LO35 IDEA series Light oil burners
Contents
1. oe i A V W WV V A V 0660000600 Z 6 E FS 7 1111 4 AL Alarm device kbr Cable link required only when no oil pre heater is used BV Fuel valve 1 Lock out reset button EK2 Remote lock out reset button FS Flame signal FSV Flame signal amplifier K Contacts of control relay LED 3 colour signal lamps M Burner motor OW Release contact of oil pre heater 11 Pre purge time t3 Pre ignition time t3n X Post ignition time A Beginning of start up sequence with burners using an oil pre heater A Beginning of start up sequence with burners using no oil pre heater Controller output signals summ Required input signals OH Oil pre heater QRB Photoresistive detector QRC Blue flame detector bl 2 blue br brown sw black R Control thermostat or pressurestat SB Safety limit thermostat Si External primary fuse W Limit thermostat or pressure switch Z Ignition transformer t4 Interval from flame signal to release BV2 Ignition safety time tw X Waiting time for oil pre heating B T2. LMO14 4 EK1 uC1 control HC2 la LED E Y K1 2 FSV 4 K3 Y lt 000 0 O u OAO OO SB R OW tHEK2 ORB 9 NN Ml rar OH xe N QRC i R L 2 Bv1 9 Bein 7130 01 0700 LMO24 LMO44 7130a02e 0700 Control sequence LMO14 RA A B C D DW 7 TL SB tw OH OW 7 C4 X 1 74 JE 217 A V WV V A V 522002404040 ce 8847 4 Only with LMO14 113A2 re ignition GE z E E FS 217 7130d02e 0700 A V 275 LMO24 LMO44
3. 12 Aboul he use of Tuel DUNDES M M 13 SETTING RH 14 SET Ecol Ir 14 PIDO PUD acetate 14 eG OUI m DM O voces 15 PE TOW TO TS ache cs om 16 Combustion head E 16 PARTI OPERATION Mc c M 18 OPERATION NE P 18 PART Ill i kh iu cw B rd uu iria 19 ROUTINE MAINTENANCE OPERATIONS _ 19 Disassembling the components plate 19 Disassembling the TOZZI A 20 Replacing he ClO COO 21 Checking the detection current 20 000000000000000000 21 12215022 216 9 21 TROUBLE ROSTIN CHv
4. Position Description 1 MOTOR GROUP 1 1 MOTOR 1 2 FAIRLEAD AND FLEXIBLE HOSES 1 3 FAN WHEEL 1 4 PIN 1 5 MOTOR SUPPORT PLATE 1 6 INSPECTION GLASS 1 7 RUBBER FAIRLEAD 1 8 NUT 1 9 SCREW 1 10 PUMP 1 11 PLASTIC COUPLING FOR MOTOR PUMP 2 TRANSFORMER GROUP 2 1 BRACKET 2 2 CONTROL BOX SOCKET 2 3 CONTROL BOX 2 4 TRANSFORMER 2 6 PHOTORESISTOR 3 COMBUSTION HEAD AND NOZZLE HOLDER GROUP 3 1 NOZZLE HOLDER GROUP 3 1 1 NOZZLE HOLDER EXTENSION 3 1 2 ADJUSTING PLATE 3 1 3 WASHER 3 1 4 NOZZLE HOLDER 3 1 5 RING 3 2 COMBUSTION HEAD WITH ELECTRODES 3 2 1 SWIRL VANE 3 2 2 INGNITION ELECTRODE 3 0 PIPE 3 4 NOZZLE 3 5 IGNITION CABLES 4 BLAST TUBE 5 COVER GROUP 5 1 COVER FIXING SCREW 5 2 RUBBER COVER FOR UNLOCK PUSHBUTTON 5 3 COVER 6 HOUSING GROUP 6 1 SCREW 6 2 AIR DAMPER 6 3 PIN 6 4 HOUSING 6 5 AIR INLET 6 6 AIR DAMPER INDEX 6 7 FAIRLEAD 7 GRID 8 BLAST TUBE FLANGE 9 FLANGE GASKET 28 C I B UNIGAS M039116CE CAN 2 A C 1 y f 7 lt YW Y A f gt y Y p 22 lt Y VN A f j 7 fi N H j A wo y NN 4 fi SAU Wi P 4 29 SPARE PARTS C I B UNIGAS M039116CE Desription Code LO 35 LO 35 P CONTROL BOX 2020473 2020473 EVG COIL or SUNTEC PUMP 2580402 2580
5. 17 C I B UNIGAS M039116CE 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 BURNER SHUT DOWN RESET THE CONTROL BOX BY MEANS OF THE RESET PUSHBUTTON IF A SECOND SHUT DOWN TAKES PLACE CALL THE TECHNICAL SERVICE WITHOUT TRYING TO RESET FURTHER
6. 22 EXTERNAL AIR INTAKE KIT ASSEMBLY WHEN SUPPLIED eeeeseeeessseeeeeeennn nnn 23 ELECTRICAL WIRING DIAGRAMS 24 BURNER EXPLODED VIEW V 28 PART sarees S 30 Pe NA fee E s A 31 WARNINGS THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO DUCT INSTALLATION AND MAINTENANCE THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS IN THE SECOND SECTION OF THIS MANUAL WE HIGHLY RECOMMEND TO READ IT CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE GENERAL INTRODUCTION The equipment must be installed in compliance with the regulations in force following the manufacturer s instructions by qualified per sonnel Qualified personnel means those having technical knowledge in the field of components for civil or industrial heating systems sanitary hot water generation and particularly service centres authorised by the manufacturer Improper installation may cause injury to people and animals or damage to property for w
7. LO35 IDEA series Light oil burners MANUAL OF INSTALLATION USE MAINTENANCE LIB UNIGAS BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES C I B UNIGAS M039116CE TABLE OF CONTENTS Ll Lebe TU 3 zz EE Pa HON c 5 GS M P 5 How to interpret the burner s Performance curve 6 ee P E 7 Foronmmanco CUNO S sen u 7 Waa CITC SOM 8 MOUNTINGS AND CONNECTIONS Di DII Rn SR RR RR Y RR Y RR E DR COD AR RA ARR NR YR RR YR RS 9 mico 9 BICCHICAl CONMCCHONS NR 10 dAran 01065 E 11 Light oil supply pipeline SIZING m 11 MONO UPE SVE ON e E EA EE P 11 Assembling the flexible light oil hoses
8. 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 and test methods C I B UNIGAS M039116CE GENERAL FEATURES Burners of this series are characterised by high performaces and width of the performance curves when the pressure in the combu stion chamber is high They are also characterised by other important functional features there are plugs which can be easily con nected to the boiler and to the detecting probes a pressure plug in the combustion chamber all mechanical components are mounted on a plate which can be quickly taken off for maintenance The head is adjustable through a graduated screw 1 8
9. 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 e Connect voltage using the boiler s master power switch e Make sure that the flame control device has not shut down and reset if necessary using the reset button pressing the clear rubber seal on the burner cover e Make sure that the set of thermostats or pressure switches triggers burner operation e The burner starting cycle begins the flame control device switches on the burner s fan and the ignition transformer switches on at the same time e end of the pre ventilation time the light oil solenoid valve is powered and the burner ignites e The ignition transformer stays ON for a few seconds after the ignition of the flame post ignition time and at the end of this time is switched off by the circuit C I B UNIGAS M039116CE 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 THE FUEL MANAUL CUTOFF VALVES CLOSED ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL ROUTINE MAINTENANCE OPERATIONS e In
10. 2 3 4 5 7 6 Flange Combustion head inside Photoresistor Control box with unlock pushbutton Solenoid valve Pump Transformer Blast tube CON OOF WD The fuel coming from the supply line is pushed by the pump to the nozzle and then into the combustion chamber where the mixture between fuel and air takes place and consequently the flame In the burners the mixture bertween fuel and air to perform clean and efficient combustion is activated by atomisation of oil into very small particles This process is achieved making pressurised oil pass through the nozzle The pump main function is to transfer oil from the tank to the nozzle at required quantity and pressure To adjust pressure pumps are provided with a pressure governor except some models for which a separate adjusting valve is provided Other pumps are provided with two pressure governors one for high and one for low pressure in double stage systems with one nozzle In the double stage burners the electric actuator that moves the air damper allows the optimisation of the gas flue values as to get an efficient combustion The position of the combustion head determines the burner output The air comburent and fuel light oil are for ced into the combustion chamber as to let the flame light up C I B UNIGAS M039116CE 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
11. Phase Burner in operation signaling lamp Burner lockout signaling lamp Flame control device SIEMENS Burner power supply terminal board Fan motor Neutral Thermostats or pressure switches Ignition transformer Thermostat pressure switch on boiler 1 Power supply 230V 50Hz 1N a c 2 Don t reverse phase with neutral 3 Ensure the burner is properly hearthed 25 9c Electrical diagram cod 01 362 Rev 2 Burners with pre heater SIEMENS LOA24 LMO14 LMO24 7 8 230V 50Hz 2 C EI MOTORE VENTILATORE FAN MOTOR CONNETTORE ALIMENTAZIONE SUPPLY CONNECTOR Data 37 05 1997 PAED i usns 1d SEGUE TOTALE Dis 01 562 2 2 39116 0W SVOINN 919 LOA24 LMO24 MA MV ATTENTION C I B UNIGAS M039116CE Time counter Light oil solenoid valve Fuse Photoresistor Line switch Phase Burner in operation signaling lamp Burner lockout signaling lamp Flame control device SIEMENS Burner power supply terminal board Fan motor Neutral Light oil pre heater Pre heater resistor Thermostats or pressure switches Ignition transformer Pre heater thermostat Thermostat pressure switch on boiler 1 Power supply 230V 50Hz 1N a c 2 Don t reverse phase with neutral 3 Ensure the burner is properly hearthed 27 C I B UNIGAS M039116CE BURNERS EXPLODED VIEW
12. 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 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
13. 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 1 draw a vertical line matching the furnace input value and an horizontal line matching the backpressure value The burner is suitable if the intersection point A is inside the performance curve combustione mbar Contropressione in camera di O N WO A AD Potenza kW Fig 1 Burner model identification Burners are identified by burner type and model Burner model identification is described as follows 1035 Model G S A 1 38 4 5 6 7 EE 3 OPERATION TN Single stage S Standard 4 BLAST TUBE L Long Standard 6 SPECIAL VERSION Y Special Z External air inlet 7 BURNER OUTFIT with pre heater C I B UNIGAS M039116CE SPECIFICATIONS BURNERS LO35 LO35 P 0 18 2 Powersupply 1 230V 50H Emme WW 7 Electric motor Total power consumption SS 3 _ Qe _ 3 Pemaerpowrcnumia w o Meme _ NOTE ON THE WORKING SERVICE e the SIEMENS
14. unscrewing the 4 V Position the gasket supplied in the appro fasten the grid to the volute and screws priate seat in the burner volute and insert then remove the grid the T volute plug Position the gasket in the seat of the Position the gasket in the seat of the External air intake mounted on the burner air inlet and reassemble the air inlet burner cover is recommended to cut the gasket obliquely its splicing and gluing point in order to increase the contact surface e Reassemble the burner component plate and cover NOTE When re assembling the component plate make sure that the air damper pin P enters its housing B see Fig 14 External air intake kit Code 3300023 spare parts list Description Quantity Code Gasket 2 meters 2110409 External air intake 1 1012101 Volute plug 1 2210214 Self tapping air intake fixing presa Ds i a x ggio p 2 526140015 23 ELECTRICAL WIRING DIAGRAMS Electrical diagram cod 01 361 Rev 2 Standard versions 230V 50Hz IN a c MOTORE VENTILATORE FAN MOTOR CONNETTORE ALIMENTAZIONE SUPPLY CONNECTOR Date 3 05 1697 PE 1 SEGUE TOTALE Dis 01 461 2 2 39116 0W SVOINN 919 LOA24 LMO24 MA MV N ST TA TS ATTENTION C I B UNIGAS M039116CE Time counter Light oil solenoid valve Fuse Photoresistor Line switch
15. 402 EVG COIL or DANFOSS PUMP 2580701 2580701 BLAST TUBE standard 30900F2 30900F2 BLAST TUBE long 30900F3 30900F3 IGNITION CABLES 6050152 6050152 COVER 1011802 1011802 IGNITION ELECTRODES 2080283 2080283 FUEL FILTER 2090027 2090027 FLEXIBLE HOSES 234FX22 234FX22 PHOTORESISTOR 2510029 2510029 PLASTICCOUPLING FOR MOTOR PUMP 2940095 2940055 GASKET 2110055 2110055 ELECTRIC MOTOR 2180705 2180705 PUMP SUNTEC 2590130 2590130 PUMP DANFOSS 2590309 2590309 NOZZLE HOLDER standard 30200C6 30200C8 NOZZLE HOLDER long 30200C7 30200C9 COMBUSTION HEAD 3060185 3060185 DANFOSS IGNITION TRANSFORMER 2170231 2170231 COFI IGNITION TRANSFORMER 2170139 21 0139 FIDA IGNITION TRANSFORMER 2170310 2170310 NOZZLE 60 26100 26100 FAN WHEEL 2150048 2150048 30 C I B UNIGAS M039116CE SIEMENS OIL BURNERS AUTOMATIC CONTROLLER LOA24 Use LOA safety devices are intended for use solely with QRB photoresi stors for lighting and controlling low capacity forced air light oil burners with max capacity 30 kg h in accordance with standard DIN 4787 The One or two flamess are lit through electrical connections with or without post ignition To replace LAI AND LAB WITH LOA LOA models can be used as replacement for LAI and LAB controllers by means of the adapter KF8819 and without the need to change the electrical wiring Because the LOA is smaller in dimensions when it is used with the adapter the external dimension
16. LMO control box automatically stops after 24h of continuous working The control box immediately starts up auto matically e SIEMENS LOA control box for safety reasons one controlled shutdown must be performed after 24 hours of continuous opera tion Performance curves 5 1035 LO35 G TN x xx A P E 2 E 1 5 15 gt gt 1 2 lt eI DO 0 5 0 5 2 T O 0 0 VA O 22 0 5 0 5 lt 60 1 4 10 20 30 40 50 10 20 30 40 kW kW Overall dimensions Version with external air inlet Standard version U men max C minimax adl max de CIB UNIGAS M039116E Boiler plate drilling template co co T s 2 2 eqni 1se g C I B UNIGAS M039116CE MOUNTINGS AND CONNECTIONS Packing Burners are despatched in cardboard packages whose dimensions are standard and long blast tube versions 280mm x 265mm x 400mm L x P x H external air inlet version 330mm x 295mm x 500mm L x P x H Packing cases of this kind are affected by humidity and are not suitable for stacking The following are placed in each packing case 1 2 1 1 gasket to be inserted between the burner and the boiler flexible oil pipes oil filter envelope containing this manual To get rid of the burne
17. Y OBSERVE THE DATA PLATE Before connecting the burner to the mains pay attention that the plant power on switch is in Off position and find the burner connector Burner power supply connector CONN LINEA 8453121 NIG IL A MA Bp Co a NO E Pid ER s e COLFLB 1 x IL pS S Tp 250 Fig 5 Time counter Fuse IL Line switch L Phase LB Burner lockout signalling lamp LF Burner operation signalling lamp N Neutral ST Thermostats or pressure switches group TS Boiler safety thermostat IMPORTANT before operating the burner be sure that the connector is linked as showed the diagram UNIGAS M039116CE Installation diagram of light oil pipes AN PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL From tank Totank 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 delay the valve clos
18. ault according to the error code table can be activated by pressing the lock out reset button for more than 3 seconds Error code table Possible cause Blink code 2 blinks No establishment of flame at the end of TSA e Faulty or soiled fuel valves e Faulty or soiled flame detector e Poor adjustment of burner no fuel e Faulty ignition 3 blinks 4 blinks 5 blinks 6 blinks 7 blinks Free Extraneous light on burner startup Free Free Too manny losses of fleme during operation limitattion og the number of repetitions e Faulty or soiled fuel valves e Faulty or soiled flame detector e Poor adjustment of burner 8 blinks ok kx Ax x x x 9 blinks kx Ax A A 10 blinks Yd kk ck ke A x kx Time supervision oil pre heater Free Wiring error or internal error output contacts C I B UNIGAS M039116CE During the time the cause of fault is diagnosed the control outputs are deactivated e Burner remains shut down e Fault status signal AL at terminal 10 is activated The diagnosis of the cause of fault is quit and the burner switched on again by resetting the burner control Press lock out reset button for about 1 second 3 seconds Connection diagram and internal diagram
19. do so do not allow children or inexperienced persons to use equipment The unit input cable shall not be replaced by the user In case of damage to the cable switch off the unit and contact qualified personnel to replace When the unit is out of use for some time the electric switch supplying all the power driven components in the system i e pumps burner etc should be switched off 3b FIRING WITH GAS LIGHT 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 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 Before the burner is commissioned qualified personnel should ins pect the following a 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 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 wi
20. e An external filter should always be installed in the suction line upstream of the fuel unit C I B UNIGAS M039116CE SETTINGS Oil rate adjustment Priming the pump Prior to start up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pump seal to break E ac Before carrying out the adjustment it is necessary to start up the fuel pump proceeding as follows 1 remove the burner cover 2 start the burner up by turning the main switch to on 3 the thermostat ST contacts close 4 waitfor the EVG solenoid valve to open 5 remove the FR photoresistor and light it up 6 bleed the air from the pressure gauge port see paragraph Light oil pumps If the burner locks press the unlock pushbutton P placed on the upper side of the burner and repeat the steps above The fuel flow rate is set choosing a nozzle that matches with the boiler output and setting the pump s maximum inlet pressure to 12 bar see the hydraulic diagram in To choose the correct nozzle refer to Tab 4 as for setting the pump pressure see paragraph Light oil pumps For further information on fuel pumps refer to paragraph About the use of light oil pumps Note all pumps are set to 12 bar The nozzle rate must be higher than the rate referred to the minimum burner output Key Fig 7 EVG Light oil solenoid valve M Manometer P Pump Tab 4 Choice of the oil nozzl
21. e Single stage burners 10 bar 12 bar kcal h kcal h kcal h 0 75 2 85 29 100 33 8 3 12 31 800 36 9 df 34 400 40 0 85 3 23 33 000 38 3 3 54 36 100 41 9 3 82 39 000 45 3 The pump is factory set to a pressure of 12 bar LIGHT OIL PUMPS Pump Suntec AS47 A Viscosity Fuel temperature Maximum inlet pressure Minimum inlet pressure Maximum Return pressure Maximum speed Pump DANFOSS BFP21R3 Viscosity Fuel temperature Maximum inlet pressure Maximum Return pressure Maximum speed Key Pressure governor Manometer Vacuum gauge Solenoid valve Nozzle Suction Return CON O A WD C I B UNIGAS M039116CE 2 12 mm s cSt 0 60 2 bar 0 45 bar to avoid gasing 2 bar 3600 rpm 1 3 12 mm s cSt 0 70 2 bar 2 bar 0 35 barto avoid gasing 3600 rpm Fig 8 C I B UNIGAS M039116CE Air flow adjustment Air flow is adjusted by working on the V screw Fig 9 The position of the air damper is indicated on the graduated scale where Point indicates the completely closed position Fig 9 Fig 10 Combustion head adjustment Adjust the combustion head using a screwdriver on the VR Fig 10 screw by either rotating counter clockwise to drive the head to the all forwards position or clockwise to drive it to the all backwards position Fig 11 All backwards position Fig 12 All towards position ATTENTION Once the adjus
22. es not close within 10 minutes the burner control will initiate lock out Controlled intermittent operation After no more than 24 hours of continuous operation the burner control will initiate an automatic safety shut down followed by a restart Control sequence in the event of fault If lock out occurs the outputs for the fuel valves and the ignition will immediately be deactivated 1 second undervoltage threshold In the event of a premature faulty flame signal during t1 Lock out at the end of t1 Prevention of start up lock out after no more than 40 seconds If the burner does not ignite during Lock out at the end of TSA TSA In the event the flame is lost during Max 3 repetitions followed operation by lock out Oil pre heater s release contact does ne Lock out not close within 10 min Lock out In the event of lock out the LMO remains locked lock out cannot be changed and the red signal lamp will light up This status is also maintai ned in the case of a mains failure Resetting the burner Whenever lock out occurs the burner control can immediately be reset To do this keep control the lock out reset button depressed for about 1 second 3 seconds Ignition program with LMO24 113A2 If the flame is lost during TSA the burner will be reignited but not later than at the end of TSAmax This means that several ignition attempts can be made during TSA refer to Program seque
23. hich 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 Incase of breakdown and or defective unit operation disconnect the unit Make no attempt to repair the unit or take any direct action Contact qualified personnel only Units shall be repaired exclusively by a servicing centre duly authorised by the manufacturer with original spare parts Failure to comply with the above instructions is likely to impair the unit s safety To ensure equipment efficiency and proper operation it is essential that maintenance operations are performed by qualified personnel at regular intervals following the manufacturer s instructions 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 beh
24. ime of flame establishment C Operating position D Controlled shut down by R Microcontroller 1 2 Microcontroller 2 34 C I B UNIGAS M039116CE General unit data Mains voltage 230 V 10 15 96 AC 110 V 10 96 15 96 Mains frequency 50 60 Hz 6 External primary fuse Si 5 A slow Power consumption 12 VA Mounting orientation optional Weight approx 200 g Degree of protection IP 40 Perm cable lengths max 3 m ata line capacitance of 100 pF m Detector cable laid separately 20 m Remote reset 20m Max perm amperage at 2 0 6 LMO14 24 1 44 Terminal 1 Terminals 3 and 8 3A 5A Terminals 4 5 6 and 10 1A 1A Flame supervision with QRB and QRC QRB QRC Min detector current required with flame 45 70ypgA Min detector current permitted without flame 5 5 5 5 Max possible with flame tipically 100 uA 100 LA Measurement circuit for detector current 11 12 LMO 11 12 1 bl SW eis bl sw br 7130v02 0700 uA DC uA DC QRB QRC1 Key uA DC DC microamperometer with an internal resistance of 5 max bl Blue SW Black br Brown 35 55 ERNIGAS Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 Internet www cibunigas it E mail cibunigas cibunigas it Note Specifictions and and data subject to change Errors and omissions e
25. ind 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 For all the 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 burner should be installed in a suitable room with ventilation openings complying with the requirements of the regulations in force and sufficient for good combustion Only burners designed according to the regulations in force should be used 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 ca
26. ing mE 4 Automatic interceptor 12 the device without a timer 5 One way valve 6 Gate valve 7 Quick closing gate valve outside the tank or boiler rooms Light oil supply pipeline sizing Gravity feeding single pipe Siphon feeding two pipes Suction feeding two pipes L Maximum pipeline lenght depending by its diameter and tank position Monotube system Burners leave the factory equipped for two pipe feeding They can be adapted for a mono tube system recommended in the case of gravity feed Refer to the paragraph About the use of the pumps for further details 11 C I B UNIGAS M039116CE Assembling the flexible light oil hoses To connect the flexible light oil hoses to the pump P proceed as follows remove the burner cover Assemble the rubber seal on the flexible light oil hoses and the power cord as shown in the figure while also re assem bling the cable clamp plate C Reassemble the burner component plate and cover Screw the rotating nut of the two flexible hoses on the pump being careful to avoid inverting the inlet and return lines Eee e Insert the rubber seal in its seat in the burner volute and fas ten it in place using the V screws C I B UNIGAS M039116CE About the use of fuel pumps Make sure that the by pass plug is not used in a single pipe in
27. ion would be compromised Check the electrodes position after any intervention on the combustion head To remove the combustion head proceed as follows remove the burner cover unscrew the fixing screws disconnect the ignition cable CA unscrew the fixing nuts and shift the combustion head off its housing adjust the electrodes E to replace them if necessary disconnect the cables and unscrew V remove the electrodes and replace them to clean the combustion head use a vacuum cleaner to scrape off the scale use a metallic brush replace all the items reversing the procedure NO Of WD Checking the detection current See the diagram in to measure the detection current If the signal doesn t suit the suggested value verify the electric terminals the cleaning of the combu stion head and the position of the photoelectric cell and replace it if required 45 pA mod LMO14 24 Minimum current intensity with flame 70 uA mod LOA24 Maximun current intensity without flame 5 5 uA mod LMO14 24 LOA24 Maximum possible current intensity with 100 pA mod LMO14 24 flame 210 WA mod LOA24 Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner s main switch to O Off position 2 disconnect the power mains 3 close the fuel cock of the supply line Burner s disposalln case of disposal follow the instructions according to the laws in force in your country about the Disp
28. nce Limitation of repetitions If the flame is lost during operation a maximum of 3 repetitions can be made If the flame is lost for the 4th time during operation the burner will initiate lock out The repetition count is restarted each time controlled switching on by R W SB takes place In the event of a premature faulty flame signal during tw Operation Lock out reset button EK is the key operating element for resetting the burner control and for activating deactivating the diagnostic functions The multicolour LED is the key indicating element for both visual diagnosis and interface diagnosis A Red o Yellow Colour code table Status Colour code Colour Oil pre heater heats Yellow waiting time tw ignition phase ignition 00000000000 Yellow off controlled Operation flame o k O Operation flame not o k JOLIOLIOLIOLIOLU Green off Undervoltage 04040404040 Yellow red Fault alarm AAAAAAAAAAA Hed Output of fault code refer AOAOAOAOAO Red off to Fault code table Extraneous light prior to HALDALDABALBAD Greens burner start up Interface diagnosis AA4A4AAAAAAAAAA A Red flicker light Key O Off e Yellow Green A Red Diagnosis of cause of fault After lock out the red fault signal lamp remains steady on In that condition the visual diagnosis of the cause of f
29. no flame at the end of safety time the controller locks out imme diately Absence of flame during operation If there is no flame during operation the controller cuts off the supply of fuel and automatically initiates a fresh start up programme at the end of t4 the start up programme ends Whenever there is a safety stop terminals 3 8 and 11 are de energised in less than 1 second at the same time a remote lockout signal is transmit ted through terminal 10 The controller can be reset after c 50 seconds C I B UNIGAS M039116CE SIEMENS OIL BURNERS AUTOMATIC CONTROLLER SIEMENS LMO14 LMO24 LMO44 The LMO burner controls are designed for the start up and supervision of single or 2 stage forced draught oil burners in intermittent operation Yellow burning flames are supervised with photoresistive detectors QRB blue burning flames with blue flame detectors QRC In terms of housing dimensions electrical connections and flame detectors the LMO are identical to the LOA oil burner controls Preconditions for startup e Burner control is reset e All contacts in the line are closed e Noundervoltage e Flame detector is darkened no extraneous light Undervoltage e Safety shut down in the operating position takes place should the mains voltage drop below about AC 165 V e Restart is initiated when the mains voltage exceeds about AC 175 V Time supervision oil pre heater If the oil pre heater s release contact do
30. nt after first starting the burner by following the procedure illustrated in Disassembling the components plate e Before proceeding to maintenance operations remove the component plate of the burner P by unscrewing the V1 V2 V3 screws and the F securing pin see next figure e Couple the plate in one of the ways illustrated in Fig 13 and Fig 14 in order to facilitate maintenance operations C I B UNIGAS M039116CE Fig 13 Fig 14 Disassembling the nozzle A Before disassembling the nozzle measure the real position A see Tab 5 and make a note in the panel below e Unscrew the V screw that fastens the combustion head and remove the head from the nozzle holder Fig 15 Fig 16 AN In order to remove the nozzle it is important to use two wrenches as shown in to avoid damaging the burner compo nent plate e Reassemble the combustion head by respecting the position A measured previously making sure to fasten the V screw Fig 15 IMPORTANT the electrodes in Fig 14 must be positioned at the sides of the combustion head NOTE When re assembling the component plate make sure that the pin for the air damper P enters its housing see Fig 14 20 UNIGAS M039116CE Replacing the electrodes ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc otherwise the boiler s operat
31. osal of materials 21 C I B UNIGAS M039116CE 22 TROUBLESHOOTING PROBLEM Lu N gt gt T z gt lt lt SE 9 lt QO I I LL A LLI r Orr gt E EN O i ec zo ao tx gt Ona SE 6c 2 mo seo ui lt con 2 lt Z Co o LLI zr 52 2 ci 2 25 amp m 5 CAUSE a MAINS SWITCH OPEN e FUSES INTERVENTION e MAXIMUM PRESSURE SWITCH FAULT e AUXILIARIES RELAY FUSES INTERVEN e TION CONTROL BOX FAULT e e o e e SMOKY FLAME e e IGNITION TRANSFORMER FAULT e IGNITION ELECTRODES DIRTY OR BAD e POSITION DIRTY NOZZLE o FUEL SOLENOID VALVE DEFECTIVE e e PHORESISTANCE DIRTY OR DEFEC e e TIVE HIGH LOW FLAME THERMOSTAT e DEFECTIVE FUEL LOW PRESSURE e FUEL FILTERS DIRTY e e e C I B UNIGAS M039116CE EXTERNAL AIR INTAKE KIT ASSEMBLY WHEN SUPPLIED The burner may be supplied with an external air intake with components contained in the kit provided separately Code 3300023 Proceed as follow for assembly e Remove the burner cover e Disassemble the burner component plate see Smontaggio della piastra componentiDisassembling the components plateDe smontaje de la placa iiitiaidii on page 41 Remove the two V screws that Remove the air inlet by
32. own takes place call the Technical Service without trying to RESET further 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 is vital that all saftey requirements are met In case of any doubt ask for an accurate inspection of electrics by qualified personnel since the manufacturer cannot be held liable for damages that may be caused by failure to correctly earth the equipment Qualified personnel must inspect the system to make sure that it is adequate to take the maximum power used by the equipment shown on the equipment rating plate In particular make sure that the system cable cross section is adequate for the power absorbed by the unit No adaptors multiple outlet sockets and or extension cables are per mitted to connect the unit to the electric mains An omnipolar switch shall be provided for connection to mains as required by the current safety regulations The use of any power operated component implies observance of a few basic rules for example do not touch the unit with wet or damp parts of the body and or with bare feet do not pull electric cables do not leave the equipment exposed to weather rain sun etc unless expressly required to
33. r s packing follow the procedures laid down by current laws on disposal of materials Fitting the burner to the boiler To install the burner into the boiler proceed as follows ON Oa FWD on the boiler s door hole fix the 4 stud bolts according to the drilling template showed on paragraph Overall dimensions fix the flange of the burner to the boiler install the burner into the boiler according to the reference showed on Fig 3 fix the flange to the boiler s stud bolts D without completely fastening loosen the VS screws in order to let the blast tube move back and forth install the burner making the blast tube move into the flange as to reach the right position according to the boiler utilisation fasten the VS screws tighten the 4 stud blolts D completely seal the space between the blast tube and the refractory lining with appropriate insulating material ceramic fibre cord or refractory cement Fig 2 Fig 3 Once the burner is installed execute the electrical and hydraulic connections according to the schemes showed in the next para graphs C I B UNIGAS M039116CE Electrical connections ATTENTION READ CAREFULLY THE WARNINGS SECTION AT THE BEGINNING OF THIS USER S MANUAL REVERSE THE PHASE AND NEUTRAL CONNECTIONS FIT A DIFFERENTIAL THERMAL MAGNET SWITCH ADE RESPECT THE BASIC SAFETY RULES MAKE SURE OF THE CONNECTION TO THE EARTHING SYSTEM DO NOT QUATE FOR CONNECTION TO THE MAINS STRICTL
34. reduction in the mains voltage operate on a special electronic circuit which in the event of the power supply falling below 165V stops the burner switching on without releasing the fuel and locks out the apparatus 31 Wiring diagram of the programme To ensure correct wiring it is essential to observe local standards and fol low the instructions of the burner manufacturer with regard to assembly and start up Program s legend Emp Controller output signals Required input signals Burner start up with light oil pre heater OH A Burner start up without light oil pre heater B Flame lit C Normal operation D Normal stop through R tw Oil pre heating time until operational all clear given through contact OW tl Pre purge time t3 Pre ignition time t2 Safety time t3n X Post ignition time t4 Interval between the flame lighting and energising of solenoid 2a at terminal 5 Internal layout AL Optical alarm BV Fuel valve EK Reset button FR Flame relay fr Flame relay contacts FS Flame alight signal G Burner motor K Flame relay anchor to delay the tzl command in the event of a premature flame signal or endorse it where the signal is correct OH light oil pre heater OW Operational all clear contact QRB Photo resistant cell flame detector R Thermostat or pressure switch TZ programmer bimetal system tz TZ contacts V Flame signal amplifier W Safety thermostat or p
35. ressure switch Z Ignition transformer The above are safety devices To tamper with them in any way may have unforeseeable conse quences Do not open them Y B C D R W urnpianmnnmmmn mpm mma 1 8 OW 9 3 5 Lou Lun ovn py M mr 2 svo J aes gt gt 5 e Technical characteristics Voltage Frequency External fuse Contact flow terminal 1 terminal 3 Terminal flow terminals 4 5 amp 10 terminals 6 amp 7 terminal 8 Absorbed cap Protection Premitted temp operational transport amp storage Emplacement Mass weight C I B UNIGAS M039116CE 220V 15 240V 10 or 100V 15 110V 10 50 60Hz 6 max 10A slow action 5A 5A incl capacity absorbed by motor and pre heater 1A 2A 5A 3VA IP40 20 60 C 50 60 C any controller 180g socket 50g AGK accessories 12 g 32 Commands in the event of operational interference Stray light premature ignition During pre purge and or pre ignition there should be no flamesignal If there is a flame signal eg from premature ignition due to a faulty solenoid external light short circuit in the photoresisto or wiring malfunction in the flame signal amplifier etc at the end of pre purge and safety time the controller locks out the burner and stops the fuel flow even during safety time Absence of flame If there is
36. rry 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 supporting air to obtain a combu stion efficiency level at least equal to the lower level required by the regulations in force check the unit operation for proper combustion to avoid any harmful or polluting unburnt gases in excess of the limits permitted by the regulations in force 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 Incase of a burner shut down reser the control box by means of the RESET pushbutton If a second shut d
37. s are almost identical which means that there is no need to move the reset button Performance The controllers just need plugging in so they can be mounted in almost any position on the burner on the electrical panel or on the control panel The casing is made of robust heat resistant plastic and contains e the thermic programmer operating a multiple switch control system with ambient temperature compensator e flame signal amplifier with flame relay e warning light indicating lockout and associated sealed reset button The plug in socket also made of robust heat resistant plastic contains the 12 terminals and also e 3neutral terminals ready wired up to terminal 2 e 4earth terminals for earthing the burner e 2 supplementary terminals numbered 31 and 32 The socket has two openings at the bottom for the leads 5 others with threaded connection for cable holders PG11 or 3 4UNP for non metallic sleeves are located on a mobile stuffing box one on either side and 3 on the front There are two flexible metal tongues on the sides of the socket for moun ting To dismantle it only requires gentle pressure with a screw driver in the slot of the mounting guide The base dimensions of the socket are exaclty the same as for types LAB LAI and there is no difference in the diameter of the reset button the two mounting screws and the flange of the burner earth Safety at low voltage levels Safety devices against any
38. spection and cleaning of the light oil filter cartridge Replace if necessary e Check the overall condition of the flexible light oil hoses and make sure there are no signs of leakage e Inspection and cleaning of 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 replaced e disassembly inspection and cleaning of the combustion head Respect the measurements listed in Tab 5 carefully during re assembly e Inspection and cleaning of ignition electrodes and respective ceramic insulators clean adjust and replace if necessary see page 21 e Disassemble and clean the light oil nozzle see Disassembling the nozzle on page 20 AN Important cleaning must be performed using solvent and not metal tools e end of maintenance operations after first reassembling the burner light the flame and check its shape replacing the nozzle whenever a questionable flame shape appears Whenever the burner is used intensely we recommend preventively replacing the nozzle at the start of each heating season e Inspect and thoroughly clean the flame detection photoresistor and replace if necessary In case of doubt check the detection cur re
39. stallation 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 seal junc tions preferred Junction threads elbow joints and couplings should be sealed with removable sg component The number of junc tions should be kept to a minimum as they are a possible source of leakage 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 possibl
40. tements are accomplished check that the factory set values are observed Tab 5 If it was necessary to change that values according to the utilisation make a note of them in the table below as for the maintenance operations NOZZLE 60 45 C I B UNIGAS M039116CE A C 4 3 45 6 6 6 3 45 6 6 Tab 5 B _ D C A The regulations quoted on the following charts are referred to the pump adjusted at 10 and 12 bar respectively Tab Type LO35 G TN x xx A 60 k kgih 410 ve dexseting Ar damper index setting 0 40 10 1 52 1 1 0 50 10 1 90 1 5 2 5 0 60 10 2 28 2 5 4 5 0 65 10 2 47 CES 6 0 75 10 2 85 4 5 6 5 0 85 10 3 30 6 8 Tab 6b Type LO35 G TN x xx A 60 kgih 11096 Me dexseting Ar damper index setting 0 40 12 1 66 1 5 1 5 0 50 12 2 08 1 5 3 5 0 60 12 2 50 3 5 9 0 65 12 2 70 4 5 6 5 0 75 12 3 12 5 5 7 5 0 85 12 3 53 8 8 Tab 6c Type LO35 G TN x xx P QU Cambustion head air damper index setting 0 40 10 1 27 0 5 2 0 50 10 1 71 1 5 3 5 0 60 10 2 23 2 5 5 5 0 65 10 2 45 3 6 5 0 75 10 2 84 4 5 6 5 0 85 10 2 88 6 7 5 Tab 6d Type LO35 G TN x xx P Es Quae Combustion head damper index setting 0 40 12 1 36 0 5 2 5 0 50 12 1 88 1 5 4 0 60 12 2 44 3 5 6 0 65 12 2 66 4 5 6 5 0 75 12 3 05 5 7 5 0 85 12 3 12 7 8
41. th 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 switches the telephone or any other item likely to generate sparks b immediately open doors and windows to create an air flow to purge the room C close the gas valves contact qualified personnel Do not obstruct the ventilation openings of the room where gas appliances are installed to avoid dangerous conditions such as the development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic
42. xcepted
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