PG30 - PG60 PG70 - PG81 Double-stage Light oil
Contents
1. Hoy 4 1 SB tw OH um kak p am 4 3 Am y X BV1 7 4 X Bv2 ma s ala Bn sd TSA gt rb 3 Bn _ 7 7 gt Fs Pail et LEE y lt q 11 7130403 0700 AL Alarm device kbr Cable link required only when no oil pre heater is used BV Fuel valve 1 Lock out reset button EK2 Remote lock out reset button FS Flame signal FSV Flame signal amplifier Contacts of control relay LED 3 colour signal lamps M Burner motor OW Release contact of oil pre heater t1 Pre purge time t3 Pre ignition time tn Post ignition time Beginning of start up sequence with burners using heater A Beginning of start up sequence with burners using no oil pre heater Controller output signals mmm Required input signals OH Oil pre heater QRB Photoresistive detector Blue flame detector R W 4 1 SB N IL OH gt 8 J MT gt 3 X gt 4 2 gt 6 t 44 gt FSs 4 gt2. 15 ADJUSTNIENIS 16 PIS HAG TAO TUG NOW u 16 19 Adjustments for burners with hydraulic ram 21 Adjusting the combustion head 22 Calibration of air pressure switch when provided 22 t X 23 OPERATION 23 je e 25 ROUTINE MAINTENANCE 25 25 Correct position of electrodes and combustion head 26 TRE TONING electrodos uuu u 27 Cleaning and replacing the detection
3. bl SW bl SW br 7130v02 0700 uA DC uA DC Bild DC microamperometer with an internal resistance of 5 max bl Blue SW Black br Brown SIEMENS OIL BURNERS AUTOMATIC CONTROLLER LOA24 Use LOA safety devices are intended for use solely with QRB photoresi stors for lighting and controlling low capacity forced air light oil burners with max capacity 30 kg h in accordance with standard DIN 4787 The One or two flamess are lit through electrical connections with or without post ignition To replace LAI AND WITH LOA LOA models can be used as replacement for LAI and LAB controllers by means of the adapter KF8819 and without the need to change the electrical wiring Because the LOA is smaller in dimensions when it is used with the adapter the external dimensions are almost identical which means that there is no need to move the reset button Performance The controllers just need plugging in so they can be mounted in almost any position on the burner on the electrical panel or on the control panel The casing is made of robust heat resistant plastic and contains e the thermic programmer operating a multiple switch control system with ambient temperature compensator e flame signal amplifier with flame relay e warning light indicating lockout and associated sealed reset button The plug in socket also made of robust heat resistant plastic con
4. PH o30 o9 11 12 13 18 14 14 18 15 18 16 16 18 030 035 0 36 0 40 1 2 1 5 1 6 1 7 1 7 1 8 1 9 1 9 2 0 2 1 2 1 2 2 2 4 0 40 045 0 45 0 50 0 50 0 55 1 6 2 1 2 2 2 3 24 2 5 2 6 27 2 7 2 8 2 9 3 0 3 3 0 55 065 065 0 70 2 1 27 2 8 2 9 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 4 2 0 70 0 75 0 75 0 80 0 80 0 85 2 5 3 3 3 4 3 6 3 7 3 9 4 0 4 1 4 2 4 4 4 5 4 6 5 0 0 85 1 00 1 00 1 10 3 3 4 2 4 4 4 6 4 8 5 0 5 2 5 3 5 5 5 7 5 8 60 6 5 1 10 120 36 46 48 59 52 54 56 58 60 62 63 65 71 120 1 35 4 0 5 2 5 4 5 7 5 9 6 1 6 3 6 5 6 7 69 7 1 7 3 150 44 57 60 63 65 68 70 73 75 77 79 amp i 89 150 _ 165 165 1 75 5 2 6 7 7 0 7 3 7 6 7 9 8 2 8 5 8 7 9 2 9 5 10 4 1 75 20 59 77 80 2 00 2 50 7 4 10 0 10 5 10 9 11 3 11 7 12 1 12 5 12 8 13 2 13 5 14 8 2 50 300 89 5 120 126 134 186 i44 145 150 154 158 162 178 30 3 25 96 12 4 13 1 13 6 14 2 14 7 15 2 15 7 16 2 16 7 17 2 17 6 19 3 3 25 3 50 3 50 4 00 4 00 4 50 13 3 17 2 18 1 18 9 19 6 20 4 21 1 21 8 22 5 23 1 23 8 244 26 7 4 50 5 00 5 00 6 50 7 00 7 50 8 00 17 8 23 0 24 1 25 2 26 2 27 2 22 2 28 7 30 1 31 5 32 7 34 0 6 50 7 00 7 50 8 00 9 50 10 00 11 00 12 00 13 00 13 50 14 00 15 00 16 00 17 00 18 00 19 00 19 50 20 00 22 00 24 00 25 00 26 7 32 6 42 1 44 2 46 1 48 0 49 8 51 6 53 3 54 9 56 5 58 1 59 6 65 2 40 0 51 7 54
5. remove check and clean the combustion head page 25 when reassembling carefully observe the measures on page 25 check the ignition electrodes and their ceramic insulators clean adjust and replace if necessary remove and clean the oil nozzles IMPORTANT do not clean the nozzles using metallic or sharp utensils use only solvents or steam at the end of maintenance operations refit the burner turn it on and check the combustion If in doubt replace the defec tive nozzle s In case of intensive use of the burner the nozzles must be replaced at the end of the working season check and carefully clean the flame detection photoresistor if necessary replace it and if in doubt check the detection current fol lowing the diagram on page 27 clean and grease levers and rotating parts Light oil filter maintenance For correct and proper servicing proceed as follows 1 cutoff the required pipe section 2 unscrew the filter cup remove the filtering cartridge wash it with gasoline if necessary replace it check the tightening O rings and replace them if necessary 4 replace the cup and restore the pipe line Removing the combustion head and the oil gun 1 Remove the top cover 2 remove the photoresistor from its seat unscrew the revolving connectors E in figure on the fuel pipes use 2 spanners to avoid loosening the connections attached to the distributor block 4 loosen screw to free th
6. rg 3 5 4 at 2 26 tz 2 0 1 OD 4 0 E gt lt lt 9 80 120 160 200 240 280 320 360 400 440 0 100 200 300 400 500 600 700 800 kW kW PG70 PG81 14 8 14 12 12 z 40 10 5 8 8 2 T 6 6 rz E OD 2 2 lt gt ea 0 5 di O c 200 400 600 800 1000 1200 1400 1600 1800 2000 200 300 400 500 600 700 800 900 1000 1100 1200 kW kW To get the input in kcal h multiply value in kW by 860 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature 15 C NOTE The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests but does not represent the regulation range of the machine On this diagram the maximum output point is usually reached by adj suting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is rea ched setting the combustion head to its MIN position During the first ignition the combustion head is set in order to find a compromise between the burner output and the generator specifications that is why the minimum output may be different from the Per formance curve minimum Overall dimensions C CL A B A BL pepe E F 8 R N Paso s00 150 340 650 270 230 50 121 151 282 MO 219 166 600 244 844 1042 300 285 585 153 1
7. e Remove the cover from the burner electrical panel e Execute the electrical connections to the power supply terminal board as shown check the direction of the fan pump motor see next paragraph and replace the electrical panel cover WARNING The burner is provided with a jumper between terminals 6 and 7 in the event of connecting the high low flame thermostat remove this jumper before connecting the thermostat IMPORTANT while connecting electric supply wires to burner s teminal block be sure that ground wire should be longer than phase and neutral ones Burners PG70 PG81 Burners PG30 PG60 PG70 PG81 not fitted with printed circuit fitted with printed circuit NE VI u ds da b BARRA DI TERRA EARTH TERMINAL ERDSCHLUSSKABEL d SOLO VERSIONI TRIFASE ONLY VERSIONS A A A OFT Gy NUR DREIPHASIGE O O NL 54678910 J
8. PG30 PG60 PG70 PG81 Double stage Light oil Burners MANUAL OF INSTALLATION USE MAINTENANCE DIB UNIGAS BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES TABLE OF CONTENTS 3 G u sas 5 GENERAL PEATUPES 5 How to interpret the burner s Performance curve 5 OCHIN E u u uuu uuu u 5 Span u 6 uu T 7 2 11121937 8 MOUNTINGS AND CONNEGTION etn u vd ken 9 uis onun muumini E n u as 9 FIUNO TNC DUmer to Ihe DONT 9 9 Hydraulic diagrams for light oil supplying circuits 10 Installation diagram of light oil pipes 11 Sizing the pipeline REM 12 About the use of fuel PUMPS cm 12 Connecting the light oil flexible hoses E 13 14 15 F liipin o qe
9. ab UN I JD 5 LB ay 400 Fig 6 B lt hb bse Bie L4 J MCT ST TAB LB r TERMINAL BLOCK FOR CONNECTION ON PRIN MV TED CIRCUIT MONOPHASE BURNERS ONLY NOS 2 2 LXER IS AU m Fig 7 Power supply terminal board on triphase burners only 7 o gt ad 21 618853 1 f Terminal board Fig 8 Fan pump motor rotation PG30 excluded Once the burner electrical connection is accomplished remember to check the motor rotation Motor must rotate in the direction shown on the casing In the event of wrong rotation reverse the three phase supply and check again the motor rotation NOTE Burners are provided for three phase 400 V supply and in the case of three phase 230 V supply it is necessary to modify the electrical connections inside the terminal box of the electric motor and replace the thermal cutout relay 15 UNIGAS 965 ADJUSTMENTS ATTENTION before starting the burner up be sure that the manual cutoff valves are open Be sure that the mains switch 15 closed Before starting up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pump seal to break ATTENTION During commissioning operations do not let the burner operate with insufficient air flo
10. 06 08 010 012 26 28 010 912 0 10 37 95 150 0 10 37 95 150 0 5 12 42 107 150 0 5 9 33 84 150 1 13 47 118 150 1 7 28 73 150 2 19 65 150 150 2 4 19 50 107 19 65 150 150 1 10 27 60 4 22 74 150 150 4 0 0 5 13 SUNTEC AN67C SUNTEC AN67C H m L m H m L m 010 912 214 916 010 212 214 916 0 6 27 70 150 0 6 27 70 150 0 5 7 31 79 150 0 5 5 23 62 132 1 8 34 87 150 1 4 20 53 114 2 13 48 121 150 2 2 13 36 79 3 13 48 121 150 3 0 6 19 44 4 15 55 138 150 4 0 0 2 9 SUNTEC AJ6 J6 E6 SUNTEC AJ6 J6 E6 H m L m H m L m 2010 912 014 916 10 012 214 916 0 5 13 27 47 0 5 13 27 47 0 5 6 15 30 52 0 5 4 12 23 41 1 7 17 33 58 1 3 10 20 36 2 9 21 40 70 2 2 6 13 24 3 10 24 47 80 3 0 3 7 13 4 12 28 53 92 4 0 0 0 2 SUNTEC J7CCC E7 SUNTEC J7CCC E7 H m L m H m L m 2010 212 014 916 10 912 014 916 0 2 7 16 29 0 7 16 29 76 0 5 2 8 18 33 0 5 6 14 26 67 1 3 10 20 37 1 5 12 22 58 2 4 12 25 44 2 2 7 14 40 3 5 14 29 52 3 0 3 7 21 4 6 17 33 59 4 0 0 0 3 L pipeline lenght in meters About the use of fuel pumps e Make sure that the by pass plug is not used in a single pipe installation because the fuel unit will not function properly and damage to the pump and burner motor could result e Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth thus obstructing them e After fi
11. etc unless expressly required to do so do not allow children or inexperienced persons to use equipment e The unit input cable shall not be replaced by the user In case of damage to the cable switch off the unit and contact qualified personnel to replace When the unit is out of use for some time the electric switch supplying all the power driven components in the system i e pumps burner etc should be switched off 3b FIRING WITH GAS LIGHT OR OTHER FUELS GENERAL The burner shall be installed by qualified personnel and com pliance with regulations and provisions in force wrong installation can cause injuries to people and animals or damage to property for which the manufacturer cannot be held liable e Before installation it is recommended that all the fuel supply system pipes be carefully cleaned inside to remove foreign matter that might impair the burner operation e Before the burner is commissioned qualified personnel should ins pect the following the fuel supply system for proper sealing b the fuel flow rate to make sure that it has been set based on the firing rate required of the burner the burner firing system to make sure that it is supplied for the desi gned fuel type d the fuel supply pressure to make sure that it is included in the range shown on the rating plate e thefuel supply system to make sure that the system dimensions are adequate to the burner firing rat
12. lt Only with LMO14 113A2 re ignition t3n t3n Z If pL e FS a m 7130402 0700 12 br brown sw black R Control thermostat or pressurestat SB Safety limit thermostat Si External primary fuse W Limit thermostat or pressure switch Z Ignition transformer t4 Interval from flame signal to release BV2 TSA Ignition safety time tw Waiting time for oil pre heating B Time of flame establishment C Operating position D Controlled shut down by R uC1 Microcontroller 1 uC2 Microcontroller 2 General unit Mains voltage AC 230 V 10 15 AC 120 V 10 15 Mains frequency 50 60 Hz External primary fuse Si 6 3A slow Power consumption 12 VA Mounting orientation optional Weight Degree of protection Perm cable lengths approx 200 g IP40 to be ensured through mounting max 3m at line capacitance of 100 pF m Detector cable laid separately 10m Remote reset laid separately 20m 14 LMO24 LMO44 Terminal 1 5A 5A 5A Terminals 3 and 8 3A 5A 5A Terminals 4 5 and 10 1A 1A 1A Terminals 6 1A 1A 2A Flame supervision with QRB and QRC QRB QRC Min detector current required with flame 45 7OUA Min detector current permitted without flame 5 5 pA 5 5 pA Max possible with flame tipically 100 pA 100 pA Measurement circuit for detector current 11 12 LMO 11 12 1 7130 01 0700
13. 218021101 2180256 SOLENOID VALVE SIRAI 2190419 2190419 2190419 SOLENOID VALVE OROFLAM 2190638 2190638 2190638 HYDRAULIC RAM 2330056 2330056 2330056 2330056 FLEXIBLE HOSES 2340001 2340001 2340002 2340002 ACTUATOR BERGER 2480057 2480057 2480041 2480041 ACTUATOR SIEMENS 24800A3 24800A3 24800A3 24800A3 PHOTORESISTOR mod SIEMENS QRB 2510003 2510003 2510003 2510003 MOTOR PUMP JOINT 2540055 2540104 2540116 2540116 PUMP mod SUNTEC 2590170 2590101 2590103 2590109 PUMP mod DANFOSS I a 2 2590320 NOZZLE 0 75 6 00 GPH 45 2610002 2610002 NOZZLE 0 75 6 00 GPH 60 2610004 2610004 2610004 NOZZLE 6 50 35 GPH 45 2610016 2610016 2610016 NOZZLE 6 50 35 GPH 60 2610017 2610017 COMBUSTION HEAD 3060173 3060174 3060141 30601A7 BLAST TUBE standard 3090033 3090034 30900A9 30900G8 BLAST TUBE extended 3090035 3090038 30900B2 30900G9 IGNITION CABLES 6050010 6050109 6050133 6050133 PRINTED CIRCUIT BOARD 6100552 6100552 6100552 29 C I B UNIGAS M03965CE ELECTRICAL WIRING DIAGRAMS Wiring diagram 07 348 BV Fan motor contactor coil CTV Fan motor thermal cutout terminals CV Fan motor contactor terminals EVG1 Solenoid valve 1st stage EVG2 Solenoid valve 2nd stage F Fuses FR Photoresistor IG Main switch IL Auxiliaries line switch L Phase LAF Burner in high flame signaling lamp LB Flame lockout signaling lamp LBF Burner in low flame signaling lamp LEVG1 Opening of solenoid valve EVG1
14. Fig 1 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 Burner model identification Burners are identified by burner type and model Burner model identification is described as follows Type PG60 Model AB S A 1 2 3 4 5 6 1 BURNER PG30 PG60 PG70 PG81 2 FUEL G Light oil A Biodiesel 3 OPERATION AB Double stage 4 BLAST TUBE S StandardStandard L Extended 6 BURNER VERSION A Standard M With hydraulic ram C I B UNIGAS M03965CE Technical specifications suem _ m Foar 0 000 __ NOTE Choosing nozzle for light oil consider Hi equal to 10200 kcal kg NOTE ON THE BURNER WORKING SERVICE e Burners provided with Siemens LOA24 44 control box for safety reasons one controlled shutdown must take place every 24 hours of continuous operation e Burners provided with Siemens LMO24 44 control box the control box automatically stops after 24h of continuous working The control box immediately starts up automatically UNIGAS 965 Performance PG30 PG60 6 9 8 5 7 o 4 6
15. Installation diagram of light oil pipes A PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL From tank Totank Fig 5 Double pipe system The burner is supplied with filter and flexible hoses all the parts upstream the filter and downstream the return flexible hose must be installed by the customer As far as the hoses connection see the related paragraph Key Only for installations with gravity siphon or for 1 Burner ced circulation feed systems If the device installed 2 Flexible hoses fitted is a solenoid valve a timer must be installed to 3 Light oil filter fitted delay the valve closing 4 Automatic interceptor The direct connection of the device without a timer may cause pump breaks 5 One way valve 6 Gate valve 7 Quick closing gate valve outside the tank or boiler rooms The provided pumps can be installed both into single pipe and double pipe systems Single pipe system a single pipe drives the oil from the tank to the pump s inlet Then from the pump the pressurised oil is driven to the nozzle a part comes out from the nozzle while the othe part goes back to the pump In this system the by pass plug if provided must be removed and the optional return port on the pump s body must be sealed by steel plug and washer Double pipe system as for the single pipe system a pipe that connects the tank to the pump s inlet is used besides another pip
16. VB VRT VRT VRT position position Note loosen VB screw to free the VRT screw adjust the head and then remember to fasten VB again Attention if it is necessary to change the head position repeat the air and gas adjustments described above Calibration of air pressure switch when provided To calibrate the air pressure switch proceed as follows Remove the transparent plastic cap e Once air and gas setting have been accomplished startup the burner e During the pre purge phase the operation turn slowly the adjusting ring nut VR in the clockwise direction to increase the adju sting pressure until the burner locks out then read the value on the pressure switch scale and set it to a value reduced by 15 Repeat the ignition cycle of the burner and check it runs properly Refit the transparent plastic cover on the pressure switch 22 UNIGAS 965 LIMITATIONS OF USE THE BURNER 15 AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CON NECTED TO A HEAT GENERATOR E G BOILER HOT AIR GENERATOR FURNACE ETC ANY OTHER USE IS TO BE CONSI DERED IMPROPER AND THEREFORE DANGEROUS THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE ENTRUSTING THE INSTALLATION OF IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORI SED BY THE COMPANY MANUFACTURING THE BURNER A FUNDAME
17. fasten the ignition electrodes remove the electrodes and replace them referring to the values quoted on Fig 16 OI C0 nm Cleaning and replacing the detection photoresistor To clean replace the photoresistor proceed as follows disconnect the system from the electrical power supply shut off the fuel supply remove the photoresistor from its slot clean it using a clean cloth do not use any burner cleansing sprays if necessary replace it insert the photoresistor into its slot Checking the detection current To measure the detection signal follow the diagram on the next picture the signal is not in the advised range check the electrical contacts the cleaning of the combustion head the position of the photore sistor and if necessary replace it MC TERMINAL BLOCK Fn LHG24 Maximum current intensity without flameMini current intensity with flame Maximum current intensity without flame 5 5pA Maximum possible current intensit with flamey 45pA 100pA 100pA Fig 17 Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner s main switch to O Off position 2 disconnect the power mains 3 close the fuel manual valve of the supply line Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials 27 UNIGAS 965 TROUBLES
18. no extraneous light Undervoltage e Safety shut down in the operating position takes place should the mains voltage drop below about AC 165 V e Restart is initiated when the mains voltage exceeds about AC 175 V Time supervision oil pre heater If the oil pre heater s release contact does not close within 10 minutes the burner control will initiate lock out Controlled intermittent operation After no more than 24 hours of continuous operation the burner control will initiate an automatic safety shut down followed by a restart Control sequence in the event of fault If lock out occurs the outputs for the fuel valves and the ignition will immediately be deactivated 1 second After a mains failure After voltage has fallen below the Restart undervoltage threshold In the event of a premature faulty signal during 1 Prevention of start up lock out after no more than 40 seconds If the burner does not ignite during oqe it inen t TSA TSA In the event the flame is lost during Max 3 repetitions followed operation by lock out Oil pre heater s release contact does Lock out not close within 10 min Lock out In the event of lock out the LMO remains locked lock out cannot be changed and the red signal lamp will light up This status is also maintai ned in the case of a mains failure Resetting the burner In the event of a premature faulty flame signal during
19. photoresistor 00 9 27 27 Seasonal SIOD uuu 27 PINT OVS gt u unu uu 27 TROUBLE TAIN 28 oP E be MN EN 29 ELECTRICAL WIRING DIAGRAMS ieoi 30 APPENDIX WARNINGS THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO DUCT INSTALLATION AND MAINTENANCE THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS IN THE SECOND SECTION OF THIS MANUAL WE HIGHLY RECOMMEND TO READ IT CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE GENERAL INTRODUCTION The equipment must be installed in compliance with the regulations in force following the manufacturer s instructions by qualified per sonnel Qualified personnel means those having technical knowledge in the field of components for civil or industrial heating systems sanitary hot water generation and particularly service centres authorised by the manufacturer Improper installation may cause injury to people and animals or dam
20. second 3 seconds Connection diagram and internal diagram LMO14 EK1r lt N pC1 HC control uC2 LED lY gt FSV 200 0 OOOO SB R OW gt EKO W xx j OH US Ta N ORC Si SW L M Z BV1 7130a01e 0700 LMO24 LMO44 uC contol o E 7130 02 0700 Control sequence LMO14 LMO24 LMO44
21. see picture 11 The cam that enables the second stage solenoid valve to open EVG2 valve must be set between the other two cams 12 drive the burner to high flame by means of the thermostat TAB if TAB is not present insert a bridge between T6 and T8 contacts on the related connector see page 15 13 adjust the high flame air flow rate acting on the related cam in order to get the right combustion values 14 drive the burner to low flame by means of the thermostat TAB or remove the bridge between T6 and T8 contacts on the related connector see page 15 15 adjustthe low flame air flow rate acting on the related cam in order to get the right combustion values 16 Replace the actuator cover PG60 PG70 PG81 1 remove the electric panel cover 2 prime the oil pump by means of the related contactor check the motor rotation and keep pressed for some seconds until the oil cir cuit is charged 3 bleed the air from the M pressure gauge port of the pump see picture below loosening the cap without removing it then release the contactor Suntec AJ6 Suntec J6 4 Remove actuator cover 5 Turn the burner on by means of its main switch A Fig 13 if the burner locks LED on in control panel press the RESET button C on the control panel Fig 13 page 23 6 the burner up by means of the thermostat series and wait until the pre purge time comes to an end 7 Keep the burner to the low flame stage by disconnecti
22. signaling lamp LEVG2 Opening of solenoid valve EVG2 signaling lamp LOA44 SIEMENS control box LMO44 SIEMENS control box LT Fan motor thermal cutout signaling lamp LTA Ignition transformer in operation signaling light MA Burner supply terminal board MC Burner components connection terminal block MV Fan motor N Neutral Pl Priming pushbutton 2nd nozzle PS Flame reset after lockout pushbutton ST Thermostats or pressure switches group STA SQN Actuator for air damper TA Ignition transformer TAB High low flame thermostat if fitted remove the bridge between terminals 6 and 7 on terminal board MA TV Fan motor thermal cutout ATTENTION 1 Electric supply 400V 50 2 a c 2 Don t reverse phase and neutral 3 Make sure that the burner is properly hearted 30 FU1 0 L1 L2 L3 MA MA MA MC FR Oma Oma MA 1 35 dpe MC VENTILATORE FAN MOTOR 2 0 2 0 2 0 PO as 1 0 8 10 h E Data 29 10 1996 u 1 SEGUE TOTALE 2 4 pis 07 348 SIEMENS 5232 2 ooo oo SIEMENS SQN72 2A 4 A20 PI 36 EVG1 EVG2 9 LEVG1 3 37 19 2 e P jc cte Data an 1 2 SEGUE TOTALE Dis N 07 348 3 4 SUPPLY TERMINAL BOARD D QUADRO QG MORSETTIERA MORSETTIERA A
23. the pushbutton C on the frontal panel of the electrical board e Check the thermostats or pressure switches enable the burner to operate e The burner start up cycle begins the contrl box activates the burner fan and meanwhile the ignition transformer signalled by the light H on the front panel pre purgephase lasts some seconds according to the control box type provided with the burner e end of pre purgue time the first stage solenoid valve EV1 is energised indicated by the LED D on the display panel and the burner lights e The ignition transformer remains on for some seconds after the flame is lit post ignition time after this time it is cut out and the light H tunrs off e The burner is on in the low stage led G on after 5 15 sec according to the control box type it goes into the two stage mode and turns automatically to high flame or remains in low flame according to the system demands High or low flame opera tion is shown by the light F high flame or light G low flame The light E is on when the solenoid valve of the high flame is open feeding the nozzle of the second stage 23 UNIGAS 965 control panel 61000E8 A lt o T U gt Fig 14 Reset pushbutton version with con Fig 13 trol box without remote reset Main switch Burner lockout light Reset button for flame
24. tw Whenever lock out occurs the burner control can immediately be reset do this keep control the lock out reset button depressed for about 1 second lt 3 seconds Ignition program with LMO24 113A2 If the flame is lost during TSA the burner will be reignited but not later than at the end of TSAmax This means that several ignition attempts can be made during TSA refer to Program sequence Limitation of repetitions If the flame is lost during operation a maximum of 3 repetitions can be made If the flame is lost for the 4th time during operation the burner will initiate lock out The repetition count is restarted each time controlled switching by R W SB takes place Operation resetting the burner control and for activating deactivating the Lock out reset button EK is the key operating element for e diagnostic functions The multicolour LED is the key indicating element for both visual diagnosis and interface diagnosis S 1 Yellow Green Colour code table Status Colour code Colour Oil pre heater heats Yellow waiting time tw Yellow off controlled Operation flame o k 000000000000 Green Operation flame not o k omomomomomo Green off Undervoltage 15151515161 Yellow red Fault alarm SSSSSSSSSSS Red Output of fault code refer off to Fault code table Extraneous light prior to burner start
25. up Interface diagnosis SSSSSSSSSSSSSS Red flicker light Key m Off Yellow 5 Diagnosis of cause of fault After lock out the red fault signal lamp remains steady on In that condition the visual diagnosis of the cause of fault according to the error code table can be activated by pressing the lock out reset button for more than 3 seconds Error code table Possible cause Blink code 2 blinks No establishment of flame at the end of TSA e Faulty or soiled fuel valves e Faulty or soiled flame detector e Poor adjustment of burner no fuel e Faulty ignition 3 blinks 4 blinks 5 blinks 6 blinks 7 blinks Xe x xx Free Extraneous light on burner startup Free Free Too manny losses of fleme during operation limitattion og the number of repetitions e Faulty or soiled fuel valves e Faulty or soiled flame detector e Poor adjustment of burner 8 blinks kkkkkkkk 9 blinks kkkkkkkkk 10 blinks ok A x x x xx Time supervision oil pre heater Free Wiring error or internal error output contacts During the time the cause of fault is diagnosed the control outputs are deactivated e Burner remains shut down e Fault status signal AL at terminal 10 is activated The diagnosis of the cause of fault is quit and the burner switched on again by resetting the burner control Press lock out reset button for about 1
26. 2 56 6 58 9 61 2 63 3 65 4 67 4 69 4 71 3 73 1 80 1 47 5 61 3 64 3 67 1 72 5 75 0 77 5 79 9 82 2 84 4 86 6 94 9 56 4 72 7 76 3 79 7 82 9 86 1 89 1 92 0 94 9 97 6 100 3 102 9 112 7 34 5 36 1 37 7 65 2 84 2 88 3 92 3 39 3 40 8 99 7 103 2 106 6 109 8 113 0 116 1 119 1 28 1 29 1 30 0 30 8 31 7 32 5 35 6 35 2 36 3 37 4 38 5 39 6 40 6 44 5 42 2 43 6 44 9 46 2 47 5 48 7 53 4 7965 998 1027 1056 188 130 5 790 9 50 10 00 11 00 12 00 13 00 13 50 14 00 15 00 16 00 17 00 18 00 19 00 19 50 20 00 22 00 24 00 25 00 2800 774 996 1044 105 118 1178 213 1259 1298 1936 1372 1542 2500 2 UNIGAS 965 Prior to start up the burner make sure that return pipe to tank is obstructed Any obstruction would cause the pump seal to break e Check that the combustion parameters are in the suggested limits Priming the pump and adjustments PG30 Before carrying out the adjustment it is necessary to start up the fuel pump proceeding as follows 1 remove the electric panel cover 2 remove the solenoid valve coil B connector on pump see picture below to avoid the light oil to get into the combustion chamber 3 start the burner up by means of the control panel switch switch to ON Fig 13 and by means of the thermostats pressure switches series when the EVG lamp turns to on see cha
27. 82 350 269 190 Paro ees 450 95 1145 360 350 710 198 228 375 Wio 330 233 655 340 490 1025 1175 S70 365 735 234 264 375 S30 238 B C 2 measure referred to burner fitted with standard blast tube BL CL 2 measure referred to burner fitted with extended blast tube 3O08S96 0W SVOINN UNIGAS 965 MOUNTINGS AND CONNECTIONS Packing The burners are dispatched in wooden packages whose dimensions are PG30 1000 x 550 x 460 mm L x P x H PG60 1200 x 670 x 540 mm L x P x H PG70 PG81 1280 x 850 x 760 mm L x P x H Packing cases of this kind are affected by humidity and are not suitable for stacking The fol lowing are placed in each packing case burner light oil flexible hoses light oil filter gasket to be inserted between the burner and the boiler envelope containing this manual To get rid of the burner s packing follow the procedures laid down by current laws on disposal of materials Fitting the burner to the boiler To install the burner into the boiler proceed as follows CONDO OF WN make a hole on the closing door of the combustion chamber as described on paragraph Overall dimensions place the burner to the boiler lift it up and handle it according to the procedure described on paragraph Handling the burner place the 4 stud bolts 5 on boiler s door according to the bur
28. HOOTING THE BURNER DOESN T START THE BURNER REPEATS PRE PURGE NOISY FUEL PUMP THE BURNER DOESN T START AND STOPS THE BURNER STARTS AND STOPS THE BURNER DOESN T SWITCH TO HIGH FLAME THE BURNER STOPS DURING OPERATION THE BURNER STOPS AND REPEATS THE CYCLE DURING OPE RATION MAIN SWITCH OPEN LINE FUSE INTERVENTION MAX PRESSURE SWITCH FAULT FAN THERMAL CUTOUT INTERVENTION AUXILIARY RELAIS FUSES INTERVENTION CONTROL BOX FAULT ACTUATOR FAULT SMOKEY FLAME IGNITION TRANSFORMER FAULT IGNITION ELECTRODE DIRTY OR WRONG POSITIONED DIRTY NOZZLE FUEL SOLENOID VALVE DEFECTIVE PHOTORESISTOR DIRTY OR DEFECTIVE HI LO FLAME THERMOSTAT DEFECTIVE WRONG POSITION OF ACTUATOR CAMS FUEL PRESSURE TOO LOW DIRTY FUEL FILTERS 28 SPARE PARTS UNIGAS 965 Desription Code PG30 PG60 PG70 PG81 LOA24 2020445 LOA24 2020445 CONTROL BOX LMO24 2020453 1 24 2020453 44 2020455 44 2020455 ELECTRODES 2080205 2080205 2080205 2080205 LONG IGNITION ELECTRODES 2080206 2080206 2080206 2080206 FUEL FILTER 2090025 2090025 2090025 2090025 GASKET 2110004 2110013 2110033 2110033 FAN WHEEL 2150006 2150043 2150018 2150069 IGNITION TRANSFORMER 2170302 2170302 2170302 2170302 ELECTRIC MOTOR 2180714 2180020
29. ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it Note Specifications and and data subject to change Errors and omissions excepted
30. LIMENTAZIONE 1 IG ST TAB LB 4 00V a c SERVOCOMANDO SERRANDA ARIA AIR DAMPER ACTUATOR BERGER STA6B2 41 62N13L s MV ALTA FIAMMA HIGH FLAME SOSTA BASSA FIAMMA STAND BY AND LOW FLAME APERTURA EVG2 OPEN EVG2 ee gt amp m QUADRO QG MORSETTIERA MORSETTIERA COMPONENT BRUCIATORE BURNER COMPONENT TERMINAL BOARD VG SQN72 2A4A20 6 EVG1 SERVOCOMANDO SERRANDA ARIA Al DAMPER ACTUATOR ALTERNA TIVE BERGER STA6B2 41 62N13L ROSSO RED BLU BLUE IV IV BLACK ALTA FIAMMA HIGH FLAME SOSTA BASSA FIAMMA STAND BY AND LOW FLAME APERTURA EVG2 OPEN EVG2 Data dese 5 SEGUE TOTALE pis 07 348 4 p wr Jp E FOTORESISTENZA RILEVAZIONE PHOTORESISTOR FLAME DETECTOR FUSBLIDIUNEA MAINS SWITCH AUXILIARY LINE SWITCH AN MOTOR CONTACTOR URNER IN HIGH FLAME INDICATOR LIGHT INDICATOR LIGHT FOR OPENING OF ELECTRO VAL VE EVG1 3 KM1 5 UJ UJ I Til Til N TI gt ES c c BF BURNER LOCK OUT INDICATOR LIGHT O BURNER IN LOW FLAME INDICATOR LIGHT _ O INDICATOR LIGHT FOR OPENING OF ELECTRO VALVE SIEMENS SQN72 2A4A20 AIR DAMPER ACTUAT
31. NDO STADIO BRUCIATORE STAGE BURNER START BUTTON FLAME UNLOCK BUTTON PULSANTE SBLOCCO FIAMMA FLAME UNLOCK BUTTON IEMENS SQN72 2A4A20 SERVOCOMANDG SERRANDA AIR DAMPER ACTUATOR ERIES OF THERMOSTATS OR PRESSURE SWITCHES GNITION TRANSFORMER SAFETY THERMOSTAT OR PRESSURE SWITCH BARRA DI TERRA EARTH TERMINAL ALIMENTAZIONE AUSILIARI BRUCIATORE BURNER AUXILIARY SUPPLY VEDI FOGLIO 1 SEE SHEET 1 TS teH gt FU4 5 MV N Data 1071272007 PRES AE SEGUE TOTALE 18 141 QG MORSETTIERA COLLEGAMENTO LINEA MOTORE TRIFASE MOTOR THREE PHASES AND ELECTRIC SUPPLY CONNECTION TERMINAL BOARD PE L L L U MIN 6 3A T MAX 10A T UJ 3 Loo E L 400V a c Dis N SIEMENS BURNERS AUTOMATIC CONTROLLER SIEMENS LMO14 LMO24 LMO44 The LMO burner controls are designed for the start up and supervision of single or 2 stage forced draught oil burners in intermittent operation Yellow burning flames are supervised with photoresistive detectors QRB blue burning flames with blue flame detectors QRC In terms of housing dimensions electrical connections and flame detectors the LMO are identical to the LOA oil burner controls Preconditions for startup e Burner control is reset e All contacts in the line are closed e Noundervoltage e Flame detector is darkened
32. NTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR S CONTROL AND SAFETY UNITS CONTROL THERMOSTAT SAFETY ETC WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE E G DISCONNECTION EVEN PARTIAL OF THE ELECTRICAL LEADS OPENING THE GENERATOR DOOR DISMANTLING OF PART OF THE BURNER NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE OPERATE ONLY THE MAIN SWITCH WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH AND ON THE RESET BUTTON IN CASE OF A BURNER SHUT DOWN RESET THE CONTROL BOX BY MEANS OF THE RESET PUSHBUTTON IF A SECOND SHUT DOWN TAKES PLACE CALL THE TECHNICAL SERVICE WITHOUT TRYING TO RESET FURTHER WARNING DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR COUPLING FLANGE CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT OPERATION ATTENTION before starting the burner up be sure that the manual cutoff valves are open Be sure themains switch is closed Read carefully th Warnings chapter e the switch A on the burner control panel to the ON position e Check the control box is not locked LED on in this case press the reset button accessible from the upper side of the electrical board see next picture or
33. OR ALTERNATIVE SERIE TERMOSTATI PRESSOSTATI SERIES OF THERMOSTATS OR PRESSURE SWITCHES GNTION TRANSFORMER TAB ITERMOSTATO PRESSOSTATO ALTA BASSA FIAMMA HIGH LOW THERMOSTAT PRESSURE SWITCHES TERMICO MOTORE VENTILATORE FAN MOTOR THERMAL Data 2971071996 PERCER Revisione 05 5 4 TOTALE pis 07 348 4 UNIGAS 965 Wiring diagram 18 141 BV CN1 CTV EVG1 EVG2 F FU FILTRO FQ FR IG IL L LAF LB LBF LEVG1 LEVG2 LF LOA24 LMO24 LOA44 LT LTA MC1 MV N PI PS ST STA SQN TA TAB TV ATTENTION Fan motor contactor coil Connector for triphase version Fan motor thermal cutout terminals Fan motor contactor terminals Solenoid valve 1st stage Solenoid valve 2nd stage Fuses FU 6 3A triphase versions FU 10A monophase versions Line noise filter optional Connector on electrical board front panel Photoresistor Main switch Auxiliaries line switch Phase Burner in high flame signaling lamp Flame lockout signaling lamp Burner in low flame signaling lamp Opening of solenoid valve EVG1 signaling lamp Opening of solenoid valve EVG2 signaling lamp Burner in operation signaling lamp SIEMENS control box SIEMENS control box SIEMENS control box Fan motor thermal lockout intervention signaling lamp only triphase versions Ignition transformer in operation signaling lamp Terminal block for triphase supply and triphase motor connection Fan motor N
34. VENTILATORE AN MOTOR LINE FUSES USIBILE DI LINEA INE FUSE NTERRUTTORE LINEA BRUCIATORE URNER LINE SWITCH NTERRUTTORE GENERALE AINS SWITCH NTERRUTTORE LINEA AUSILIARI UXILIARY LINE SWITCH CONTATTORE MOTORE VENTILATORE AN MOTOR CONTACTOR rn m lt m lt mn F m APPARECCHIATURA MONITOR DEVICE COD 6100552 O STA6B2 41 STA4 5B0 37 SERVOCOMANDO SERRANDA ARIA ALTERNATIVO AIR DAMPER ACTUATOR ALTERNATIVE SERVOCOMANDO SERRANDA ARIA AIR DAMPER ACTUATOR AIR DAMPER ACTUATOR ALTERNATIVE STA4 5B0 37 037 63N30L STA6B2 41 62N13L SQN72 2 A4A20 ALTA ST2 ALTA FIAMMA ROSSO ALTA FIAMMA HIGH FLAME HIGH FLAME RED HIGH FLAME I SOSTA ACCENSIONE E BASSA FIAMMA ST1 SOSTA ACCENSIONE E BASSA FIAMMA II BLU SOSTA ACCENSIONE E BASSA FIAMMA STAND BY IGNITION AND LOW FLAME STAND BY IGNITION AND LOW FLAME Il BLUE STAND BY IGNITION AND LOW FLAME I APERTURA EVG2 MV APERTURA EVG2 IV NERO APERTURA EVG2 OPEN EVG2 OPEN EV02 IV BLACK OPEN EVG2 SERVOCOMANDO SERRANDA ARIA ALTERNATIVO SIGLA ITEM___ DESCRIZIONE F1 NDICATOR LIGHT BURNER OPERATION LOA2 LMO2 LMO4 APPARECCHIATURA CONTROLLO FIAMMA CONTROLBOX T NDICATOR LIGHT FOR MOTOR OVERLOAD THERMAL CUTOUT LAMPADA SEGNALAZIONE TRASFORMATORE DI ACCENSIONE GNITION TRANSFORMER INDICATOR LIGHT AN MOTOR PI PULSANTE INNESCO SECO
35. age to property for which the manufacturer cannot be held lia ble e Remove all packaging material and inspect the equipment for inte grity In case of any doubt do not use the unit contact the supplier The packaging materials wooden crate nails fastening devices plastic bags foamed polystyrene etc should not be left within the reach of chil dren as they may prove harmful Before any cleaning or servicing operation disconnect the unit from the mains by turning the master switch OFF and or through the cut out devices that are provided e Make sure that inlet or exhaust grilles are unobstructed Incase of breakdown and or defective unit operation disconnect the unit Make no attempt to repair the unit or take any direct action Contact qualified personnel only Units shall be repaired exclusively by a servicing centre duly authorised by the manufacturer with original spare parts Failure to comply with the above instructions is likely to impair the unit s safety To ensure equipment efficiency and proper operation it is essential that maintenance operations are performed by qualified personnel at regular intervals following the manufacturer s instructions e When a decision is made to discontinue the use of the equipment those parts likely to constitute sources of danger shall be made har mless Incase the equipment is to be sold or transferred to another user or in case the original user should mov
36. control device only burners fitted with remote reset for flame control device Signalling light of the opening of 1st stage solenoid valve Signalling light of the opening of 2nd stage solenoid valve High flame operation signalling light Low flame operation signalling light Ignition transformer in operation signalling light Overload tripped signalling light PG30 excluded 24 UNIGAS M03965CE At least once year carry out the maintenance operations listed below In the case of seasonal servicing it is recommended to carry out the maintenance at the end of each heating season in the case of continuous operation the maintenance is carried out every 6 months WARNING ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL ROUTINE MAINTENANCE e Check and clean the cartdrige of the fuel filter replace it if necessary see next paragraph e carefully check the fuel flexible hoses for leaks check and clean the filter on the fuel pump bilter must be thoroughly cleaned at least once in a season to ensure correct working of the fuel unit To remove the filter unscrew the four screws on the cover When reassemble make sure that the filter is mounted with the feet toward the pump body If the gasket between cover and pump housing should be damaged it must be replaced
37. ctive 2004 108 CEE on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for house hold and similar purposes Safety requirements Light oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for house hold and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Heavy oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards CEI EN 60335 1 Household and similar electrical appliances SafetyPart 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Light oil burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electroma
38. e RESET pushbutton If a second shut down takes place call the Technical Service without trying to RESET further e The unit shall be operated and serviced by qualified personnel only in compliance with the regulations in force 3 GENERAL INSTRUCTIONS DEPENDING ON FUEL USED 3a ELECTRICAL CONNECTION For safety reasons the unit must be efficiently earthed and installed as required by current safety regulations e is vital that all saftey requirements are met In case of any doubt ask for an accurate inspection of electrics by qualified personnel since the manufacturer cannot be held liable for damages that may be caused by failure to correctly earth the equipment e Qualified personnel must inspect the system to make sure that it is adequate to take the maximum power used by the equipment shown on the equipment rating plate In particular make sure that the system cable cross section is adequate for the power absorbed by the unit e No adaptors multiple outlet sockets and or extension cables are per mitted to connect the unit to the electric mains An omnipolar switch shall be provided for connection to mains as required by the current safety regulations The use of any power operated component implies observance of a few basic rules for example do not touch the unit with wet or damp parts of the body and or with bare feet do not pull electric cables do not leave the equipment exposed to weather rain sun
39. e and that the system is equipped with all the safety and control devices required by the regulations in force e When the burner is to remain idle for some time the fuel supply tap or taps should be closed SPECIAL INSTRUCTIONS FOR USING GAS Have qualified personnel inspect the installation to ensure that a the gas delivery line and train are in compliance with the regulations and provisions in force all gas connections are tight the boiler room ventilation openings are such that they ensure the air supply flow required by the current regulations and in any case are sufficient for proper combustion not use gas pipes to earth electrical equipment Never leave the burner connected when not in use Always shut the gas valve off In case of prolonged absence of the user the main gas delivery valve to the burner should be shut off Precautions if you can smell gas a do not operate electric switches the telephone or any other item likely to generate sparks b immediately open doors and windows to create an air flow to purge the room C close the gas valves contact qualified personnel Do not obstruct the ventilation openings of the room where gas appliances are installed to avoid dangerous conditions such as the development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Dire
40. e and leave the unit behind make sure that these instructions accompany the equipment at all times so that they can be consulted by the new owner and or the installer e Forall the units that have been modified or have options fitted then original accessory equipment only shall be used e This unit shall be employed exclusively for the use for which it is meant Any other use shall be considered as improper and there fore dangerous The manufacturer shall not be held liable by agreement or otherwise for damages resulting from improper installation use and failure to comply with the instructions supplied by the manufacturer 2 SPECIAL INSTRUCTIONS FOR BURNERS The burner should be installed in a suitable room with ventilation openings complying with the requirements of the regulations in force and sufficient for good combustion Only burners designed according to the regulations in force should be used e This burner should be employed exclusively for the use for which it was designed Before connecting the burner make sure that the unit rating is the same as delivery mains electricity gas oil or other fuel Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stopped When the decision is made to discontinue the use of the burner the user shall have qua
41. e that connects the pump s return port to the tank as well The excess of oil goes back to the tank this installation can be considered self ble eding If provided the inside by pass plug must be installed to avoid air and fuel passing through the pump Burners are factory set for double pipe systems They can be suited for single pipe system recommended in the case of gravity feed as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rotation referring to the pump shaft Caution Changing the direction of rotation all connections on top and side are reversed PG30 Suntec AS57 PG60 Suntec 67 PG70 Suntec AJ6 PG81 Suntec J6 Suntec AS57 67 Suntec AJ6 Suntec 46 11 Bleeding in two pipe operation is automatic it is assured a bleed flat on the piston In operation the plug of a pressure gauge port must be loosened until the air is evacuated from the system Sizing the pipeline UNIGAS 965 ISyphon twin pipe feed Twin pipe suction feed SUNTEC AS57C SUNTEC AS57C H m L m H m L m
42. e threaded rod AR then screw out the 2 screws V holding the washer and the screw again 5 remove the whole assembly as shown in figure 6 clean the combustion head and the oil gun by means of a vacuum cleaner to scrape off the scale use a metallic brush Note to replace the combustion head reverse the procedure described above 25 UNIGAS 965 Correct position of electrodes and combustion head AR AN Fig 15 ATTENTION avoid the electrodes to in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the electrodes position after any intervention on the combustion head To guarantee a good ignition the measures showed on the next picture Fig 16 must be observed Be sure to tight the screw on the electrodes group before reassembling the combustion head 9 11 3 5 4 5 C 8mm D 3mm Fig 16 26 UNIGAS 965 Replacing the ignition electrodes ATTENTION avoid the electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the electrodes position after any intervention on the combustion head To replace the ignition electrodes proceed as follows 1 remove the burner cover disconnect the electrodes cables remove the combustion head see par Removing the combustion head loose screw that
43. ease the opening angle of the actuator move the cam to a lower position the actuator will close to the new position of ST1 to increase the low flame position move the cam higher to the required position make the bridge between the 6 and 7 terminals only for a while and then remove it immediately the actuator will move for just few degrees towards the high flame then it will move down to the new ST1 low flame position now charge the oil ciruit of the second nozzle by pressing 1 button see next picture MA P1 the 3rd cam drives the opening of the 2nd stage solenoid valve EVG2 and must be set between the other two cams however nearto ST1 The cycle goes on and il the thermostat TAB is connected the control box drives the burner to high flame If there is not theTAB thermostat place a bridge between terminals 6 and 7 on the MA terminal block see picture above By means of ST2 cam adjust the air flow rate in high flame stage to increase the high flame position and consequently to increase the degrees move the cam to a higher position the actuator will move to the new ST2 position to decrease the high flame position move the cam to a lower position remove the bridge between 6 and 7 terminals only for a while then replace it the actuator will shift just few degrees towards the low flame position and then will move to the new high flame position Once the adjustmet is performed check again that the combustion
44. eutral 2nd nozzle priming pushbutton Flame reset pushbutton only for LOA44 Thermostats or pressure switches group Actuator for air damper Ignition transformer High low flame thermostat if fitted remove the bridge between terminals 6 and 7 on terminal block MA Fan motor thermal cutout only triphase versions 1 Electric supply 400V 50Hz 3Na c and 230V 50Hz 1N a c 2 Don t reverse phase and neutral 3 Make sure that the burner is properly hearted 31 12 46 FRONTALE QUADRO x FRONT CONTROL PANEL PULSANTE SBLOCCO FIAMMA SOLO LOA44 LMO24 LMO44 FLAME UNLOCK BUTTON LOA44 LMO24 LMO44 ONLY SIEMENS LOA24 44 LMO24 111 LMO24 255 LMO44 255 s m STA CIRCUITO STAMPATO PRINTED CIRCUIT BOARD COD 6100552 MV CN1 VERSIONE CON MARTINETTO IDRAULICO WITH HYDRAULIC RAM VERSION BARRA DI TERRA EARTH TERMINAL ooo P N L BERGER STA4 5B0 37 63N30L ALIMENTAZIONE AUSILIARI BRUCIATORE GOJOR BURNER AUXILIARY SUPPLY VEDI FOGLIO 2 BERGER STA6B2 41 62N13L SEE SHEET 2 SIEMENS SQN72 2A4A20 Data KOs 1272007 E SEGUE TOTALE Dis N 18 141 2 2 a Se ELETTROVALVOLA GASOLIO 11 STADIO LIGHT OIL SOLENOID VALVE 2nd STAGE ELETTROVALVOLA GASOLIO DI SICUREZZA SAFETY LIGHT OIL SOLENOID VALVE OTORESISTENZA RILEVAZIONE FIAMMA HOTORESISTOR FLAME DETECTOR USIBILE BI LINEA INE FUSE USIBILI LINEA MOTORE
45. gnetic compatibility Harmonised standards UNI EN 676 Gas Burners EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Heavy oil burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods UNIGAS 965 GENERAL FEATURES The fuel coming from the supply line is pushed by the pump to the nozzle and then into the combustion chamber where the mixture between fuel and air takes place and consequently the flame In the burners the mixture bertween fuel and air to perform clean and efficient combustion is activated by atomisation of oil into very small particles This process is achieved making pressurised oil pass through the nozzle The pump main function is t
46. lame lit C Normal operation D Normal stop through R tw Oil pre heating time until operational all clear given through contact OW tl Pre purge time t3 Pre ignition time t2 Safety time tn Post ignition time t4 Interval between the flame lighting and energising of solenoid 2a at terminal 5 Internal layout AL Optical alarm BV Fuel valve EK gt Reset button FR Flame relay fr Flame relay contacts FS Flame alight signal G Burner motor K Flame relay anchor to delay the tzl command in the event of a premature flame signal or endorse it where the signal is correct OH light oil pre heater OW Operational all clear contact QRB Photo resistant cell flame detector H Thermostat or pressure switch TZ programmer bimetal system tz TZ contacts V Flame signal amplifier W Safety thermostat or pressure switch Z Ignition transformer The above are safety devices tamper with them in any way may have unforeseeable conse quences Do not open them R W ALIREEISIIIIYTIT II TI IINITWTITITITITTITITITIETITII OH f OW M fd F4 II L u FS L L l Technical characteristics Voltage Frequency External fuse Contact flow terminal 1 terminal 3 220V 15 240V 10 or 100V 15 110V 10 50 60Hz 6 max 10A slow action 5A incl capacity absorbed b
47. lified personnel carry out the following operations a Remove the power supply by disconnecting the power cord from the mains b Disconnect the fuel supply by means of the hand operated shut off valve and remove the control handwheels from their spindles Special warnings Make sure that the burner has on installation been firmly secured to the appliance so that the flame is generated inside the appliance firebox e Before the burner is started and thereafter at least once a year have qualified personnel perform the following operations set the burner fuel flow rate depending on the heat input of the appliance b gt the flow rate of the combustion supporting air to obtain a combu stion efficiency level at least equal to the lower level required by the regulations in force check the unit operation for proper combustion to avoid any harmful or polluting unburnt gases in excess of the limits permitted by the regulations in force sure that control and safety devices are operating properly e sure that exhaust ducts intended to discharge the products of combustion are operating properly f on completion of setting and adjustment operations make sure that all mechanical locking devices of controls have been duly tightened 0 make sure that a copy of the burner use and maintenance instruc tions is available in the boiler room Incase of a burner shut down reser the control box by means of th
48. lling the tank wait before starting the burner This will give any suspended impurities time to deposit on the bottom of the 12 UNIGAS 965 tank thus avoiding the possibility that they might be sucked into the pump e initial commissioning a dry operation is foreseen for a considerable length of time for example when there is long suction line to bleed To avoid damages inject some lubrication oil into the vacuum inlet e Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the joint noise and overloading the gears e Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical seal junc tions preferred Junction threads elbow joints and couplings should be sealed with removable sg component The number of junc tions should be kept to a minimum as they are a possible source of leakage e Donotuse PTFE tape the suction and return line pipes to avoid the possibility that particles enter circulation These could depo sit on the pump filter or the nozzle reducing efficiency Always use O Rings or mechanical seal copper or aluminium gaskets jun ctions if possible e Anexternal filter should always be installed in the suction line upstream the fuel unit Connecting the light oil flexible hoses To connect the flexible light oil hoses to the pump proceed as follows acco
49. ner s drilling template described on paragraph Overall dimensions fasten the 4 stud bolts place the gasket on the burner flange install the burner into the boiler fix the burner to the stud bolts by means of the fixing nuts according to the next picture After fitting the burner to the boiler ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement Keys Burner Fixing nut Washer Sealing gasket Stud bolt Blast tube Handling ATTENTION The Ihandling operations must be carried out by specialised and trained personnel If these opera tions are not carried out correctly the residual risk for the burner to overturn and fall down still persists To move the burner use means suitable to support its weight see paragraph Technical specifications UNIGAS 965 Hydraulic diagrams for light oil supplying circuits Fig 2 Gravity circuit Sek NU j ZZ Fig 3 Ring circuit HH P M Fig 4 Suction circuit Key Manual valve Light oil filter Light oil feeding pump One way valve Flexible hoses Relief valve NOTE in plants where gravity ring feed systems are provided install an automatic interception device see n 4 Fig 5 UNIGAS 965
50. ng the TAB thermostat remove the bricge between terminals 6 and 7 8 Proceed as follows acting on the ST1 actuator cam to adjust the air flow rate in the low flame stage checking the combustion values IV III 60 5 4 5 PG70 PG81 Berger STA6 PG60 PG70 PG81 Siemens SQN72 Refer to the next table for cams functions Air adjustment in high flame cam ST2 red Air adjustment in low flame Stand by Ignition cam ST1 blue Auxiliary cam for the opening consent to the second fuel valve w IV black e Berger STA4 this actuator is not provided with the manual control of the air damper The adjustment of the cams is carried out by means of a screwdriver by twisting the VS screw located inside the cam e Berger STA6 this actuator is not provided with the manual control of the air damper The adjustment of the cams is carried out by 20 10 11 12 13 14 15 16 17 18 19 20 UNIGAS 965 Siemens SQN72 a key is provided to move cams and IV the other cams can be moved by means of screws the Siemens actuator the AUTO MAN mode is provided see picture by removing the bridge between the 6 and 7 terminals of the TAB thermostat the actuator moves to the position degrees set for the ST1 cam low flame cam to decrease the low flame position and then decr
51. o transfer oil from the tank to the nozzle at required quantity and pressure To adjust pressure pumps are provided with a pressure governor except some models for which a separate adjusting valve is provided Other pumps are provided with two pressure governors one for high and one for low pressure in double stage systems with one nozzle In the double stage burners the electric actuator that moves the air damper allows the optimisation of the gas flue values as to get an efficient combustion The position of the combustion head determines the burner output The air comburent and fuel light oil are for ced into the combustion chamber as to let the flame light up How to interpret the burner s Performance curve To check if the burner is suitable for the boiler to which it must be installled the following parameters are needed e furnace input in kW or kcal h KW kcal h 860 e backpressure data are available on the boiler ID plate or in the user s manual Example Furnace input 600kW Backpressure 4 In the Performance curve diagram Fig 1 draw a vertical line matching the furnace input value and an horizontal line matching the backpressure value The burner is suitable if the intersection point A is inside the performance curve Campo di lavoro bruciatori combustione mbar Contropressione in camera di A s Potenza kW
52. parameters are in the set limits Replace the actuator cover Adjustments for burners with hydraulic ram air damper hydraulic ram low flame air adjustment high flame air adjustment Air setting The low flame air setting must be carried out first a Low fire setting To set the low flame proceed as follow 1 2 3 4 Break off the contact of the second stage regulator unscrew the locking nut 2 and turn directly the body of the air damper ram 1 Turn clockwise to increase the air flow of the low flame stage turn counterclockwise to decrease the air flow The air damper index 5 shows the damper positioning At the end of settings lock again the nut 2 b High flame setting To set the high flame proceed as follow 1 2 3 4 Close the contact of the second stage regulator and unlock the nut 3 turn the nut 4 Turning counterclockwise the high flame air flow increases turning clockwise the air flow decreases The air damper index 5 shows teh damper positioning At the end of settings lock again the nut 9 NOTICE during the point b regulations the point a remains unchanged WARNING for operation with hydraulic damper ram the pump must not be set to a pressure lower than 12 bar 21 UNIGAS 965 Adjusting the combustion head To let the burner operate at a lower output turn clockwise the VRT screw and move progressively the combustion head back towards the MIN position
53. pter on page 23 remove the photoresistor FR Fig 12 from its slot and light it up bleed the air from the M pressure gauge port of the pump slightly loosing the cap and without removing it Fig 11 turn the burner off replace the photoresistor FR Fig 12 into its slot reconnect the B coil on the pump Fig 11 light the burner if the burner locks press the unlock pushbutton placed on the upper side of the burner and repeat the steps above 10 figurawhen the flame lights up press the P1 pushbutton on the PCB see picture below for a while to fill the second nozzle pipe O ON O O MA P1 NOTE The oil flow rate depends on the choosen nozzle The air rate can be adjusted by means of the air damper actuator cams see picture below Refer to the next table for cams functions Berger STA4 5 Siemens SQN72 I red Air adjustment in low flame Stand by Ignition cam Auxiliary cam for the opening consent to the second fuel valve aw e Berger STA this actuator is not provided with the manual control of the air damper The adjustment of the cams is carried out by Air adjustment in high flame cam 19 UNIGAS 965 means screwdriver by twisting VS screw located inside the cam e Siemens SQN72 a key is provided to move cams and IV the other cams can be moved by means of screws On the Siemens actuator the AUTO MAN mode is provided
54. rding to the pump provided 1 remove closing nuts A and R on the inlet and return connections of the pump 2 screw rotating nut of the two flexible hoses on the pump being careful to avoid exchanging inlet and return lines see the arrows marked on the pump that show the inlet and the return see prevoius paragraph Suntec AS57 Suntec AN67 Suntec AJ6 Suntec J6 13 UNIGAS M03965CE Light oil The pumps provided with these burners can be e PQG30 Suntec AS57 e 60 Suntec AN67 PG 70 Suntec AJ6 81 Suntec J6 Suntec AS57 C Oil viscosity 2 12 cSt Oil temperature 0 60 C Rotation speed 3600 rpm max Suntec AN67 C Ovos 12 708 Rotation speed 3600 rpm max 2 75 cSt 0 45 bar to avoid gasing Rated speed 3600 rpm max Suntec J6 J7 Oil viscosity 2 8 200 cSt Oil temperature 0 90 Max suction pressure 1 5 bar retum pressure Rotation speed 3600 rpm max Key Pressure governor Pressure gauge Vacuum gauge Solenoid valve Nozzle Suction Return by pass plug inserted OF 14 965 Electrical RESPECT THE BASIC SAFETY RULES MAKE SURE OF THE CONNECTION TO THE EARTHING SYSTEM DO REVERSE THE PHASE AND NEUTRAL CONNECTIONS FIT A DIFFERENTIAL THERMAL MAGNET SWITCH ADE QUATE FOR CONNECTION TO THE MAINS STRICTLY OBSERVE THE DATA PLATE
55. tains the 12 terminals and also e 3neutral terminals ready wired up to terminal 2 e 4earth terminals for earthing the burner e 2 supplementary terminals numbered 31 and 32 The socket has two openings at the bottom for the leads 5 others with threaded connection for cable holders PG11 3 4UNP for non metallic sleeves are located on a mobile stuffing box one on either side and 3 on the front There are two flexible metal tongues on the sides of the socket for moun ting To dismantle it only requires gentle pressure with a screw driver in the slot of the mounting guide The base dimensions of the socket are the same as for types LAB LAI and there is no difference in the diameter of the reset button the two mounting screws and the flange of the burner earth Safety at low voltage levels Safety devices against any reduction in the mains voltage operate on a special electronic circuit which in the event of the power supply falling below 165 stops the burner switching on without releasing the fuel and locks out the apparatus Wiring diagram of the program To ensure correct wiring it is essential to observe local standards and fol low the instructions of the burner manufacturer with regard to assembly and start up Program s legend Emp Controller output signals Required input signals A Burner start up with light oil pre heater OH A Burner start up without light oil pre heater B F
56. w danger of formation of carbon monoxide if this should happen make the fuel decrease slowly until the normal combustion values are achieved IMPORTANT the combustion air excess must be adjusted according to the in the following chart Recommended combustion parameters Recommended 20 CO Recommended O Light oil 11 5 13 Adjusting the fuel flow rate The fuel rate is setting choosing properly sized nozzles and adjusting the fuel pressure at the pump inlet see the diagram Fig 10 To choose the nozzles refer to tables below for pump pressure regulation see next tables Key EV Fuel solenoid valve EVG1 Fuel solenoid valve low flame EVG2 Fuel solenoid valve high flame M Manometer P Pump Fig 10 16 UNIGAS 965 Choosing the light oil nozzles PUMP PRESSURE bar OUTPUT kW kg h II NOZZLE G P H sso 1 150 18 08 18 0 35 2 0 0 600 90 858 850 80 780 780 6409 62 650 980 60 55 89 90 1250 1 075 000 105 4 11 00 16 00 10 00 15 00 90 14 00 1500 1 290 000 126 5 13 00 19 50 12 00 18 00 11 00 16 00 1750 1 505 000 147 5 15 00 22 00 14 00 20 00 13 00 19 50 2000 1 720 000 168 6 17 00 26 00 16 00 24 00 15 00 22 00 Tab 1 17 UNIGAS 965 nozzle rates eae Pere
57. y motor and pre heater v 650 090 A Terminal flow terminals 4 5 amp 10 1A terminals 6 amp 7 2A terminal 8 5A Absorbed cap Protection IP40 Premitted temp operational 20 60 C transport amp storage 50 60 Emplacement any controller 180g socket 50g AGK accessories 12 g Commands in the event of operational interference Stray light premature ignition During pre purge and or pre ignition there should be no flamesignal If there is a flame signal eg from premature ignition due to a faulty solenoid external light short circuit in the photoresisto or wiring malfunction in the flame signal amplifier etc at the end of pre purge and safety time the controller locks out the burner and stops the fuel flow even during safety time Absence of flame If there is no flame at the end of safety time the controller locks out imme diately Absence of flame during operation If there is no flame during operation the controller cuts off the supply of fuel and automatically initiates a fresh start up programme at the end of t4 the start up programme ends Whenever there is a safety stop terminals 3 8 and 11 are de energised in less than 1 second at the same time a remote lockout signal is transmit ted through terminal 10 The controller can be reset after c 50 seconds Mass weight UNIGAS C I B UNIGAS S p A Via L Galvani 9 35011 Campodarsego PD
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