G6 - G10 - G18 - Arzatoare CIB Unigas
Contents
1. To connect the flexible light oil hoses to the pump proceed as follows according to the pump provided 1 remove the closing nuts A and R on the inlet and return connections of the pump 2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the inlet and return lines see the arrows marked on the pump that show the inlet and the return see prevoius paragraph Delta A1L2 Delta VM 1LR2 12 UNIGAS M039223CB Electrical connections Respect the basic safety rules make sure of the connection to the earthing system do not reverse the phase and neutral connections fit a differential thermal magnet switch adequate for connection to the mains A ATTENTION before executing the electrical connections pay attention to turn the plant s switch to OFF and be sure that the burner s main switch is in 0 position OFF too Read carefully the chapter WARNINGS and the Electrical connections section To execute the electrical connections proceed as follows 1 remove the cover from the electrical board unscrewing the fixing screws 2 execute the electrical connections to the supply terminal board as shown in the wiring diagrams 3 refit the cover 13 UNIGAS 039223 ADJUSTMENTS ATTENTION before starting the burner up be sure that the manual cutoff valves are open and check that the pres sure upstream the2. UNIGAS C G6 G10 G18 24 Vdc voltage supplied single stage burners MANUAL OF INSTALLATION USE MAINTENANCE CIB UNIGAS BURNERS BRUCIATORI BRULERS BRENNER QUEMADORE TABLE OF CONTENTS WARNINGS es 3 PART INSTALLATION uuu P 5 a ed ee eh el ae 5 How to interpret the burner Performance curve a 5 Matching the bumer to bale aaa 6 Burner model Identification ide 7 7 SIZED V 8 Performance Curves DE 8 MOUNTINGS AND CONNECTIONS 9 9 Fitting the burner to the ir 9 Hydraulic diagrams for light oil supplying circuits 10 Installation diagram of light oil pipes enne 000000 000000010010010000001001001 11 About the se of fuel Pumps E E 11 S 12 Connecting the light oil flexible N
3. O I x cro 2 xo lt 5 20 oz 220 ES 2 Or gt PX zo En uz usos c zb zz ce m m ma MAIN SWITCH OPEN o LINE FUSES INTERRUPTED o MAX TEMPERATURE THERMOSTAT FAULTY FAN MOTOR THERMAL CUTOUT INTERVENTION o AUXILIARY FUSE INTERRUPTED o CONTROL BOX FAULT o e o o o SMOKY FLAME o IGNITION TRANSFORMER FAULT o IGNITION ELECTRODES DIRTY OR WRONG POSITIO e NED DIRTY NOZZLE OIL SOLENOID VALVE FAULTY o o PHOTORESISTOR DIRTY OR FAULTY OIL LOW PRESSURE o OIL FILTERS DIRTY e o 21 22 BURNER EXPLODED VIEW POS DESCRIPTION POS DESCRIPTION 1 COVER 22 PHOTORESISTOR BRACKET 2 CAPACITOR 23 MANIFOLD 3 MOTOR 24 PIPE 4 CONTROL BOX 25 COMBUSTION HEAD ADJUSTING SCREW 5 CONTROL BOX BASE 26 6 CONTROL BOX BRACKET 27 PUMP CONNECTOR 6A CONTROL BOX SPACER 28 PUMP 7 TRANSFORMER 29 FLEXIBLE HOSES 8 BURNER BODY 30 FILTER 9 FAN WHEEL 31 PIPE 10 NOZZLE HOLDER ASS Y 32 AIR DAMPER 11 NOZZLE 34 PHOTORESISTOR BASE 12 NOZZLE BRACKET 35 COUPLING 13 BOTTOM 36 COUPLING 14 PRE HEATER ASS Y 37 COUPLING 15 IGNITION CABLE 38 HYDRAULIC RAM 16 IGNITION ELECTRODE 39 IGNITION ELECTRODE 17 C
4. 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 Clean and examine the oil filter cartdrige and replace it if necessary e examine the flexible oil pipes and check for possible leaks e 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 e dismantle examine and clean the combustion head see next paragraph reassembling the combustion head be careful to respect the measures in Fig 17 e check the electrodes and their ceramic insulators clean and adjust the electrodes if necessary replace them see related para graph e dismantle and clean the oil nozzles IMPORTANT don t use metallic or sharp utensils but solvent or steam to clean the nozzles at the end of these maintenance procedures refit the burner turn it on and verify the combustion if in doubt replac
5. code and times are those required Checking at start Before any ignition attempt make sure that the combustion chamber is free from oil then make sure that e ifthe starting attempt occurs with the flame detector obscured the con troller performs a lockout at the end of safety time e ifstart up attempt occurs with extraneous light the controller proceeds to lockout within the time equivalent to safety time only in versions where this option is available e when the flame detector is obscured in running position the oil valve s is are de energized within 1 second and the controller goes to lockout after a recycle e The intervention of regulators limiters or safety devices causes a shut down of the controller according to the application type Operating times and cycle are in compliance with the ones declared for the used controller type Operation Once the thermostats are closed the controller energizes the burner motor in this phase the device proceeds to a self checking process of the flame detection and safety circuit At the end of pre purge time the output of the first oil valve is powered If flame is detected at the end of safety time the controller de energizes the ignition transformer and goes to run ning position At the end of safety time in the double stage controllers the ignition transformer is de energized and contemporaneously the output of the second oil valve is energized If no flame is detected
6. Fig 2 UNIGAS M039223CB Burner model identification Burners are identified by burner type and model Burner model identification is described as follows Type G10 Model G TN S Y 1 9 4 5 6 1 BURNER TYPE G6 G10 G18 2 FUEL G Light oil 3 OPERATION Available versions TN Single stage 4 BLAST TUBEBLAST TUBE 5 Standard L Extended 5 DESTINATION COUNTRY see data plate 6 BURNER VERSION Y Special version 24Vdc power supply Specifications BURNER TYPE G6 G10 G18 Output min max kW 29 70 58 116 105 209 Fuel Light oilLight oil Light oil rate min max kg h 2 5 6 5 10 9 18 Light oil viscosity cSt 40 C 2 74 Light oil density kg m 0 84 Power supply 24 Vdc Motor w 110 180 180 Total power consumption W 210 280 280 Weight approx kg 15 5 17 18 Operation Single stage Operating temperature C 10 50 Storage Temperature C 20 60 NOTE Choosing the nozzle for light oil consider Hi equal to 10200 kcal kg NOTE ON THE WORKING SERVICE Burners provided with Siemens LOA24 control box for safety reasons one controlled shutdown must take place every 24 hours of continuous working UNIGAS M039223CB Overall dimensions mm A B B L C L D E F G H K M P G6 290 53 67 53 177 343 357 343 467 310 75 385 80 101 190 M8 112 G1
7. determines the energetic quality and the geometry of the flame Fuel and comburent are routed into separated ways as far as the zone of flame generation combustion cham ber How to interpret the burner 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 s ID plate or in the user s manual Example Furnace input 600kW Backpressure 4mbar In the Performance curve diagram Fig 2 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 UNIGAS M039223CB Campo di lavoro bruciatori combustione mbar N Contropressione in camera di 100 200 300 400 500 600 700 800 900 Potenza kW Fig 1 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 C Matching the burner to the boiler The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose dimensions are described in the diagram In case the burner must be coupled with boilers with a combustion chamber smaller in dia meter or shorter than those described in the dia
8. electrodes position after any intervention on the combustion head e Fix a stable surface to lean on the burner during maintenance e To gain access to the combustion head and to the nozzles slacken the screw on the blast tube and remove it from the part that remains fixed to the boiler e guarantee a good ignition observe the measures shown in the table below e sure to tight the screw that fix the electrodes group before reassembling the burner D Fig 16 NOZZLE A B D 60 4 3 4 6 G6 45 8 4 4 6 60 6 4 4 6 G10 G18 45 10 5 4 6 Tab 3 Cleaning replacing the 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 clean replace the electrodes proceed as follows 1 remove the combustion head as described in the previous paragraph 2 remove the electrodes ass y and clean them 3 order to replace the electrodes unscrew the fixing screws and remove them place the new electrodes being careful to observe the measures quoted in the previous paragraph reassemble the electrodes and the combustion head following the procedure in the reversed order Cleaning and replacing the detection photocell To clean replace the detection photoresistor proceed as f
9. 0 275 86 206 361 481 340 40 380 89 99 230 M8 132 G18 275 87 207 362 482 340 40 380 114 134 280 M8 132 L 2 measure referred to burner provided with extended blast tube Performance Curves 1 4 1 2 0 8 0 6 0 4 0 2 0 4 10 30 50 70 90 110 130 150 170 190 210 230 BACK PRESSURE IN COMBUSTION CHAMBER mbar 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 at 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 UNIGAS M039223CB MOUNTINGS AND CONNECTIONS Packing Burners are despatched in cardboard packages whose dimensions are mm 340mm x 415mm x 415mm Packing cases of this kind are affect
10. ATORE LB LAMPADA SEGNALAZIONE BLOCCO BRUCIATORE V OTORE VENTILATORE SERIE TERMOSTATI PRESSOSTATI TRASFORMATORE DI ACCENSIONE TERMOSTATO PRESSOSTATO DI SICUREZZA E Data 25 09 2009 ED Revisione 01 2 TOTALE Dis 01 555 2 BRAHMA G22 CONTROL BOX Installation directions The controllers are safety devices guarantee and responsibility of the manufacturer will be debarred if the products are tempered with by the user e Make sure that a regulation shutdown occurs every 24 hours to allow the controller self checking its efficiency non permanent operation systems e The controller must be connected and disconnected without power supply The controller can be mounted in any position Avoid exposure to dripping water A ventilated installation ambient and a quite low temperature ensure the longest life of the controller e Before installing or replacing the controller make sure that its type
11. H 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 1 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 damage to property for which the manufacturer cannot be held lia ble 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 Make sure that inlet or exhaust grilles are unobstructed e Incase of breakdown and or defective unit operation disconnect th
12. OMBUSTION HEAD 40 FLANGE 18 BLAST TUBE 41 GASKET 19 GASKET 42 BLAST TUBE 20 FLANGE 43 COMBUSTION HEAD 21 PHOTORESISTOR 44 NOZZLE HOLDER ASS Y EIETEBEON SVDINN EI UNIGAS M039223CB 23 UNIGAS M039223CB SPARE PARTS Desription Code G6 G10 G18 COVER 3010019 3010019 3010019 CONTROL BOX 2020225 2020225 2020225 IGNITION ELECTRODE 2080203 2080203 2080203 OIL FILTER 2090027 2090027 2090027 GENERATOR GASKET 2110021 2110021 2110021 FAN WHEEL 2150003 2150004 2150004 IGNITION TRANSFORMER 2170040 2170040 2170040 FAN MOTOR 21802C9 21802C7 21802C7 FLEXIBLE HOSE 2340001 2340001 2340001 PHOTORESISTOR 2510004 2510004 2510004 MOTOR PUMP COUPLING 2540101 2540102 2540102 PUMP 2590038 2590038 2590038 NOZZLE 2610004 2610004 2610004 STANDARD COMBUSTION HEAD 3060139 3060102 3060102 STANDARD BLAST TUBE 30900A2 3090005 3092006 EXTENDED BLAST TUBE 30900A1 3090008 3090009 IGNITION CABLE 6050119 6050122 6050122 24 BRAHMA G22 S03N 24V DC 5 4 2 2 1 mm2 BIANCO WHITE 1 2 4 mm2 ROSSO RED K PACHAM 6 mm2 NERO BLACK YEP MOTORE VENTILATORE N MOTO MORSETTIERA ALIMENTAZIONE
13. OS S ieai 12 Electrical connections 12 ADJUSTMENTS hatu mu E uS bc I S 14 Adjustments brief description 22 e a e e aa 14 Adjustment proced re die 14 Adjusting the combsutior 16 PART IL OPERATION u ul lll l 17 EE 17 PART MAINTENANCE t sen lines 18 ROUTINE MAINTENANCE 18 Light oil filter maintenance A oda 18 Removing the combustion head iaa a 18 Cleaning and replacing the detection photocell eese eene tnnt nnns nnne nnns etes anna sns sens nn 19 Checking the detection current eine nnn 0888 8008000010801 1 1 1 0 1 10 01 01 012 10101011 20 ITEM 20 B rnerdisposal 20 TROUBLESHOOTING 5 EET 21 BURNER EXPLODED VIEW H 22 SPARE PAR TS 24 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 BOT
14. SUPPLY TERMINAL BOARD Data 25 09 2009 FOGLIO Revisione 01 1 TOTALE Dis 01 555 SIGLA ITEM FUNZIONE FUNCTION BRAHMA 622 SO3N 24V DC APPARECCHIATURA CONTROLLO FIAMMA CONTROL BOX EVG ELETTROVALVOLA GASOLIO LIGHT OIL SOLENOID VALVE FR FOTORESISTENZA RILEVAZIONE FIAMMA PHOTORESISTOR FLAME DETECTOR FU1 2 FUSIBILE DI LINEA LINE FUSE G NTER RUTTORE GENERALE AINS SWITCH VENTILATORE FA OTOR CONTACTOR LB LAMPADA SEGNALAZIONE BLOCCO NDICATOR LIGHT FOR BURNER LOCK OUT V VENTILATORE FA OTOR SERIE TERMOSTATI PRESSOSTATI SERIES OF THERMOSTATS OR PRESSURE SWITCHES TRASFORMATORE DI ACCENSIONE GNITION TRANSFORMER TERMOSTATO PRESSOSTATO DI SICUREZZA SAFETY THERMOSTAT OR PRESSURE SWITCH SIGLA ITEM FUNZIONE FUNCTION BRAHMA 622 SO3N 24V DC APPARECCHIATURA CONTROLLO FIAMMA ELETTROVALVOLA GASOLIO FR FOTORESISTENZA RILEVAZIONE FIAMMA FUSIBILE DI LINEA Y BIL RUTTORE GENERALE A CONTATTORE MOTORE VENTIL
15. URNER 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 A ATTENTION before starting the burner up be sure that the manual cutoff valves are open and check that the pres sure upstream the gas train complies the value quoted on paragraph Technical specifications e Turn on the power supply by the main switch e Check the control box is not locked eventually release it by means of the pushbutton PS placed under the hole on the burner cover e Check the series of thermostats or pressure switches enable the burner to operate e The start cycle of the burner begins the control box starts the burner fan and meanwhile energises the ignition transformer e Atthe end of the pre purge the solenoid valve of the selected fuel and the ignition transformer are both energised and the burner starts up e The ignition transformer remains in operation for some seconds after the flame appears post ignition time then at the end of this time it is turned off 14 Fig 15 17 UNIGAS M039223CB At least once a year carry out the maintenance operations listed below In the case of seasonal servicing it is recommended to carry
16. al 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 PTFE tape on 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 An external filter should always be installed in the suction line upstream of the fuel unit 11 Light oil pumps Pump DELTA A Oil viscosity Oil temperature Maximum inlet pressure Maximum Return pressure Minimum inlet pressure Maximum speed Keys pressure governor By pass Return Inlet Vacuum gauge port Pressure gauge port To the nozzle Solenoid valve Cartridge filter OO O QO Pump DELTA VM1LR2 Oil viscosity Oil temperature Maximum inlet pressure Maximum Return pressure Minimum inlet pressure Maximum speed Keys pressure governor Pressure gauge port Vacuum gauge port Solenoid valve To the nozzle Inlet Return Q N Connecting the light oil flexible hoses UNIGAS M039223CB 1 2 12 mm s cSt 60 C max 2 bar 2 bar 0 5 bar to avoid gasing 3500 rpm 2 50 mm s cSt 0 60 2 bar 2 bar 0 5 bar to avoid gasing 3600 rpm
17. argin it corresponds to a double light inten sity comparing with the minimum value the limit value is about 0 8V in case the value of the measured voltage is higher try to better orientate the photocell or to clean it gt Terminal no 9 V 0 5V DC Neutral terminal Connection diagram G22 OR1 SINGLE FLAME 109 8 7 6 5 4 3 2 1 N FR I T EV1 58 TR N N GF2 OR2 DOUBLE FLAME 0 9 8 7 N te TR EV2 EVA N N Cycle diagram N N L X e a Ni 4 X G22 OR1 220 110 V G22 OR1 12V and 24V ger eng TV Keys I main switch T thermostat MB burner motor FR flame detector SB lockout signal EV1 first valve EV2 second valve TR ignition device F fuse Techcnical data Power supply 220V 50 60Hz upon request 110V 50 60Hz 24V dc and ac 50 60Hz 12V dc and ac 50 60Hz Operating temperature 10 C 60 C Protection degree with base IP 40 Times Pre purge time TV 20 C 15 20 8 Safety time TS 20 C 5 10 s Response time in case of flame failure 1 s Power consumption 220V 50Hz 6 5 VA 12V 24V 1VA Internal fuse For 220V and 110V supply voltage 6 3 A time delay For 24V and 12V supply voltage 10 A time delay Externsl fuse For 220V and 110V supply voltage 4 A fast blow For 24V and 12V supply voltage 10 A fast blow Weight including connection base about 240 g Max
18. contacts rating 220V Imax Thermostat 6 0 A cosg gt 0 4 Motor 2 0 A cose gt 0 4 Ignition transformer 2 0 A gt 0 4 0 5 A cos gt 0 4 2 0 5 cosg gt 0 4 Pre heater 0 5 A 1 0 Lockout signal 1 0 A cose 1 0 Max contacts rating 8 12V e 24V Imax Thermostat 10 A cos gt 0 4 Motor 4 0 A cose gt 0 4 Ignition transformer 3 0 A gt 0 4 EV1 1 5 A gt 0 4 2 1 5 A gt 0 4 Lockout signal 1 0 A cose 1 0 CIB UNIGAS C I B UNIGAS S p A Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201 269 web site www cibunigas it e mail cibunigas cibunigas it Note Specifications and and data subject to change Errors and omissions excepted
19. d 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 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 etc unless expressly required to do so do not allow children or inexperienced persons to use equipment Theunit 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 OIL OR OTHER FUELS GENERAL The burner shall be installed by qualified personnel and in com pliance with regulations and provisions in force wrong installation can cause injuries to people and animals or damage to prop
20. e 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 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 move 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 Forallthe units that have been modified or have options fitted then original accessory equipment only shall be used 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 b
21. e burner connected when not in use Always shut the gas valve off 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 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 Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 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 CEI EN 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 req
22. e the defective noz zle or nozzles If the burner is used intensively it is recommended to replace the nozzles at the start of the operating season e check and clean carefully the flame detection photoelectric cell if necessary replace it and if in doubt verify the detection circuit with the burner in operation e Check and clean the gas filter cartridge if necessary replace it see next paragraghs e Check and clean the fuel filter cartdrige replace if necessary e Check and clean the filter inside the light oil pump filter 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 repla ced An external filter should always be installed in the suction line upstream of the fuel unit Check the fuel hoses for possible leaks Remove check and clean the combustion head see page 18 Check ignition electrodes clean adjust and if necessary replace them see page 19 Check and carefully clean the flame detector replace it if necessary if in doubt check the detection current once the burner starts up see page 20 e Remove and clean the fuel nozzle IN Important cleaning must be performed using solvent not metal tools At the end of maintenance operations after the b
23. ed by humidity and are not suitable for stacking The following are placed in each packing case burner with gas train detached gasket to be inserted between the burner and the boiler oil flexible hoses oil filter 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 Hydraulic diagrams for light oil supplying circuits Key Fig 3 Gravity circuit Fig 4 Ring circuit Fig 5 Suction circuit Manual valve Light oil filter Light oil feeding pump One way valve Flexible hoses Relief valve MA UNIGAS M039223CB NOTE in plants where gravity or ring feed systems are provided install an automatic interception device see n 4 Fig 6 10 C I B UNIGAS M039223CB Installation diagram of light oil pipes AN PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL 7 6 4 3 From tank 411 i 5 1 6 Fig 6 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 Only for installations with gravity siphon or for Key ced circ
24. erty for which the manufacturer cannot be held liable 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 Before the burner is commissioned qualified personnel should ins pect the following a 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 c 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 the fuel supply system to make sure that the system dimensions are adequate to the burner firing rate and that the system is equipped with all the safety and control devices required by the regulations in force 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 Donotuse gas pipes to earth electrical equipment Never leave th
25. gas train complies the value quoted on paragraph Technical specifications Be sure that the mains switch is 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 flow danger of formation of carbon monoxide if this should happen make the gas decrease slowly until the normal combustion values are achieved A IMPORTANT the combustion air excess must be adjusted according to the in the following chart Recommended combustion parameters Fuel Recommended CO Recommended 95 Light oil 11 5 13 2 9 4 9 Adjustments brief description e Check that the combustion parameters are in the suggested limits e Check the flow rate e Adjust the combustion air and oil flow rate Adjustment procedure The light oil flow rate is set by choosing a nozzle that suits the boiler utilisation output and setting the delivery and return pressure values according to the ones quoted in the table below as far as reading the pressure values see next paragraphs Keys EV EV1 Light oil solenoid valve M Pressure gauge P Pump P Fig 7 Pump pressure 12 bar factory set M t Choice of the
26. gram please contact the supplier to verify that a correct matching is possible with res pect of the application involved To correctly match the burner to the boiler verify the necessary input and the pressure in combustion chamber are included in the burner performance curve otherwise the choice of the burner must be revised consulting the burner manu facturer To choose the blast tube lenght follow the instructions of the boiler manufacturer In absence of these consider the following e Cast iron boilers three pass flue boilers with the first pass in the rear part the blast tube must protrude no more than 100 mm into the combustion chamber e Pressurised boilers with flame reversal in this case the blast tube must penetrate at least 50 100 mm into combustion chamber in respect to the tube bundle plate The length of the blast tubes does not always allow this requirement to be met and thus it may be necessary to use a suitably sized spacer to move the burner backwards or to design a blast tube tha suites the utilisation please contact the manifacturer Key a Heat output in kW b Lenght of the flame tube in meters Flame tube firing intensity in MW m d Combustion chamber diameter m sur 42312 Na b Fig 2 Firing intensity diameter and lenght of the test flame tube as a function of the heat input in kW o oooo 0 1 12 78 40 70100 190 880 1200 2450 1
27. ing air to obtain a combu stion efficiency level at least equal to the lower level required by the regulations in force c 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 d make sure that control and safety devices are operating properly e make 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 g make sure that a copy of the burner use and maintenance instruc tions is available in the boiler room e Incase of a burner shut down reser 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 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 Itis 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 Qualifie
28. le end Fig 12 Fig 13 Attention change the head position only if necessary If it is necessary to change the head position repeat the air and gas adjust ments as described above 16 UNIGAS M039223CB LIMITATIONS OF USE THE BURNER IS 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 FUNDAMENTAL 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 B
29. necessary to prime the fule pump accroding to the next procedure 1 remove the burner cover 2 remove the solenoid valve coil B on pump P Fig 8 to avoid the light oil to get into the combustion chamber 3 start the burner up by means of the main switch and by means of the thermostatsW pressure switches series 4 rremove the detection probe FR Fig 8 and light it up VBS Fig 8 5 bleed the air from the M pressure gauge port of the pump P slightly loosing the cao and without removing it Fig 9 Caution The nozzle flow rate at 12bar must be higher than the flow rate referred to the burner minimum output Fig 9 Turn the burner off replace the detection probe into its slot reconnect the B coil on the pump Fig 8 turn the burner on if it locks out press the unlock pushbutton PS Fig 10 placed in the burner upper side and repeat the proce dure ON 10 The oil flow rate depends on the chosen nozzle 15 UNIGAS M039223CB 11 Checking the combustion values adjust the air flow rate acting on the VSB screw Fig 8 Fig 11 screw to decrease the flow rate and unscrew to increase it 12 Turn the burner off and then on again Fig 11 Adjusting the combsution head Turn VRTclockwise or counterclockwise according to the output to gain minimum or maximum If the combustion head is to be repla ced the position on Fig 16 Tab 2 must be observed according to the nozz
30. nsert 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 Bleed Bleeding in two pipe operation is automatic it is assured by a bleed flat on the piston In one pipe operation the plug of a pressure gauge port must be loosened until the air is evacuated from the system 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 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 filiing the tank wait before starting the burner This will give any suspended impurities time to deposit on the bottom of the tank thus avoiding the possibility that they might be sucked into the pump e Oninitial commissioning a dry operation is foreseen for a considerable length of time for example when there is a 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 Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical se
31. oil nozzle nozzle Size PUMP PRESSURE bar 8 9 10 11 12 13 14 15 16 17 18 GPH Flow rate kg h 0 40 1 36 1 44 1 52 1 59 1 66 1 73 1 80 1 86 1 92 1 98 2 04 0 50 1 70 1 80 1 90 1 99 2 08 2 17 2 25 2 33 2 40 2 48 2 55 0 60 2 04 2 16 2 28 2 39 2 50 2 60 2 70 2 79 2 88 2 97 3 06 0 65 2 21 2 34 2 47 2 59 2 70 2 82 2 92 3 02 3 12 3 22 3 31 0 75 2 55 2 70 2 85 2 99 3 12 3 25 3 37 3 49 3 60 3 71 3 82 0 85 2 89 3 06 3 23 3 39 3 54 3 68 3 82 3 95 4 08 4 21 4 33 1 00 3 40 3 60 3 80 3 98 4 16 4 33 4 49 4 65 4 80 4 95 5 10 1 10 3 74 3 96 4 18 4 38 4 58 4 76 4 94 5 12 5 29 5 45 5 61 1 20 4 08 4 32 4 56 4 78 4 99 5 20 5 39 5 58 5 77 5 94 6 12 1 25 4 25 4 50 4 75 4 98 5 20 5 41 5 62 5 82 6 01 6 19 6 37 1 35 4 59 4 86 5 13 5 38 5 62 5 85 6 07 6 28 6 49 6 69 6 88 1 50 5 10 5 41 5 70 5 98 6 24 6 50 6 74 6 98 7 21 7 43 7 64 1 65 5 61 5 95 6 27 6 57 6 87 7 15 7 42 7 68 7 93 8 17 8 41 1 75 5 95 6 31 6 65 6 97 7 28 7 58 7 87 8 14 8 41 8 67 8 92 2 00 6 80 7 21 7 60 7 97 8 32 8 66 8 99 9 30 9 61 9 91 10 19 2 25 7 64 8 11 8 55 8 96 9 36 9 74 10 11 10 47 10 81 11 14 11 47 1 2 14 UNIGAS M039223CB Before performing adjustments it is
32. ollows Disconnect the system from the electrical power supply Shut off the fuel supply remove the photoresistor from its slot see next figure clean it if dirty with a dry and clean cloth if necessary replace the photoresistor replace the photoresistor into its slot O 19 UNIGAS M039223CB Checking the detection current Before turning the burner on or in case of maintenance check the flame signal while the burner is operating measure by means of a multimeter the voltage betwenn terminal 9 and the neutral The voltage measured must be lower than 0 5Vdc as shown on picture below This value assures a safety margin because it corresponds to a illumination twice the minimum required the operating limit for the device is 0 8V If the measured value is higher try to better set it or clean it if dirty Morsetto n 9 Terminal no 9 V 0 5V DC h Morsetto di neutro Neutral Fig 17 Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner main switch to O Off position 2 disconnect the power mains 3 close the fuel 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 20 UNIGAS M039223CB TROUBLESHOOTING z o 2 02 OF JOTO no LL c5 E 025 EO 0 lt oF zZz
33. uirements 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 electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI 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 CEI EN 60335 1 Household and similar electrical appliances Safet
34. ulation feed systems If the device installed is a solenoid valve a timer must be installed to delay the valve closing The direct connection of the device without a timer may cause pump breaks Burner Flexible hoses fitted Light oil filter fitted Automatic interceptor One way valve Gate valve Quick closing gate valve outside the tank or boiler rooms O Q Q N The pumps that are used 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 pulg 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 pipe that connects the pum 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 come out from the factory provided for double stage 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 i
35. urner reassembly light the flame and check its shape replacing the nozzle whenever a questio nable flame shape appears Whenever the burner is used intensely we recommend preventively replacing the nozzle at the start of each heating season e Clean and grease sliding 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 3 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 Remove the burner cover by unscrewing the fixing screws Remove the FR detection probe from its slot disconnect the electrodes cables and remove the light oil pipe Unscrew the four screws that fasten the head ass y Unscrew the screws that fasten the gas manifold C The operator must pull the burner towards him her self to take the combustion head out Clean the combustion head by means of a vacuum cleaner scrape the scale off using a metallic brush Note to reassemble the burner follow the procedure above in the reversed oredr 18 C I B UNIGAS M039223CB Adjusting the electrodes and nozzle position ATTENTION avoid the electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the
36. urner 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 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 qualified 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 e Make sure that the burner has on installation been firmly secured to the appliance so that the flame is generated inside the appliance firebox Before the burner is started and thereafter at least once a year have qualified personnel perform the following operations a set the burner fuel flow rate depending on the heat input of the appliance b setthe flow rate of the combustion support
37. within safety time at the end of the same the controller proceeds to lockout and so the valve ignition transformer and motor are de energized and the lockout signal is activated The following cycle diagrams are useful to better understand the operation of the single controllers Abnormal operations 220V and 110V G22 controller an extraneous light or a fault in the amplifier which corresponds to the flame condition leads to a continuous pre purge condition 220V and 110V GF2 controller an extraneous light or a fault in the amplifier which corresponds to the flame condition causes the controller to lockout in the time equivalent to safety time All controllers with 24V and 12V an extraneous light or a fault in the amplifier which corresponds to the flame condition causes the controller to lockout in the time equivalent to safety time Controller Reset When the controller has gone to lock out a 10 second interval should be allowed before attempting to reset it if this interval is not allowed the con troller may not be reset Flame Signal Test It s extremely important to test the flame signal level before starting up the burner or in case of a maintenance operation To effect this test it s enough to have a multimeter and while the burner is in the running state to measure the voltage between terminal 9 and the neutral one which must be lower than 0 5V dc as shown in the next picture This value gua rantees a sufficient safety m
38. y 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 M039223CB GENERAL FEATURES This series represents monobloc gas burners made in die cast aluminium housing the combustion head position can be adjusted which allows a good performance Gas valve group Blast tube Combustion head ass y Burner flange Burner cover Q N 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 passing through the nozzle The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which a separate regulating valve is provided Other pumps are provided with two pressure regulators one for the high and one for low pressure in double stage systems with one nozzle The adjustable combustion head can improve the burner performance The combustion head
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