LO140 LO200 Light oil burners
Contents
1. Colour code table Status Colour code Colour Pe eae desi Yellow waiting time tw Ignition phase ignition Imimimimiml Yellow off controlled Operation flame o k Operation flame not o k omomomomomo Green off Undervoltage 1515151515 Yellow red Fault alarm SSSSSSSSSSS Red Output of fault code refer to Fault code table SCORE Extraneous light prior to burner start up Interface diagnosis SSSSSSSSSSSSSS Red flicker light Key m Off Yellow o Green s 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 Faulty or soiled fuel valves Faulty or soiled flame detector Poor adjustment of burner no fuel Faulty ignition 3 blinks Free 4 blinks Extraneous light on burner startup 5 blinks Free 6 blinks Free 7 blinks Too manny losses of fleme during operation limitattion og the number of repetitions Faulty or soiled fuel valves Faulty or soiled flame detector Poor adjustment of burner 8 blinks Time supervision oil pre heater 92. LO140 LO200 Light oil burners MANUAL OF INSTALLATION USE AND MAINTENANCE BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES M039154CE Rel 4 0 09 2011 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 PRODUCT INSTALLATION AND MAINTENANCE THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS IN THE SECOND SECTION OF THIS MANUAL WE HIGHLY RECOMMEND TO READ IT CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE 1 GENERAL INTRODUCTION e The equipment must be installed in compliance with the regulations force following the manufacturer s instructions by qualified personnel 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 liable e Remove all packaging material and inspect the equipment for integrity 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 ch
3. 4 Fuse only for double stage models 5 Combustion head inside 6 Photoresistor 7 Unlock pushbutton for control box 8 Transformer 9 Solenoid valve 10 Cover 11 Pump 12 Pump motor 13 Actuator double stage burners 14 Air inlet The fuel coming from the supply line is pushed by the pump 11 to the nozzle and then into the combustion chamber where the mixture between fuel and air takes place and consequently the flame In the burners the mixture bertween fuel and air to perform clean and efficient combustion is activated by atomisation of oil into very small particles This process is achieved making pressurised oil passing through the nozzle The pump 11 main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which a separate regulating valve is provided Other pumps are provided with two pressure regulators one for the high and one for low pressure in double stage systems with one nozzle In the double stage burners the electric servocontrol 13 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 s output The air comburent and fuel light oil are forced into the combustion chamber as to let the flame light up How to interpret the burner s Performance cu
4. Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Heavy oil burners European directives Directive 2009 142 EC Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC 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 PART I INSTALLATION GENERAL FEATURES This series is characterised by high performaces and width of the performance curves when the pressure in the combustion chamber is high They are also characterised for other important functional features there are plugs which can be easily connected 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 They can be provided as Single stage or Double stage burners Single stage the burner operates at one output level Double stage the burner operates at two output levels high flame and low flame Keys 1 Control panel with startup switch only for double stage models 2 Flange 3 Blast tube
5. They can be suited for single pipe system recommended in the case of gravity feed as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rotation referring to the pump shaft Caution Changing the direction of rotation all connections on top and side are reversed 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 12 About the use of fuel pumps Make sure that the by pass plug is not used in a single pipe installation because the fuel unit will not function properly and damage to the pump and burner motor could result Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth thus obstructing them After filling the tank wait before starting the burner This will give any suspended impurities time to deposit on the bottom of the tank thus avoiding the possibility that they might be sucked into the pump On initial commissioning a dry operation is foreseen for a considerable length of time for example when there is a long suction line to bleed To avoid damages inject some lubrication oil into the vacuum inlet Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the jo
6. ask for an accurate inspection of electrics by qualified personnel since the manufacturer cannot be held liable for damages that may be caused by failure to correctly earth the equipment e Qualified personnel must inspect the system to make sure that it is adequate to take the maximum power used by the equipment shown on the equipment rating plate In particular make sure that the system cable cross section is adequate for the power absorbed by the unit No adaptors multiple outlet sockets and or extension cables are permitted to connect the unit to the electric mains An omnipolar switch shall be provided for connection to mains as required by the current safety regulations The use of any power operated component implies observance of a few basic rules for example do not touch the unit with wet or damp parts of the body and or with bare feet do not pull electric cables do not leave the equipment exposed to weather rain sun etc unless expressly required to do so do not allow children or inexperienced persons to use equipment 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 decision is made to discontinue the use of the burner the user shall have qualified personnel carry out the following operations 2 When the unit is out of use for some time the electric switch supplying all th
7. ra ro rar ass r os one 240 53 98 ron os 024 sna 7 64 8 11 8 55 8 96 9 36 9 74 10 11110 47 10 81111 14 11 47 11 78 12 09 12 39112 698 12 96 13 24113 51 am e om os os eor pm rar 1200 1243 1276 ros en a Tab 2 PUMP PRESSURE bar Air rate setting Single stage burners Remove the burner cover unscrewing the fixing screws Slacken the nut DR Move the index ID through the graduated slot working on the screw VR towards or to increase or decrease the air flow rat according to the data measured by the combustion tester Tighten the nut DR again The graduated index shows the opening angle of the air damper 18 Double stage burners Air damper position is set by means of the actuator cams both in low and high flame As for the setting refer to the next table During the first setting set the cam Ill between the cams and ll Then passing from the low to the high flame stage or viceversa change the setting according to the flame composition if cam is too near to the low flame position cam Il flue gas can take place because there is more fuel than air if cam Ill is too near to high flame cam the flame could fade because of too much air The graduated index connected to the actuator shows the opening angle of the air damper AUTO MAN Berger STA Siemens SQN72 Note to move the cams use e Berger STA the cams adjustement mus
8. IGNITION TRANSFORMER FAULT IGNITION ELECTRODES DIRTY OR BAD POSITION DIRTY NOZZLE FUEL SOLENOID VALVE DEFECTIVE PHORESISTANCE DIRTY OR DEFECTIVE HIGH LOW FLAME THERMOSTAT DEFECTIVE BAD POSITION OF SERVOCONTROL CAMS FUEL LOW PRESSURE FUEL FILTERS DIRTY WIRING DIAGRAMS WARNING 1 Electrical supply 230V 50Hz 1N a c 2 Don t reverse phase with neutral 3 Ensure to the burner a proper earthing See the attached wiring diagrams WIRING DIAGRAM SE01 361 Single stage burner WIRING DIAGRAM SE18 068 Double stage burner 24 BURNERS EXPLODED VIEW SINGLE STAGE BURNERS o o 84 COVER FIXINGSCREW RUBBER COVER FOR UNLOCKING PUSHBUTTON _ _ L _ e e 0 Position Description 123 NOZZLE 124 NOZZLE HOLDER 132 SOCKET FOR CONTROL BOX 13 3 TRANSFORMER 44 IGNITION CABLES 29 26 DOUBLE STAGE BURNERS Position Descripion es BUSH 68 AIRDAMPERSHAFT 69 PLATESHT ooo B o PNP Position Description TT 12 13 4 NOZZLE 4 27 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 Yel
9. blinks Free 10 blinks Wiring error or internal error output contacts During the time the cause of fault is diagnosed the control outputs are deactivated Burner remains shut down 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 lt 3 seconds Connection diagram and internal diagram LMO14 4 EKiF 55 pC contr LED T Yki K2 FSV AM Am a re TV EX 3 an TEALA P 8 17 4 5 9 11 12 L z _ i aa SB 8 G owl ORE VN AL L5 OH N ORC Si 1 cy L MH FE N I 3 71X 0700 LMO24 LMO44 EgE1 4 V PA pe 1 com Hea LED Y ki p row T I Kx Y 7 F F amt F Jj T a 78 i SU T FEIT n Q i 1 lsipee 1 Y p I V 51 d b IAL RO ORC a1 1 L M Z 5 21 Control sequence R B W 1 oH OH m OW gt L 3 e 3 H 1 an 6 A i Set EE Tr ri e Only with 11342 ne gnilion FS 53 7
10. is meant Any other use shall be considered as improper and therefore 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 he 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 e Only burners designed according to the regulations in force should be used e This burner should be employed exclusively for the use for which it was designed Before connecting the burner make sure that the unit rating is the same as delivery mains electricity gas oil or other fuel Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stopped a Remove the power supply by disconnecting the power cord from the mains b Disconnect the fuel supply by means of the hand operated shut off valve and remove the control handwheels from their spindles SPECIAL WARNINGS Make sure that the burner has on installation been firmly secured to the appliance so that the flame is generated inside the appliance firebox Before the burner is started and thereafter at least once a year ha
11. not obstructed Any obstruction would cause the pump seal to break IMPORTANT the combustion air excess must be adjusted according to the in the following chart Recommended combustion parameters Recommended CO2 Recommended CO2 Recommended CO2 Light oil 11 5 13 2 9 4 9 Priming the pump and Oil rate adjustment Before starting with the adjustments it is necessary to prime the oil pump as follows Remove the burner cover start up the burner with double stage models turn the burner main switch A to On Fig 5 make the ST thermostat contacts close see chapter WIRING DIAGRAMS wait until the EVG solenoid valve opens remove the photoresistor FR and ligth it up 6 bleed the air from the pressure port see paragraph Light oil pumps If the burner locks out press the unlock pushbutton P Fig 5 and repeat the procedure Proceed with the adjustements according to the single stage or double stage operation of the burner described below oS m c 3 ES z J R T j pn j lt k i 1 2 j i 7 EVG e Single stage burners 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 Fig 6 To choose the correct nozzle refer to Tab 1 as for setting the pump pressure see paragraph Light oil pumps AN Note pumps are
12. 20 140 160 180 200 220 KW To get the input in kcal h multiply value in kW by 860 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 C NOTE The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests but does not represent the regulation range of the machine On this diagram the maximum output point is usually reached by adjsuting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is reached setting the combustion head to its MIN position During the first ignition the combustion head is set in order to find a compromise between the burner output and the generator specifications that is why the minimum output may be different from the Performance curve minimum MOUNTINGS AND CONNECTIONS Packing The burners are dispatched in cardboard packages whose dimensions are e Standard blast tube mm 600 x 370 x 400 W x H x D e Extended blast tube mm 750 x 370 x 400 W x H x D e Packing cases of this kind are affected by humidity and are not suitable for stacking The following are placed in each packing case e burner e light oil flexible hoses e light oil filter e gasket to be inserted between the burner and the boiler e envelope containing documentation To get rid of the burner s packing and in the event of scrapping of the latter follo
13. ED 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 AUTHORISED 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 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 CAUTION before starting the burner up be sure that the manual cutoff valves on the feeding line and on the retu
14. e maintenance is carried out every 6 months WARNING ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL ROUTINE MAINTENANCE e Inspection and cleaning of the light oil filter cartridge replace if necessary see next paragraph e check the overall condition of the flexible light oil hoses and make sure there are no signs of leakage e inspect and eventually clean the filter inside the light oil pump filter must be thoroughly cleaned at least once in a season to ensure correct working of the fuel unit To remove the filter unscrew the four screws on the cover When reassemble make sure that the filter is mounted with the feet toward the pump body If the gasket between cover and pump housing should be damaged it must be replaced e disassembly inspection and cleaning of the combustion head Respect the measurements listed in Tab 3 on page 22 e inspection and cleaning of ignition electrodes and respective ceramic insulators clean adjust and replace if necessary e disassemble and clean the light oil nozzle see Pulizia della testa di combustione e dell ugelloCleaning the combustion head and the nozzle on page 22 Important cleaning must be performed using solvent and not metal tools e Atthe end of maintenance operations after first reassembling the burner light the flame and check i
15. e 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 e The burner shall be installed by qualified personnel and in compliance with regulations and provisions in force wrong installation can cause injuries to people and animals or damage to property for which the manufacturer cannot be held liable e Before installation it is recommended that all the fuel supply system pipes be carefully cleaned inside to remove foreign matter that might impair the burner operation Before the burner is commissioned qualified personnel should inspect the following a the fuel supply system for proper sealing b the fuel flow rate to make sure that it has been set based on the firing rate required of the burner c the burner firing system to make sure that it is supplied for the designed fuel type d the fuel supply pressure to make sure that it is included in the range shown on the rating plate e the fuel supply system to make sure that the system dimensions are adequate to the burner firing rate and that the system is equipped with all the safety and control devices required by the regulations in force When the burner is to remain idle for some time the fuel supply tap or taps should be closed SPECIAL INSTRUCTIONS FOR USING GAS Have qualified personnel inspect the installation to ensure that a the gas delive
16. ed into the boiler go on with the electrical and hydraulic connections according to the diagrams shown on the following paragraphs Matching the burner to the boiler The burners described in this manual have been tested with combustion chambers that comply with EN267 regulation and whose dimensions are described in the diagram In case the burner must be coupled with boilers with a combustion chamber smaller in diameter or shorter than those described in the diagram please contact the supplier to verify that a correct matching is possible with respect of the application involved To correctly match the burner to the boiler verify the necessary input and the pressure in combustion chamber are included in the burner performance curve otherwise the choice of the burner must be revised consulting the burner manufacturer To choose the blast tube lenght follow the instructions of the boiler manufacturer In absence of these consider the following e Castiron boilers three pass flue boilers with the first pass in the rear part the blast tube must protrude no more than 100 mm values between 0 and 100mm into the combustion chamber e Pressurised boilers with flame reversal in this case the blast tube must penetrate at least 50 100 mm into combustion chamber in respect to the tube bundle plate The length of the blast tubes does not always allow this requirement to be met and thus it may be necessary to use a suitably sized spacer to move
17. essary disconnect the cables and unscrew VE remove the electrodes and replace them clean the combustion head by means of a vacuum cleaner use a metallic brush to scrape off the scale reassemble all the items in the reversed order observing the electrodes position see next paragraph Before disassembly the nozzle and the electrodes disconnect the cables CV Fig 10 measure the positions quoted in Fig 11 and make a note in the table on Tab 3 Unscrew the V screw that fastens the combustion head and remove the head from the nozzle holder Fig 10 Unscrew the VE screw that fastens the electrodes remove and clean or replace them In order to remove the nozzle it is important to use two wrenches as shown in Fig 10 to avoid damaging the burner component plate clean or replace the nozzle reassemble tall the elements remember to fasten the V and VE screws and re connect the cables CV Fig 10 respecting the positions measured previously and quoted on the table below reassemble the components plate and the burner s cover Fig 10 boiler operation would be compromised Check the electrodes position after any intervention on the ATTENTION avoid the electrodes to get touch with metallic parts blast tube head etc otherwise the combustion head ATTENTION check that the factory set values are observed Tab 3 If it was necessary to change that values according to the utilisation make a note of the
18. ildren 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 Make sure that inlet or exhaust grilles are unobstructed In case of breakdown and or defective unit operation disconnect the unit Make no attempt to repair the unit or take any direct action Contact qualified personnel only Units shall be repaired exclusively by a servicing centre duly authorised by the manufacturer with original spare parts Failure to comply with the above instructions is likely to impair the unit s safety To ensure equipment efficiency and proper operation it is essential that maintenance operations are performed by qualified personnel at regular intervals following the manufacturer s instructions e When a decision is made to discontinue the use of the equipment those parts likely to constitute sources of danger shall be made harmless In case 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 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
19. int noise and overloading the gears Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical seal junctions preferred Junction threads elbow joints and couplings should be sealed with removable sg component The number of junctions 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 deposit on the pump filter or the nozzle reducing efficiency Always use O Rings or mechanical seal copper or aluminium gaskets junctions if possible An external filter should always be installed in the suction line upstream of the fuel unit Light oil pumps Pumps provided according to the burner model are SINGLE STAGE BURNER Suntec AS47 DOUBLE STAGE BURNER Suntec AT2 Suntec 547 0 60 return pressure 2 bar Rotation speed 3600 rpm max Keys 1 Pressure governor 2 Pressure gauge port 3 Vacuum gauge port 4 Solenoid valve 5 To the nozzle 7 8 Return 13 SutecAT2 Max return pressure Rotation speed 3600 rpm max Keys 1 Low pressure regulation first stage 2 Pressure gauge port 3 Vacuum gauge port 4 Solenoid valve 4a High low pressure solenoid valve 5 To the nozzle 6 High pressure regulation second stage 7 Inlet 8 Return with internal by pass plug Connecting the oil flexible hoses To connec
20. irements Light oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 EC 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 household 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 EC on electromagnetic compatibility Harmonised standards CEI 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 2009 142 EC Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC 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
21. low 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 L MO are identical to the LOA oil burner controls Preconditions for startup Burner control is reset All contacts in the line are closed No undervoltage Flame detector is darkened no extraneous light Undervoltage 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 AC 175 V Time supervision oil pre heater If the oil pre heaters 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 lt 1 second After a mains failure After voltage has fallen below the Restart undervoltage threshold In the event of a premature faulty PLURES flame signal during t1 Prevention of start up lock out after no more than 40 seconds If the burner does not ignite during of TSA TSA In the event the flame is lost during Max 3
22. m in the table below as for the maintenance operations A B 60 8 4 4 6 45 10 5 4 6 6 Tab 3 22 A Fig 11 Cleaning and replacing the detection photoresistor To clean replace the photoresistive detector remove it from its slot To clean the photoresistor use a clean cloth not cleaning sprays Check the detection current MORSETTIERA MG To measure the detection current refer to the diagram in Fig 12 If the signal doesn t suit the suggested value verify the electric terminals the cleaning of the combustion head and the position of the photoelectric cell and replace it if required Fa cuore ene Seasonal stop To stop the burner in the seasonal stop proceed as follows e turn the burner main switch to 0 Off position e disconnect the power mains e Close the fuel valve of the supply line Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials 23 TROUBLESHOOTING BURNER DOESN T REPETITION OF PRE PURGE NOISY FUEL PUMP BURNER DOESN T START AND LOCKS BURNER STARTS AND BURNER DOESN T SWITCH TO HIGH FLAME BURNER LOCK DURING OPERATION BURNER LOCKS AND REPEATS CYCLE DURING OPERATION MAINS SWITCH OPEN FUSES INTERVENTION MAXIMUM PRESSURE SWITCH FAULT AUXILIARIES RELAY FUSES INTERVENTION CONTROL BOX FAULT SERVOCONTROL FAULT SMOKY FLAME
23. repetitions followed operation by lock out Oil pre heater s release contact does Lock out not close within 10 min Lock out In the event of lock out the LMO remains locked lock out cannot be changed and the red signal lamp will light up This status is also maintained 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 sequence Limitation of repetitions If the flame is lost during operation a maximum of 3 repetitions can be made If the flame is lost for the 4th time during operation the burner will initiate lock out The repetition count is restarted each time controlled switching on by R W SB takes place In the event of a premature faulty flame signal during tw Operation ua 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 m S red yellow 0 green EK 29
24. rn are open Be that the mains switch is closed Read carefully the WARNINGS chapter in this manual Startup the burner by the boiler s master power switch as for double stage models turn the burner main switch A to On make sure that the control box has not shut down and reset if necessary using the reset button pressing the clear rubber seal on the burner cover make sure that the set of thermostats or pressure switches triggers burner operation in double stage models L1 LED lights on the burner starting cycle begins the control box switches on the burner s fan the ignition transformer switches on at the same time in double stage models LT LED lights on at the end of the pre purge time the light oil solenoid valve is powered and the burner starts up 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 it is switched off Double stage burners after the start up the burner remains in the low flame operation in double stage models L1 on or switches to the high flame stage in double stage models L2 on according to the plant needs m di Double stage version 20 PART Ill MAINTENANCE 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 th
25. rve To check if the burner is suitable for the boiler to which it must be installled the following parameters are needed furnace input in kW or kcal h kW kcal h 860 backpressure data are available on the boiler s ID plate or in the user s manual Example Furnace input kW 600 Backpressure mbar 4 In the Performance curve diagram Fig 2 draw a vertical line matching the furnace input value and an horizontal line matching the backpressure value The burner is suitable if the intersection point A is inside the performance curve F L4 N l ATT IT TITI INT 100 200 300 400 500 600 700 800 900 Contropressione in camera di combustione mbar Potenza kW Fig 1 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 C Burner model identification Burners are identified by burner type and model Burner model identification is described as follows Type LO140 Model S 1 2 3 4 5 6 1 BURNER LO140 LO200 2 FUEL G Light oil 3 OPERATION TN Single stage AB Double stage 4 BLAST TUBE S Standard 5 DESTINATION COUNTRY see burner ID plate A Standard 6 VERSION Y Special Specifications BURNERS LO140 G TN LO140 G AB 10200 G TN LO200 G AB Output min max KW 80 40 38 160 80 20 38 200 ss Po
26. ry line and train are in compliance with the regulations and provisions in force b all gas connections are tight c 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 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 d 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 2009 142 EC Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requ
27. set to 12 bar The nozzle rate must be higher than the rate referred to the minimum burner output 16 Light oil solenoid valve Pressure gauge Pump Choice of the oil nozze Single stage burners size GPH B M kg h kcal h kW kcal h kW 58 000 63 600 69 000 64 000 69 900 76 000 68 000 74 200 80 000 77 500 84 800 92 000 87 200 95 400 103 000 97 000 106 000 115 000 116 000 127 200 137 000 135 800 148 750 160 700 155 200 170 000 183 700 174 600 191 250 206 650 Tab 1 e Double stage burners The oil flow rate is adusted by choosing the correct nozze spill back type whose size matches the boiler utilisation input and by setting the delivery and return pressure according to the values on diagram in Fig 7 Setting the light oil pump Adjust the ignition stage of the pump to 8 bar first stage After 10 seconds the control box switches to the second stage the pump setting must be fixed to 24 bar by means of the adjusting screw see paragraph Light oil pumps NOTE The nozzle oil rate at 8 bar must be higher than the oil rate at the minimum burner output x EVI NC Governor 2nd stage EV2 NQ Governor 1st stage 1st stage 8 bar 2nd stage 24 bar Fig 7 17 Choice of the oil nozzle Double stage burner Nozzle size GPH ee ot Flow rate kg h ees es ses ss
28. stalled by the customer As far as the hoses connection see the related paragraph Keys Burner Flexible hoses fitted Light oil filter fitted Automatic interceptor One way valve Gate valve pO pr Poco Quick closing gate valve outside the tank or boiler rooms Only for installations with gravity siphon or forced circulation feed systems If the device installed is a solenoid valve a timer must be installed to delay the valve closing The direct connection of the device without a timer may cause pump breaks The pumps that are used can be installed both into single pipe and double pipe systems Single pipe system a single pipe drives the oil from the tank to the pump s inlet Then from the pump the pressurised oil is driven to the nozzle a part comes out from the nozzle while the othe part goes back to the pump In this system the by pass plug if provided must be removed and the optional return port on the pump s body must be sealed by steel plug and 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 pump s return port to the tank as well The excess of oil goes back to the tank this installation can be considered self bleeding If provided the inside by pass plug must be installed to avoid air and fuel passing through the pump Burners come out from the factory provided for double pipe systems
29. t be performed by means of screwdriver acting on the VS screw placed inside the cam e Siemens SQN72 provided with key for cams and IV with scerws for the other cams The Berger actuator is not provided with the manual control for the air damper The Siemens actuator is provided with AUTO MAN mode see pictures above High flame position to be set at 90 red Low flame and ignition position III orange Stand by position to be set at 0 II blue Combustion head adjustment To adjust the combustion head position and consequently the burner output proceed as follows 1 remove the burner cover unscrewing the fixing screws 2 by means of a screwdriver turn counterclockwise to move towards the combustion head picture below or clockwise to move the head backwards picture below The ID index shows how much the head moves a All backwards position All forwards position ATTENTION Once the adjustements are accomplished check that the factory set values are observed Tab 3 page 22 If it was necessary to change that values according to the utilisation make a note of them in the Tab 3 page 22 as for the maintenance operations 19 PART II OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR E G BOILER HOT AIR GENERATOR FURNACE ETC ANY OTHER USE IS TO BE CONSIDER
30. t the flexible light oil hoses to the pump proceed as follows 1 remove the burner cover unscrewing the fixing screws 2 remove the closing nuts A and B on the inlet and return connections of the pump 3 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 paragraph see Double stage burnersLight oil pumpsLight oil pumpsSingle stage burners on page 12 4 unscrew the V screw place the flexible hoses as shown in figure and then tighten it again 5 replace the cover LLL PU re 035 A WARNING if fuel used is BIODIESEL some components must be replaced Please contact our Technical Department for further details 14 Electrical connections Respect the basic safety rules make sure of the connection to the earthing system do not reverse the phase and neutral connections fit a differential thermal magnet switch adequate for connection to the mains ATTENTION before executing the electrical connections pay attention to turn the plant s switch to OFF and be sure that the burner s main switch is in 0 position OFF too Read carefully the chapter WARNINGS and the Electrical connections section Before connecting the burner to the mains be sure that its switch is on Off position and find the burner s connectors WARNING The burner is provided with a jumper bet
31. the burner backwards or to design a blast tube tha suites the utilisation please contact the manifacturer 2 0 eS Li 1 5 LER Se As 2 rir 0 Su Keys 3 P7 4 0 8 2 0 a Heat output in kW 1 0 b Length of the flame tube in meters 0 6 b 0 5 Flame tube firing intensity MW m3 05 U 0 3 d Combustion chamber diameter m 0 2 Fig 3 Firing intensity diameter and lenght of the test flame tube as a function of the heat input in kW 0 1 42 26 40 70100 190 480 1200 2450 Fig 3 10 Hydraulic diagrams for light oil supplying circuits Gravity circuit N Ring circuit Tas IIIA LEBEN qe gt gt gt gt Suction circuit Keys 1 Manual valve 2 Light oil filter Eh 3 Ligh t oil fee ding pump 4 One way valve 5 Flexible hoses 6 Relief valve NOTE in plants where gravity or ring feed systems are provided install an automatic interception device see n 4 Fig 4 11 Installation diagram of light oil pipes PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL 7 6 4 3 FAR lt 6 5 2 Fig 4 Double pipe system The burner is supplied with filter and flexible hoses all the parts upstream the filter and downstream the return flexible hose must be in
32. ting orientation optional Weight approx 200 g Degree of protection IP40 to be ensured through mounting Perm cable lengths max 3m at line capacitance of 100 pF m Detector cable laid separately 10m Remote reset laid separately 20m LMO14 LMO24 LMO44 Terminal 1 Terminals 3 8 Terminals 4 5 and 10 1A 1A 1A Terminals 6 1A 1A 2A Flame supervision with QRB and QRC QRB QRC Min detector current required with flame 45 uA 70 uA Min detector current permitted without flame 5 5 5 5 uA Max possible with flame tipically 100 pA 100 pA Measurement circuit for detector current i 1 LNO 1 1 12 1 bl ew Tec O TE bil br i DG pA DC ORC 1 Key ADC microamperometer with internal resistance of 5 kW max bl Blue SW Black br Brown 31 CB UNIGAS Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it Note Specifications and and data subject to change Errors and omissions excepted
33. ts 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 current after first starting the burner by following the procedure illustrated in Fig 12 Light oil filter maintenance For correct and proper servicing proceed as follows cutoff the required pipe section unscrew the filter cup remove the filtering cartridge wash it with gasoline if necessary replace it check the tightening O rings and replace them if necessary replace the cup and restore the pipe line Cleaning the combustion head and the nozzle 1 Before proceeding to maintenance operations turn the burner to off 2 remove the cover unscrewing the fixing screws 3 emove the component plate of the burner P by unscrewing the V1 V2 V3 and V4 screws and the F securing pin gh MS v 4 AER 4 Hang the plate in the way shown in Fig 9 in order to facilitate maintenance operations 21 After the disassembling the burner plate the combustion head can be removed as follows O O O20 cx O unscrew the fixing screw VT disconnect the ignition cable CA unscrew the fixing nuts D and remove the combustion head from its housing adjust the electrodes to replace them if nec
34. ve qualified personnel perform the following operations a set the burner fuel flow rate depending on the heat input of the appliance b set the flow rate of the combustion supporting air to obtain a combustion efficiency level at least equal to the lower level required by the regulations in force c check the unit operation for proper combustion to avoid any harmful or polluting unburnt gases in excess of the limits permitted by the regulations in force d make sure that control and safety devices are operating properly e make sure that exhaust ducts intended to discharge the products of combustion are operating properly f on completion of setting and adjustment operations make sure that all mechanical locking devices of controls have been duly tightened g make sure that a copy of the burner use and maintenance instructions is available in the boiler room In case of a burner shut down reser the control box by means of the RESET pushbutton If a second shut down takes place call the Technical Service without trying to RESET further e The unit shall be operated and serviced by qualified personnel only in compliance with the regulations in force 3 GENERAL INSTRUCTIONS DEPENDING ON FUEL USED 3a ELECTRICAL CONNECTION For safety reasons the unit must be efficiently earthed and installed as required by current safety regulations It is vital that all saftey requirements are met In case of any doubt
35. w the procedures laid down by current laws on disposal of materials Handling the burner WARNING The handling operations must be carried out by specialised and trained personnel If these operations are not carried out correctly the residual risk for the burner to overturn and fall down still persists To move the burner use means suitable to support its weight see paragraph Technical specifications The burner is designed to work positioned according to the picture below For different installations please contact the Technical Department BOTTOM Montaggio del bruciatore alla caldaia To install the burner into the boiler proceed as follows 1 on the boilers door hole fix the 4 stud bolts according to the drilling template shown 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 2 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 9 seal the space between the blast tube and the refractory lining with appropriate insulating material ceramic fibre cord or refractory cement c N Once the burner is install
36. wa cS 6 F31 LMO24 LMO44 v E R ec n Jumpy ee ee ee ee terr 4 2 tw zg I 6 E Srey oo AL Alarm device kbr Cable link required only when no oil pre heater is used BV Fuel valve EK1 Lock out reset button 30 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 OWRelease contact of oil pre heater t1 Pre purge time t3 Pre ignition time t3n 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 signal Required input signals OH Oil pre heater QRB Photoresistive detector QRC Blue flame detector bl 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 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 C1 Microcontroller 1 uC2 Microcontroller 2 General unit data Mains voltageAC 230 V 10 96 15 AC 120 V 10 96 15 Mains frequency 50 60 Hz 6 External primary fuse Si 6 3A slow Power consumption 12 VA Moun
37. ween 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 Identification of the connectors Burner power supply connector HIGH LOW flame connector CONNETTORE LINEA 7 POLI LONNET TORE LINEA 7 PUL LONNETTORE 4 POL TAB 7 PINS SUPPLY CONNECTOR 7 PINS SUPPLY CONNECTOR TAB 4 PINS CONNECTOR F a Es is lt es A MIN G6 3A T MAX 10 IMPORTANT before operating the burner be sure all connectors are linked as shown in the diagrams As far as connections see the attached wiring diagrams 15 SETTING THE OIL FLOW RATE ATTENTION before starting the burner up be sure that the manual cutoff valves are open and check that the pressure upstream the gas train complies the value quoted on paragraph Technical specifications Be sure that the mains switch is closed ATTENTION During commissioning operations do not let the burner operate with insufficient air flow danger of formation of carbon monoxide if this should happen make the fuel decrease slowly until the normal combustion values are achieved WARNING NEVER LOOSE THE SEALED SCREWS OTHERWISE THE DEVICE WARRANTY WILL BE INVALIDATE Prior to start up the burner make sure that the return pipe to the tank is
38. wersupply Protection Regulation Simgestage Double stage Single stage Double stage Approx weight s sa w x O Operating temperature 10 50 kg Working service x Light oil net calorific value Hi 10210 kcal kg NOTE ON THE BURNER WORKING SERVICE Burners provided with Siemens LOA24 control box for safety reasons one controlled shutdown must take place every 24 hours Burners provided with Siemens LMO24 44 control box the control box automatically stops after 24h of continuous working The control box immediately starts up automatically Biodiesel Viscosity 1 9 6 cSt 40 C Net calorific value Hi 8950 kcal kg Overall dimensions mm C min max Boiler recommended drilling tempelate AS BS CS measures referred to burner with standard blast tube AL BL CL measures referred to burner with extended blast tube Performance range LO140 G TN LO140 G AB N IN LN 160 180 Q Z Y n c 5 lt 0 TO rz oe lt gt m m gt O LO200 G AB EE EES EET I AEE TITTLE yy INE mS ea oc a a BACK PRESSURE IN COMBUSTION CHAMBER mbar 80 100 1
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