PG91 PG92 PG93 - Arzatoare CIB Unigas
Contents
1. 13 About the use of fuel pumbs P 13 Ola 14 Electrical connections rds 15 O c iiec 15 enu ge cH 16 Adjustments 18 G HO 18 Oil Flow Rate Settings by means of Berger STM30 actuator a 18 Adjustment by the Siemens SQL33 actuator 21 LOI CAO 24 Calibration of air pressure switch when provided 24 PARTI OPERAIONaci 25 OPERATION EH 25 Burner conto DANG 26 PET 27 ROUTINE MAINTE NANCE 31 TCE sz e 27 FICINOVING2. uuu uuu 28 Z Sua VIG OU QUO EE 28 Correct position of electrodes and 221 29 Replacing the ignition electrodes 29 Cleaning and replacing the detection photoresistor nnns 29 m Q 30 l MM E 30 TROUBLE SAIA PII E u 31 SPARE FART s UR UI 32 uu 94 ELEC TRIGAL WIRING DIAGRANS uuu u 35 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 S
3. L M Z BV1 br DE 7130a02e 0700 Sequenza dei comandi LMO14 R A A B C D Ww 753 1 tw Is OH 3 x mp 8 Mc Z 3 MT 3 X BV1 174 4 t1 Di ues ZL 6 t IN 11 FS gt Only with LMO14 113A2 re ignition B i n n QD z TL JC 6 K gt FS 7 I JL 4 e 7130d02e 0700 LMO24 LMO44 R A A B C D W 4 1 Bn tw 98 3 Am 17 4 Z lt T Xavi ZZ Am 4 X BV2 p 5 Gr zt Ze 6 E 7 ZZ lt q Bn Bn oe 4 fs 7 gt 6 FS Z Al 27 DIDI lt q ax 7130403 0700 12 Legenda AL Dispositivo di allarme Kbr collegamento per cavo necessario solo per bruciatori senza preriscaldatore di gasolio BV Valvola del combustibile EK1 Pulsante di sblocco EK2 Pulsante di sblocco a distanza FS Segnale di presenza fiamma FSV Amplificatore del segnale di fiamma K Contatti del rel di comando LED Luci spia a tre colori M Motore del bruciatore OW Contatto di consenso del preriscaldatore t1 Tempo di preventilazione t3 Tempo di preaccension
4. Progressive Fully modulating Light oil burners MANUAL OF INSTALLATION USE MAINTENANCE 8 UNIGAS BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES UNIGAS M039186CB TABLE OF CONTENTS WARNINGS 3 5 CENERAL FEATURE lle oaa ayaka aasma aasan ahus 5 How to interpret the burner s Performance iii 6 MT u 7 E 7 guion eee 8 MOUNTINGS AND 9 9 aiugeg Telsu qoni cbEe m P 9 Fanano I D 10 Hydraulic diagrams for light oil supplying circuits n 10 Installation diagram of light oil pipes Gud Vd pd laca mod a e i 11 Blogo oin o T Y 12 Assemoling Te light oll lexible
5. 1 SEGUE TOTALE Dis 0 352 2 4 36 Y MC CET KT2 4 x M 10sec LEVG 31 Y MC 1 9 i iu dl 1 9 aE a i a 1 9 KA2 3 2 3 50133 03 577 20 240 15 51 64 TM P Data 17127160967 PREIS SEHE DE SEGUE TOTALE 392 5 4 Dis N NX NS lt lt O um QD z z emizliaim un wir oljo gt ria Z T oa 2 2 amp zu d C Un Va LI LY LY a MV TA 50133 03 FR EVG STM30 24015 51 641NLP CAMME SERVOCOMANDO SERVOCOMANDO SERRANDA ARIA ALTERNATIVO EVO SERVO CONTROL CAMS AIR DAMPER SERVO CONTROL ALTERNATIVE 501233209 S M30 24015 51 641NLP Y1 ALTA FIAMMA ALTA HIGH FLAME HIGH FLAME Y2 SOSTA E ACCENSIONE Il SOSTA E ACCENSIONE STAND BY AND IGNITION STAND BY AND IGNITION 3 BASSA FIAMMA Ill BASSA FIAMMA LOW FLAME LOW FLAME 6 CONSENSO ALLA PARTENZA V CONSENSO ALLA PARTENZA INPUT TO START INPUT TO START Data 17127160967 5 ESSE Revisione 04 2 5 SEGUE TOTALE Dis Ne 352 4 ih j 1 roi 1 i BE OO ooo ER FORE RLEVRZIONE AA Poo roresisTon Ti 77727777 TERMOSTATO PRESSOSTATO ALTA BASSAFIAMMA HIGH LOW THERMOSTAT PRESSURE SWITCHES FAN MOTOR THERMAL Data 1 742 4096 BEI 9 NN SEGUE TOTALE Dis
6. gt un a 2 na MV TA saL33 03 FR EVG STM30 24015 51 641NLP CAMME SERVOCOMANDO SERVOCOMANDO SERRANDA ARIA ALTERNATIVO Ae ACTUATOR CAMS AIR DAMPER ACTUATOR ALTERNATIVE SUL 33 03 STM30 245015 51 641NLP Y1 ALTA FIAMMA ALTA FIAMMA HIGH FLAME HIGH FLAME Y2 SOSTA E ACCENSIONE II SOSTA E ACCENSIONE STAND BY AND IGNITION STAND BY AND IGNITION 3 BASSA FIAMMA Ill BASSA FIAMMA LOW FLAME LOW FLAME 6 CONSENSO ALLA PARTENZA V CONSENSO ALLA PARTENZA INPUT TO START INPUT TO START Data 23 02 2000 Revisione O S 4 SEGUE TOTALE Ds 0 401 5 5 Bi E cun il m H llt coi cio cui lu yl s O C jS NENNEN EI DEINDE Eva gt RETROVAVOLAGASQUO o UGHTOLSQENODVANE 0 TRANSDUCER VOLTAGE OUTPUT TRANSDUCER CURRENT OUTPUT SIEMENS Loata CHOW APPARECCHIATURA CONTROLLO FIAMMA CONTROL BOX BURNER MODULATOR SERIES OF THERMOSTATS OR PRESSURE SWITCHES AIR DAMPER ACTUATOR ALTERNATIVE TRANSFORMER Tm _ FAN MOTOR THERMAL Data 23 02 2000 412 SEGUE TOTALE Dis N 401 5 APPARECCHIATURA DI COMANDO E CONTROLLO FIAMMA SIE MENS LMO14 LMO24 LMO44 Le apparecchiature di controllo f amma LMO sono progettate per l avviamento e il controllo di bruciatori a gasolio mono o bistadio con tirag gio forzato a funzionamento intermittente Le fiamme gialle vengono con trollate dai rivelatori a
7. 0 352 4 ein Cr ca _ Lio s lh Lor Li _ a ah ie i dB Li iS ci amp 00V 3N N EN FU10 FU1 2 PMA Q MOTORE VENTILATORE FAN MOTOR SIEMENS LOA4 amp 4 LMO44 10 10 h 1 0 _ 182 Dota 23 02 2000 P Pra TARU RE SEGUE TOTALE Ds 0 401 5 2 KT2 4 KA2 3 2 23 3 0 30 28 32 O mc O Mc KA2 3 2 3 3 0 LAF 9 33 229 1230 O MC Pme Pm Data 23 02 2000 sero Rx SEGUE TOTALE Ds 0 401 5 SIEMENS RWF40 0x0 Q Y1 Y2 013015 L1 N TE CAVO 7 xO 5mmq LLI Lg Sle Siz CABLE 5 FU e Sls 2A OS un gt i 2 m CONN 7 PINS 2 9 CMF 1 9 1 9 2 9 2 9 xx ATTENZIONE COLLEGAMENTO SONDE CON CONNETTORE 7 POLI WARNING PROBE CONNECTION WITH 7 PINS CONNECTOR VERDE GREEN Gl sp TEMP SD TEMP SIEMENS QAE2 QAC2 QAM2 PT1000 1000 OHM 0 C PT100 100 OHM 0 C SD 4 20mA DANF0SS SD 0 10V Data 23 02 2999 disse TPS SD PRESS 215 SIEMENS SEGUE TOTALE 4 5 MARRONE BROWN GL Dis N 401 SS SR N lt INS L E L O OJO 22 Se miz ia m r e oe 5 2 o5z lt i TEM ge ES 7 27 gt
8. 8 The high low flame operation is showed by the F LED turning on off Burner control panel Keys P Fig 23 A ON OFF main switch B Lockout signalling lamp C Conreol box release pushbutton D X Signalling lamp for light oil solenoid valve opening E Thermal cutout intervention signalling lamp High flame operation signalling lamp G Low flame operation signalling lamp H Ignition transformer operation signalling lamp P Siemens RWF40 modulator Q Manual operation mode switch 26 UNIGAS M039186CB At least once a 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 N THE FUEL MANAUL CUTOFF VALVES CLOSED ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL ROUTINE MAINTENANCE e Check clean the cartdrige of the fuel filter replace it if necessary see next paragraph e carefully check for leaks the fuel flexible hoses 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 th
9. durante il funzionamento la fiamma viene a mancare per la quarta volta il bruciatore andra in blocco Il conteggio delle ripetizioni riparte ogni volta che interviene l accensione comandata tramite R W SB Funzionamento Il pulsante di sblocco EK l elemento chiave per lo sblocco zione delle funzioni di diagnostica II LED a tre colori l elemento chiave per l indicazione della dia gnosi visiva e A dell apparecchio di controllo fiamma e per l attivazione disattiva della diagnosi dell interfaccia S Rosso 1 Giallo Verde Tabella dei codici di colore Stato Codice colore Colore II preriscaldatore di gasolio in funzione Giallo tempo di attesa tw Fase di accensione I Giallo spento accensione controllata Funzionamento 000000000000 Verde fiamma regolare Funzionamento omomomomomo Verde spento fiamma non regolare Abbassamento di I i 15151515161 Giallo Rosso tensione Anomalia allarme SSSSSSSSSSS Rosso Codice di anomalia vedi Tabella dei codici smsmsmsmsm Rosso spento di anomalia Luce estranea prima dell avviamento del OSOSOSOSOSO Verde Rosso bruciatore Rosso Diagnosi o SSSSSSSSSSSSSS intermittenza dell interfaccia veloce Legenda m Spento 1 Giallo Rosso Diagnosi della causa di anomalia In questa condizione possibile attivare il sistema di diagnostica che indica la causa dell
10. CONNECTIONS FIT DIFFERENTIAL THERMAL MAGNET SWITCH ADE QUATE FOR CONNECTION TO THE MAINS STRICTLY OBSERVE THE DATA PLATE e Remove the cover from the burner electrical panel e Execute the electrical connections to the power supply terminal board as shown here following check the direction of the motor see next paragraph and replace the cover of the electrical panel 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 Progressive burners Probes connection G1 sp TEMP SD TEMP SIEMENS QAE2 QAC2 QAM2 PT1000 1000 OHM 0 C PT100 100 OHM 0 C SD 4 20mA DANFOSS SD 0 10V Probes connection oby means of the 7 pins plug Fig 14 see Fig 12 for connections SD PRESS SIEMENS QBE Fig 14 Motor rotation Once the burner electrical connection is accomplished remember to check the rotation of the fan motor The motors must rotate in the direction showed on their 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 c
11. E in figure on the fuel pipes use 2 spanners to avoid loosening the connections attached to the distributor block loosen VRT screw to free the threaded rod AR then screw out the 2 screws V holding the washer R and the screw VRT again remove the whole assembly as shown in figure clean the combustion head 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 Removing the oil gun Once the combustion head is removed as described before remove the oil gun as foloows 1 OI c nm unscrew the connectors from the 2 oil pipes E in figure using 2 spanners to avoid loosening the connections attached to the distri butor block loosen the screw VB remove the gun with the light oil nozzle holder clean the oil gun by means of a vacuum cleaner to scrape off the scale use a metallic brush replace the oil gun if necessary Note To re assemble follow the procedure above in reversed order 28 UNIGAS M039186CB Correct position of electrodes and nozzle ATTENTION avoid the ignition electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler s 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 24 must be observed Be sure to tighten the screw on th
12. PERSIST WITH THE RESET BUTTON AND CONTACT QUALIFIED PER SONNEL WHO WILL PROCEED TO ELIMINATE THE MALFUNCTION 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 25 UNIGAS M039186CB OPERATION switch is closed ATTENTION before starting the burner up be sure that the manual cutoff valves are open usre that the mains 1 Setto the ON position the switch on the control panel of the burner 2 Checkthe control box is not in the lockout position light B must be off in such a case reset it by the reset pushbutton C 3 Check the series of thermostats or pressure switches sends the burner the signal to operate 4 startup sequence begins the control box ignites the fan pump motor and energises the ignition transformer as well signalled by the light H on the burner control panel 5 At the end of the pre purge stage the light oil solenoid valve EVG is energised signalled by the lamp G on the control panel and the burner is on 6 The ignition transformer is energized for few seconds after the ignition of the flame post ignition time and at the end of this time is de energised light H off 7 After the ignition the servocontrol moves to the high flame position for some seconds then the operation begins and the burner switches to high flame or to low flame according to the plant demand
13. fasten the 4 stud bolts 5 place the gasket on the burner flange 6 install the burner into the boiler 7 fixthe burner to the stud bolts by means of the fixing nuts according to the next picture 8 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 1 Burner 2 Fixing nut 3 Washer 4 Sealing gasket 5 Stud bolt 7 Blast tube Handling the burner 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 The unpacked burner must be lifted and moved only by means of a fork lift truck The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck the forks must be inserted into the A anb B ways Remove the stirrup only once the burner is installed to the boiler C I B UNIGAS M039186CB Hydraulic diagrams for light oil supplying circuits Key Fig 3 Gravity circuit Kl Fig 4 Ring circuit ES Fig 5 Suction circuit Manual valve Light oil filter Light oil feeding pump One way valve A F
14. fotoresistenza QRB le fiamme blu dai rivelatori QRC In termini di ingombro collegamenti elettrici e rivelatori di fiamma la serie identica agli apparecchi di controllo fiamma LOA Condizioni indispensabili per l avviamento e Apparecchio di controllo fiamma sbloccato e Tutti i consensi della linea di alimentazione sono chiusi e Non ci sono abbassamenti di tensione e rilevatore di fiamma al buio nessuna luce estranea Sicurezza alle basse tensioni e Nel normale funzionamento se la tensione scende al di sotto di 165V ca l apparecchio esegue un arresto di sicurezza e Quando la tensione supera 175V ca l apparecchio si riavvia automati camente Controllo del tempo di intervento del preriscaldatore di gasolio Se il contatto di consenso del preriscaldatore di gasolio non si chiude entro 10 minuti l apparecchio di controllo fiamma andr in blocco Funzionamento intermittente Dopo non pi di 24 ore di funzionamento continuo l apparecchio effettua un arresto di sicurezza automatico e quindi si riavvia Sequenza dei comandi in caso di anomalia In caso di blocco vengono disattivate immediatamente le uscite delle val vole del combustibile e l accensione 1 secondo Dopo una interruzione di tensione Hiavviamento Dopo che la tensione scesa sotto la Qe I Riavviamento soglia minima consentita Nel caso di presenza prematura del segnale di fiamma o di segnale Arresto di blocco al termine d
15. head position repeat the air and gas adjustments described above 13 the air and oil rate are now adjusted at the maximum power stage go on with the point to point adjustement on the SV adjusting cam as to reach the minimum output point 14 asforthe point to point regulation in order to set the cam foil shape move the low flame microswitch cam lll a little lower than the maximum position 90 15 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position 16 move cam Ill low flame towards the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw that refers to a lower position screw V to increase the rate unscrew to decrease in order to get the pressure as showed on diagram in Fig 28 according to the requested rate 17 Move again cam lll towards the minimum to meet the next screw on the adjusting cam and repeat the previous step go on this way as to reach the desired low flame point 18 The low flame position must never match the ignition position that is why cam III must be set 20 30 more than the ignition posi tion Turn the burner off then start it up again If the adjustment is not correct repeat the previous steps 20 UNIGAS M039186CB Adjustment by the Siemens SQL33 actuator 1 Open the electrical panel to check the fan pump motor rotation and act directly on the its contactor CV see next picture
16. into the combu stion chamber as to let the flame light up UNIGAS M039186CB 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 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 Campo di lavoro bruciatori combustione mbar gt O gt N A Q O N Contropressione in camera di 100 200 300 400 500 600 700 800 900 Potenza kW Fig 2 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 C Burner model identification Burners are identified by burner type and model Burner model identification is described as follows ypePG92 Model G PR S A 1 3 4 5 6 BURNER TYPE PG91 PG92 PG93 FUEL G Light oil A Biodiesel 1 OPERATION Available versions R Progressive MD Fully modulating P BLAST TUBE S Standard L Extended BURNER VERSION Standard C I B UNIGAS M0
17. keep pressed for some seconds until the oil circuit is charged 3 Turn the burner on by means of its main switch A if the burner locks LED B on in the control panel press the RESET button C on the control panel see next picture see chapter OPERATION on page 26 SQL330 actuator cams AB High flame cam BF Low flame cam B plastic cam G cam locking lever CP Start signal cam 21 UNIGAS M039186CB 5 Start the burner up by means of the thermostat series and wait unitl the pre purge phase comes to end 6 the burner starts up with the actuator on the ignition position set it to the MAN manual mode by the MAN AUTO selector ignition position read on the air damper index ID1 see picture on pag 23 7 disconnect the TAB thermostat removing the wire from the terminal no 6 or by setting MAN on the RWF40 modulatore or by set ting by means of the switch only for fully modulating burners 8 set the actuator on the manual mode MAN by means of the MAN AUTO switch see next pictures 9 manually drive the adjusting cam SV to the high flame position and set the actuator to the AUTO mode by the related switch see picture to lock the adjusting cam 10 the nozzle suplly pressureis already factory set and must not be changed Only if necessary adjust the supply pressure as follows see related paragraph insert a pressure gauge into the port
18. or polluting unburnt gases in excess of the limits permitted by the regulations in force 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 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 case of repeated burner shut downs do not continue re setting the unit manually Contact qualified personnel to take care of such defects 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 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 th
19. 0 Tenere premuto il pulsante di sblocco per circa 1 secondo 3 secondi Schema elettrico e schema interno LMO14 Z uC control LED Y 7 2 2 4 6 9 lt 6 9 lt 9 lt SB x R OW Jeka O w OH AL N QRC Si jl 1 bl sw L MHA gt S N dcs 7130 01 0700 LMO24 LMO44 uc contol i K2 o To 1 a 8 3 1 2 I OH Bv2b ORC i
20. 185 PG92 1253 1426 242 294 467 419 918 422 935 422 513 266 296 360 464 M12 417 280 310 295 649 213 185 9 1253 1426 243 294 467 460 918 422 935 422 513 266 296 360 464 M12 417 280 310 295 649 213 185 BS standard blast tube BL extended blast tube 829816 0H SV9SINn 8 TO UNIGAS M039186CB MOUNTINGS AND CONNECTIONS Packing The burners are dispatched in wooden pakages whose dimensions are 1730mm x 1280mm x 1020mm 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 1 2 1 1 1 burner H 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 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 1 make a hole on the closing door of the combustion chamber as described on paragraph Overall dimensions 2 place the burner to the boiler lift it up and handle it according to the procedure described on paragraph Handling the burner 3 place the 4 stud bolts 5 on the hole of the boiler s door according to the burner s drilling plate described on paragraph Overall dimensions 4
21. 2480040 2480007 SERVOCONTROL mod BERGER STMS0 2480090 2480090 2480090 PHOTORESISTOR mod SIEMENS QRB 2510003 2510003 2510003 COUPLING 2540121 2540121 2540134 PRESSURE GOVERNOR 2570054 2570054 2570077 BURNER MODULATOR 2570112 2570112 2570112 PUMP mod SUNTEC 2590118 2590119 2590120 PUMP mod DANFOSS 2590310 2590311 2590312 NOZZLE mod BERGONZO A3 2610202 2610202 NOZZLE mod FLUIDICS WR2 50 2610203 OIL GUN standard 2700217 2700217 27002 OIL GUN long 2700223 2700223 27002xx COMBUSTION HEAD 3060160 3060161 3060161 BLAST TUBE standard 30910C5 30910C6 30910C6 BLAST TUBE long 3091082 3091084 3091084 IGNITION CABLES 6050129 6050129 6050129 829816 0H SV9SINn ATO S ELECTRIC WIRING DIAGRAMS ATTENTION 1 Electric supply 230V 400V 50Hz 3 a c 2 Don t reverse phase and neutral 3 Make sure that the burner is properly hearted Wiring diagram 07 352 Rev 4 Progressive Burners Wiring diagram 07 401 Rev 5 Fully modulating Burners 829816 0H SV9SINn ATO 1 0 FU1 2 T M OMA TV PS E pu 12 413 ma IL H FU1 3 A 6 3 OMA ST TV MA LB LT 1 K 9 T MA 2 0 e qus nA s ER 3 e 20 pe 20 MOTORE VENTILATORE FAN MOTOR ho ere 10 sa 10 sa 18 Data 17127160967
22. 39186CB Technical specifications Fuel Light oil e IP40 NOTE Choosing the nozzle for light oil consider Hi equal to 10200 kcal kg Electric motor Total power consumption Index of protection Operating temperature Storage temperature Working service NOTE ON THE WORKING SERVICE the Siemens LMO control box automatically stops after 24h of continuous working The control box immediately starts up automatically Performance curves PG91 PG92 18 18 gt 16 16 14 14 o 12 12 T 10 10 2508 I 6 6 4 4 O 2 2 0 0 400 800 1200 1600 2000 2400 400 800 1200 1600 2000 2400 2800 kW kW PG93 14 12 10 8 6 4 2 0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 KW BACK PRESSURE IN COMBUSTION CHAMBER mbar COMBUSTION CHAMBER mbar C To get the input in kcal h multiply value in kW by 860 Data are referred to standard conditions atmosferic pressure at 1013mbar ambient temperature at 15 Overall dimensions mm boiler drilling plate burner flange AS AL AA BS BL BB CC D E F G H K L M N Omin Omax W Y 2 PG91 1259 1432 242 300 473 419 918 422 935 422 513 238 268 360 464 M12 417 280 310 295 649 196
23. ECOND 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 e 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 e 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 e 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 authorise
24. STANDARD COMPLETE OIL GUN OIL GUN HOLDER COMBUSTION HEAD IGNITION CABLE PUMP MOTOR MOUNTING FLANGE SPACER FAN WHEEL MOTOR OIL MANIFOLD PRESSURE GAUGE PRESSURE GOVERNOR BRACKET SPACER Bird kos q K 0101070 O 001 OO FAN OC pm a o DAWN La ila p o Ph ITEM DESCRIPTION ACTUATOR ACTUATOR SHAFT BRACKET AIR INTAKE DAMPER AIR INTAKE DAMPER AIR INTAKE LOUVER SHAFT LOUVER SHAFT ADJUSTING CAM SHAFT ADJUSTING CAM SCREW CA 8 9 3 LEVERAGE 8 9 4 8 9 5 8 9 6 JOINT JOINT FAIRLEAD FAIRLEAD AIR INLET CONE BURNER HOUSING COVER GENERATOR GASKET INSPECTION GLASS PHOTORESISTOR COUPLING 829816 0H SV9SINn ATO C I B UNIGAS M039186CB 33 76 I SPARE PARTS Desription Code PG91 PG92 PG93 CONTROL BOX 2020455 2020455 2020455 IGNITION ELECTRODES 2080206 2080206 2080206 FUEL FILTER 2090018 2090018 2090018 GASKET 2110048 2110048 2110048 FAN WHEEL 2150031 2150033 2150032 IGNITION TRANSFORMER 2170302 2170302 2170302 ELECTRIC MOTOR 2180276 2180277 2180206 SOLENOID VALVE 2190403 2190403 2190403 FLEXIBLE HOSESL 1500 1 2340004 2340004 2340004 FLEXIBLE HOSES L 335 3 8 2340087 2340087 2340087 FLEXIBLE HOSES L 385 3 8 2340088 2340088 2340088 ADJUSTING CAM FOIL 2440013 2440013 2440013 SERVOCONTROL mod SIEMENS SQL 2480040
25. 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 Do not use 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 An external filter should always be installed in the suction line upstream of the fuel unit 13 UNIGAS M039186CB Light oil circuit The fuel is pushed into the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor The solenoid valve 2 set the fuel immission into the combustion chamber The part of fuel that is not burnt goes back to the tank through the return circuit The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see pag 22 Fig 7 Stand by nl O Fig 8 Prepurge Fig 9 Low flame Fig 10 High flame Key Light oil pump Light oil solenoid valve Nozzle Actuator Adjusting cam pressure gauge Pressure regulator One way valve N O NN 14 UNIGAS M039186CB Electrical connections RESPECT THE BASIC SAFETY RULES MAKE SURE OF THE CONNECTION TO THE EARTHING SYSTEM DO NOT REVERSE THE PHASE AND NEUTRAL
26. ale and set it to a value reduced by 15 e Repeat the ignition cycle of the burner and check it runs properly e Refit the transparent plastic cover on the pressure switch 24 C I B UNIGAS M039186CB 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 THE EVENT OF REPEATED LOCKOUTS DO NOT
27. anomalia interpretabile in base alla tabella dei codici di errore sufficiente tenere premuto il pulsante di sblocco per pi di tre secondi Numero lampeggi Tabella dei codici di errore Possibile causa 2 lampeggi Mancanza di fiamma al termine del tempo TSA Valvole combustibile difettose o sporche Hivelatore di fiamma difettoso o sporco Regolazione imprecisa del bruciatore man canza di combustibile e Accensione difettosa 3 lampeggi Posizione libera 4 lampeggi Luce estranea all avviamento del bruciatore 5 lampeggi Posizione libera 6 lampeggi KKKKKK Posizione libera 7 lampeggi KKKKKKK Numero eccessivo di mancanze di fiamma durante il funzionamento limitazione del numero di ripetizioni del ciclo di avviamento Valvole del combustibile difettose o sporche Hivelatore di fiamma difettoso o sporco e Regolazione imprecisa del bruciatore 8 lampeggi ck xx 9 lampeggi kkkkkkkkk 10 lampeggi kkkkkkkkkk Controllo del tempo di intervento del preriscaldatore di gasolio Posizione libera Errore di cablaggio o errore interno contatti in uscita Mentre in corso la diagnosi della causa dell anomalia le uscite dei comandi sono disattivate e bruciatore rimane spento Sbloccando l apparecchio di controllo fiamma si interrompe la diagnosi della causa dell anomalia e il bruciatore si accende nuovamente e Siattiva il segnale di anomalia AL al morsetto 1
28. ceed as follows according to the pump provided 1 remove the closing nuts 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 Suntec TA UNIGAS M039186CB About the use of fuel pumps 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 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 After filling 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 On initial 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 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
29. d 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 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 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 de
30. e tn Tempo di post accensione Inizio della sequenza di avviamento bruciatori con pre riscaldatore di gasolio A Inizio della sequenza di avviamento per bruciatori senza pre riscaldatore di gasolio Segnali di uscita dell apparecchio EN Segnali necessari in ingresso Legenda OH Preriscaldatore di gasolio QRB Rivelatore a fotoresistenza QRC Rivelatore di fiamma blu bl blu br marrone SW nero H Termostato o pressostato di regolazione SB Termostato di sicurezza Si Fusibile esterno W Termostato o pressostato di sicurezza Z Trasformatore di accensione t4 Intervallo tra il segnale di fiamma e il consenso a BV2 TSA Tempo di sicurezza all accensione tw Tempo di attesa per il preriscaldamento del gasolio B Tempo per la presenza di fiamma C Posizione di funzionamento D Arresto di regolazione tramite uC1 1 uC2 Microprocessore 2 Caratteristiche tecniche Tensione AC 230 V 10 15 AC 110 V 10 15 Frequenza 50 60 Hz 6 Fusibile esterno Si 5 A fusione lenta Potenza assorbita 12 VA Posizione di montaggio qualsiasi Peso 200 g circa Protezione IP 40 Lunghezza massima consentita dei cavi max 3 m capacit di linea 100 pF m Lunghezza del cavo del rivelatore 20 m posa separata Sblocco a distanza 20m Corrente massima ammessa a 5 gt 0 6 LMO14 LMO24 LMO44 Morsetto 1 5A 5A Morsetti 3 e 8 3A Morsetti 4 5 6 e 10 1A 1A Supervisione d
31. e Before the burner is commissioned qualified personnel should ins pect the following a the fuel supply system for proper sealing b 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 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 sw
32. e electrodes group before reassembling the combustion head x Fig 24 Replacing the ignition electrodes ATTENTION avoid the ignition electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler s 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 B that fasten the ignition electrodes remove the electrodes and replace them referring to the values quoted on Fig 24 C0 nm Cleaning and replacing the detection photoresistor When cleaning the photoresistive detector always use a clean cloth If necessary remove it from its slot to replace it 29 UNIGAS M039186CB Checking the detection current To measure the detection signal follow the diagram in Fig 25 If 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 Minimum current intensity with flame 45 Maximum current intensity without flame 5 5 Maximum possible current intensit with flame 100pA Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner s main s
33. e feet toward the pump body If the gasket between cover and pump housing should be damaged it must be replaced e remove check and clean the combustion head page 28 when reassembling carefully observe the measures on page 29 e check the ignition electrodes and their ceramic insulators clean adjust and replace if necessary page 29 e 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 e check and carefully clean the flame detection photoresistor page 29 if necessary replace it and if in doubt check the detection current following the scheme in Fig 25 e clean and grease leverages and rotating parts Light oil filter maintenance For correct and proper servicing proceed as follows 1 shut off fuel in the line section being serviced 2 unscrew the tray 3 remove the filter cartridge from its support and wash it with petrol or replace if necessary check seal O Ring replace if necessary 4 reassemble the tray and restore fuel flow 27 UNIGAS M039186CB Removing the combustion head 5 6 Remove the top cover remove the photoresistor from its seat unscrew the revolving connectors
34. e 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 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 e 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 the system i e pumps burner etc should be switched off 3b FIRING WITH GAS LIGHT OIL OR OTHER FUELS GENERAL e 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 property 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
35. ella fiamma con QRB e QRC QRB QRC Min intensit di corrente di rivelazione necessaria con fiamma 45 uA 70 pA Min intensit di corrente di rivelazione necessaria senza fiamma 5 5 uA 5 5 uA Massima intensit di corrente possibile 100 pA 100 pA Circuito per la misurazione della corrente di rilevazione 11 12 1 LMO bl SW 7130v01 0700 bl Sw 7130v02 0700 uA DC uA DC Legenda UA Microamperometro DC con resistenza interna da 5k W max bl Blu sw Nero br Marrone CB 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 Specifictions and and data subject to change Errors and omissions excepted
36. g screw VR see Fig 17 as to get the nozzle pressure at 20bar or 25bar according to the nozzle model Bergonzo or Fluidics nozzle see page 18 Pressure gauge port Fig 18 Fig 19 in order to get the maximum oil flow rate adjust the pressure reading its value on the PG pressure gauge without changing the air flow rate set during the gas operation adjustments see prevoius paragraph checking always the combustion parameters the adjustment is to be performed by means of the SV adjusting cam screw see picture when the cam has reached the high flame position To adjust the air flow rate in the high flame stage loose the RA nut and screw VRA as to get the desired air flow rate moving the rod TR towards the air damper shaft the air damper opens and consequently the air flow rate increases moving it far from the shaft the air damper closes and the air flow rate decreases Note once the procedure is perfomed be sure that the blocking nut RA is fasten Do not change the position of the air damper rods UNIGAS M039186CB TR RA VRA 12 Only if necessary change the combusiton head position to let the burner operate at a lower output loose the VB screw and move progressively back the combustion head towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment is accomplished VRT VB MIN position MAX position Attention if it is necessary to change the
37. i difettoso durante t1 tempo di t1 preventilazione Nel caso di presenza prematura del si Viene impedito l avviamento segnale di fiamma o di segnale arresto di blocco dopo non pi di 40 secondi difettoso durante tw tempo di pre riscaldamento Se il bruciatore non si accende durante il tempo TSA In blocco al termine di TSA Max 3 ripetizioni del ciclo di avviamento seguite da blocco fiamma In caso di mancanza fiamma in funzionamento II contatto di consenso del preriscaldatore di gasolio non si chiude Arresto di blocco entro 10 minuti Arresto di blocco In caso di blocco l apparecchio LMO rimane in blocco il blocco non pu essere modificato e si accende la lampada spia rossa Anche nel caso di mancanza di tensione l apparecchio reagisce allo stesso modo Sblocco del bruciatore In caso di blocco e possibile sbloccare immediatamente l apparecchio di controllo fiamma E sufficiente tenere premuto il pulsante di sblocco per circa 1 secondo 3 secondi Programma di accensione con LMO24 113A2 In caso di mancanza fiamma durante il tempo TSA il bruciatore viene riacceso ma non dopo il termine di TSAmax Pertanto durante il tempo di TSA possibile effettuare diversi tentativi di accensione vedi Sequenza del ciclo Limite di ripetizioni Se si verifica una mancanza di fiamma durante il funzionamento l appa recchio ripete il ciclo di avviamento per un massimo di tre volte Se
38. ic 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 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 a
39. itches 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 aQ 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 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 electromagnet
40. iver on the slot F to move the BF cam BF 22 low flame position must never match the ignition position that is why BF must be set 20 30 more than the ignition posi tion NOTE to change the low flame position act exclusively on the actuator cam 23 Now agjust the pressure switch if provided see page 24 23 UNIGAS M039186CB Fully modulating burners To adjust the fully modulating burners use the switch on the burner control panel see next picture instead of the TAB thermo stat as described on the previous paragraphs about the progressive burners Go on adjusting the burner as described before paying attention to use the CMF switch intead of TAB The CMF position sets the oprating stages to drive the burner to the high flame stage set CMF 1 to drive it to the low flame stage set CMF 2 To move the adjusting cam set CMF 1 or CMF 2 and then 0 0 stop CMF 1 high flame operation CMF 2 high flame operation flame operation 3 automatic operation Calibration of air pressure switch when provided To calibrate the air pressure switch proceed as follows e Removethe transparent plastic cap e Once air and gas setting have been accomplished startup the burner e During the pre purge phase o the operation turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout then read the value on the pressure switch sc
41. lexible hoses e Relief valve NOTE in plants where gravity or ring feed systems are provided install an automatic interception device see n 4 UNIGAS M039186CB Installation diagram of light oil pipes A PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL From tank To tank Fig 6 Double pipe system The burner is supplied with filter and flexible hoses all the parts upstream the filter 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 mE 4 Automatic interceptor The direct connection of the device without a timer 5 One way valve may cause pump breaks 6 Gate valve 7 Quick closing gate valve outside the tank or boiler rooms 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 plug if provided must be removed and the optional return port on the pump s body must be sealed by steel plug and wa
42. nd test methods UNIGAS M039186CB GENERAL FEATURES The burners of this series represent monoblock burners made in die cast aluminium housing with relative flange to work on heating generators The output range is from 700kW to 4000kW according to the model They can be provided in progressive or fully modulating version 10 11 Fig 1 Gun and head adjusting ring nut Control panel Electrical panel Burner cover Burner flange Blast tube combustion head ass y Photoresistance Pressure governor Air intake 10 Adjusting cam 11 Pump 12 Actuator ON O cO The fuel coming from the supply line is pushed by the pump 11 to the nozzle and then into the combustion chamber where the mix ture 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 11 main function is to transfer oil from the tank to the nozzle at required quantity and pressure To adjust pressure pumps are provided with a pressure governor The electric actuator 12 moves the air damper and 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 forced
43. on Attention if it is necessary to change the head position repeat the air and oil adjustments described above 14 once the air and oil flow rate have been adjusted at the maximum output go on with the point to point adjustment on the SV adju sting cam as to reach the minimum output point gradually move the adjusting cam in order to adjust each of the V screws as to describe the cam foil shape 15 to change the SV position set the actuator on the manual mode turn the adjusting cam SV and set again the actuator to the AUTO mode to lock the adjusting cam 16 acton the V screw that mathces the bearings referring to the adjusting cam position 17 to adjust the next screw set again the actuator mode to MAN turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw adjust it and go on this way to adjust all the screws in order to set the cam foil shape accor ding to the combustion values read 18 Once the cam foil shape is defined reconnect the TAB thermostat reconnecting the wire to the terminal no 6 or setting the RWF40 burner modulator to AUTO or the CMF switch to 3 only for fully modulating burner 19 Turn the burner off then start it up again 20 Once the pre purge time comes to end drive the burner to the high flame stage by the TAB thermostat check the combustion values 21 drive the burner to low flame if necessary adjust the low flame size output by inserting a screwdr
44. onnections inside the terminal box of the electric motor and replace the thermal cutout relay UNIGAS M039186CB ADJUSTING LIGHT OIL FOLW RATE Light oil nozzles The light oil flow rate can be adjusted choosing a by pass nozzle that suits the boiler utilisation s output and setting the delivery and return pressure values according to the values quoted on diagrams on Fig 15 and Fig 16 according to the burner type Nozzles provi ded are the following according to the burner type As far as reading the pressure values see next paragraphs PG91 PG92 Bergonzo Fig 16 PG93 Fluidics WR2 Fig 15 DELIVERY RETURN RETURN NOZZLE PRESSURE PRESSURE MAX PRESSURE MIN bar bar bar BERGONZO A3 5 recommended Example Fulidics as far as over 100kg h nozzle the 8096 of the nozzle rated flow rate is achieved with 18bar return pressure see picture above Pressure at nozzle 357psi FLOW RATE kg h Press all ugello Press all ugello 22 50 10 905 357 psi 25 polverizzazione 300 psi Pressione al ritorn Pressure on return 20 Pressione al ritorno Pressure on return LIZA TL 200 psi Up to 100kg h fino a 100 kg h 100 psi Flow rate 20 40 60 100 Portata Fig 15 Example Bergonzo if a 220kg h flow rate BERGONZO nozzle is provided set the return pressure at 11bar supply at 20bar on the delivery to get a 220kg h flow rate If the return pressure needed is 5bar in
45. oxide 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 Light oil 11 5 13 2 9 4 9 Adjust the air and fuel flow rates at the maximum output high flame first by means of the air damper and the adjusting cam respec tively e Check that the combustion parameters are in the suggested limits e Checkthe flow rate e Then adjust the combustion values corresponding to the points between maximum and minimum set the shape of the adjusting cam foil The adjusting cam sets the air fuel ratio in those points regulating the opening closing of the fuel governor e Set now the low flame output acting on the low flame microswitch of the actuator in order to avoid the low flame output increasing too much or that the flues temperature gets too low to cause condensation in the chimney Adjustment procedure To change the burner setting during the testing in the plant follow the next procedure according to the actuator model provided mod Berger 5 30 or mod Siemens SQL Oil Flow Rate Settings by means of Berger STM30 actuator 1 Open the electrical panel to check the fan pump motor rotation and act directly on its contactor CV see next picture keep pressed for some seconds until the oil circuit is charged 2 bleed the air from the M pressu
46. re gauge port Fig 17 by loosing the cap without removing it then release the contactor Suntec Fig 17 3 Before starting the burner up drive the high flame actuator microswitch matching the low flame one in order to let the burner ope rates at the lowest output to achieve safely the high flame stage 4 Turn the burner on by means of its main switch A if the burner locks LED B on in the control panel press the RESET button C on the control panel see next picture see chapter OPERATION on page 26 CON 11 UNIGAS M039186CB be sure that the actuator cam for the Startup enabling signal when used is about 5 more than the ignition cam start the burner up by means of the thermostat series and wait until the pre purge time comes to an end drive the burner to high flame stage by means fo the thermostat TAB Then move progressively the microswitch to higher values until it reaches the high flame position always check the combustion values and eventually adjusting the oil pressure see next step MAN AUTO STM30 Actuator cams High flame Il Stand by and Ignition Ill Low flame V Start enabling signal the nozzle suplly pressureis already factory set and must not be changed Only if necessary adjust the supply pressure as follows see related paragraph insert a pressure gauge into the port showed on Fig 18 and act on on the pump adjustin
47. sher 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 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 come out from the factory provided 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 Suntec TA 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 11 C I B UNIGAS M039186CB Light oil pumps Suntec Oil viscosity 4 450 cSt Cil temperature 0 140 C Max return pressure 5 bar Rotation speed 3600 rpm max Key Pressure regulator Pressure Vacuum gauge port to measure inlet pressure vacuum Pressure gauge port Suction To the nozzle Return ON Oa Assembling the light oil flexible hoses To connect the flexible light oil hoses to the pump pro
48. showed on Fig 21 and act on on the pump adjusting screw VR see Fig 20 as to get the nozzle pressure at 20bar or 25bar according to the nozzle model Bergonzo or Fluidics nozzles see page 18 Pressure gauge port Fig 21 Fig 22 11 order to get the maximum oil flow rate adjust the pressure reading its value on the PG pressure gauge without changing the air flow rate set during the gas operation adjustments see prevoius paragraph checking always the combustion parameters the adjustment is to be performed by means of the SV adjusting cam screw see picture when the cam has reached the high flame position 12 To adjust the air flow rate in the high flame stage loose the RA nut and screw VRA as to get the desired air flow rate moving the rod TR towards the air damper shaft the air damper opens and consequently the air flow rate increases moving it far from the shaft the air damper closes and the air flow rate decreases Note once the procedure is perfomed be sure that the blocking nut RA is fasten Do not change the position of the air damper rods VRA 13 Only if necessary change the combusiton head position to let the burner operate at a lower output loose the VB screw and move 22 UNIGAS M039186CB progressively back the combustion head towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment is accomplished VRT VB MIN position MAX positi
49. signed 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 e 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 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
50. stead act on the V adjusting screw on the pressure regula tor see chapter ADIUSTMENTS The flow rate will then be about 95kg h see the example shown on the Bergonzo diagram on next page 60 Reference Pression initiale 20 atm Vorlaufdruck konstant 20 atu UNIGAS M039186CB 29 16 Charles Bergonzo S A Moutier suisse Gicleur d bits variables 9 16 i Rucklaufd sen NA 4 88 8858988 48 asia bi q 4 Sin CM DE 5 WRK 11710 NUYU ARAMA NMU NN H i SS ESSE LING NN PYAAR NINS AN ANTNIN COLE TITO Rucklaufdruck n 240 n wo N w os 5555 8 m Nw 9 S x Gus 9 m N N H sn Fig 16 17 C I B UNIGAS M039186CB Adjustments brief description ATTENTION before starting the burner up be sure that the manual cutoff valves are open 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 mon
51. witch to O Off position 2 disconnect the power mains 3 close the fuel cock 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 30 C I B UNIGAS M039186CB TROUBLESHOOTING 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 31 NT WNT S win o F olala loll I BURNER EXPLODED VIEW ITEM DESCRIPTION STANDARD BLAST TUBE FRONT CONTROL PANEL LIGHT LIGHT LOCK OUT RESET BUTTON PROTECTION SWITCH BOARD COVER LONG IGNITION ELECTRODE CLOSING PLATE
Download Pdf Manuals
Related Search