PG60 PG70 PG81 - Arzatoare CIB Unigas
Contents
1. 13 8 6 6 14 LON OTOZ 15 cci u E A E ES 16 Fan PUNO MAO TOOT E E 16 AL D cim 17 Adjustments Drief 9 1 18 218 ae nee eet 17 Ags 61 6 8 16 01 17 Adjustment by the Berger 5 30 actuator 18 Adjustment the Siemens 501 33 servocontrol suu raes ina eirian ET A EEEE AERE ER ES EEEE TRES 21 Fully modulating uu u u 25 Calibration of air pressure switch when provided 25 PARTI OPERA NON S 26 Sixio ie 26 BUTE COMMON NO 27 PART 2 2 4 41 1 1 1 u 28 ROUTINE2. A Hed Yellow J Green Colour code table Status Colour code Colour Oil pre heater heats Yellow waiting time tw Ignition phase ignition Yellow off controlled Operation flame o k sus Green Operation flame o k JOLIOLIOLIOLIOLU Green off Undervoltage 04040404040 Yellow red Fault alarm Red Output of fault code refer AOAOAOAOAO Red off to Fault code table Extraneous light prior to start up Interface diagnosis Red flicker light Key O Off Yellow Green 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 fault according to the error code table can be activated by pressing the lock out reset button for more than 3 seconds Error code table Blink code Possible cause 2 blinks No establishment of flame at the end of TSA e Faulty or soiled fuel valves Faulty or soiled flame detector Poor adjustment of burner no fuel Faulty ignition 3 blinks 4 blinks 5 blinks 6 blinks 7 blinks Xx xA xA 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
3. 28 Light oil filter maintenance 28 Removing the combustion head and the oil gun 29 Removing the oil gun PG70 PG81 nnn nnn 29 Correct position of electrodes and combustion head 30 Replacing the ignition electrodes esas 30 Cleaning and replacing the detection photocell 30 Biilze diseNis Noi u eioeiq nE 31 S Ol 31 1510 0 1 ISOS oe acer 31 TROUBLE SHOOTIN PH 31 ELECTRICAL WIRING 32 SPAREPART 43 APPPND Ger 44 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
4. 30 Siemens SQL33 CIB UNIGAS 039191 Adjustment by the Berger 5 actuator 1 2 Open the electrical panel to check the motor rotation and act directly its solenoi starter see next picture keep pressed until the oil circuit is charged bleed the air from the M pressure gauge port Fig 14 by loosing the cap without removing it then release the solenoid starter Suntec AJ6 Suntec J6 Danfoss RSB Fig 14 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 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 the control panel see next picture see chapter OPERATION on page 26 EA B STAND BY sure that the actuator for the Startup enabling signal when used is 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 18 UNIGAS 039191 values eventually adjusting the oil p
5. ROUTINE MAINTENANCE e Check and clean the cartdrige of the fuel filter replace it if necessary see next paragraph carefully check for leaks the fuel flexible hoses check and clean the filter on the fuel pump bilter must be thoroughly cleaned at least once in a season to ensure correct working of the fuel unit To remove the filter unscrew the four screws on the cover When reassemble make sure that the filter is mounted with the feet toward the pump body If the gasket between cover and pump housing should be damaged it must be replaced remove check and clean the combustion head page 29 when reassembling carefully observe the measures on page 29 check the ignition electrodes and their ceramic insulators clean adjust and replace if necessary remove and clean the oil nozzles IMPORTANT do not clean the nozzles using metallic or sharp utensils use only solvents or steam at the end of maintenance operations refit the burner turn it on and check the combustion If in doubt replace the defec tive nozzle s In case of intensive use of the burner the nozzles must be replaced at the end of the working season e check and carefully clean the flame detection photoresistor if necessary replace it and if in doubt check the detection current fol lowing the diagram on page 31 clean and grease levers and rotating parts Light oil filter maintenance For correct and proper servicing proceed as follows 1 shut off
6. 4 C X 72 mi gt m gt 5 u Bn u 21 8 TSA 75 5 2 7 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 time t3 Pre ignition time tn 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 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 2 TSA Ignition safety time tw Waiting time for oil pre heating B Time of flame establishment C Operating position D Controlled shut down by R Microcontroller 1 uC2 Microcontroller 2 General unit data Mains voltage AC 230 V 10 15 AC 110 V 10 15 50 60 Hz 6 Si slow Mains frequency External primary fuse Power consumption 12 VA
7. G locking lever CP cam for start up enabling signal 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 pag 24 7 disconnect the TAB thermostat removing the wire from the terminal no 6 by setting MAN the RWF40 modulator or by setting 0 by means of the CMF 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 showed on Fig 19 Fig 20 and act on the pump adjusting screw VR see Fig 18 as to get the nozzle pressure at 20bar Bergonzo nozzles see diagram on page 15 22 UNIGAS 039191 Pressure gauge port Fig 19 Light oil manifold PG60 Pressure gauge port Fig 20 Combustion head with light oil gun PG70 PG81 11 order to get the maximum oil flow rate adjust the pressure readi
8. PG60 PG70 PG 1 Progressive Fully modulating Light oil burners MANUAL OF INSTALLATION USE MAINTENANCE UNIGAS BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES CIB UNIGAS M039191CA TABLE CONTENTS WARNINGS G 3 S ccs ese scone 5 GENERAL FEATURES uu uuu 5 How to interpret the burner s Performance Curve 5 pel a 5 FP CHIONMANCE CUOIVES 6 CITC 7 MOUN INGO AND 8 TO 8 Sl SP asua 8 Hydraulic diagrams for light oil supplying circuits 9 OF HOD ON Bele uu 10 About the use of fuel RR 11 Eo DUTOS usu OI 12 Connecting the light oil flexible hoses
9. Scr pss PT1000 F 1000 OHM 0 C IL vA n 2 90V ST LAB LB Fig 11 PT100 100 OHM 0 C Fully modulating burners CN j E 12 9 4 11 ps OS gt SD 4 20mA DANFOSS FI Fig 13 SD 0 10V Probes connection see Fig 12 SD PRESS SIEMENS QBE Fan pump motor rotation Once the burner electrical connection is accomplished remember to check the motor rotation Motor must rotate in the direction showed on the casing In the event of wrong rotation reverse the three phase supply and check again the motor rotation NOTE Burners are provided for three phase 400 V supply and in the case of three phase 230 V supply it is necessary to modify the electrical connections inside the terminal box of the electric motor and replace the thermal cutout relay CIB UNIGAS M039191CA ADJUSTMENTS 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 t
10. 200 cSt Oil temperature 10 120 nist maximum pressure Maximum return pressure 4 bar Minimum inlet pressure 0 45 to avoid gasing Rotation speed max 3600 rpm Key 1 Pressure governor 2 Pressure gauge 3 Suction 4 To nozzle 5 Return UNIGAS 039191 Oil temperature suction pressure Rotation speed 3600 rpm max Danfoss 2 1 Pressure governor 2 Pressure vacuum gauge port to measure inlet pressure vacuum 3 Pressure gauge port 5 Suction 7 To nozzle 8 Return Connecting the light oil flexible hoses To connect the flexible light oil hoses to the pump proceed 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 AJ6 Suntec J6 Danfoss RSB30 CIB UNIGAS M039191CA 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
11. 2020445 24 2020453 44 2020412 44 2020455 44 2020412 44 2020455 IGNITION ELECTRODES 2080205 2080206 2080206 2 FUEL FILTER 2090016 2090025 2090018 1 GASKET 2110013 2110033 2110033 1 FAN WHEEL 2150013 2150018 2150068 1 IGNITION TRANSFORMER 2170106 2170106 2170302 1 ELECTRIC MOTOR 2180020 218021101 2180206 1 SOLENOID VALVE 2190420 2190403 2190403 1 FLEXIBLE HOSE 2340002 2340002 2340003 2 FLEXIBLE HOSES L 275 2340091 2340091 1 FLEXIBLE HOSES L 335 3 8 2340087 2340087 1 ADJUSTING CAM FOIL 2440013 2440013 2440013 2 SERVOCONTROL mod SIEMENS 2480009 2480022 2480022 1 SERVOCONTROL mod BERGER 2480053 2480090 2480090 1 PHOTORESISTOR mod SIEMENS 2510003 2510003 2510003 1 PRESSURE GOVERNOR 2570054 2570054 2570054 1 PUMP mod SUNTEC 2590103 2590109 2590118 1 PUMP mod DANFOSS 2590320 2590310 1 NOZZLE mod BERGONZO 2610202 2610202 2610202 1 standard 2700212 1 OIL GUN long 2700215 1 COMBUSTION HEAD 3060175 3060147 30601C1 1 BLAST TUBE standard 3090034 30900A9 30900G8 1 BLAST TUBE long 3090038 3090032 30900G9 1 IGNITION CABLES 6050109 6050010 6050133 2 43 CIB UNIGAS M039191CA SIEMENS OIL BURNERS AUTOMATIC CONTROLLER LMO24 LMO44 The LMO burner controls are designed for the start up and supervision of single or 2 stage forced draught oil burners in inte
12. 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 m 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 Improper installation may cause injury to people and animals or damage to property for which the manufacturer cannot be held lia ble e Remove all packaging material and inspect the equipment for inte grity In case of any doubt do not use the unit contact the supplier The packaging materials wooden crate nails fastening devices plastic bags foamed polystyrene etc should not be left within the reach of chil dren as they may prove harmful 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 dir
13. Mounting orientation optional Weight approx 200 g Degree of protection IP 40 Perm cable lengths max 3 m at a line capacitance of 100 pF m Detector cable laid separately 20m Remote reset 20m Max perm amperage at cos 0 6 Terminal 1 5A Terminals 3 and 8 5A Terminals 4 5 6 and 10 1A Flame supervision with QRB and QRC QRB QRC Min detector current required with flame 45 70 pA Min detector current permitted without flame 5 5 HA 5 5 Max possible with flame tipically 100 100 Measurement circuit for detector current 11 12 11 12 1 bl SW 7130v01 0700 bl SW br 7130v02 0700 uA DC uA DC h d DC with internal resistance of 5 bl Blue SW Black br Brown M CEB UNIGAS 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
14. 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 possible An external filter should always be installed in the suction line upstream of the fuel unit 11 CIB UNIGAS 039191 Light oil pumps The pumps provided with these burners can be e PG60 Suntec AJ6 e PG70 Suntec J6 Danfoss RSB30 PG81 Suntec TA2 Danfoss KSM50 Viscos Oil temperature Inlet maximum pressure Inlet minimum pressure 0 45 bar to avoid gasing Rated speed 3600 rpm max Oll temperature Min suction pressure Max suction pressure Key 1 Pressure governor 2 Pressure gauge 3 Vacuum gauge 5 Nozzle 7 Suction 8 Return Danfoss RSB Oil viscosity 2 5
15. the burner into the boiler fix the burner to the stud bolts by means of the fixing nuts according to the next picture After fitting the burner to the boiler ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement Keys 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 UNIGAS 039191 Hydraulic diagrams for light oil supplying circuits Fig 2 Gravity circuit Kl Fig 3 Ring circuit on ES Fig 4 Suction circuit Key Manual valve Light oil filter Light oil feeding pump One way valve 1 4 Flexible hoses e Relief valve A NOTE in plants where gravity or ring feed systems provided install automatic interception device see 4 UNIGAS 039191 Installation diagram of light oil pipes A PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL From tank To tank The burner
16. 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 e 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 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 Requisiti di sicu rezza impianti elettrici National standards UNI 7824 Monobloc nebuliz
17. 0 SD TEMP SD TEMP LANDIS QAE2 0AC2 QAM2 PT1000 1000 OHM 0 C 1 61 12 1381 13C 100 100 0 M In G G 138 A ABA 1 SD 0 4 20mA 50 0 10 SD PRESS LANDIS VERDE GREEN ATTENZIONE COLLEGAMENTO SONDE WARNING PROBE CONNECTION Data 53 02 9000 PREP 50809 2 3 SEGUE TOTALE Dis 0 401 4 5 VOLELBEOW SVOINN GIO QG MA MORSETTIERA ALIMENTAZIONE SUPPLY TERMINAL BOARD cr CAMME SERVOCOMANDO SERVO CONTROL CAMS 50122222 1 ALTA HIGH FLAME Y2 SOSTA E ACCENSIONE STAND BY AND IGNITION 3 BASSA FIAMMA LOW FLAME 6 CONSENSO ALLA PARTENZA INPUT TO START SERVOCOMANDO SERRANDA ARIA ALTERNATIVO ATTENZIONE COLLEGAMENTO SONDE x x WARNING PROBE CONNECTION QG MORSETTIERA ALIMENTAZIONE SUPPLY TERMINAL BOARD AIR DAMPER SERVO CONTROL ALTERNA TIVE STM30 24Q15 51 64 1NLP II V ALTA FIAMMA HIGH FLAME SOSTA E ACCENSIONE STAND BY AND IGNITION BASSA FIAMMA LOW FLAME CONSENSO ALLA PARTENZA INPUT TO START O O O gt gt 50133 03 FR EVG STM30 24015 51 641NLP EVG 1 Doto 23 02 2000 PRES Revisione 04 5 4 SEGUE TOTALE 0 401 5 5 VOLELBEOW SVOINN GIO SPARE PARTS CIB UNIGAS M039191CA Desription Code Quantity PG60 PG70 PG81 CONTROL BOX LOA24
18. 0122 26122 225 gn 2 VAAL 71 r elm LZ a Toss Sees Kg h j 30 242422 LEAL mS Kg h 2222 CCC x Z 16 lt C Lem LEE Q kg h 2 75 Kg h t r 4 E P oLECLLLLLLLL 22 4 5 8 9 Fig 10 15 CIB UNIGAS M039191CA Electrical connections RESPECT THE BASIC SAFETY RULES MAKE SURE OF THE CONNECTION TO THE EARTHING SYSTEM DO NOT REVERSE THE PHASE AND NEUTRAL CONNECTIONS FIT A DIFFERENTIAL THERMAL MAGNET SWITCH ADE QUATE FOR CONNECTION TO THE MAINS STRICTLY OBSERVE THE DATA PLATE Remove the cover from the burner electrical panel e Execute the electrical connections to the power supply terminal board as shown check the direction of the fan pump motor see next paragraph and replace the electrical panel cover WARNING The burner is provided with a jumper between terminals 6 and 7 in the event of connecting the high low flame thermostat remove this jumper before connecting the thermostat IMPORTANT while connecting electric supply wires to burner s teminal block be sure that ground wire should be longer than phase and neutral ones Progressive burners Probes connection OO O M A 12 13C SD TEMP SD TEMP SIEMENS QAE2 QAC2 QAM2 lt p PO
19. 6 Stand by nl O Fig 7 Prepurge Fig 8 Low flame Fig 9 High flame Key Light oil pump Light oil solenoid valve Nozzle Servocontrol Adjusting cam pressure gauge Pressure regulator One way valve 14 CIB UNIGAS M039191CA 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 diagram on Fig 9 NOZZLE HIGH FLAME LOW FLAME NOZZLE SUPPLY PRESSURE RETURN PRESSURE RETURN PRESSURE bar bar bar recommended BERGONZOR3 720 T3 Example Bergonzo if 220kg h flow rate BERGONZO nozzle is provided set the return pressure at 11bar supply at 20bar the delivery to get a 220kg h flow rate If the return pressure needed is 5bar instead act on the V adjusting screw on the pressure gover see chapter on page 18 The flow rate will then be about 95kg h see the example showed the Bergonzo diagram Charles Bergonzo S A Moutier suisse 609 Gicleur d bits variables 9 16 Pression initiale 20 atm Reference Rucklaufdusen 29 16 Vorlaufdruck konstant 20 atu ILLI Eel 70 220 200 _ Z k s 200 4 180 Kgjh 150 ALLA 160 kg h 2 140 1 AANA E Ip 8 E a 7 22 12
20. APPENS 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 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 OPERATION ATTENTION before starting the burner up be sure that the manual cutoff valves are open and check that the mains switch is closed 1 Set to the ON position the switch A on the control panel of the burner 2 Check the control box is not the lockout position light 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 The startup sequence begins the control box ignites the fan 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 EVG1 is energised signalled by the lamp G on the control panel and th
21. E PROBE CONNECTIONS LANDIS RWF40 000 Y2 01301411 M1 61 U1 G G SD TEMP LANDIS Pt1000 50 0 4 2 SD PRESS LANDIS QBE620O FOGLIO 1 DI 1 CODICE REV OS 617 O03 VOLELBEOW SVOINN GIO GE PG70 PG81 Complete keys BERGER STM30 BERGER actuator alternative CMF Operation manual switch 0 stop 1 high flame 2 low falme 3 automatic EVG Oil solenoid valve FR Photoresistor FU1 0 Line Fuse FU1 2 Line Fuse FU1 3 Auxiliary Line Fuse IG Main switch IL Main switch KA2 3 Auxiliary relay 1 7 Fan motor contactor KT2 4 Delayed relay L Phase LAF Burner in high flame signalling lamp LB Burner lockout signalling lamp LBF Burner in low flame signalling lamp LEVG EVG solenoid valve opening signalling lamp LPGmin Gas in the network signalling lamp LT Lockout of fan motor thermal cutout signalling lamp LTA ignition transformer signalling lamp MV Fan motor N Neutral PS Control box release pushbutton Pt100 3 wires temperature probe Pt100 RWF40 000 SIEMENS Burner modulator SD 0 4 20mA Probe connection with signal 0 20 4 20 SD 0 10V Probe connection with signal 0 10 SD PRESS 3 wires pressure probe SIEMENS 620 SD TEMP 2 wires temperature probe Pt1000 SIEMENS QAE2 QAC2 SIEMENS LMO44 Control box SIEMENS SQL SIEMENS Air damper actuator ST Thermostats or pressure switches series TA Ignition transformer TAB High low flame
22. Faulty or soiled flame detector e Poor adjustment of burner 8 blinks kk A x x 9 blinks Free 10 blinks Wiring error or internal error output contacts Time supervision oil pre heater CIB UNIGAS M039191CA During the time the cause of fault is diagnosed the control outputs are deactivated e Burner remains shut down Fault status signal 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 lt 3 seconds Connection diagram and internal diagram uc contol teEK2 838 OH Bv2 f QRC lt Control sequence R x B D 7 74 4 1 OH am 2 7 7
23. RY RELAIS FUSES INTERVENTION CONTROL BOX FAULT SERVOCONTROL FAULT SMOKEY FLAME IGNITION TRANSFORMER FAULT IGNITION ELECTRODE DIRTY OR WRONG POSITIONED DIRTY NOZZLE FUEL SOLENOID VALVE DEFECTIVE PHOTORESISTOR DIRTY OR DEFECTIVE e HI LO FLAME THERMOSTAT DEFECTIVE WRONG POSITION OF SERVOCONTROL e CAMS FUEL PRESSURE TOO LOW DIRTY FUEL FILTERS e 31 ce ELECTRICAL WIRING DIAGRAMS PG60 CAV Fan motor contactor auxiliary contacts CCMF Operation manual switch 0 stop 1 high flame 2 low falme 3 automatic CR1 Auxiliary relay contacts CRT Delayed relay contacts CTV Fan motor thermal cutout contacts CV Fan motor contactor contacts EVG Oil solenoid valve 4 Fusese FR Photoresistor IG Main switch IL Main switch L Phase LAF Burner in high signalling lamp LB Burner lockout signalling lamp LBF Burner in low flame signalling lamp LEVG EVG solenoid valve opening signalling lamp LOA24 LMO24 SIEMENS control box LMO44 SIEMENS control bo LT Lockout of fan motor thermal cutout signalling lamp LTA ignition transformer signalling lamp MA Burner supply terminal block MC Components connections terminal block MV Fan motor N Neutral PS Control box release pushbutton only with LMO24 Pt100 3 wires temperature probe Pt100 H1 Auxiliary relay RT Delayed relay RWF40 000 SIEMENS burner modulator SD 0 4 20mA Probe
24. TERNATIVO QG MC MORSETTIERA ALIMENTAZIONE SUPPLY TERMINAL BOARD AIR DAMPER SERVO CONTROL ALTERNATIVE STM30 24Q15 51 641NLP II V ALTA FIAMMA HIGH FLAME SOSTA E ACCENSIONE STAND BY AND IGNITION BASSA FIAMMA LOW FLAME CONSENSO ALLA PARTENZA INPUT TO START TA 50133 03 FR EVG STM30 24015 51 641NLP EVG Data 11 12 1996 Revisione 0 5 Dis 07 352 PREC FOGLIO SEGUE TOTALE VOLELBEOW SVOINN 8IO 65 Wiring diagram 07 401 Rev 4 Fully modulating Burners 70 81 L0 1 2 5 4 5 66 7 8 9 SIEMENS 10 44 LMO44 LOOV 3N a c 7771 10 ST PE MOTORE VENTILATORE 10 Data 23 02 2000 TRE 58989 71 SEGUE TOTALE Dis 07 401 2 5 VOLELBEOW SVOINN GIO 07 0 1 2 3 4 5 6 7 8 9 50133 03 SIEMENS LMO44 S7M30 24Q 15 51 64 36 MC KA2 3 KT2 4 AAS J M LEVG LBF 33 229 230 MC OMc 31 MC 3 0 3 0 3 0 1 1 9 3 0 12 22 Data 23 02 2000 9969 Revisione 04 2 SEGUE TOTALE Dis 07 401 3 5 VOLELBEOW SVOINN GIO SIEMENS RWF40 0x0 Y1 Y2 013 Qi4 L1 N M1 61 U1 G G 20900
25. connection with signal 0 20 4 20 SD 0 10V Probe connection with signal 0 10 SD PRESS 3 wires pressure probe SIEMENS 620 SD TEMP 2 wires temperature probe Pt1000 SIEMENS QAE2 QAC2 ST Thermostats or pressure switches series STA12B3 41 63N21L BERGER actuator STA15B3 41 83N21L BERGER actuator alternative TA Ignition transformer TAB High low flame thermostat if fitted remove the connection between terminals 6 and 7 on terminal block MA TC Thermocoupling connection TV Fan motor thermal cutout ACTUATOR CAMS BERGER STM30 The modulator includes a limit switch terminals Q13 and Q14 it stops the burner if the work parameter overcomes set differential ATTENTION 1 Electric supply 400V 50Hz 2 Don t reverse phase and neutral 3 Make sure that the burner is properly hearted VOLELBEOW SVOINN GIO Wiring diagram 05 556 Rev Progressive Burners PG60 CIB UNIGAS M039191CA O 2 O 7 Q Z lt 5 1 SQNS30 251A STA1xB3 41 x VG LANDIS LOA 24 24 TAB LB ST 400V I I 33 1 BE CODICE CODE REV 556 05 FOGLIO SHEET o5 1 ve Wiring diagram 05 617 Rev 3 Fully modulating Burners PG60 LB EM OC E LANDIS LOA 24 LMO 24 EVG ATTENZIONE WARNING LANDIS SQN30 251A BERGER STA1xB3 41 x3N21 COLLEGAMENTI SOND
26. ded 6 VERSION A Standard UNIGAS 039191 Technical specifications Output 151 791 291 1047 264 1900 Light oil rate min max kg h 13 67 25 88 22 160 Fuel Light oil Viscosity 1 3 20 C Power supply 400V 50Hz Electric motor Total power consumption Approx weight Operation Progressive Fully modulating Operating temperature 10 50 Storage temperature 20 60 Working service Intermittent ON THE BURNER WORKING SERVICE e Burners provided with Siemens LOA24 control box for safety reasons one controlled shutdown must take place every 24 hours e Burners provided with Siemens LMO24 44 control box the control box automatically stops after 24h of continuous working control box immediately starts up automatically Performance curves PG60 PG70 0 8 6 kW PG81 2 0 BACK PRESSURE CCOMBUSTION CHAMBER mbar 0 200 400 600 800 1000 7200 100 00 00 2000 kW 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 C BACK PRESSURE IN CCOMBUSTION CHAMBER mbar N IN N O N o o 0 00 200 300 400 500 600 1700 800 900 200 300 400 500 600 700 800 900 00 100 700
27. e 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 the burner switches to high flame or to low flame according to the plant demand 8 The high low flame operation is showed by the F LED turning on off 26 CIB UNIGAS M039191CA control panel PG60 PG70 PG81 lt o ON OFF main switch Lockout signalling lamp Conreol box release pushbutton Signalling lamp for light oil solenoid valve opening Thermal cutout intervention signalling lamp High flame operation signalling lamp Low flame operation signalling lamp Ignition transformer operation signalling lamp Siemens modulator Manual operation mode switch O O 27 UNIGAS 039191 At least once year carry out the maintenance operations listed below In the case of seasonal servicing it is recommended to carry out the maintenance at the end of each heating season in the case of continuous operation the maintenance is carried out every 6 months WARNING ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL
28. ect action Contact qualified personnel only Units shall be repaired exclusively by a servicing centre duly authorised by the manufacturer with original spare parts Failure to comply with the above instructions is likely to impair the unit s safety To ensure equipment efficiency and proper operation it is essential that maintenance operations are performed by qualified personnel at regular intervals following the manufacturer s instructions e When a decision is made to discontinue the use of the equipment those parts likely to constitute sources of danger shall be made har mless Incase the equipment is to be sold or transferred to another user or in case the original user should 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 For all 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 e The burner should be installed in a suitable room with ventilation op
29. emove the photoresistor from its slot clean it using a clean cloth do not use any cleansing spray if necessary replace it insert the photoresistor into its slot Ol 30 CIB UNIGAS M039191CA Checking the detection current To measure the detection signal follow the diagram on the next picture 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 45uA Maximum current intensity without flame 5 5uA Maximum possible current intensit with flamey 45pA 100A 100A Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 the burner s main switch to 0 Off position 2 disconnect the power mains 3 close the fuel manual valve of the supply line Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials 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 AUXILIA
30. enings complying with the requirements of the regulations in force and sufficient for good combustion Only burners designed according to the regulations in force should be used This burner should be employed exclusively for the use for which it was designed Before connecting the burner make sure that the unit rating is the same as delivery mains electricity gas oil or other fuel Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stopped When the decision is made to discontinue the use of the burner the user shall have qualified personnel carry out the following operations 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
31. er burners for liquid fuels Characteristics and test methods Heavy oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards CEI EN 60335 1 Household and similar electrical appliances SafetyPart 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Light oil burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Heavy oil burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equi
32. f air pressure switch when provided To calibrate the air pressure switch proceed as follows Remove the transparent plastic cap e Once air and gas setting have been accomplished startup the burner e During the pre purge phase the operation turn slowly the adjusting ring nut VR in the clockwise direction to increase the adju sting pressure until the burner locks out then read the value on the pressure switch scale and set it to a value reduced by 15 Repeat the ignition cycle of the burner and check it runs properly Refit the transparent plastic cover on the pressure switch 25 CIB UNIGAS M039191CA 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 H
33. 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 28 UNIGAS 039191 Removing the combustion head and the oil 1 2 3 4 5 6 Remove the top cover remove the photoresistor from its seat unscrew the revolving connectors E in figure on the fuel pipes use 2 spanners to avoid loosening the connections attached to the distributor block 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 and the oil gun by means of a vacuum cleaner to scrape off the scale use a metallic brush Note to replace the combustion head reverse the procedure described above PG60 qa Removing the oil PG70 PG81 Once the combustion head is removed as described before remove the oil gun as foloows 1 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 No
34. he pump seal to break During commissioning operations do not let the burner operate with insufficient air flow danger of formation of carbon monoxide if this should happen make the gas decrease slowly until the normal combustion values are achieved AN IMPORTANT the combustion air excess must be adjusted according to the the following chart Recommended combustion parameters Recommended Recommended Os 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 respec tively e Check that the combustion parameters in the suggested limits Check the oil flow rate e Then adjust the combustion values corresponding to the points between maximum and minimum set the foil shape of the adju sting cam The adjusting cam sets the air fuel ratio in those points regulating the opening closing of the fuel governor 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 STM30 mod Siemens SQL e PG60 Berger 5 12 e PG70 PG81 Berger
35. ion repeat the air gas adjustments described above 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 to change the SV position set the actuator on the manual mode MAN turn the adjusting cam SV and set again the actuator to the AUTO mode to lock the adjusting cam act on the V screw that mathces the bearings referring to the adjusting cam position 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 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 Turn the burner off then start it up again Once the pre purge time comes to end drive the burner to the high flame stage by the TAB thermostat check the combustion values drive the burner to low flame if necessary adjust the low flame size output by inserting a screwdriver on the slot F to move the BF cam 24 CIB UNIGAS 039191 22 The
36. 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 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 CDD m 4 Automatic interceptor The direct connection of the device without a timer 5 Onewayvav t may cause pump breaks 6 Gate valve 7 Quick closing gate valve outside the tank or boiler rooms The provided pumps can be installed both into single pipe and double pipe systems Single pipe system a single pipe drives the oil from the tank to the pump s inlet Then from the pump the pressurised oil is driven to the nozzle a part comes out from the nozzle while the othe part goes back to the pump In this system the by pass pulg if provided must be removed and the optional return port on the pump s body must be sealed by steel plug and washer Double pipe system as for the single pipe system a pipe that connects the tank to the pump s inlet is used besides another pipe that connects the 5 return port to the tank as well The excess of oil goes back to the tank this installation be considered self ble eding If provided the inside by pass plug must be installed to avoid air and fuel passing through the pu
37. 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 TR VRA 12 The burner is factory set with the head in its MAX position maximum output PG60 To let the burner operate at a lower output turn clockwise the VRT screw and move progressively the combustion head back towards the MIN position PG70 PG81 To let the burner operate at a lower output loose the VB screw and move progressively the combustion head back towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment is accomplished PG70 PG81 MIN position position Attention if it is necessary to change the 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 as for the 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 909 20 CIB UNIGAS 039191 15 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position 16 move cam low flame towards the minimum to move the actuator towards the low flame until the
38. kW I OVERALL DIMENSIONS A B 725 210 460 1035 raat 825 340 480 1165 A BL Paso 760 248 442 1008 4 1035 1165 BL eb Pare L boiler drilling plate VOLELBEOW SVOINN 8IO CIB UNIGAS M039191CA MOUNTINGS AND CONNECTIONS Packing The burners are dispatched in wooden pakages whose dimensions are PG60 1200 670 x 540 mm PG70 PG81 1280 x 850 x 760 mm Packing cases of this kind are affected by humidity and are not suitable for stacking The following are placed in each packing case burner light oil flexible hoses light oil filter gasket to be inserted between the burner and the boiler envelope containing this manual To get rid of the burner s packing follow the procedures laid down by current laws on disposal of materials Fitting the burner to the boiler To install the burner into the boiler proceed as follows 1 2 3 CON 0 make a hole the closing door of the combustion chamber as described on paragraph Overall dimensions place the burner to the boiler lift it up and handle it according to the procedure described on paragraph Handling the burner place the 4 stud bolts 5 on the hole of the boiler s door according to the burner s drilling plate described on paragraph Overall dimensions fasten the 4 stud bolts place the gasket on the burner flange install
39. ll the fuel supply system pipes be carefully cleaned inside to remove foreign matter that might impair the burner operation e Before the burner is commissioned qualified personnel should ins pect the following a the fuel supply system for proper sealing b the fuel flow rate to make sure that it has been set based on the firing rate required of the burner 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 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 e When the burner is to remain idle for some time the fuel supply tap or taps should be closed SPECIAL INSTRUCTIONS FOR USING GAS Have qualified personnel inspect the installation to ensure that a the gas delivery line and train are in compliance with the regulations and provisions in force all gas connections are tight the boiler room ventilation openings are such that they ensure the air supply flow required by the current regulations and in any case are sufficient for proper combustion Do not use gas pipes to earth electrical equipment Never leave the burner connected when not in use Always shut the gas valve off case of prolonged absence of the
40. low flame position must never match the ignition position that is why BF must be set 20 30 more than the ignition tion NOTE to change the low flame position act exclusively on the actuator cam 23 Now adjust the pressure switch when provided see next paragraphs Fully modulating burners To adjust the fully modulating burners use the CMF 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 2 and then CMF 0 CMF 0 stop CMF 1 high flame operation CMF 2 low flame operation CMF 3 automatic operation To adjust the air rate in low flame and in the intermediate points proceed as follow 1 Keep pushed for 5 seconds the EXIT button on the modulator for further details see the burner modulator manual when the LED with the hand symbol lights up press the arrow button driving the actuator to the maximum opening position progressively 2 stop its stroke when it meets each screw V adjust the air rate by adjusting the V screw that matches each bearing 3 Push the EXIT button to quit the manual mode Calibration o
41. mp Burners are factory set for double stage systems They can be suited for single pipe system recommended in the case of gravity feed as decribed before To change from a 1 system to a 2 pipe system insert the by pass plug G as for ccw rota tion referring to the pump shaft Caution Changing the direction of rotation all connections on top and side are reversed Danfoss RSB30 Twin pipe installation Suntec AJ6 Suntec J6 Single pipe installation UNIGAS 039191 Suntec Danfoss KSM L Bleed Bleeding in two pipe operation is automatic it is assured by a bleed flat on the piston In one pipe operation the plug of a pressure gauge port must be loosened until the air is evacuated from the system About the use of fuel pumps 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
42. ng 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 Fig 21 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 TR VRA 13 The burner is factory set with the head its MAX position maximum output 23 UNIGAS 039191 60 To let the burner operate at a lower output turn clockwise the VRT screw and move progressively the combustion head back towards the MIN position PG70 PG81 To let the burner operate at a lower output loose the VB screw and move progressively the combustion head back towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment is accomplished 16 17 19 20 21 VB 70 81 MIN position position Attention if it is necessary to change the head posit
43. pment 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 CIB UNIGAS 039191 GENERAL FEATURES Monobloc burners of this series are made die cast aluminium housing with relative flange to work heating generators The output range is from 150kW to 1900kW according to the model They can be provided in progressive or fully modulating version 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
44. position of the combustion head determines the burner output The air comburent and fuel light oil are for ced into the combustion chamber as to let the flame light up How to interpret the burner s Performance curve To check if the burner is suitable for the boiler to which it must be installled the following parameters are needed e furnace input in kW or kcal h KW kcal h 860 e backpressure data are available on the boiler ID plate or in the user s manual Example Furnace input 600kW Backpressure 4 In the Performance curve diagram Fig 1 draw a vertical line matching the furnace input value and an horizontal line matching the backpressure value The burner is suitable if the intersection point A is inside the performance curve Campo di lavoro bruciatori combustione mbar Contropressione in camera di O N A Q Q Potenza kW Fig 1 Data are referred to standard conditions atmospheric pressure 1013mbar ambient temperature at 15 Burner model identification Burners are identified by burner type and model Burner model identification is described as follows PG60 Model PR S 1 2 3 4 5 6 BURNER 60 70 81 1 2 FUEL G Light oil A Biodiesel 3 OPERATION Available versions Progressive Fully modulating 4 BLAST S Standard L Exten
45. ressure see next step STA12 Actuator cams ST2 High flame STO Stand by and Ignition ST1 Low flame ST2 MV Startup signal ST1 STO MAN AUTO STM30 Actuator cams High flame Stand by Ignition I Low flame V Startup signal 9 the nozzle supply pressure is already factory set and must not be changed Only if necessary adjust the supply pressure as fol lows see related paragraph insert a pressure gauge into the port showed on Fig 15 Fig 16 and on on the pump adjusting screw VR see Fig 14 as to get the nozzle pressure at 20bar Bergonzo nozzles see diagram on Fig 10 Pressure gauge port Fig 15 Light oil manifold PG60 Pressure gauge port Fig 16 Combustion head with light oil gun PG70 PG81 UNIGAS 039191 10 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 Fig 17 when the cam has reached the high flame position 11 adjust the air flow rate in the high flame stage loose the RA nut and screw 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
46. rmittent 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 Restart is initiated when the mains voltage exceeds about 175 V Time supervision oil pre heater If the oil pre heater s release contact does not close within 10 minutes the burner control will initiate lock out Controlled intermittent operation After no more than 24 hours of continuous operation the burner control will initiate an automatic safety shut down followed by a restart Control sequence in the event of fault If lock out occurs the outputs for the fuel valves and the ignition will immediately be deactivated 1 second After a mains failure After voltage has fallen below the Restart undervoltage threshold In the event of a premature faulty flame signal during 11 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 the even
47. t the flame is lost during Max 3 repetitions followed operation by lock out Oil pre heater s release contact does HAN 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 lt 3 seconds Ignition program with LMO24 113A2 If the flame is lost during TSA the burner will be reignited but not later than at the end of TSAmax This means that several ignition attempts be made during TSA refer to Program sequence Limitation of repetitions In the event of a premature faulty flame signal during tw If the flame is lost during operation a maximum of 3 repetitions can be made If the flame is lost for the 4th time during operation the burner will initiate lock out The repetition count is restarted each time controlled switching by R W SB takes place 44 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
48. te To re assemble follow the procedure above in reversed order 29 UNIGAS 039191 Correct position of electrodes combustion head 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 tight the screw on the electrodes group before reassembling the combustion head a ROG usss G usus 4 Ter ri 1 i a p 4 5 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 W nm Cleaning and replacing the detection photoresistor To clean replace the photoresistor proceed as follows disconnect the system from the electrical power supply shut off the fuel supply r
49. 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 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 safety reasons the unit must be efficiently earthed and installed as required by current safety regulations 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 b
50. thermostat if fitted remove the connection between terminals 6 and 7 on terminal block MA TC Thermocoupling connection TV Fan motor thermal cutout ACTUATOR CAMS SIEMENS SQL33 High Stop ignition Sart signal The modulator includes a limit switch terminals Q13 and Q14 it stops the burner if the work parameter overcomes set differential ATTENTION 1 Electric supply 400V 50Hz 2 Don t reverse phase and neutral 3 Make sure that the burner is properly hearted VOLELBEOW SVOINN GIO 98 Wiring diagram 07 352 Rev 3 Progressive Burners PG70 PG81 89 jJ a j 211 Jp 1 51 7 J q 27 17535 8 7 SIEMENS 10 44 7 LOOV a c 10 2 0 e iv ee IT 2 0 2 0 10 1 0 1 0 12 18 _ x _ Data 1171271598 71 SEGUE TOTALE Dis 07 352 2 4 VOLELBEOW SVOINN GIO 46 1 9 1 9 1 9 1 9 2 24 50133 03 7 30 24015 51 64 Doto 71 12 1996 Dis N Of 222 SEGUE 5 FOGLIO 2 TOTALE 4 VOLELBEOW SVOINN GIO 86 QG MORSETTIERA ALIMENTAZIONE SUPPLY TERMINAL BOARD CAMME SERVOCOMANDO SERVO CONTROL CAMS 50133 03 Y1 ALTA FIAMMA HIGH FLAME Y2 SOSTA ACCENSIONE STAND BY AND IGNITION 3 BASSA FIAMMA LOW FLAME 6 CONSENSO ALLA PARTENZA INPUT TO START SERVOCOMANDO SERRANDA ARIA AL
51. 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 10 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 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 Adjustment by the Siemens SQL33 servocontrol 1 Open the electrical panel to check the fam motor rotation and act directly on the related solenoid starter See next picture keep pressed until the oil circuit is charged CV A 2 bleed the air from the M pressure gauge port Fig 18 by loosing the cap without removing it then release the solenoid starter Suntec AJ6 Suntec J6 Danfoss RSB 21 UNIGAS 039191 3 the burner on by means of its main switch if the burner locks LED on the control panel press the RESET button C the control panel see next picture see chapter OPERATION on page 26 rA STAND BY SQL330 actuator cams AB High flame cam BF Low flame cam plastic cam
52. y 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 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 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 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 a
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