strictly prohibited!
Do not modify the machine!

Improper use can cause hazards for personnel and can damage the machine.

Ammann is not liable for damages and injuries resulting from improper use.

neutral Translation of the Original Operating Instructions 29

Operating instructions - MIBG burner
Use and product description

3 Description of the MIBG type burner

3.1 Size 1 (without equipment for gas)

2
8 4 6

10 11 5 3 9

MIBG monoblock burner with built-in fan

operating range 7-10 MW
1 Housing rear 7 Air flap actuator
2 Housing front 8 RLV actuator
3 Ignition gas burner transformer 9 Electrical junction box
4 Ignition gas burner 10 Pneumatic material
5 Flame pipe 11 Hydraulics
6 Nozzle rod/oil nozzle insert

30 Translation of the Original Operating Instructions neutral

3.2 Size 2 and 3 (with equipment for gas)

1 11

10

2 7 5 4 6 14 13 8 12

MIBG monoblock burner with built-in fan

operating range 14 - 26 MW
1 Housing 8 Nozzle rod/oil nozzle insert
2 Ignition gas burner transformer 9 Air flap actuator
3 Ignition gas burner 10 RLV actuator
4 Flame pipe 11 Sound insulation
5 gas distributor 12 Electrical junction box
6 Gas connection 13 Pneumatic material
7 Gas flap actuator 14 Hydraulics

• Compact, robust
• State-of-the-art combustion technology
• Service-friendly
• Efficient soundproofing
• Low-emission
• Control facility with status indication

neutral Translation of the Original Operating Instructions 31

Operating instructions - MIBG burner
Use and product description

3.3 MIBG burner type key

MIBG - 3.20- NELS - VL870 - U R - GO - HD - DZ**

Position of the fittings ***

L = left
R = right
U= rotated version
(standard version has fan at top)

Ignition (EL only)DZ=direct

Projecting flame tube length [mm]

Fuel (also combinations*)

N = Gas
Fl = Liquid gas, liquid Operating pressure (EL and S only)
EL = Light oil HD = high pressure
S = Heavy oil ND = low pressure

Size/operating range Gas flap position

GO = top
Monoblock industrial burner GU = bottom

* Combination order:
1 Gaseous fuels (under standard conditions)
2 Liquid fuels (under standard conditions)

** Additional designations:
• TNV Thermal afterburning
• FU Frequency converter

*** View standing behind the burner, looking in the direction of the flame (burner
mounted on plant)

32 Translation of the Original Operating Instructions neutral

 MIBG natural gas (N) / -liquid gas, liquid (Fl) / light oil (EL) / heavy oil
(S) with electronic compound

MIBG burners are fully-automatic ventilation burners with ventilation and

modulating output regulation for the combustion of natural gas (N), liquid gas (Fl),
light oil (EL) and heavy oil (S). The burner can also be configured as a dual-fuel
burner.

The burner housing has an air intake shaft with air flaps.

The intake side of the fan is equipped with a soundproofing hood with air deflection
for optimum soundproofing.

An electronic control unit is used for continuous control of the fuel quantity and the
combustion air.

The starting procedure is managed by an automatic firing system that is integrated

in the electronic control unit, which provides optimum safety in any operating mode
in conjunction with a flame monitoring device.

There is an air deficiency switch between the fan and the air flaps for monitoring
the combustion air.

Ignition is carried out by an automatic gas ignition burner, which is ignited itself by
a high-voltage spark.

The ignition burner can be operated using either natural gas or propane gas.
When light oil (EL) is being used on its own, a direct ignition device can also be
used. Ignition takes place via a high-voltage spark directly at the combustible fuel
mixture.

neutral Translation of the Original Operating Instructions 33

Operating instructions - MIBG burner
Use and product description

Oil

The oil burner lance is equipped with an automatic zero shut-off which is opened
via a pneumatic piston and closed using spring power. The zero shut-off takes
place using a shut-off needle behind the nozzle plate. (TüV tested zero shut-off).

The output is controlled by high pressure (HD) in the oil with an oil quantity
regulator, which is adjusted by an internal control actuator via the electronic unit
with infinitely variable positioning. At low pressure (ND), the power is regulated by
the oil quantity regulator in the supply.

A solenoid valve in the oil supply, oil return and the shut-off needle behind the
nozzle plate prevent oil escaping from the nozzle when the burner is
non-operational.

A thermostat at the heavy oil supply monitors the maximum and minimum
temperature.

Two pressure switches monitor the oil pressure.

A high-pressure plate nozzle is used for the HD oil atomization.

A Y external atomizer nozzle is used for the ND oil atomization.

34 Translation of the Original Operating Instructions neutral

 Gas

The gas is mixed with the swirled air using a gas distribution ring.

The output is controlled by a gas control flap, which is adjusted by a control

actuator via the electronic unit with infinitely variable positioning.

Two solenoid valves located after each other prevent gas from escaping when the
burner is not operating.

Both solenoid valves are checked for leaks before every start-up by a fully
automatic valve testing system.

With natural gas-only burners the ignition burner is operated using natural gas.

Switching over from one fuel function to another takes place automatically via the
burner controller.

neutral Translation of the Original Operating Instructions 35

Operating instructions - MIBG burner
Use and product description

3.4 Electrical direct ignition

EL-HD
15

30
MZE

EL-ND

a) b)

Important: One opening of the oil nozzle must be aligned to the electrode cent
to ensure fuel ignition (see figure b)).

36 Translation of the Original Operating Instructions neutral

3.5 Ignition gas burner

on site Burner
20

23.5
3 5 2 6 1

5
4

1 Ignition gas burner

2 Double solenoid valve incl. gas filter and quantity regulation
3 Gas pressure regulator with SAV
4 Propane gas cylinder
5 Measuring connection, inlet pressure: max. 500 mbar
6 Measuring connection, outlet pressure:
Propane 10-20 mbar,
natural gas 20 - 40 mbar

neutral Translation of the Original Operating Instructions 37

Operating instructions - MIBG burner
Use and product description

3.6 Combined ignition devices (MZE)

3.6.1 MZE for NEL/S size 1

5 1 6

3 2 4

2 3 4 7

1 Retaining tube 5 Ignition gas burner

2 Atomised air connection 6 Swirler
3 Oil supply connection 7 Ignition gas supply solenoid valve
4 Oil return connection 8 Ignition transformer

38 Translation of the Original Operating Instructions neutral

3.6.2 MZE for NEL/S size 2 and 3

10

7
5

9 2 8 3

1 Retaining tube 6 Ignition gas burner

2 Front panel 7 Swirler
3 Ignition gas connection 8 Ignition gas supply solenoid valve
4 Oil supply connection 9 Pneumatic DG return
5 Oil return connection 10Ignition transformer

neutral Translation of the Original Operating Instructions 39

Operating instructions - MIBG burner
Use and product description

3.6.3 Removing OE-DG

3 6

4 1 5 2

ATTENTION!
Oil hoses
 Switch off the oil supply before loosening the metal hoses (1 + 2) and release
the pressure.

ATTENTION!
Oil outlet
 Catch leaking oil in a suitable container!
 Loosen the oil hoses of the flow (1) and return (2) line on the nozzle linkage (not
on the hydraulic system)
 Loosen the hose (3) for the air supply to the pneumatic retraction of the nozzle
rod on the nozzle rod (not on the maintenance unit) and the hose (6) for the
pneumatic atomisation on the nozzle rod
 Loosen the clamping screw (4) of the nozzle linkage holder and the locking
screw (5) on the cover plate of the nozzle linkage
 Pull the nozzle rod out backwards

NOTE
The installation is carried out in the reverse order.

40 Translation of the Original Operating Instructions neutral

3.7 Nozzle linkage DG-32/40-ELS-HD

3.7.1 General

Oil flow C-C C

B C
B-B
Oil return

3 10 7 1 9

The OE-DG 32/40 is a nozzle linkage for return plate nozzles with needle shut-off
facility. The shut-off needle (7) is pressed onto the nozzle plate (9) by a strong
spring (10) in the drive piston (3). The shut-off needle is opened pneumatically.
Reliable closing therefore occurs under any circumstances. (certified TüV test
DIN EN ISO 23553).

The drive piston (3) opens with compressed air (6-bar dried and filtered air)
controlled by a three-way valve (DIN EN ISO 23553). The piston pulls the shut-off
needle into the correct position when it opens.

Delivery pressure of up to 30 bar and oil temperatures of up to 160°C.

neutral Translation of the Original Operating Instructions 41

Operating instructions - MIBG burner
Use and product description

To the extent required by DIN EN 746-2, additional electrically actuated safety

solenoid valves are installed in the fuel pipes at the burner.

A dirt trap with a maximum mesh width of 0.5 mm must be installed upstream of
the safety solenoid valves and the nozzle linkage.

The liquid gas (Fl) is fed via a separate

gas safety line.

Applicable country and usage regulations must be observed for use outside of the
area of application of DIN EN 746-2.

3.7.2 Installing the nozzle

The sealing surfaces at the nozzle plate, both sides of the turbulence chamber
plate (1) and the nozzle head of the DG must not be damaged in order to provide
a proper seal. No foreign matter must be used to seal these surfaces.

Insert the nozzle (9) and the turbulence chamber plate (1), absolutely clean, into
the union nut, in the correct sequence and position.

A little high-temperature grease must be applied to the thread of the nozzle head
so that the union nut can be screwed back on again without problems.

Tighten the union nut with the nozzle and turbulence chamber plate by hand.
Tighten the union nut with a spanner.

42 Translation of the Original Operating Instructions neutral

3.8 Nozzle rod DG-32/40-ELS-ND

3.8.1 General

B-B

C -C

10 1

3 7 9

The OE-DG 32/40 ND is a nozzle linkage for Y external atomizer nozzles (1) with
needle shut-off facility.
Air or steam with an input pressure of 5-6 bar is used as atomizer medium.

The shut-off needle (7) is pressed onto the reverser plate (9) by a strong spring (10)
in the drive piston (3). The shut-off needle is opened pneumatically.

Reliable closing therefore occurs under any circumstances. (certified TüV test
DIN EN ISO 23553).

The drive piston opens with compressed air (6-bar dried and filtered air) controlled
by a three-way valve (DIN EN ISO 23553). The piston pulls the shut-off needle into
the correct position when it opens.

Oil delivery pressure 7.5 - 10 bar and oil temperatures up to 160°C

neutral Translation of the Original Operating Instructions 43

Operating instructions - MIBG burner
Use and product description

To the extent required by DIN EN 746-2, additional electrically actuated safety

solenoid valves are installed in the fuel pipes at the burner.

A dirt trap with a maximum mesh width of 0.5 mm must be installed upstream of
the safety solenoid valves and the nozzle linkage.

The liquid gas (Fl) is fed via a separate

gas safety line.

Applicable country and usage regulations must be observed for use outside of the
area of application of DIN EN 746-2.

3.8.2 Installing the nozzle

The sealing surfaces on the nozzle (1), on both sides of the reverser plate (9) and
on the nozzle head of the DG must be free from damage, in order to guarantee
perfect sealing. No foreign matter must be used to seal these surfaces.

Insert the nozzle and the reverser plate, absolutely clean, into the union nut in the
correct sequence and position.

A little high-temperature grease must be applied to the thread of the nozzle head
so that the union nut can be screwed back on again without problems.

Tighten the union nut with the nozzle and reverser plate by hand. Tighten the union
nut with a spanner.

44 Translation of the Original Operating Instructions neutral

3.9 Oil quantity regulator OE-RLV (200-4000 l/h)

11
2 1 1 3

6
4
8 7
9

10

1 O-Ring 29.82 x 2.62 8 Installation hole for heating cartridge

2 O-Ring 10.82 x 1.78 (only with S = heavy oil)

3 O-Ring 6.75 x 1.78 9 Fixing screw for heating cartridge

(only with S = heavy oil)
4 O-Ring 14.00 x 1.78
10Controller scale with control range of
5 Maximum flow rate adjusting 90o
screw Scale pos. 0 = volumetric flow rate =
6 Locking screw 0
Scale pos. 10 = max. volumetric flow
7 Installation thread for temperature
rate (variable from 200 – 4000 l/h)
probe (only with S = heavy oil)
11Plug cap

neutral Translation of the Original Operating Instructions 45

Operating instructions - MIBG burner
Use and product description

3.9.1 Maximum flow rate adjustment

1 Unscrew plug (11).

2 Undo locking bolt (6) by max. 1 turn.

3 Set required maximum flow rate using adjusting screw (5).

(Increase the volumetric flow rate by turning anticlockwise, reduce volumetric
flow rate
by turning clockwise; Regulator position 9).

4 Re-tighten locking bolt (6).

5 Re-fit plug (11).

If the OE-RLV is replaced, please pay attention to the flow direction (In/Out).

46 Translation of the Original Operating Instructions neutral

3.10 Actuators (servo motors)

3.10.1 Actuator for oil delivery regulator, gas valve and air valves

Technical data actuator

Voltage 230V 50/60Hz
Runtime 60 sec. 90°
Travel distance 90°
Torque 20 Nm
reinforced
Gears face geared
Plate gear
Material ETG 100
Bearing CuZn40 Al2, maintenance free
Switches 3 switches
Pin circuit
1 pc. 0-5000 ohms, Novotechnik,
Potentiometer
TÜV certified
Rated input 6.45 VA
Motor
rated output 1.85 W
Housing Metal housing, hammer blow paintwork
Protection class IP 65

neutral Translation of the Original Operating Instructions 47

Operating instructions - MIBG burner
Use and product description

48 Translation of the Original Operating Instructions neutral

 Safe working practices

neutral Translation of the Original Operating Instructions 49

Operating instructions - MIBG burner
Safe working practices

1 General notes
The machine MIBG burner must be fitted with the necessary safety equipment in
accordance with the Machinery Directive and EN 536.

Improper conduct can result in health risks or damage to the machine.

Observe the following safety instructions for all operating modes.

The operator is responsible for suitable access to non-fixed work areas, e.g.
platform ladders, scaffolding or lifting platforms. The operator is also responsible
for providing safety gear for work that involves a risk of falling.

Check the screw connections as per the inspection cycle

( Instructions in subchapter 2 "Inspection and maintenance intervals", page 147
ff.).

The prescribed torques for tightening fastening bolts can be found in Subchapter
12 "Tightening torques", page 74 ff..

50 Translation of the Original Operating Instructions neutral

2 Recommended protective and safety equipment
Symbol Type of protective- or Area of application
safety equipment

A helmet must be worn by all persons at

Helmet
the plant.

Protective gear, in other words all-in-one

overalls without any folds and lapels,
Protective gear
must be worn by all persons working on
the plant or on the machines.

Safety boots with steel toe caps must be

Safety boots
worn by all persons at the plant.

Safety gloves must be worn by all

Safety gloves persons working on the plant or on the
machines.

Safety glasses are required when

working with aggregate. They prevent
dust and small stones from entering the
Safety glasses eyes.
Safety glasses are often worn together
with lightweight respiratory protection.

neutral Translation of the Original Operating Instructions 51

Operating instructions - MIBG burner
Safe working practices

Symbol Type of protective- or Area of application

safety equipment

A safety visor is required when working

with hot bitumen.
Safety visor
It protects the face from burns caused by
spraying bitumen.

Ear defenders must be worn in areas

Ear defenders
where the noise level exceeds 85 dBA.

Lightweight respiratory protection must

be used in areas and for work where
aggregate dust can occur, for example.
Lightweight respiratory protection
Aggregate dust can significantly restrict
the airways. This can have serious
effects, including suffocation.

Heavyweight respiratory protection must

be used in areas and for work where
vapours can occur in concentrated form,
for example.
Particularly when working in bitumen
tanks, heavyweight respiratory
Heavyweight respiratory protection protection is a minimum requirement.
Heavyweight respiratory protection
includes respirator masks with screw
filters.
A breathing mask is
recirculation-dependent.

52 Translation of the Original Operating Instructions neutral

Symbol Type of protective- or Area of application
safety equipment

Breathing apparatus can be used as an

alternative to heavyweight respiratory
protection when working in tanks and
silos.
Particularly when working on the floor of
tanks and silos, a respirator mask is not
Breathing apparatus
sufficient on its own as it depends on the
circulating air.
Breathing apparatus does not depend on
circulating air and is therefore suitable
for use on the floor of non-ventilated
tanks and silos.

A safety belt must be worn when working

Safety belt at a great height (> 0.5m) and must be
secured with suitable equipment.

neutral Translation of the Original Operating Instructions 53

Operating instructions - MIBG burner
Safe working practices

3 Coordination and supervision

In accordance with the EC Construction Site Directive 92/57/EEC, a health

and safety plan must first be prepared before starting work on large-scale
projects and compliance with the plan must be monitored and continuously
updated according to the circumstances on-site by appointed health and
safety coordinators during planning and realisation. Construction work must
be supervised by experienced and technically experienced personnel.

The operator is responsible for ensuring that related work is supervised by experi-
enced and knowledgeable personnel and must appoint a responsible person, a
coordinator, to coordinate the work.

NOTE
Possible related work includes maintenance as well as assembly, dismantling and
transport. This also covers maintenance work carried out as a result of faults during
operation.

The coordinator can be the operator or a person appointed by the operator.

The coordinator is responsible for the correct performance of work and for safety
on site.

The coordinator must have sufficient experience and expertise for the work to be
performed and must monitor the safe performance of work and any related
measures.

54 Translation of the Original Operating Instructions neutral

 The operator and the coordinator are jointly responsible for ensuring that related
work is only carried out by expert personnel or under the supervision of expert
personnel.

The operator or the coordinator is responsible for preparing and maintaining a

health and safety plan.

The operator is responsible for suitable access to non-fixed or temporay work

areas, e.g. platform ladders, scaffolding or lifting platforms. The operator is also
responsible for providing and using safety gear for work that involves a risk of
falling.

neutral Translation of the Original Operating Instructions 55

Operating instructions - MIBG burner
Safe working practices

4 Coordination of work
Safety at work for individuals and work groups includes hazards to persons in
close proximity that are not part of the same work group.

Only the timely coordination of all persons working at the plant can ensure that
reciprocal hazards are eliminated.

In addition to compliance with official regulations and requirements, the following

must also be observed:
• Maintain contact
• Make arrangements
• Be considerate
• Observe agreements

The coordinator or the operator is responsible for this coordination.

56 Translation of the Original Operating Instructions neutral

5 Work instruction
All work carried out at the plant must follow a written work instruction available on-
site that contains all of the necessary safety information.
This includes maintenance and repair instructions as well as assembly and
dismantling instructions.

Written form can be waived if the work in question does not require any special
safety information.

Depending on the degree of severity, safety information can include the following:
• The weights of the parts being processed
• The storage of the parts
• The suspension points of the parts
• The arresters of the parts on lifting gear
• The nature of the transport of parts
• The transport position to be used during transport
• The installation of the auxiliary constructions required for processing (e.g.
assembly or dismantling)
• The sequence of work and the dismantling or assembling of the building section
• The required load-bearing capacity of the lifting gear used

neutral Translation of the Original Operating Instructions 57

Operating instructions - MIBG burner
Safe working practices

• Measures to guarantee the load-bearing capacity and stability of buildings and

building sections, even during the individual working steps
• Measures for safe equipping and preparation of permanent and non-permanent
or temporary workstations and access to them
• General plans or drawings with details on these workplaces and entry routes
• Measures to prevent personnel falling or slipping whilst carrying out work
• Measures to prevent objects falling
• Notes on first aid and fire protection

58 Translation of the Original Operating Instructions neutral

6 Suitability of personnel
Work on an Ammann plant and individual components must only be carried out by
trained, qualified personnel that are approved by Ammann.

Work at or on a plant may involve working at a great height. Work performed at a

great height, in other words work where there is a risk of falling, is deemed to be
work carried out at a height of more than 0.5m.

The personnel employed for work at height must be physically suitable. A special
preliminary medical examination is recommended for personnel who are employed
to work in areas where there is a risk of falling.

DANGER! DANGER OF FALLING!

Assembly work carried out overhead or at great height (> 0.5m)!
 Work in areas with a risk of falling must only be carried out by personnel who do
not suffer from fainting or dizzy spells or similar conditions.

In the majority of cases, such conditions are not apparent. Ask your employees to
notify their supervisor if they suffer or have suffered from fainting or dizzy spells or
similar conditions, even if only temporary.

Work on elevated workplaces or at great height must only be carried out if the site
offers a secure access, stable frame and a suitable means of preventing falls
(safety belt/harness) .

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Operating instructions - MIBG burner
Safe working practices

Choice of staff
Welding on load-bearing parts must only be carried out by suitably trained and
approved welders.

Choice of staff
Work on electrical equipment at the plant must only be carried out by a qualified
electrician or by persons instructed under the guidance and supervision of a
qualified electrician in accordance with electrical regulations.

Choice of staff
Work on gas equipment (gas consumer installations) must only be carried out by
personnel who are suitably trained!

Choice of staff
Work on hydraulic equipment must only be carried out by personnel with specialist
knowledge and experience of dealing with hydraulic systems!

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7 5 safety rules
When working on electrical plant or operating equipment (
( Subchapter 8 "Working with electrical systems", page 65 ff. be sure to observe
the following 5 safety rules (DIN VDE 0105-100:2005-06, Chapter 6):

 Isolate (page 61)

 Secure against restarting (page 62)

 Check disconnection (page 63)

 Earth and short circuit (page 63)

 Cover or shield any nearby live parts (page 64)

The explanations to the individual safety rules marked in italics below are partial
excerpts from DIN VDE 0105-100:2005-06, Chapter 6. These excerpts are used
purely to explain the safety rule in question in greater detail. These quotes are used
solely for the purpose of more detailed explanation of the corresponding safety
rule.

Isolate

The part of the plant on which work is being carried out must be isolated from the
mains supply. Isolation must be carried out using neutral sections in the air or
similar isolation to ensure that there is no flashover.

Notify the plant operative of the site at which you will be working and which parts
of the plant must be isolated.

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Safe working practices

Securing against restart

All switching devices used to isolate the workplace must be secured against
restarting by locking the activation mechanism.
If there are no locking mechnisms available, similar tried and trusted measures
must be taken to secure against restarting.
If an auxiliary power supply is required to active the switching devices, this must be
disconnected.

Unauthorised access must be prohibited by displaying corresponding signs.

NOTE
Hang a sign on the disconnected main switch to notify other personnel of the
following information:

 Work is being carried out on the electrical plant.

 Who is carrying out this work?
 What part is work being carried out on?

Display the sign so that is can be easily seen and cannot be removed easily. If you
cannot affix the sign directly to the switch, attach a clearly assigned sign nearby.

If restarting is prevented by remote control, the actuation of the switching devices

on site must also be disabled. All transmission and locking systems that are used
for this purpose must be reliable.

Parts of the plant that are still live after being isolated, e.g. condensors and cables,
must be discharged using suitable operating materials.

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 Check disconnection

All-pole disconnection must be checked at or as close as possible to the workplace.

This state must be checked for disconnected parts of the plant as instructed. This
includes, for example, the use of fixed and/or movable voltage detectors. These
voltage detectors must be tested at least immediately before and, if possible, also
after use.

Earth and short circuit

In high-voltage systems and low-voltage systems all parts on which work is carried
out must be earthed and short-circuited at the workplace.
The earthing and short-circuit devices must first be connected to the earthing
system and then to the parts being earthed. The earthing and short-circuit devices
must be visible from the workplace where possible. Otherwise they must be placed
as close as possible to the workplace.

If conductors are interrupted or connected during work and there is a risk of differ-
ences in potential, suitable measures must first be taken at the workplace such as
bridging and/or earthing.

In all cases care must be taken to ensure that the earthing and short-circuit
devices, cables and connectors are suitable and are designed for the short-circuit
stress at the installation site.

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Safe working practices

It must also be ensured that the earthing and short-circuiting measures remain
active for the entire duration of the work. If the earthing and short-circuiting has to
be removed whilst measurements or tests are conducted, additional or other
suitable safety measures must be taken.

If earthing and short-circuiting is provided via a remote-controlled earthing switch,

the switch position of the earthing switch must be reliably transmitted by the remote
control system.

Cover or shield any nearby live parts

If parts close to the workplace cannot be isolated, additional safety measures must
be taken prior to commencing work as in "Working close to live parts".

Working close to live parts:

Work must only be carried out close to live parts , if suitable measures are taken to
ensure that live parts cannot be touched or that the hazard area cannot be
accessed.

Electrical hazards close to live parts can be avoided by using protective equipment,
covers, cases or isolating jackets.

NOTE
If you have any questions about the 5 safety rules or special circumstances, please
consult and comply with DIN VDE 0105-100:2005-06 or similar local regulations.

64 Translation of the Original Operating Instructions neutral

8 Working with electrical systems

NOTE
Disconnect the plant immediately in the event of faults in the electrical power
supply!

The operator must ensure that the electrical equipment of a plant is inspected and
checked.

Choice of staff
The operator must also ensure that work carried out on electrical plant or operating
materials is only performed by a qualified electrician or by instructed personnel
under the guidance and supervision of a qualified electrician and that electrical
regulations are observed!

Before carrying out any work on electricial systems, be sure to inform the plant
operative of the nature of the work.

Make arrangements with other personnel working at the plant regarding mainte-
nance work and the need to switch parts of the plant on/off.

Only use original fuses with the recommended amperage when replacing fuses.

Defects such as loose connections or damaged cables must be immediately

repaired by a qualified electrician.

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Safe working practices

With singed cables, check the entire

electrical circuit associated with them.
 Resolve the cause of the defect
 Replace any other parts that could have caused the fault.
 This reduces the possibility of a new fault occuring.
 Remove the defect
 Always replace plugs and connectors with the same part. In doing so, follow the
codings

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9 Welding, burning and grinding
Welding, burning and grinding must only be carried put if approved in writing by the
plant manager.

NOTE
Post a fire watch during any welding, burning and grinding work!

Before welding, burning or grinding, be sure to remove any dust and other combus-
tible materials from the machine and its surrounding area.

Ensure adequate ventilation when welding, burning or grinding.

Be sure to observe any national regulations on working in enclosed spaces!

Clean the machine by wetting or spraying the work area.

Make sure that no water comes into contact with electrical components.

Before welding, remove the electronic inserts from the filling level probes on the
part.
The electricity supply to the welding device damages the electronics in the filling
level probe.

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Safe working practices

Connect the opposite pole on the welding device to the framework of the respective
part or directly to the welded part.

Connect the opposite pole as tightly as possible to the weld.

NOTE
After completing a repair, cool the work area to ambient temperature and look for
possible sources of ignition and hot spots!

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10 Working with pneumatic and hydraulic systems

Choice of staff
The operator must ensure that work on pneumatic systems is only carried out by
personnel with special expertise and experience in pneumatics!

NOTE
Read and follow the notes on maintenance, repair, assembly or dismantling in the
compressor manufacturer's operating instructions!

You can find the relevant manufacturer's operating manuals in the component- and
supplier documents.

The plant operative is responsible for the following points:

• Work on compressed air systems must only be carried out if the pressure has
first been released
• The leaktightness of fittings and lines must be inspected during operation
Leaks must be reported immediately to the plant manager.
• All hoses must be replaced at defined or approriate intervals, even if there are
no signs of defects
• All lines, hoses and screws must be inspected regularly for leaks and visible
damage
Damage must be repaired immediately to prevent any risk of injury!

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Safe working practices

Maintenance and assembly personnel are responsible for the following points:
• The system sections and compressed air hoses on parts or assemblies on which
repairs are carried out must first be unpressurised before work commences and
must be secured with a padlock to prevent restarting
• Condensate that forms in the lines must be regularly drained
• Compressed air hoses must be professionally laid and mounted
The connections must not be mixed up!
Fittings as well as the length and quality of hose lines must meet the
specifications.
• Pneumatic consumers that are not lubricated by a maintenance unit must be
lubricated manually at regular intervals
• When refilling oil, the surrounding area must first be cleaned to prevent any
contamination entering the oil
• When lubricating parts the grease must be applied approrpriately but sparingly
A thin film of grease is sufficient.
• On the cylinders it is important that the grease pockets on the double hydraulic
seals are also filled with grease
• Compressed air equipment must be dismantled in a low-dust area

Oil separator

If the permissible pressure difference of 1 bar is reached, the maintenance or

operating personnel must ensure that the filter cartridge in the oil separating tank
is replaced.

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 Oil circuit

After working on the oil circuit, be sure to carry out the following steps:
1 Check the oil level and top up if necessary.
2 Temporarily switch on the ccompressor unit and observe it during this time.
3 Switch off the compressor unit.
4 Check the oil level again.
5 Top up the oil taken from the line and cooling system.

ATTENTION!
Risk of fire and explosion!
Increased friction can occur when mixing various types of oil.
 Never mix different types of oil!

Maintenance unit

The maintenance units ensure uniform oiling and filter the compressed air.

The operator is responsible for choosing the right oil.

The sealing elements and pneumatic lines must not affect the equipment and must
match the grease used for permanent lubrication.
Follow the manufacturer's lubrication guidelines!

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Safe working practices

11 Working in silos, drums, tanks, etc.

The following notes apply when accessing the
• drying cylinder
• filter
• screen
• hot aggregate silo
• aggregate scale
• mixer
• any connected silos and tanks

Wear protective clothing, helmet and protective gloves.

Use personal protective equipment (harness/safety belt) when working at a great

height (> 0.5 m).

For your own safety, you must always be supervised by another person outside of
the building section.

Remain in constant contact with this person.

If visible contact is not possible, maintain audio contact with this person.

Leave the building section immediately if contact is loss with the supervising
person.

This person must immediately check and taken emergency measures if contact is
lost with the person inside the building section.

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 Safety first!
Never carry out work inside building sections without supervision!

NOTE
Be sure to observe applicable local regulations on working in enclosed spaces!

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Safe working practices

12 Tightening torques

12.1 DIN 18 800 Part 7

The necessary tightening torques, preload forces for screws 10.9 and rotation
angles comply with DIN 18 800 Part 7 and can be found in the following table.

1 2 3 4 5 6
Preload the screw according to the:
b) Angular c) Rotation
a) Torque
momentum angle
Required method
method method
preload Tightening torque to be
Screw Preload
force applied Mv Preload
torque
force to be
MoS2 to be applied
lightly oiled applied Fv2
lubricated1 Mv2
kN Nm Nm kN Nm
1 M 12 50 100 120 60 10
2 M 16 100 250 350 110
50
3 M 20 160 450 600 175
4 M 22 190 650 900 210
100
5 M 24 220 800 1100 240
6 M 27 290 1250 1650 320
7 M 30 350 1650 2200 390 200
8 M 36 510 2800 3800 560
1
As the values of Mv depend greatly on the lubrication of the thread, compliance
with these values must be confirmed by the screw manufacturer.
2Independent of the lubrication of the thread and the support surfaces of nut and
screw

Required tightening torques, preload forces and angles for 10.9 screws according to DIN 18800
Part 7

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12.2 ISO 4017

Tightening torque
Thread size Strength class
(Nm)
M 12 8.8 85
M 16 8.8 210
M 20 8.8 425
M 24 8.8 730

12.3 Bolts

Tightening torque
Thread size Strength class
[Nm]
M6 4.6 5.2
M8 4.6 13
M 12 4.6 45

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Safe working practices

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 Technical data

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Technical data

1 General notes
Specifications on the electrical connections can be found in the electrical
documentation.

The electrical documentation is provided separately from these operating

instructions.

Technical data on the individual components and supplier parts can be found in the
operating instructions of the corresponding manufacturer.

You can find the relevant manufacturer's operating manuals in the component- and
supplier documents.

78 Translation of the Original Operating Instructions neutral

2 Overview of technical data

2.1 Output table

MIBG Fuel Operatin Power N Fl EL S Throughput

Model g [MW] [Nm /h] [kg/h]
3 [kg/h] [kg/h] [Nm3/h]
pressure
1.07 N / Fl / EL / S HD / ND 7 700 551 590 630 8‘750
1.10 N / Fl / EL / S HD / ND 10 1‘000 787 843 910 12‘500
2.14 N / Fl / EL / S HD / ND 14 1‘400 1102 1180 1273 17‘500
3.16 N / Fl / EL / S HD / ND 16 1‘600 1260 1349 1455 20‘000
3.18 N / Fl / EL / S HD / ND 18 1‘800 1465 1518 1636 22‘500
3.20 N / Fl / EL / S HD / ND 20 2‘000 1575 1678 1818 25‘000
3.24 N / Fl / EL / S HD / ND 24 2‘400 1890 2024 2182 30‘000
3.26 N / Fl / EL / S HD / ND 26 2‘600 2047 2192 2328 32‘500
!

Fuel Calorific value Fuel form

Gas (N) 36.0 MJ/Nm3 Natural gas
Liquid gas, liquid (Fl) 46.35 / 45.7 MJ/kg Propane / butane
Light oil (EL) 42.7 MJ/kg Fuel oil, extra light
Heavy oil (S) 40.2 MJ/kg Fuel oil

Explanation of terms

Operating pressure: HD = high pressure

Operating pressure: ND = low pressure

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Technical data

2.2 Dimensions and weights – burner with fan

E
A

Size 1
NW

C
H
AD
ID
1 8 x Ø 15

VL L
TK

G
TK
2

B A E
S

C
H
AD
ID

NW VL L
Value 2 and 3
Example:
RL
Right motor
Left fittings
0000

MIBG L/R-NELS-VL, with ventilation

Model A B C AD ID E L H VL S TK1* TK2* G NW kg
1.07 728 -- 1213 410 335 819 1451 510 670 -- 442 530 430 65
1.10 728 -- 1213 410 380 819 1451 510 670 -- 442 530 430 80
2.14 939 1049 1652 546 475 602 1557 740 750 650 -- 630 580 80
3.16 958 1068 1977 650 475 683 1575 919 870 650 710 792 660 100
3.18 958 1068 1977 650 515 683 1575 919 870 650 710 792 660 100
3.20 963 1068 1977 650 545 683 1575 919 870 650 710 792 660 100
3.24 1037 1068 1977 650 580 683 1575 919 870 650 710 792 660 100
3.26 1037 1068 1977 650 580 683 1575 919 870 650 710 792 660 100

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3 Combustion pressure drop
The pressure drop via the mixture ignition device (MZE) for burners with fuels or
fuel combinations N, Fl, EL, NEL; S, NS is max. 25 mbar.

3.1 Pump pressure / delivery quantity

High pressure (HD)

Pump pressure Delivery quantity

1.8 times the max. oil throughput rate plus the necessary
Supply 30 bar
overflow quantity at the oil pressure controller

Low pressure (ND)

Pump pressure Delivery quantity

1.5 times the max. oil throughput rate plus the necessary
Supply 7.5 bar
overflow quantity at the oil pressure controller

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Operating instructions - MIBG burner
Technical data

3.2 Burner oil nozzles / oil quantity regulator

High pressure (HD)

The type and size of the 32 oil nozzle is adapted to the respective maximum output
of the burner. All MIB burners are equipped with the OE-RLV oil quantity regulator.

Low pressure (ND)

The type and size of the 32-Y oil nozzle is adapted to the respective maximum
output of the burner. All MIB burners are equipped with the OE-RLV oil quantity
regulator.

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3.3 Oil atomization

High pressure (HD)

• A minimum pressure of 30 bar is required in the flow for atomizing the light oil
(EL) and the heavy oil (S)
• The oil viscosity for atomization may be max. 12mm2/S or 2o Engler

Low pressure (ND), oil- and liquid gas atomisation with compressed air
• The atomizer medium (compressed air) is conditioned by the maintenance unit
• The required atomiser quantity is approx. 10 weight percent of the maximum oil
quantity at 6 bar
• It must be possible to set the oil pressure before the oil quantity regulator (OE-
RLV) to a constant value between 7.5 and 12 bar
• The oil viscosity for atomization may be max. 12mm2/S or 2o Engler

The range is for N / Fl burners at 1:5

for EL/S burners at 1:3

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Technical data

3.4 Gas pressures

Natural gas N

upstream of the gas valve 150 - 200 mbar

in the burner head approx. 80 - 100 mbar at full output.

Liquid gas, liquid (Fl)

before the burner 11 bar at full power

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4 Nameplate

Burner type MIBG-3.22-NEL-VL870-RL-HD

Motor 45.0 kW 83.0 / 48.0 A 400 /690 V 50 Hz

Type of fuel Heating oil EL QN oil max. 22500 kW

Type of dust QN dust max. kW

Type of gas Natural gas QN gas max. 22500 kW

Oil pressure 30 bar Gas pressure 25 mbar

Fan wheel Fan pressure stat. 50 mbar

DIN-DVGW-Nr. SVGW-Nr.

BN VKF-Nr.

Part no. AF-S-BR05170A-001 Plant no.

Serial number A021 - 14 Year of constr. 2014

Country of destination

The nameplate contains all relevant machine data (example data).

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Technical data

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 Transport

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Operating instructions - MIBG burner
Transport

1 Hazards during transport

The dangers arising during transport are listed in the following table.

Danger source Hazard Measure

Train staff.
Only use tested lifting tackle in
Caution! perfect condition.
Loading and Danger of injuries!
unloading the HGV Note the information labels at the
due to falling loads suspension points.
Wear personal protective
equipment.

Caution! Train staff.

Fixing the burner
Danger of injuries! Note loading instructions.

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2 General notes

NOTE
Ammann accepts no liability for damages caused by improper transport. This
excludes transport carried out by Ammann.

Be sure to read the following notes prior to transport:

• The transport of components must only be carried out by trained, qualified
personnel or by instructed persons under the guidance of qualified personnel
• Use the transport locks provided for transport
• Only use defined and marked transport routes
• Observe road blocks and hazardous areas
• Keep traffic routes free
• When unloading next to tracks, keep a minimum distance of at least 0.5m
between the load and the furthest unloading part of the crane or vehicle
• Deposit the loads so that they cannot slide, roll, topple or fall
• Check the load-bearing capacity of the ground and use planks or beams as a
base if required
• Plan out each transport carefully
• Use suitable auxiliary aids such as roller carriages, pushcarts or special load-
carrying equipment. Do not overload these auxiliary aids
• Only use load-carrying equipment that prevents the unintentional self-
loosening of the load

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Operating instructions - MIBG burner
Transport

• Do not use any motor vehicles, E-carts or fork-lift trucks, cranes, lifts, continuous
conveyors and elevating work platforms without appropriate training or
instruction
Only specially appointed and trained, qualified personnel may use these
machines.
• Ensure that no persons can go under suspended loads
• Make sure that industrial trucks are never used to transport people
• Check the lifting accessories (rope, chains, thimbles, shackles, etc.) for damage
and only use parts that are still intact
• Secure the load on the transport vehicle properly and use the suspension points
provided

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3 Cranes

NOTE
Unless otherwise indicated in the order, the specifications or other written
documents on cranes, be sure to observe the following information.

The use of a crane with the following specifications is recommended when trans-
porting and assembling the components:
• Load-bearing capacity 70 t
• Working radius up to 40 m

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Operating instructions - MIBG burner
Transport

4 Suspension rings and lifting gear

Suitable lifting gear must only be attached to suitable suspension rings and
suspension points. These lifting rings and suspension points are marked in yellow
and black.

If there are no suspension rings or suspension points marked, attach the lifting gear
to fixed parts of the machine. Make sure that the machine cannot be damaged as
a result.

Use chains, wire ropes or lifting straps or slings to suspend loads.

Expert instruction of the personnel responsible for transport the components by

crane, e.g. notes on the correct use of the lifting gear (angles, etc.) is essential.

The responsibility for this instruction lies with the operator or the operator's
appointed coordinator or safety officer.

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4.1 Suspension of the burner

A
Installation size 1 Installation size 2 and 3

NOTE
Always use shackles (A) for the suspension

4.2 Dimensions and weights – MIBG burner

The dimensions and weights can be found in the table in Chapter "Dimensions and
weights – burner with fan" starting on page 80

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Transport

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 Assembly and
commissioning

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Operating instructions - MIBG burner
Assembly and commissioning

1 Hazards during assembly

1.1 Burner

Danger source Hazard Measure

Do not stand under suspended

Transport of compo- Attention
loads! Use protective equipment
nents by crane - suspended load
(helmet)!

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 Danger source Hazard Measure

When working on system parts that

are not equipped with permanent
access, use safe equipment for
accessing elevated areas and use
safety equipment (harness). It is
Bolt the machine to recommended that you use
Caution!
the support frame assembly lifts or platforms. When
Tripping hazard!
working in the lower area, platform
ladders with solid working surfaces
Plant parts are signif- can also be used. Permanent
Caution!
icant height access must be equipped with
Danger of falling!
(> 0.5m) railings or support railing and
baseboards. Always secure
yourself from falling! Special caution
is required if work at considerable
heights is additionally impeded by
wind!

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Operating instructions - MIBG burner
Assembly and commissioning

Danger source Hazard Measure

Do not take hold of electrical

connections. Regularly check
electrical components, such as
cables, overload protection,
Caution! earthing and insulation. Ensure that
Electrical hazard! electrical connections have been
Electrical devices
dismantled according to regulations
and connections (electric shocks and and as intended. Only carry out
burns) work on parts of the plant which
have been de-energized in
accordance with the 5 safety regula-
tions (Chapter "5 safety rules"
starting on page 61)!

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1.1.1 Oil supply

Danger source Hazard Measure

Check the lines visually for leakages

at regular intervals!
Caution!
Risk of poisoning After installation, carry out a
Complete
pressure test on the lines with
oil supply Due to oil escaping water!
from leaking lines!
Always wear personal protective
equipment!

Caution!
Danger of injuries! Switch off the oil supply before
Complete Due to escaping oil! installation!
oil supply Secure the valve with a padlock to
After-effects:
· Fires prevent unintentional reactivation!
· Explosions

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Assembly and commissioning

1.1.2 Gas supply

Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Caution! Keep suitable extinguishing devices
Risk of fire and ready!
Gas explosion!
Read and observe the information
From escaping gas via signs!
leaking lines!
Do not remove information
signs!
Replace missing or illegible infor-
mation signs immediately!

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 Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Keep suitable extinguishing devices
Caution! ready!
Risk of fire and
explosion! Read and observe the information
signs!
From escaping
liquefied gas via leaking Do not remove information
Liquid gas signs!
lines!
Replace missing or illegible infor-
Liquid gas is heavier mation signs immediately!
than air and collects f you smell gas, immediately close
close to the ground. the manual valve on the liquid-gas
tank!
If it penetrates into the drainage
system, notify the
competent authorities.

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Operating instructions - MIBG burner
Assembly and commissioning

Danger source Hazard Measure

Caution!
Danger of suffocation
From escaping f you smell gas, immediately close
liquefied gas via leaking the manual valve on the liquid-gas
lines! tank!
Liquid gas Liquid gas is heavier In the event of a massive uncon-
than air and collects trolled escape of gas, immediately
close to the ground. leave your workplace and inform the
Liquid gas can cause responsible person on site!
suffocation by
displacing oxygen.

Caution!
Mixing of fuels Fuels must never be mixed!
Risk of explosion!

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2 Preparing for assembly

2.1 Inspections before installation

When the delivery arrives at the plant, check to see that it is complete.
The exact scope of delivery can be found in the order confirmation.

Check the components for transport damage.

Check that the correct version has been delivered.

Remove foreign material and packaging.

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Assembly and commissioning

3 Assembly

3.1 General notes

The majority of components are supplied pre-assembled. Exceptions are

described below.

The assemblies are pre-assembled on the ground as far as possible and the
components are installed as shown in the assembly diagrams.
Be sure to install and attach all components as shown in the assembly diagrams.

Remove the retaining clips before installing the component unless otherwise
indicated.

Entry routes (stairs, platforms and ladders) are assembled along with their related
components.
Assemble all of the entry routes for a component, including guardrails and other
safety equipment, before assembling the next component.

At the disconnecting points between the components, only use screws with the size
and quality indicated in the screw lists or assembly drawings. This applies in
particular when reassembling after maintenance or conversion of the plant.

When making the screw connections, use the tightening torques according to DIN
18800 Part 7 (Chapter "Tightening torques" starting on page 74).

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 Power and operating supply connections (electricity, compressed air, fuels, water)
must only be connected to the respective lines when setting up the plant.

The supply lines are sometimes pre-assembled. During assembly the lines on the
various components must be connected to each other or to individual components
according to the assembly diagram.

ATTENTION!
Risk of spray and overrun!
Isolation work on fluid lines and fittings must only be carried out after checking the
tightness of the connections.

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Operating instructions - MIBG burner
Assembly and commissioning

3.2 Power and operating supplies

Prior to assembly, the necessary supply connections must be in place. The

connections required are:
• Electrical connection
• Pneumatic connection
• Oil supply connection
• Gas supply connection
• Water supply connection

Only use the plugs and connectors provided.

Make sure that the seat of the connections is correct.

3.3 Electrical connection

Earth all parts of the plant.

Run the individual wires from the wire routing to the terminal board via the shortest
route. This helps to prevent damage to the wires caused by vibration.

Insert the electrical connectors as labelled and indicated in the wiring diagrams.
The wiring diagrams can be found in the electrical documentation.

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3.4 Pneumatic connection

Lay the pneumatic lines to the consumers in accordance with the

pneumatic diagrams.

Pneumatic lines, excluding pre-assembled lines, are generally cut the required
length on site.

When cutting pneumtatic lines, be sure to take account of any possible movements
of the component.

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Operating instructions - MIBG burner
Assembly and commissioning

3.5 Assembly sequence for MIBV burner

NOTE
The burner is delivered completely pre-assembled

Transport: Use
shackles for suspending the burner.

Retaining pin
8xM12

Hexagon nut 8xM12 with washer Outlet

flange-mounted position

• Carefully lift the burner aligned to the drum outlet

• Push precisely over the retaining pins

ATTENTION!
Do not damage the bolt thread

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 Assembly sequence for MIBV burner
(continued)!
• Screw in the top two retaining nuts to such an
extent that the burner can be lowered until the
burner flange contacts the drum outlet
• Mount and tighten the remaining nuts
• Remove the crane and hoist

The burner is assembled

• Assemble all supply lines for electrical power and

fuel supply in accordance with the diagram
provided

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Operating instructions - MIBG burner
Assembly and commissioning

4 Initial set-up

4.1 General notes

Ammann burners are tested before delivery. In other words, all possible settings
such as limit switch positions have been preset wherever possible.

The operating instructions for all supplied components such as control, gas control
system, hydraulic elements, pumps etc., must be taken from the original
documents of the respective manufacturers.

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4.2 Commissioning preparations

The following actions must be taken before commissioning the burner:

• Burner control. monitoring, safety systems, and components must be checked
for correct settings and functionality
• The direction of rotation and feedback mechanisms of the air and fuel actuators
must be checked by manually operating the electronic compound controller
before the burner is started up. (See the operating instructions of the electronic
compound controller)
• The dryer system and its infrastructure must be checked for operational
readiness
• The oil supply up to the ball valves at the burner must be vented
• The oil delivery pressure must be set to approx. 7.5 bar at low pressure and
30 bar at high pressure
• The gas pressure must be set to the value specified in the gas control system
documentation
• Preheating is operational for heavy oil
• The gas line must be vented as far as the solenoid valves. The safety fixtures in
the gas line, such as VSAV and VSBV, must be checked for correct settings and
functionality
• The pre-ventilation time must be calculated according to EN 746-2 (formula:
volume of the combustion chamber, including all systems up to the chimney [m3]
divided by the volume flow of the burner fans [m3/h]) and programmed in the
burner control

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Assembly and commissioning

4.3 Burner commissioning/start-up

NOTE
The burner must only be started up by an Ammann service engineer or experts who
have been trained by Ammann!

When the start-up preparations are complete, the following actions must be
performed:

Open mechanical valves

NOTE
The mechanical valves must be opened before the function test is performed!

Check function sequence without flame

NOTE
De-energise the electrical supply cables to the fuel valves and main ignition
gas valve.

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4.3.1 Start conditions and start procedure without flame
Ignition transformer, ignition gas, and main fuel valves are de-energised!
(monitoring steps not fully displayed)

+ = 1; O = 0 Burner on Fl N EL S-ND
Oil temperature min. O
Heat tracing +
Transfer pump + +
Burner pump +
Oil preheating +
Oil temperature min. +
Burner fan + + + +
Gas density test +
Density test fault +
Air actuator + + +
Fuel actuator + +
Pre-ventilation + + +
Air pressure monitor + + +
Fuel actuator Backing pump + +
Pre-ventilation O O O
Fuel actuator +
Burner pump + +
Main fuel valves +
Ignition transformer + + + +
Ignition gas valves + + + +
Flame monitor
Burner relay fault + + +
Ignition transformer
Main fuel valves
Burner relay nozzle
shut-off valve
Atomised air valve
Ignition gas valves
Burner relay fault
Flame monitor
Ignition gas valves
Burner relay fault
Burner relay operation
Control enable

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Assembly and commissioning

4.3.2 Start conditions and start procedure with ignition flame, without main
flame
Mail fuel valves are de-energised! Exception: N-burner
 1. Main fuel valve is connected. 2. Main fuel valve is de-energised.
(monitoring steps not fully displayed)

+=1
Burner on Fl N EL S-ND
O=0
Oil temperature min. O
Heat tracing +
Transfer pump + +
Burner pump +
Oil preheating +
Oil temperature min. +
Burner fan + + + +
Gas density test +
Air actuator + + + +
Fuel actuator + + +
Pre-ventilation + + + +
Air pressure monitor + + + +
Fuel actuator, backup pump + + +
Pre-ventilation O O O O
Fuel actuator +
Burner pump + +
Main fuel valves +
Ignition transformer + + + +
Ignition gas valves + + + +
Flame monitor + + + +
Ignition transformer O O O O
Main fuel valves + + +
Nozzle shut-off valve + +
Atomised air valve +
Burner relay fault + + +
Gas fault Pmin. +
Flame monitor
Ignition gas valves
Burner relay fault
Burner relay operation
Control enable

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4.3.3 Start conditions and start procedure with main flame
Starting conditions and starting procedure with main flame.
(monitoring steps not fully displayed)

+=1
Burner on Fl N EL S-ND
O=0
Oil temperature min. O
Heat tracing +
Transfer pump + +
Burner pump +
Oil preheating +
Oil temperature min. +
Burner fan + + + +
Gas density test +
Air actuator + + + +
Fuel actuator + + +
Pre-ventilation + + + +
Air pressure monitor + + + +
Fuel actuator, backup pump + + +
Pre-ventilation O O O O
Fuel actuator +
Burner pump + +
Main fuel valves +
Ignition transformer + + + +
Ignition gas valves + + + +
Flame monitor + + + +
Ignition transformer O O O O
Main fuel valves + + +
Nozzle shut-off valve + +
Atomised air valve +
Flame monitor + + + +
Ignition gas valves O O O O
Burner relay operation + + + +
Control enable + + + +

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Assembly and commissioning

4.3.4 Adjusting the basic load flame

Oil:
• Start the burner
• See oil quantity regulator OE-RLV (200 - 4000 l/h)
• The return pressure for the used nozzle system at base load is approx. 8 –
10 bar in the case of light oil EL and approx. 12 – 14 bar in the case of heavy oil
S
• At low pressure, the oil pressure upstream of the nozzle is approx. 2 bar at base
load

Natural gas N:
• The minimum gas output is adjusted by positioning the gas flap servo drive
• Gas pressures: Upstream of gas flap 150 mbar; in burner head approx. 1 –
3 mbar

Liquid gas Fl:

• Gas pressure at entry to the gas safety line is 11 bar
• Setting in accordance with ND

4.3.5 Adjustment at full load

Oil:
• The rest of the controlled range can be adjusted by programming load points
with linear distribution. Scale values at the oil quantity regulator from position 9
to approx. position 0, decreasing
• Delivery pressure at full load: 30 bar (return pressure approx. 24 bar)

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 Natural gas:
• The remaining control range is controlled via linearly distributed load points
• The natural gas volume must be measured
• Gas pressures: Upstream of gas flap 150 mbar; in the gas head 80 – 100 mbar

ATTENTION!
Risk of poisoning!
In order to avoid soot or CO formation, the O2 and CO values in the waste gases
must be measured throughout the setting tasks.

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Assembly and commissioning

4.4 Function check at burner

When the burner is being started up or modified, the following checks must be
performed:

4.4.1 Functional check for oil, gas and liquid gas operation
Function Event Plain text message
Start-up with darkened Electronic unit goes to Flame problem during
flame monitoring fault ignition procedure
Start-up with flame
Electronic unit goes to
monitoring illuminated External light problem
fault when switched on.
(external light)
Normal procedure; when
burner operating, pull out Electronic unit goes to Flame problem during
flame monitoring and fault operation
darken.
Set air pressure monitor Pre-ventilation time no
Air pressure missing
to maximum value. longer elapses
Set pressure monitor
Electronic unit goes to Oil or gas safety chain
above/below its set
fault drops away.
value.

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 Oil thermostat min./max. With min.: Electronic unit Oil safety chain drops
(double instrument goes to fault away
The program sequence of
the electronic unit must be
normal up to the ignition
phase. When the solenoid
With natural gas (N) fuel,
valve opens, the start
open ball valve, and Gas safety chain drops
procedure is interrupted
close again as soon as away.
because of the lack of gas.
burner motor starts
If this is not the case, the
setting of the minimum
pressure monitor must be
checked.

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Assembly and commissioning

4.4.2 Possible faults

Event Possible fault

Burner not starting up No enable command from system
"Air flap open" or rather "Burner ignition
Enable command; Pre-ventilation position and air flap" feedback signal not
starts but no ignition procedure takes present.
place Plain text message:
Fault(s) displayed accordingly
Electronic unit goes to fault when No ignition, no ignition gas, no fuel
attempting to start, without flame
formation Oil temperature with heavy oil

Burner starts up, flame forms, Flame monitoring defective or soiled

electronic compound controller goes to Feed line defective or not enough light
fault when safety time elapses coming from flame

DANGER! EXPLOSION HAZARD!

The solenoid valves must be de-energized during pre-ventilation!
If fuel would flow into boiler during the purge time, it would cause an explosion at
the ignition!

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4.4.3 Final checks
• After the required measurements are completed, it must be ensured that all
measuring nipples are closed
• For the purpose of final inspection, the burner must be started several times and
the program operating sequence observed on the electronic control unit. Prior to
exiting the system, proper system function must be checked
• Temporary measures must not be tolerated. If this cannot be avoided in a
special case, the system must be newly calibrated by an expert after the
temporary measure is replaced by a definitive system

Finally:
• Complete the measuring report fully (including signature) and file a copy with the
burner documentation
• File the pre-ventilation time calculation with the burner documentation as well
• Instruct the operator on the "Information for the system operator" and in
particular on the measures to be taken in case of disruptions

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Assembly and commissioning

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 Operation

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Operating instructions - MIBG burner
Operation

1 Hazards during operation

1.1 Dangers during operation of the machine

The dangers that exist specifically for the burner are listed in the following table.

Danger source Hazard Measure

Caution!
If faults occur during operation, shut
Risk of burning!
the burner down in accordance with
The burner generates the 5 safety regulations and
Hot surface extremely high temper- interrupt the fuel supply!
atures. These tempera-
Allow the burner to cool down
tures can have fatal
before carrying out any work or
consequences within a
adjustments
short time.

Caution – automatic
start-up If faults occur during operation, shut
Automatic start-up The fan can be the burner down in accordance with
automatically started by the 5 safety regulations.
the control.

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1.1.1 Oil supply

Danger source Hazard Measure

Close the ball valves upstream of

the pressure gauges when
operating.
Caution! Check the lines visually for leakages
Complete Risk of poisoning at regular intervals!
oil supply Due to oil escaping After installation, carry out a
from leaking lines! pressure test on the lines with
water!
Always wear personal protective
equipment!

Close the ball valves upstream of

Caution!
the pressure gauges when
Danger of injuries!
operating.
Complete Due to escaping oil!
Switch off the oil supply before
oil supply
After-effects: installation!
· Fires
Secure the valve with a padlock to
· Explosions
prevent unintentional reactivation!

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Operation

1.1.2 Gas supply

Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Caution! Keep suitable extinguishing devices
Risk of fire and ready!
Gas explosion!
Read and observe the information
From escaping gas via signs!
leaking lines!
Do not remove
information signs!
Replace missing or illegible infor-
mation signs immediately!

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 Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Keep suitable extinguishing devices
Caution! ready!
Risk of fire and
explosion! Read and observe the information
signs!
From escaping
liquefied gas via leaking Do not remove
Liquid gas information signs!
lines!
Replace missing or illegible infor-
Liquid gas is heavier mation signs immediately!
than air and collects f you smell gas, immediately close
close to the ground. the manual valve on the liquid-gas
tank!
If it penetrates into the drainage
system, notify the
competent authorities.

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Operation

Danger source Hazard Measure

Caution!
Danger of suffocation
From escaping f you smell gas, immediately close
liquefied gas via leaking the manual valve on the liquid-gas
lines! tank!
Liquid gas Liquid gas is heavier In the event of a massive uncon-
than air and collects trolled escape of gas, immediately
close to the ground. leave your workplace and inform the
Liquid gas can cause responsible person on site!
suffocation by
displacing oxygen.

Caution!
Mixing of fuels Fuels must never be mixed!
Risk of explosion!

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2 Notes for the operator
Never operate the machine if it has a fault!

Due to the low number of personnel at each plant, each workplace is classed as
an individual workplace.

Ensure compliance with the following points:

• Only trained and instruced personnel may operate the machines of the plant
• Notices that prohibit access to the plant area for unauthorised personnel must
be installed
A barrier is recommended around the plant site.
• The operating personnel must be provided with a wireless voice connection, as
visual contact between the employees is not always guaranteed
This voice connection must function correctly and must be suitable for use at an
asphalt mixing plant.
The set-up must be carried out by an expert
• If the plant is operated at night or in poor visibilitym sufficient ligihting must be
provided
Ammann supplies the plant without lighting.
Lighting can be ordered separately.
• The reporting process for suppliers and collection customers must be set down
in writing
• Safe areas in which drivers and co-drivers of vehicles can stop must be clearly
defined
• These persons must also be instructed on the possible hazards at the plant
Define rules for the loading and unloading of vehicles.

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Operation

• All persons working in the plant area must be notified of the position and of the
function of emergency and safety equipment
• The operator is responsible for suitable access to non-fixed or temporay work
areas, e.g. fixed platform ladders, scaffolding or lifting platforms. He is likewise
responsible for making available the safety equipment for working where there
is a falling hazard

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3 Notes for operating personnel
• When at the plant be sure to wear and use the protective gear and
safety equipment provided
Read and observe the notes in the Chapter "Safety at work"”.
• Notify drivers of delivery, customer and works vehicles of the traffic regulations
applicable on site
• Only transport overhead loads if there is no-one underneath. Notify all personnel
in advance and, if applicable, other persons of the transport
• Make sure that no unauthorised personnel remains on the site
• Make sure that visitors report to the plant manager, site manager or plant
operative
• Make sure that visitors observe the health and safety regulations at the plant
• The plant operative must ensure that visitors are notified of the operating
hazards
• The plant operative must also ensure that any noise control equipment at the
plant is in the locked position during operation

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Operating instructions - MIBG burner
Operation

ATTENTION!
Danger of injuries!
Switch off the plant immediately!
 In the event of danger or emergency alarm immediately switch off the entire
plant using the "Emergency off"!
 This also applies even if there is no emergency or fault displayed on the control
panel!

In an emergency the plant operative must immediately attend the site of the
reported emergency in order to administer first aid or to take other relevant
measures.

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4 Emergency and safety equipment

4.1 General notes

Safety first!
In the event of a hazard, press the emergency stop button!

NOTE
As the operator, you must ensure that the safety equipment throughout the entire
plant is checked by qualified personnel prior to initial set-up.

The safety equipment of the delivered installation parts and delivery parts is in
accordance with the requirements of EN 60204-1.

As an operator, you must ensure that the safety equipment on the components and
parts supplied are made known to all personnel working in the plant area by means
of an instruction prior to the initial set-up.

Refer in particular to the following rules:

• In the event of an operating fault, press the nearest emergency stop button or
pull the nearrest emergency rip cord
• Ensure your own self-protection
• Suitable first aid measures must be taken
• Appropriate countermeasures must be taken
• The supervisor must be informed

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Operation

4.2 Emergency stop button

Emergency stop button

If the emergency stop button is pressed, the entire plant comes to a standstill and
all units are disconnected from the power supply. This also applies to parts of the
plant that are secured by an emergency rip cord.

NOTE
The emergency stop takes precedence over all other functions and actuations!

ATTENTION!
Safety equipment!
Before restarting the disconnected units, all emergency stop rope switches and
emergency stop buttons must be released.

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4.3 Application

Safety first!
Press the nearest emergency stop button or pull the nearest emergency rip cord if
a fault occurs during operation.

DANGER! EXPLOSION HAZARD!

In the event of faults in the combustion
 When faults occur in relation to the combustion, immediately cut the fuel supply
(close main gas valve, switch off combustion pump).

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Operation

5 Special operation

5.1 Procedure in the event of operating faults

NOTE
As an operator, you must ensure that the safety equipment provided at the plant
are made known to all personnel working in the plant area by means of an
instruction prior to the initial set-up.
Be sure to refer to the code of conduct that applies in the event of an operating
fault!

The following points must be observed in the event of an operating fault:

• Press the nearest emergency stop button or pull the nearest emergency rip cord
• Ensure your own self-protection
• Take suitable first aid measures if necessary
• Take suitable countermeasures
• Switch off the pumps
• Close all feed and discharge lines
• Switch off the heating
• Notify your supervisors

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5.2 Procedure in the event of fire

The operator must instruct all personnel of the following procedure that must be
observed in the event of fire:
• Alert the fire brigade and inform them of the nature of the burning materials
• Ensure your own self-protection
• Take suitable first aid measures if necessary
• Fight any incipient fires
• Switch off all pumps
• Close all feed and discharge lines
• Switch off the heating
• Notify your supervisors
• Direct the fire brigade and inform them over the burning material

DO NOT extinguish with WATER!

Risk of explosion!
NEVER extinguish bitumen fires with WATER!

• Cover hot pools of bitumen with sand or a suitable extinguishing material

NOTE
All work at or on bitumen storage tanks and on pipelines, pumps and fittings must
only be carried out with the approval of the operator!

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Operation

6 Troubleshooting

6.1 Fault causes

NOTE
If problems occur it is vital to analyse and document the cause and then contact
the responsible service/customer service location!

The source of dryer problems may be found in the pre-metering or fuel supply area.

Vacuum

The vacuum in the drum is kept constant by the automatic vacuum control system.
If the difference between the vacuum pressure and the ambient pressure drops in
the event of a fault, the controller triggers an alarm. If no adjustments are made and
the vacuum pressure continues to drop, the dryer and the burner are automatically
shut off. This counteracts the risk of incomplete fuel combustion. A possible
countermeasure is to reduce the mineral metering volume and the burner power.

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6.2 Action to take if the smell of gas is detected

SMOKING, NAKED LIGHT AND FIRE PROHIBITED!

Escaping gas can explode!
 Do not operate any electrical contacts or switches (bell, light, motor, lift etc.)!

 Never attempt to locate a gas leak using a flame!

 The affected rooms must be well ventilated by opening doors and windows.
Escaping natural gas will accumulate beneath the ceiling, and liquid gas will
accumulate at ground level.

 Shut off all gas valves immediately.

 Extinguish all flames in the affected rooms, adjacent rooms and connected
locations.

 Also check adjacent rooms and buildings for the smell of gas.

 Notify a plumber or the gas company.

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Operation

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 Inspection,
maintenance, repairs and
troubleshooting

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Operating instructions - MIBG burner
Inspection, maintenance, repairs and troubleshooting

1 Hazards during maintenance

1.1 Burner

The dangers that exist specifically for the burner are listed in the following table.

Danger source Hazard Measure

Caution! Before carrying out any mainte-

Risk of burning! nance work on the burner,
The burner generates disconnect the power supply as per
Hot surface extremely high temper- the 5 safety rules and shut off the
atures. These tempera- fuel supply!
tures can have fatal Allow the burner to cool down
consequences within a before carrying out any work or
short time. adjustments

Caution – automatic Before carrying out any mainte-

start-up nance work on the burner,
Automatic start-up The fan can be disconnect the power supply as per
automatically started by the 5 safety rules and shut off the
the control. fuel supply!

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1.1.1 Oil supply

Danger source Hazard Measure

Close the ball valves upstream of

the pressure gauges during mainte-
nance work.
Caution! Check the lines visually for leakages
Complete Risk of poisoning at regular intervals!
oil supply Due to oil escaping After installation, carry out a
from leaking lines! pressure test on the lines with
water!
Always wear personal protective
equipment!

Close the ball valves upstream of

Caution!
the pressure gauges during
Danger of injuries!
maintenance work.
Complete Due to escaping oil!
Switch off the oil supply before
oil supply
After-effects: installation!
· Fires
Secure the valve with a padlock to
· Explosions
prevent unintentional reactivation!

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Operating instructions - MIBG burner
Inspection, maintenance, repairs and troubleshooting

1.1.2 Gas supply

Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Caution! Keep suitable extinguishing devices
Risk of fire and ready!
Gas explosion!
Read and observe the information
From escaping gas via signs!
leaking lines!
Do not remove information
signs!
Replace missing or illegible infor-
mation signs immediately!

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 Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Keep suitable extinguishing devices
Caution! ready!
Risk of fire and
explosion! Read and observe the information
signs!
From escaping
liquefied gas via leaking Do not remove information
Liquid gas signs!
lines!
Replace missing or illegible infor-
Liquid gas is heavier mation signs immediately!
than air and collects f you smell gas, immediately close
close to the ground. the manual valve on the liquid-gas
tank!
If it penetrates into the drainage
system, notify the
competent authorities.

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Operating instructions - MIBG burner
Inspection, maintenance, repairs and troubleshooting

Danger source Hazard Measure

Caution!
Danger of suffocation
From escaping f you smell gas, immediately close
liquefied gas via leaking the manual valve on the liquid-gas
lines! tank!
Liquid gas Liquid gas is heavier In the event of a massive uncon-
than air and collects trolled escape of gas, immediately
close to the ground. leave your workplace and inform the
Liquid gas can cause responsible person on site!
suffocation by
displacing oxygen.

Caution!
Mixing of fuels Fuels must never be mixed!
Risk of explosion!

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2 Inspection and maintenance intervals

NOTE
Observe all prescribed setting, maintenance and inspection activities, intervals and
dates!
Also observe the instructions on replacing parts or subassemblies, and perform all
maintenance and inspection activities resulting from the maintenance intervals!

Plant component

This column contains the inspection location and type

Cycle

This column contains the interval at which the inspection or maintenance must be
performed.

Cycle Definition
1 day Daily before starting work or at the end of the working day
1 week At the beginning of the week
1 month On first working day of the month
3 months Every 3 months on a fixed date
6 months Every 6 months on a fixed date
1 year On a fixed date during the year
As needed If a controller error is indicated or suspected during production
Other According to the specified interval

The time specifications refer to the time of installation or last

inspection/maintenance.

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Operating instructions - MIBG burner
Inspection, maintenance, repairs and troubleshooting

Staff

This column specifies the person who must perform the inspection or maintenance.

Symbol To be carried out by

Operating staff
Maintenance staff
q
Experts
or personnel authorised by Ammann

Please also read and observe Instructions in subchapter 3 "Explanation of terms",

page 21 ff., in Chapter "Introduction and explanation of symbols", page 13 ff.

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3 Burner inspections

NOTE
Observe the setting, maintenance and inspection activities and dates prescribed
by third-party suppliers.

The manufacturer's operating instructions can be found in the part and supplier
documentation in Chapter 12 of the spare parts lists.

NOTE
When inspecting a fuel supply, follow the operating instructions of that particular
fuel supply.

Plant component Cycle To be carried out by

· Check all oil and/or gas line connections for
1 day
leaks.
· Check the burner indicator lamps on the burner
1 week
switch cabinet.
· In heavily contaminated combustion air, the
flame monitor and fan must be cleaned 1 week
regularly.
· View through inspection glass into boiler com-
bustion compartment. If any changes occur to
the shape or colour of the flame, swivel burner
1 week
open and check geometric condition of mixing
device, and also check for deposits or blocked
nozzles.
· Ensure that the burner pump is making normal
noises. Clean pump in the event of mechanical 1 week
noise or vibration.
· Check and clean the electrical and mechanical
1 year
components.
· Measurement and adjustment of combustion
1 year
values if necessary

NOTE
For troubleshooting, also read Chapter 6 starting on page 138 in the "Operation"
volume of these instructions.

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Operating instructions - MIBG burner
Inspection, maintenance, repairs and troubleshooting

4 Troubleshooting

4.1 General notes

NOTE
Read and observe the operating instructions on troubleshooting from the manufac-
turer of the individual components and supplier parts!

The manufacturer's operating instructions can be found in the part and supplier
documentation in Chapter 12 of the spare parts lists.

NOTE
In particular, read and observe the notes on troubleshooting in the operating
instructions for the control system!

NOTE
For troubleshooting, also read Chapter6 "Troubleshooting", page 138 in these
instructions.

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5 Ordering spare parts
The spare parts lists can be found in the folders marked.

The component and part documents can be found in Chapter 12 of the spare parts
lists.

You can order parts from Ammann by telephone, by post, by fax or by e-mail.

See our website at www.ammann-group.com

5.1 Address for spare parts orders

Switzerland
Ammann Asphalt AG
Eisenbahnstrasse 25
CH-4901 Langenthal
Telephone: +41 62 916 6353
Fax: +41 62 916 6677
E-mail: info.aag@ammann-group.com

Germany
Ammann Asphalt GmbH
Hannoversche Strasse 7-9
D-31061 Alfeld
Telephone: +49 5181 76 261
Fax: +49 5181 76 242
E-mail: info.aag@ammann-group.com

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Inspection, maintenance, repairs and troubleshooting

Benelux
Ammann Benelux BV
P.O. Box 64
NL-6000 AB Weert
Telephone: +31 495 453 111
Fax: +31 495 453 222
E-mail: info.abx@ammann-group.com

China
Ammann Construction Machinery Shanghai Co. Ltd.
No.1609, Hui Bin Road
Qingpu Industrial Zone
201700 Shanghai
Telephone: +86 21 5986 8811
Fax: +86 21 5986 8800
E-mail: info.acs@ammann-group.com

France
Ammann France SA
Z.I. petites haies
31-33 Rue de Valenton
FR-94046 Créteil Cedex
Telephone: +33 1 45 17 08 88
Fax: +33 1 45 17 08 90
E-Mail info.afr@ammann-group.com

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 Italy
Ammann Italy S.p.A.
Via dell´Industria, 1
It-37012 Bussolengo (VR)
Telephone: +39 045 676 4911
Fax: +39 045 670 1192
E-mail: spareparts.AIT@ammann-group.com

Austria
Ammann Austria GmbH
Neuhaus 9
A-4114 Neuhaus
Telephone: +43 7232 29 9 44 0
Fax: +43 7232 29 9 44 24
E-mail: info.aea@ammann-group.com

Poland
Ammann Polska Sp.z.o.o.
ul. Jutrzenki 84
PL-02-230 Warsaw
Telephone: +48 22 33 77 900
Fax: +48 22 33 77 929
E-mail: info.aep@ammann-group.com

Russia
OOO Ammann Russia
1st Volkonsky per, 13, bld.2
RU-127 473 Moscow
Telephone: +7 495 933 35 61
Fax: +7 495 933 35 67
E-mail: info.aru@ammann-group.com

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Operating instructions - MIBG burner
Inspection, maintenance, repairs and troubleshooting

Sweden
Stig Machine AB
Tegelbruksvägen 1
SE-74630 Bälsta
Telephone: +46 171 544 00
Fax: +46 171 541 50
E-mail: info@stigmachine.se

Ammann Scandinavia (ASC)

Slagthuset
211 20 Malmö
Telephone: +46 40 6998370

Czech Republic
Ammann Asphalt GmbH
Príkop 6
CZ-60200 Brno
Telephone: +420 545175940
Fax: +420 545175941
E-Mail pavel.kucera@ammann-group.com

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 Storage of operating
materials

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Operating instructions - MIBG burner
Storage of operating materials

1 Operator's liability
The operator accepts liability for the following points:
• The terms and conditions of the operating licence must be observed
• The provisions of the Water Resources Act (WHG) must be observed
• The Technical Rules on Combustible Liquids (TRbF) and the Ordinance on
Industrial Safety and Health (BetrSichV) must be observed
• The storage premises must not be endangered in any way by vehicle operation
internal to the plant
• Fences and safety areas must be set up around hazardous areas
• Lubricants, oils and other operating materials must be stored in separate
containers
These storage areas must be designed so that any leaks or spillages of the
above substances does not pose a threat to the groundwater.
• Collecting boxes for use cleaning cloths and other disposed waste must be
emptied in accordance with the regulations (see also Chapter "Disposal"
starting on page 173)

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2 Plant operative's liability
The plant operative accepts liability for the following points:
• Sampling points, filling and control valves or sliders, must with fitted with
rainproof collecting trays
• The holding tank must be installed to catch material and liquids which drips
or flows a necessary from the respective openings after the relevant flap or
valve has been closed
These collecting trays must be emptied and disposed in accordance with the
regulations.
• Used cleaning cloths and other disposed waster must be stored in the collecting
boxes provided

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Operating instructions - MIBG burner
Storage of operating materials

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 Decommissioning and
disassembly

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Operating instructions - MIBG burner
Decommissioning and disassembly

1 Hazards during dismantling

1.1 Burner

Danger source Hazard Measure

Caution! Do not stand under suspended

Transport of compo- Suspended load! loads!
nents by crane Risk of injury due to Use personal protective
falling loads equipment (helmet)!

During installation do not take hold

Caution! of the points at which the compo-
Danger of being nents are being assembled, unless
Remove the this is essential for installation.
crushed!
machine from the
dryer Crushing of parts of the Do not stand between fixed compo-
body between compo- nents and components that are
Aligning the machine being moved.
nents that are being
assembled. Work with extreme caution during
installation!

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 Danger source Hazard Measure

When working on plant parts that

are not provided with fixed access
ways, use secure steps and safety
equipment (tackle/safety harness).
We recommend using installation
lifts or work platforms.
Plant parts at signif- Caution!
Tripping hazard! When working in the lower area,
icant height
platform ladders with a fixed work
(> 0.5m)
surface can also be used.
Disassembly of the Caution! Permanent access ways should be
burner Danger of falling! provided with hand rails or auxiliary
rails and toe boards.
Always protect yourself from falling!
Special caution is required if work at
considerable heights is additionally
impeded by wind!

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Operating instructions - MIBG burner
Decommissioning and disassembly

Danger source Hazard Measure

Do not take hold of electrical

connections.
Regularly check the electrical com-
ponents, such as cables, overload
protection, earthing and
Caution!
insulation.
Electrical devices Electrical hazard!
and connections Make sure that electrical connec-
(electric shocks and
tions are fitted correctly and as
burns)
specified.
Only carry out work on parts of the
plant which have been de-energized
in accordance with the 5 safety reg-
ulations (page 61)!

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1.1.1 Oil supply
Danger source Hazard Measure

Check the lines visually for leakages

at regular intervals!
Caution!
Risk of poisoning! After installation, carry out a
Complete
pressure test on the lines with
oil supply Due to oil escaping water!
from leaking lines!
Always wear personal protective
equipment!

Caution!
Danger of injuries! Switch off the oil supply before
Complete Due to escaping oil! installation!
oil supply Secure the valve with a padlock to
After-effects:
· Fires prevent unintentional reactivation!
· Explosions

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Operating instructions - MIBG burner
Decommissioning and disassembly

1.1.2 Gas supply

Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Caution!
Risk of fire and Keep suitable extinguishing devices
explosion! ready!
Gas
From escaping gas via Read and observe the information
leaking lines! signs!
Do not remove information
signs!
Replace missing or illegible infor-
mation signs immediately!

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 Danger source Hazard Measure

Keep ignition sources away!

Fire, naked light and smoking are
prohibited!
Keep suitable extinguishing devices
Caution! ready!
Risk of fire and
explosion! Read and observe the information
signs!
From escaping
liquefied gas via leaking Do not remove information
Liquid gas signs!
lines!
Replace missing or illegible infor-
Liquid gas is heavier mation signs immediately!
than air and collects f you smell gas, immediately close
close to the ground. the manual valve on the liquid-gas
tank!
If it penetrates into the drainage
system, notify the
competent authorities.

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Operating instructions - MIBG burner
Decommissioning and disassembly

Danger source Hazard Measure

Caution!
Danger of suffocation f you smell gas, immediately close
the manual valve on the liquid-gas
From escaping tank!
liquefied gas via leaking
lines! In the event of a massive uncon-
Liquid gas Liquid gas is heavier trolled escape of gas, immediately
than air and collects leave your workplace and inform the
close to the ground. responsible person on site!
Liquid gas can cause Always wear personal protective
suffocation by equipment!
displacing oxygen.

Caution!
Mixing of fuels Fuels must never be mixed!
Risk of explosion!

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2 Temporary decommissioning

2.1 General notes

Decommissioning of the plant for an extended period with subsequent recommis-

sioning is referred to as temporary decommissioning.

Temporary decommissioning may be necessary, for example, if extensive mainte-

nance and repairs are required or if the plant is not operated in winter.
Please read and observe the instructions on this in the chapter "Inspection, mainte-
nance, repair and troubleshooting".

Close and secure all doors and inspection and maintenance holes on the plant.

Keep the keys to all access points secure and inaccessible to unauthorised
persons.

The plant must be emptied before it can be shut down for a long period.

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Operating instructions - MIBG burner
Decommissioning and disassembly

2.2 Measures

NOTE
As the plant operative you are responsible for ensuring that all main swtiches are
disengaged and that the safety keys are removed.

The safety keys must be kept in a secure location to prevent actuation by

unauthorised persons.

Switch off the compressed air supply and release the pressure from all lines and
devices. This also includes the compressed air tanks.

CAUTION!
Danger of injuries!
There is still a risk of injury on decommissioned plant!
 The operator is responsible for ensuring that unauthorised personnel cannot
access the plant!

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3 Decommissioning the machine

3.1 General notes

If the machine is to be disassembled, the upstream and downstream system parts

must first be shut down.

NOTE
The plant must only be decommissioned by Ammann personnel or by expert or
qualfied personnel.

If this is not the case, Ammann accepts no liability for any damages that occur!

Close and secure all doors and inspection and maintenance holes on the plant.

Keep the keys to all accesses safe and inaccessible to unauthorised persons.

The plant must be emptied before it can be decommissioned fully.

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Operating instructions - MIBG burner
Decommissioning and disassembly

4 Preparing for dismantling

4.1 Checks prior to dismantling

Check that the plant has been fully emptied.

If any residue is left in the silos, tanks or other containers when dismantling, this
can result in serious injury.

Check that the control system and all components have been disconnected and
secured against unintentional restarting prior to dismantling according to the 5
safety rules.

Make sure that all of the protective equipment required for the transport is
available.
Use the transport locks provided for the component in question.

4.2 Power and operating supplies

The required power connections must continue to be present for the dismantling
work. The connections required are:
• Electrical connection
• Pneumatic connection

Only use the plugs and connectors provided.

Make sure that the seat of the connections is correct.

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5 Dismantling

5.1 General notes

The majority of components have been supplied pre-assembled. If the plant is to

be rebuilt at another location it is advisable when dismantling to disassemble the
components to this preassembled state.
If the plant is to be decommissioned fully and disposed of, complete dismantling is
advised.

When dismantling make sure that the disassembly sequence is followed

rigidly.
Fit the dismantling or transport locks as stated for each component.

Entry routes (stairs, platforms and ladders) are dismantled along with their related
components.
Dismantle all of the entry routes for a component, including guardrails and other
safety equipment, before dismantling the next component.

Power and operating supplies (electricity, compressed air, fuels, water), which
were connected to the respective lines to supply the plant, must be disconnected
from these lines before dismantling.
Only the supply lines to tools and dismantling equipment should remain connected.

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Decommissioning and disassembly

5.2 Disassembly of the burner

1 Disassemble all supply

lines.

2 Secure the burner to a crane using suitable lifting

tackle and the suspension eyes provided for this
purpose.

3 Loosen the burner fixing screws and deposit the

burner on a pallet.

4 If the burner will not be used again, disassemble it

and dispose of the parts correctly.

The burner is disassembled

If the burner is to be used again, load it onto a

suitable transport vehicle. Note the transport
dimensions.
The burner must be protected from atmospheric
exposure and soiling with a cover (e.g. plastic film).

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 Disposal

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Operating instructions - MIBG burner
Disposal

If the system is finally to be taken out of operation, safe and environmentally-

friendly disposal of all parts, especially operating- and auxiliary supplies, must be
provided for.
However, safe and environment-friendly disposal of all waste must be ensured
during the operation as well.

The components of the following materials do not pose a risk to the environment
and can also be reused:
• Mineral
• Filler
• Mineral wool (insulation)

The following list contains the names of the materials that are typical to that system,
as well as instructions for their disposal:
• The plant is made predominantly of steel
• After disassembly steel can be scrapped
• The plant's electronics must be disposed of taking into account national and
local regulations
• Electrical lines on the other hand belong to cable scrap
• The impurities of dirtied cleaning cloths may contain residues of mineral oils and
other environmentally-hazardous materials
• Dispose of dirty cleaning cloths in an environmentally responsible manner
and in compliance with local regulations
• Oils and greases are special waste and must be disposed of by specialist
companies according to local guidelines and regulations
• Observe local requirements for the disposal of plastic parts

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 • Used operating- and auxiliary supplies must be disposed of in conformity with
national and local environmental regulations
• Condensate from the compressor system must not be released into the
environment
• Run the condensate resulting from the thickening process into storage
vessels and dispose of it in conformity with national and local environmental
regulations
• The plant's containers may still contain residues of operating supplies
• These residues can be recycled as necessary

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Operating instructions - MIBG burner
Disposal

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 Annexe

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Operating instructions - MIBG burner
Annexe

1 Supplier documents

NOTE
Read and observe the operating instructions from the manufacturers of compo-
nents and supplied parts, in particular the instructions on operation and
maintenance.

You can find the relevant manufacturer's operating manuals in the component- and
supplier documents.

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1.1 Service schedule tables

Month: . . . . . . . . . Year: . . . . . .

Daily Weekly Monthly

Date Initials Date Initials Date Initials

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Operating instructions - MIBG burner
Annexe

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