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LO 280 400 TN AB

1. z z Sri ids avot 31935 QUOISIASY onooi 4002 10 80 as 81 91 51 N33M138 30088 IHL INOWIY 035 AYL Ji p 81 91 ILLISSON VEL 3INOd VIOL VL 015 309 IS mon ow D Vivid 55 8 3 ANDISNDIY 1505 1 IV HOH YAH R 5 CE 5 T0ENE9 LE08SHVIS 02 DABIS edWVO 20 SUYI VONVYYIS 00 020 835 q 5 po eg E 30108 NYS 41 LA BUCLVALINIA 390104 I avi F2 0ENES LEORS LS 4 Y Y dial Yw iiil Tu 1 ZWN T DN E5726 Gaia Suo 22000 4 SN VIN ls Mo 8V1 6N3 05 100 ZON3 9NJ V9A3 5N3 VISO WI ZNI AW VIS AW 84 Xnv Ln 11 LI 11 wy d felina N M M LINZ CINA AE O1VdAVIS 01282 4 n 4 040059 VR 1 4 4 4 I E1111 1111 11 I II 8 H393tvddv H393uvddV 2 FWINOYS L 31V LNONI 9 HIDIYYddYy HJJ33VddV JW 1N0 4 b JIVLNOYS RE ada dadi e PR z l o 2009902 1 5 di 1 ac a R5 8 144 yrat 39 56 OWI 4 42V01 SIONVI 158 gt 2 ooooQ ooooQ v 6 2 L 8 5 9 EE 9L6M Q 94600 2 081 5 2A ay o ooo OO 5 So pono a amp oS d ai
2. 23 230V Fig 25 Single stage burners Key LAF C1 C2 Time counter LB CONN LINEAConnectors on electrical board LBF CONN TABConnectors on electrical board N F1 F3 Fuses ST IL Line switch for burner s auxiliaries TAB IM Fan motor line switch TS L Phase T lt 5 lt ji a Fig 26 High Low flame burners Burner in high flame signalling lamp high low flame and progressive versions only Burner lockout signalling lamp Burner in low flame signalling lamp high low flame and progressive versions only Neutral Thermostats or pressure switches group High Low flame thermostat Boiler safety thermostat PART I INSTALLATION 11 LIGHT OIL PIPING INSTALLATION DIAGRAM A PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIGN OF THIS MANUAL 7 6 4 3 From tank E i To tank 5 6 Fig 27 Only for installations with gravity siphon or for Burner ced circulation feed systems If the device installed Flexible hoses fitted i Pe Bor a timer must be installed to Light oil filter fitted elay the valve closing The direct connection of the device without a timer Automatic interceptor imay pause p mp breaks One way valve Gate valve Quick closing gate valve not in vicinity of tank or boiler O QI GQ NN 12 PART INSTALLATION Pump operating principle In the burners the mixture bertween oil and
3. 25 nt 25 PARTI MAINTENANCE LA 26 ROUTINE OPERATIONS Zu uu uu arenile e dean edi ee echelon eh eee 26 Removing the combustion head Er a apama apna a aaa as 26 Removing burner components plate 28 Assembling burner components plate u 28 Removing the electrodes ER 29 DISASSEMBLY OF THE NOZZLE LO280 2 2 000000000000000000000000 enne tns 29 2 5 ag ND 30 Correct position of electrodes and combustion head 31 Check the detection Curren E anelli alano 31 TROUBLESHOOTING MI IE 32 WIRING DIAGRAMS dede td eec ale bete E iaia 33 SPARE PARTS titti tenter deti i fte e n erue fede ee aeu eue 41 APPENDIX u S 43 WARNINGS THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOT
4. 11 are de energi sed in less than 1 second at the same time a remote lockout signal is transmitted through terminal 10 The controller can be reset after c 50 seconds 44 APPENDIX COMPONENTS SPECIFICATIONS LANDIS OIL BURNERS AUTOMATIC CONTROLLER LOA44 OPERATION Burners without fuel pre heater Start up thermostat and pressure switches R burner motor G and ignition transformer Z are all controlled at the same time After about 25 seconds the solenoid is energised in this period the flame amplifier is at maximum sensitivity The command to the first solenoid BV1 marks the start of the safety time during which either there is no flame in the burner and the controller locks it out or after 5 seconds the stage 2 solenoid BV2 is energised and this ends the bur ner start up programme Burners with fuel pre heater Operational all clear from contact OW which short circuits terminals 3 and 8 The burner start up programme is exactly the same as above except that it is initiated by the closing of the OW contact of the preheater OH When the flame lights the flame relay contact fr2 is short circuited and should the contact OW open that does not cause a lockout but a repetition of the cycle Commands in the event of operational interference Premature ignition Flame present during pre purge Lockout and termination of pre purge Defective components in controller or electronic programmer Lockout No f
5. CE T f E 7 IDEA RANGE LIGHT OIL BURNERS Compying with EMC 79 336 CEE LV 73 23 CEE Documentazione Tecnica CIB UNIGAS spa Campodarsego Padova Italy M039134CB Rev 1 12 06 TABLE OF CONTENTS WARNINGS u eee EEEE EA saa RN 3 PART EIINSTALLATION E 5 BURNERS CHARACTERISTICS rette alal do ape see ane YU HERE eg aaa 5 em 5 Technical Specifications u u u u q Nu e e e tace dde dete dea rele eum A eru iii 5 Overall dimensions MM x ate cease tenia 6 Performance Holl us 7 How to modify blast tube length LO400 8 MOUNTING AND CONNECTIONS 20 aaa 10 Fitting the burner to the boller 4 ti e a iit pese geb ea Eau eaae ed eeu tod vate eee y ede yen prey eed 10 LIGHT OIL PIPING INSTALLATION DIAGRAM i 12 PUMP Operating Principle e 13 about the useof fyel PUMPS tisana iecore RE EU E ER ia coi Eat AR IU IRA IE 14 Mou nting of flexible light oll Roses o Ere UR gt 14 SETLTINGIEO280 uncus ou et ale LR il a e one ico LI IE 15 Oil rate adjustment Single stage burners essen 15 Priming the Dump tota e ie p p Hi eai
6. Never leave the burner connected when not in use Always shut the gas valve off e 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 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 WARNINGS 4 BURNERS CHARACTERISTICS Burner model identification Burners are identified by burner type and model Burner model identification is described as follow LO400 Model G 2 TN S 3 4 BURNER TYPE FUEL OPERATION Available versions BLAST TUBE DESTINATION COUNTRY BURNER VERSION Technical Specifications 5 6 10280 110400 G Lightoil A Biodiesell TN Single stage AB Double stage M Modular S Standard L Long destination country see data plate A Standard Y Special M Hydraulic jack BURNERS GNA Output min max KW 115 310 70 310 Light oil rate min max kg h 9 6 26 5 8 26 Fuel Light
7. d TANYd X08 21819913 SIONVI Sd CLEMAO JN031VS SIONI NOJ Sd ONOVRD FV 18082 vl t e 8 L 9 v 4 iring w 35 PART III MAINTENANCE MANUAL AL 91 81 N 31 101 30935 QUOISINIY 00 4002 10 80 DRS 9A3 N3d0 9A3 VYNLYIdV ONY NOILINDI A8 ONVIS VSSV8 3 INDISNIDIV V1S0S VINNVId VIIVI 540 108INO2 DAYS DONVINOIOAHIS INVII 17500 9 L L 81 91 SIVNIMYIL N33M138 3908 3H JAOWIY 01350 Al 91 91 11135804 31NOd Tl 383901 IYL OISIA3Nd 35 p O a 8 olo Q o 42530 3 017142530 WILI YIDIS 9 VI 9 5 LMS m oo xnv E HILIMS 340553844 YO LVISOMYIHI ALIHYS 17734025 OLVISOSSIYA 0LVISOMMHIL 51 81 2 zg 19 L SIHILIMS 3UYUNSSIYA 1YLSOMYIHL MO01 H9H 55 8 1 OLVISOSSIYA OLVISONYIL evi YINYOISNYUL NOLLINDI 3NOISN322V 10 IYOLVNYOISVAL VI 9 o 9 5 10 1 02 0 435 HIdAYO CONVINOIONHISI 9 085 LS CONI Zdd
8. v 108090 APPENDIX COMPONENTS SPECIFICATIONS 43 Technical characteristics Voltage Frequency External fuse Contact flow terminal 1 terminal 3 Terminal flow terminals 4 5 810 terminals 6 amp 7 terminal 8 Absorbed cap Protection Premitted temp operational transport amp storage Emplacement Mass weight 220V 15 240V 10 or 100V 15 110V 10 50 60Hz 6 max 10A slow action 5A 5A incl capacity absorbed by motor and pre heater 1A 2A 5A 40 20 60 C 50 60 C any controller 1800 socket 500 AGK accessories 12 g Commands in the event of operational interference Stray light premature ignition During pre purge and or pre ignition there should be no flamesignal If there is a flame signal eg from premature ignition due to a faulty sole noid external light short circuit in the photoresisto or wiring malfunc tion in the flame signal amplifier etc at the end of pre purge and safety time the controller locks out the burner and stops the fuel flow even during safety time Absence of flame If there is no flame at the end of safety time the controller locks out immediately Absence of flame during operation If there is no flame during operation the controller cuts off the supply of fuel and automatically initiates a fresh start up programme at the end of t4 the start up programme ends Whenever there is a safety stop terminals 3 8
9. 10 74 11 01 11 27 11 52 11 77 12 01 2 25 7 4 811 855 8 96 9 36 9 74 10 11 10 47 10 1 11 14 11 47 11 78 12 09 12 39 12 68 12 96 13 24 13 51 2 50 849 9 01 9 50 9 96 10 40 10 83 11 24 11 63 12 01 12 38 12 74 13 09 13 43 13 76 14 09 14 40 14 71 15 02 3 00 10 19 10 81 11 40 11 95 12 48 12 99 13 48 13 96 1441 14 86 1529 15 71 1612 16 51 16 90 17 28 17 65 18 02 350 11 89 12 61 13 29 13 94 14 56 15 16 15 73 16 28 16 82 17 33 17 84 18 33 18 80 19 27 19 72 20 16 20 60 21 02 400 1359 14 41 1519 15 94 16 64 17 32 17 98 18 61 19 22 19 81 20 39 20 94 21 49 22 02 22 54 23 04 23 54 24 02 4 0 1529 16 22 17 09 17 93 18 72 19 49 20 23 20 94 21 62 22 29 22 93 23 56 24 17 24 77 25 35 25 92 26 48 27 03 16 PART I INSTALLATION mod 1 0280 Air rate setting Single stage burners loosen VR screw move the ID index along the graduated slot towards or in order to increase or decrease the air flow rate according to the required combustion values asten the VR screw again Double stage burners Servocontrol cams adjustement Air damper position is set by means of the servocontrol cams As for the setting refer to the next table The STA4 5B0 37 is not provided with the manual contrl for the air damper The cams adjustement must be per
10. Remove the burner s cover cover Remove the servo control s cover Start the burner and let it burn at low flame remove the bri dge between Terminals T6 and T8 Adjust the air flow in low flame by working on the appropriate cam Fig 42 Prime the second nozzle using the following procedure Start the burner When the flame appears press the P1 button Fig 40 for a few seconds to fill the second nozzle pipe The cycle continues and if the TAB thermostat is con nected the flame control apparatus brings the burner to high flame If the TAB thermostat is not connected bridge Termi nals T6 and T8 on the connector see Identification of linking connectors on page 11 and Connectors layout on printed board on page 41 Adjust the air flow at high flame by working on the appropriate cam The cam that triggers the opening of the 2nd stage fuel valve valve EVG2 must be set in an intermediate position between the other two cams Replace the cover on the servo control Replace the burner s cover Connections for pressure measurement Fig 41 20 PART I INSTALLATION Fig 40 Second nozzle s ignition pushbutton on double stage Fan air pressure port SERVOCONTROL CAMS SETTING Adjustment of cams microswitches Refer to Tab 4 for cams functions Fig 42 Berger STA4 5B037 4 Air damper position is set by means of the servocontrol cams As for the setting refer t
11. 2 39 2 50 260 270 2 79 2 88 2 97 3 06 314 322 330 338 346 353 3 60 0 65 2 21 2 34 247 259 2 70 2 82 2 92 3 02 3 12 322 331 340 349 358 3 66 374 3 83 3 90 0 75 255 270 2 85 2 99 312 325 3 37 349 360 371 382 393 403 413 423 432 441 450 0 85 2 89 306 323 3 39 354 3 68 382 395 408 421 433 445 457 468 479 4 90 500 5 11 1 00 3 40 360 380 398 416 433 449 465 480 495 5 10 5 24 537 550 563 576 5 88 6 01 1 10 3 74 396 418 438 458 476 494 5 12 529 545 561 5 76 591 606 620 634 647 6 61 1 20 408 432 456 478 499 520 5 39 558 5 77 594 612 628 645 661 676 621 7 06 721 1 25 425 4 50 475 498 520 541 5 62 5 82 601 619 6 37 654 671 688 7 04 7 20 7 36 7 51 1 35 459 486 5 13 5 38 5 62 5 85 6 07 6 28 649 6 69 6 88 7 07 725 743 761 7 78 7 94 8 11 1 50 5 10 541 570 5 98 6 24 650 6 74 6 98 721 743 7 64 7 85 806 826 845 8 64 8 83 9 01 1 65 561 5 95 627 657 6 87 7 15 742 7 68 7 93 817 841 8 64 886 908 930 9 51 9 71 9 91 1 75 5 95 6 31 665 6 97 728 758 787 8 14 841 8 67 8 92 9 16 9 40 9 63 9 86 10 08 10 30 10 51 2 00 6 80 7 21 7 60 7 97 8 32 866 8 99 9 30 961 921 10 19 10 47
12. air to perform a clean and efficient combustion is activated by atomization of oil into very small particles This process is achieved making oil passing through the nozzle at a determined pressure The pump s main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pres sure pumps are provided with a pressure regulator except for some models for which a separate regulating valve si provided Other pumps are provided with two pressure regulators one for the high and one for low pressure in tow stage systems with one nozzle These 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 pum s return port to the tank as well The excess of oil goes back to the tank this installation can be con sidered 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 facto
13. filter inside the light oil pump filter must be thoroughly cleaned at least once 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 on pag 31 carefully during re assembly e Inspection and cleaning of ignition electrodes pag 29 and respective ceramic insulators clean adjust and replace if necessary Disassemble and clean the light oil nozzles pag 29 A IMPORTANT cleaning must be performed using solvent not metal tools At the end of maintenance operations after first reassembling the burner light the flame and check its shape replacing the noz zle whenever a questionable flame shape appears Whenever the burner is used intensely we recommend preventively repla cing the nozzle at the start of each heating season Inspect and thoroughly clean the flame detection photoresistor and replace if necessary In case of doubt check the detec tion current after first starting the burner by following the procedure illustrated in Fig 69 e Clean and grease levers and rotating parts Removing the combustion head Remove the burner s cover by unscrewing the fixing screws e Slacken the light
14. property for which the manufacturer cannot be held liable Before installation it is recommended that all the fuel sup ply 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 devi ces required by the regulations in force When the burner is to remain idle for some time the fuel supply tap or taps should be closed SPECIAL INSTRUCTIONS FOR USING GAS Have qualified personnel inspect the installation to ensure that a the gas delivery line and train are in compliance with the regulations and provisions in force 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 regula tions and in any case are sufficient for proper combustion e Do not use gas pipes to earth electrical equipment
15. 35 e pesa MAINTENANCE MANUAL PART 2 01904 9002 1 1 81 PPa HILIMS 34055354 YO LVLSOWYSHL 134 5 VZZIYNIIS OLVISOSSIYA 01VISOMZIL L 51 YAWYOASNVYL NOLLINDI 3NOISN322V 3801 VWSOJS L VI SIHILIMS 34055399 YO SIVISOWYSHL dO 531935 IL VISOSSIUAALVISOMYIL 31935 15 3JIA30 YOLINOW 3AV 3 VININVIA OTIOSINOJ VsniviH223dvddav COW V0 SNIWIIS YOLOW IYOLVULNIA 38010 AW NOILVYId0 HANNA 1 YOLVIION IYOLVIINYA OLNAWVNOIZNAS 3NOIZVTVND3S YOYdWY1 31 1010 9201 YINYNG 804 YOLVIION IYOLVIINYA 022018 3NOIZVIVNB3S VOVdAV1 91 HOLIMS 3N 8 IHOLVIONYA VINI 38401114431 1 YOLIINNOISIO NIV 31V83N39 3801108831 9 3504 Id 371181505 ENI ISN4 10 371181505 INI 80123130 INVII YOLSISIYOLOHd VINIWVIA 3NOIZVA3TIM VZNILSISIYOLOH ud 3 1 0419313 10 LEON ONOSVO VIOATVAD311313 DAI CIVNOILdO 33138 NOLL VHIdO TVNOILdO OLN3AVNOIZNPH IYOVINOI L 0J NOILINNI INOIZNNH 133 5 0190 WALI V IS 6 8 4 9 S v 4 0 34 18 116 LO280 Double stage burners iagram d
16. EA asi ec i ein i b ed in ted 15 Choosing oil ioZzles aep beate cn eet a ia red ced 15 Oil rate adjustment High low flame burners iii 16 Prming tlie pump ure Lai elica ilaele 16 mod LO280 Air rat setig bae ARR ene enone 17 MOD LO400 SETLIINGS 3 22 RAN ad onirico aa 18 M aaa ira 18 E el rate adjustment i ti n p ede ete i sip eet ua aiar dtt 18 Choosing the light Ol nozzles eo latte 18 First start air rate setting MOD LO400 iii 20 SERVOCONTROL CAMS SETTING Adjustment of cams microswitches i 21 tei il ii il iene 22 PUmps 22 Pumps for mod EO400 x ee o ret Ene RO tree eite a pire eei mr iore ir 23 ADJUSTING THE GOMBUSTION HEAD i e lara rnin aden 23 PARTIE OPERATION rana alii 24 OPERATION EU i a 25 Single stage butriers iet ER PEU ie eo li nella Sl il 25
17. F 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 FUNCTIO NING OF THE BURNER THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLA TION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE E G DISCONNEC TION 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 PERSONNEL 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 24 PART Il OPERATION MANUAL FUNCIONAMIENTOOPERATION Single stage burners Turn on the burner using the switch A on the control panel Fig 48 the control panel of the single stage burner is only pro vided with the power s
18. H 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 SEC TION OF THIS MANUAL WE HIGHLY RECOMMEND TO READ IT CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE 1 GENERAL INTRODUCTION The equipment must be installed in compliance with the regulations in force following the manufacturer s instruc tions by qualified personnel e Qualified personnel means those having technical knowle dge in the field of components for civil or industrial heating systems sanitary hot water generation and particularly ser vice centres authorised by the manufacturer e Improper installation may cause injury to people and mals 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 devi ces plastic bags foamed polystyrene etc should not be left within the reach of children 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 case of breakdown and or defective unit operation disconnect the
19. Light oil Power supply 230V 50Hz Electric motor kW 0 25 0 25 Total power consumption w 0 55 0 55 Weight kg 42 42 Operation Single stage Double stage Operating temperature C 10 50 Storage Temperature C 20 60 Working service Intermittent BURNERS GNA G ABXOXXA Output min max kW 195 420 115 420 Light oil rate min max kg h 16 35 10 35 Fuel Light oil Light oil Power supply 230V 50Hz Electric motor kW 0 37 0 37 Total power consumption Ww 0 67 0 67 Weight Kg 42 42 Operation Single stage Double stage Operating temperature C 10 50 Storage Temperature C 20 60 Working service Intermittent NOTE ON THE BURNER WORKING SERVICE for safety reasons one controlled shutdown must take place every 24 WARNING if fuel used is BIODIESEL some components must be replaced Please contact our Technical Depart ment for further details hours PART I INSTALLATION 8 eDed ees 007017 pow eqni 1se q BulAjIpow se sy qn11selq 1 eqni 1se q 1 s 16 SSL 641 LEL 61 OLN 872 Ecc SIC VOL Sol 966 045 870 84 64778 874 00701 80L lt 6 SSL 621 616 OLN 872 EZZ SLZ 821 801 966 078 820 409 8728 S CEZ 08201 X d N IN 1 H 9 5 x18 58 IV SV pue eyed Buijup
20. NITION TRANSFORMER INDICATOR LIGHT MV FAN MOTOR PS LOCK OUT RESET BUTTON WITH LOA44 AND LMO ONLY SATRONIC DKO976 DKW976FLAME MONITOR DEVICE SATRONIC DKW972 FLAME MONITOR DEVICE SATRONIC TF976 FLAME MONITOR DEVICE ST SERIES OF THERMOSTATS OR PRESSURE SWITCHES SWI II STAGE BURNER START BUTTON TA IGNITION TRANSFORMER TAB HIGH LOW THERMOSTAT PRESSURE SWITCHES TS SAFETY THERMOSTAT OR PRESSURE SWITCH IF TAB USED REMOVE THE BRIDGE BETWEEN TERMINALS 6 8 SERVOCONTROL CAMS HIGH FLAME Il STAND BY IGNITION LOW FLAME Ill EVG2 OPENING WARNING 1 Electrical supply 230V 50 60Hz 2N a c 2 Do not reverse phase with neutral 3 Ensure burner is properly earthed PART III MAINTENANCE MANUAL 37 Wiring diagram 18 049 LO400 Single stage burners ay xo RD ad Nja Nl luni Nja prc aM xny vis vi M ci 275009 003 UNDA Q31Nitid OLVdAVIS OLINIMO 9L6M 0 91 6030 2 041 5 00000 Y oo 00 Eun WES 1 HUM Sd TNyd X08 2412313 7160 2 041 5 VINOD 5 Guavno NOs PART III MAINTENANCE MANUAL 38 Single stage burners 18 049 LO400 Double stage burners 81 91 ee N13M138 200719 OWH OIN 3 81 91 LIS 1 INO 1 343001 AVI OSABA S AUR xu m R WENES LE GS 15 TINO DANS 3o y ay 30 SHYI DONYWOXDARIS o WENE9 LE08S YLS E
21. NYG vivid 3NOIZVIVND3S VIS Pol HOLIMS 3N7 VINI 3401118831 YOLIINNOISIO NIVWI 11 83 39 33D11039331NI O O 2574 INT YINUNGI IYOLVIONYGY VINI 3191505 L C E ROS 9 6 Vi 679 VANI 10 NASN znd O 09596090 601016 80123130 Y0LSISIYOLOHd VINIVIJ JNOIZVAIIY VZN31SIS3380104 041 3313 WO 1H9N OMNOSVO 1373 293 Era WINS 3AA 0813313 10 LHON MOT VSSV8 OMOSYD VIOATVAOSLIT3 YILIN V11V 380 1 02 61 YILIW VSSV8 380V 1NO2 13 NOILINN INDIZNNH WILI VIDIS v L e OL 8 4 9 6 Ls MAINTENANCE MANUAL PART 36 WIRING DIAGRAMS Complete key mod LO400 C1 C2 EVG FR FU1 FU2 FU3 IL IM KA2 3 KA2 4 KM1 1 KT2 4 LAF LOW FLAME TIME METER HIGH FLAME TIME METER LIGHT OIL ELECTRO VALVE PHOTORESISTOR FLAME DETECTOR FAN MOTOR LINE FUSE LINE FUSE BURNER LINE FUSE BURNER LINE SWITCH FAN MOTOR LINE SWITCH AUXILIARY RELAY AUXILIARY RELAY FAN MOTOR CONTACTOR DELAYED RELAY BURNER IN HIGH FLAME INDICATOR LIGHT LANDIS LOA24 44 LMO 24 44FLAME MONITOR DEVICE LB INDICATOR LIGHT FOR BURNER LOCK OUT LBF BURNER IN LOW FLAME INDICATOR LIGHT LEVG1 INDICATOR LIGHT FOR OPENING OF ELECTRO VALVE EVG1 LTA IG
22. PECIFICATIONS APPENDIX COMPONENTS SPECIFICATIONS 47 NGS CIB UNIGAS Via C Colombo 9 35011 Campodarsego PD Italy Tel 39 049 9200944 Fax 39 049 9200945 9201269 Internet www cibunigas it E mail cibunigas cibunigas it
23. The burner should be installed in a suitable room with ven tilation 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 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 e 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 bur ner the user shall have qualified personnel carry out the fol lowing operations a Remove the power supply by disconnecting the power cord from the mains b Disconnect the fuel supply by means of the hand operated shut off valve and remove the control handwheels from their spindles Special warnings Make sure that the burner has on installation been firmly secured to the appliance so that the flame is generated inside the appliance firebox Before the burner is started and thereafter at least once a year have qualified personnel perform the following opera tions a set the burner fuel flow rate depending on the heat input of the appliance b set the flow rate of the combus
24. USES INTERVEN TION FLAME CONTROL DEVICE FAULT SERVOCONTROL FAULT SMOKY FLAME IGNITION TRANSFORMER FAULT IGNITION ELECTRODE DIRTY OR BAD POSITION DIRTY NOZZLE FUEL SOLENOID VALVE DEFECTIVE PHORESISTANCE DIRTY OR DEFEC TIVE HIGH LOW FLAME THERMOSTAT DEFECTIVE BAD POSITION OF SERVOCONTROL CAMS FUEL LOW PRESSURE FUEL FILTERS DIRTY 32 PART III MAINTENANCE MANUAL WIRING DIAGRAMS 04 743 LO280 Single stage burners iagram d iring w 7 z ILL3HOYVN S NOINId N Cy 70 sig 030 041002 3 31 101 30935 9002 21 81 2101212590 OO eueswey med OSSIDO V xx x NI 9 1300W 011300W 09201 1 9002 1 1 81 PIRO Ie NL ZHOS AOEZ N 9 4 LE 8 69 5 is a n 02 2 0123NN0 ads 3NOIZVIN3ATIV 3HOLL3NNOO E MARE LL BARES 1 1 1 1 YOLOW IYOLVILNIA 3840104 DE D AW DAI 1 Ma ud 3 9 ZW O O O do 3d a 8 4 9 2 0L YCOWT 72 01 SN3A3lS 6 8 L 9 S Y 2 L 0 33 PART III MAINTENANCE MANUAL 2 317101 309
25. V 4 53 5 3 553 9 YO SLVISOWYSHL 40 53935 IL VISOSSIYA LVISOWYHIL 31 35 15 98 58 78 avi 39030 YOLINON VAI OTTOBLNOI 223 ddy ZLEMMO JINONLVS O o 39 130 YOLINOW VWWYI4 011081 02 VHNLYIHIDIYYAdY 9L6MMO 9160 0 DINOULYS OWT ONY 97 01 NOLLAG 13534 110 7207 OW 3 7 01 NOD 0105 YWWYI4 0220185 31 51 Sd L YOLOW IHOLVILNIA 38010 2 4HOM YOLVIIONI YIMYOISNYYL NOILINDI 3N0ISN333V IQ IYOLVINYOISVAL INCDIZYIVNDIS VII OO Q Z9A3 3A1VA 08123T3 40 304 1HON YOLVIIONI ZDAJ VUNLYIAY 3NOIZVIVN93S 9 3 Ev ev W L9A3 3 1 08412313 40 X04 Y01LWIIONI VUNLYIAY 3NOIZVIVN93S VOVdAV1 oi lo HOM HOLVIIONI 34V MOT HINUNG IYOLVIONUA VWWVId VSSV8 INDIZVIVNDIS YOYdWYT 1391 WO 9 1H9N 801 V3IONI M01 NI 9 IYOLVIONYA VWWVId VSSV8 INDIZVIVNDIS 1 381 ov SV V 110 4201 HINUNA 804 LHOM 801 V3IONI IHOLVIONYA 022018 3NOIZVIVN93S VOVdAV 1 181 P 100 3201 HANNA 404 1 S01 V3IONI AUYOLVIONYIA 023018 3NOIZVVNB3S g1 vo o VAN 331130 YOLINOW OTIOSINO2 Vai vid323svddv OW 77 9207 SIONYT 2 0 0 5 1H9I1 Y01VIIONI 3JNV14 Y3NYN 1 VWWYId VITV 3NOIZVIVN93S vOVdAV1 9 AH9I1 Y01WDIONI NI YINYNG IHOLVIO
26. alified 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 particu lar make sure that the system cable cross section is ade quate for the power absorbed by the unit e 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 obser vance 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 50 do not allow children or inexperienced persons to use equipment The unit input cable shall not be replaced by the user In case of damage to the cable switch off the unit and contact qualified personnel to replace When the unit is out of use for some time the electric switch supplying all the power driven components in the system i e pumps burner etc should be switched off 3b FIRING WITH GAS LIGHT OIL OR OTHER FUELS GENERAL The burner shall be installed by qualified personnel and in compliance with regulations and provisions in force wrong installation can cause injuries to people and animals or damage to
27. d30200F 1 NOZZLE HOLDER Long 30200F2 Long 30200F2 2850090 2850089 PHOTORESISTOR 2510034 2510033 2510033 2510033 NOZZLES 261 261 261 261 Flexible hoses 234F x22 234Fx22 2340001 2340001 GASKET 2110059 2110059 2110059 2110059 BOARDPRINTED CIRCUIT 6100547 6100542 6100542 EVG2 ELECTRO VALVE 2190638 MOTOR PUMP COUPLING 2540055 2540055 2540055 2540055 EVG1 COIL 2580402 2580402 2580402 2580402 EVG2 COIL 2580402 PART III MAINTENANCE MANUAL 41 42 PART III MAINTENANCE MANUAL LANDIS OIL BURNERS AUTOMATIC CONTROLLER LOA24 Use LOA safety devices are intended for use solely with QRB photore sistors for lighting and controlling low capacity forced air light oil bur ners with max capacity 30 kg h in accordance with standard DIN 4787 The One or two flamess are lit through electrical connections with or without post ignition To replace LAI AND LAB WITH LOA LOA models can be used as replacement for LAI and LAB con trollers by means of the adapter KF8819 and without the need to change the electrical wiring Because the LOA is smaller in dimen sions when it is used with the adapter the external dimensions are almost identical which means that there is no need to move the reset button Performance The controllers just need plugging in so they can be mounted in almost any position on the burner on the electrical panel or on the control panel The cas
28. e Fig 13 Long blast tube 8 PART I INSTALLATION If you modify the blast tube length you have to modify also the combustion head length by reading the following instructions 1 Loosen the light oil feeding pipes connected to the nozzle holder by using two spanners size 22 10 Fig 16 Adjust cables length by pulling them very slightly as shown in Fig 17 Loosen the screw VA which tights the rod A Fig 18 and shift backward the flange as shown Tight the screw in the backward hole on the rod see picture Fig 19 Fix the two extensions supplied along with the burner inside the accessories carton box on the light oil feeding pipes Fig 20 and tight them by using two spanners size 13 and 10 Fig 21 Fix the extensions to the nozzle holder by using two spanners size 22 and 10 Fig 16 6 Assemble again the combustion head See Removing the combustion head Part III of this user s manual Q Fig 21 PART I INSTALLATION 9 MOUNTING AND CONNECTIONS Packing The burners are despatched in packages of dimensions 795 x 550 x 490 mm W x H x D Packing cases of this kind are affected by humidity the maximum number of cases to be stacked is indicated outside the packing The following are placed in each packing case 1 burner 2 light flexible hoses 1 light oil filter 1 gasket to be inserted between the burner and the boiler 1 e
29. e rate must be higher than the rate referred to the minimum burner output Key Fig 37 Single stage burners EV Fuel solenoid valve EVG1 Fuel solenoid valve low flame EVG2 Fuel solenoid valve high flame only hi lo flame burners ID V M Manometer P Pump Fig 38 Double stage burners EVG2 Choosing the light oil nozzles Tab 3a Single stage LO400 PUMP PRESSURE bar 10 12 14 NOZZLE G P H FUEL RATE kg h 4 00 15 19 16 64 17 98 4 50 17 09 18 72 20 23 5 00 18 99 20 81 22 47 5 50 20 89 22 89 24 72 6 00 22 79 24 97 26 97 6 50 24 69 27 05 29 21 7 00 26 59 29 13 31 46 7 50 28 49 31 21 33 71 8 30 31 53 34 54 37 30 9 50 36 09 39 53 42 70 18 PART INSTALLATION Tab 3b Double stage LO400 RATE OUTPUT PUMP PRESSURE kg kcal h kW 10bar 12bar 14bar 30 306 300 356 3 50 4 50 3 00 4 00 3 00 3 50 35 357 350 416 4 00 5 00 3 50 5 00 3 50 4 00 40 408 400 475 4 50 6 00 4 00 5 50 4 00 5 00 45 459 450 534 5 00 6 50 4 50 6 00 4 00 6 00 50 510 500 594 5 50 7 50 5 00 7 00 4 50 6 50 PART I INSTALLATION 19 First start and air rate setting MOD 10400 Single stage burners Set the air rate working on the screw VBS Fig 39 screw to decrease the air rate or unscrew to increase it Two stage burners The air flow can be adjusted using the air damper servo con trol cams as follows
30. es M PF X zh X yoAa Nja RUS Nja Ws RUE Lao EN M 7500 9 002 NDA 031Nu3d OLVdAVIS 01120412 C T J w Ta FREE 8 HJJ3iyddy 8 HIRIYddy Y H J33yaddy a n n T _ r oooooQ 8 L Y 8 8 9 9L6M Q 916090 INOULYS 0000 1798 ZL6MYO INOULYS d HIM Sd X08 3913313 50 1 NOD Sd GuayNo 31v 1NO44 39 PART III MAINTENANCE MANUAL Connectors layout on printed board FRONTALE 1 FRONTALE 2 NO STA e o QJ 5 0 012 4 o Q 1 AS AG PP1 M A2 B4 B5 B6 APP2 Bi B2 B3 40 PART III MAINTENANCE MANUAL SPARE PARTS DESCRIPTION CODE LO280 Single stage LO280 Doulbe stage 0400 Single stage LO400 Doulbe stage LOA24 CONTROL BOX 2020445 2020445 2020445 2020445 ELECTRIC MOTOR 2180717 2180717 2180714 2180714 IGNITION TRANSFORMER 2170231 2170231 2170231 2170231 PUMP 2590130 2590152 2590170 2590170 IGNITION CABLES 6050153 6050153 6050153 6050153 IGNITION ELECTRODES 2080283 2080283 2080259 2080259 2080260 COMBUSTION HEAD 30601C5 30601C5 30601A1 30601A0 FUEL FILTER 2090027 2090027 2090025 2090025 SERVOCONTROL 2480057 2480057 FAN 2150071 2150071 2150060 2150060 Standard 30900L3 Standard 30900L3 BLAST TUBE Long 30900L4 Long 3090014 30900G2 30900G2 Standard 30200 1 Standar
31. formed by means of a screwdriver acting on the VS screw placed inside the cam During the first setting set the cam III between the cams and Then passing from the low to high flame stage or viceversa change the setting according to the flame composi tion if cam III is too near to the low flame position cam II flue gas can take place because there is more fuel than air if cam III is too near to high flame cam the flame could fade because of too much air Fig 36 Berger STA4 5B0 37 63N30L BERGER STA4 5B0 37 6 High flame Low flame stand by ignition EVG2 opening 2nd nozzle PART I INSTALLATION 17 10400 SETTINGS Priming the pump Before carrying out the adjustment it is necessary to start up the fuel pump proceeding as follows A Prior to start up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pump seal to break Start the burner light up the photoresistor after the opening of the solenoid valve and escape the air from the pressure port Fuel rate adjustment The fuel rate is setting choosing properly sized nozzles and adjusting the fuel pressure at the pump inlet see the diagram Fig 37 and Fig 38 To choose the nozzles refer to Tab 3b and Tab 1b for pump pressure regulation see on pag 23 For further information on fuel pump see also the appendix Note all pumps are set to 12 bar The nozzl
32. he tank thus avoiding the possibility that they might be sucked into the pump On initial commissioning a dry operation is foreseen for a considerable length of time for example when there is a long suction line to bleed To avoid damages inject some lubrication oil into the vacuum inlet Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the joint noise and overloading the gears Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical seal junctions preferred Junction threads elbow joints and couplings should be sealed with removable sg component The num ber 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 alumi nium gaskets junctions if possible 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 An external filter should always be installed in the suction
33. ing is made of robust heat resistant plastic and contains the thermic programmer operating a multiple switch control system with ambient temperature compensator flame signal amplifier with flame relay e warning light indicating lockout and associated sealed reset but ton The plug in socket also made of robust heat resistant plastic con tains the 12 terminals and also e neutral terminals ready wired up to terminal 2 4earth terminals for earthing the burner e 2 supplementary terminals numbered 31 and 32 The socket has two openings at the bottom for the leads 5 others with threaded connection for cable holders PG11 or 3 4UNP for non metallic sleeves are located on a mobile stuffing box one on either side and 3 on the front There are two flexible metal tongues on the sides of the socket for mounting To dismantle it only requires gentle pressure with a screw driver in the slot of the mounting guide The base dimensions of the socket are the same as for types LAB LAI and there is no difference in the diameter of the reset button the two mounting screws and the flange of the burner earth Safety at low voltage levels Safety devices against any reduction in the mains voltage operate on a special electronic circuit which in the event of the power supply fal ling below 165V stops the burner switching on without releasing the fuel and locks out the apparatus Wiring diagram of
34. lame signal at the end of safety time Lockout No flame during post ignition Lockout No flame during normal operation Repetition of start up gramme Power cut during start up programme or operation Automatic repetition of programme when power restored Lack of sufficient power 160V Solenoid BV1 de energised sole noid BV2 de energised when flame goes out Lockout which occurs within less than 1 second cuts off power to ter minals 3 8 and 12 terminal 10 still remains live in order to activate the optical lockout indicator The controller can be reset 2 seconds after a lockout Important when external wiring is replaced ensure that it is switched on at the same phase of terminal 2 so that terminal 9 is connected up to neutral Electrical connections and programmer s layout burner start up B Flame signal with pre heater present C End of programme start of normal operation A burner start up C D normal operation without oil pre heater D normal stop Programme or command cycle tw fuel pre heating time acc to system tl pre purge time 25secs t3 pre ignition time 25secs t2 safety time max 5 secs t8n post ignition time 2 secs t4 interval between BV1 and BV2 commands 5 secs lockout from absence of flame 1 sec n relation to the moment when the flame occurs Key Internal diagram AL alarm device AR main relay with contacts BV fuel valve BR lockout relay EK lock
35. line upstream of the fuel unit Mounting of flexible light oil hoses To connect the flexible hoses to the pump proceed as follows 1 2 3 4 5 Remove burner s cover mod LO280 mod LO400 Made in France 21000 Longe arermax CE Firm A UM Fig 30 Fig 31 Fig 32 Remove the light oil pump delivery and return line plugs Screw the rotating nut D of the two flexible hoses F on the pump being careful to avoid inverting the delivery and return lines Fix the flexible hoses as shoewed on Fig 33 Fig 33 Replace burner s cover WARNING if fuel used is BIODIESEL some components must be replaced Please contact our Technical Depart ment for further details 14 PART I INSTALLATION SETTINGS 1 0280 Oil rate adjustment Single stage burners Priming the pump Before carrying out the adjustment it is necessary to start up the fuel pump proceeding as follows A Prior to start up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pump seal to break Start the burner light up the photoresistor after the opening of the solenoid valve and escape the air from the pressure port The fuel flow rate is set choosing a properly dimensioned nozzle and setting the inlet pressure on the pump see the hydraulic diagram in Fig 34 To choose the correct nozzle refer to table Tab 1 for setting of the pump pressure see pag 23 Note all pu
36. mps are set to 12 bar The nozzle rate must be higher than the rate referred to the minimum burner output Choosing oil nozzles Key Fig 34 EVG Light oil solenoid valve Manometer M P P Pump see chapter LIGHT OIL PUMPS EVG Tab 1 Choice of the oil nozzle Single stage burners NOZZLE PUMP PRESSURE bar 6 7 8 9 10 11 gt 13 14 G P H kg h 1 35 3 97 4 29 4 59 4 86 5 13 5 38 5 62 5 85 6 07 1 50 4 41 4 77 5 10 5 41 5 70 5 98 6 24 6 50 6 74 1 65 4 85 5 24 5 61 5 95 6 27 6 57 6 87 7 15 7 42 1 75 5 15 5 56 5 95 6 31 6 65 6 97 7 28 7 58 7 87 2 00 5 88 6 36 6 80 7 21 7 60 7 97 8 32 8 66 8 99 2 25 6 62 7 15 7 64 8 11 8 55 8 96 9 36 9 74 10 11 7 36 7 95 8 49 9 01 9 50 9 96 CIm 1083 11 24 3 00 8 83 9 53 10 19 10 81 11 40 11 95 12 48 12 99 13 48 3 50 10 30 11 12 11 89 12 61 13 29 13 94 14 56 15 16 15 73 4 00 11 77 12 71 13 59 14 41 15 19 15 94 16 64 17 32 17 98 4 50 13 24 14 30 15 29 16 22 17 09 17 93 18 72 19 49 20 23 5 00 14 71 15 89 16 99 18 02 18 99 19 92 20 81 21 65 22 47 5 50 16 18 17 48 18 69 19 82 20 89 21 91 22 89 23 82 24 72 6 00 17 65 19 07 20 39 21 62 22 79 23 90 24 97 25 99 26 97 6 50 19 13 20 66 22 08 23 42 24 69 25 90 27 05 28 15 29 21 PART I INSTALLATION 15 Oil rate adjustment High low flame burners Priming the pump Before carrying out the adjustment it is necessary to start up the fuel pump proceeding as f
37. nvelope containing this manual To get rid of the burner s packing and in the event of scrapping of the latter follow the procedures laid down by current laws on disposal of materials A ATTENZIONE LEGGERE SCRUPOLOSAMENTE LE AVVERTENZE RIPORTATE ALL INIZIO DEL MANUALE Fitting the burner to the boiler To perform the installation proceed as follows 1 fix 4 holes on the boiler s door according to the burner s drilling plate described on paragraph Overall dimensions place the gasket on the burner s flange install the burner into the boiler fix the burner to the stud bolt by means of the fixing nuts according to Fig 22 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 Q Key Burner Fixing nut Washer Sealing gasket Stud bolt Blast tube Q OD 10 PART INSTALLATION ELECTRICAL WIRING A ATTENTION PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL Identification of linking connectors HIGH LOW flame connector CONN TAB mod LO400 Fig 23 Burner power supply connector CONN LINEA Fig 24 IMPORTANT before operating the burner be sure all connectors are linked as indicated in the diagrams Make the electric connections following the diagrams below
38. o the next table The STA4 5B0 37 is not provided with the manual control for the air damper The cams adjustement must be performed by means of a screwdriver acting on the VS screw placed inside the cam During the first setting set the cam III inbetweens the cam and Then passing from the low to high flame stage or viceversa change the setting according to the flame composi tion if cam III is too near to the low flame position cam II flue gas can take place because there is more fuel than air if cam III is too near to low flame cam 1 the flame could be turned off because of too much air Tab 4 BERGER STA4 5BO 37 Air adjustment in high flame cam I Air adjustment in low flame Stand by Ignition cam Il Auxiliary cam for the opening consent to the second fuel valve Hl PART I INSTALLATION 21 LIGHT OIL PUMPS mod LO280 Pumps Pump Suntec AS47 A Viscosity 2 12 mm s cSt Fuel temperature 0 60 C into the pump Maximum inlet pressure 14 bar max 0 45 barto avoid the separation between air and oil Return pressure 2 bar max Rated speed 3600 rpm max Fig 43 Pump Suntec AT2 45A Viscosity range 2 12 cSt mm s Oil temperature 60 C max Inlet pressure 2 bar max 0 35 barto avoid the separation between air and oil Return pressure 2 bar max lt TS Rated speed 3600 rpm Fig 44 8 7 Keys for Suntec AS47 A pump Keys for Suntec A T2 45A pump 1 Pressure governo
39. oil pipes T1 and T2 from the pump Fig 50 e Disconnect the ignition cables CA1 and CA2 from the transformer TA Fig 51 e Remove the 4 screws V1 V4 shown in Fig 53 e Disconnect the connector CE fron the solenoid valve EV2 A ATTENTION the screw V1 is longer than the other and must be replaced in the same position e Withdraw the photoelectric cell FR from its housing Fig 54 A ATTENTION avoid to withdraw the photoelectric cell drawing its cable e Remove the combustion head from its housing as shown in Fig 55 e Clean the combustion head by a compressed air blow or in case of scale scrape it off by a scratchbrush e Replace the combustion head e Replace the burners cover 26 PART III MAINTENANCE MANUAL Fig 55 PART MAINTENANCE MANUAL 27 Removing burner components plate e Remove the combustion head see Removing the combustion head a pagina 26 e Remove the 7 screws V5 V11 which fasten the components plate Fig 56 e Remove the rod T from its housing as shown in Fig 57 e Hook the burner components plate as shown in Fig 58 Fig 57 Fig 58 Assembling burner components plate e Reassemble burner components plate and tighten the 6 screws V5 V11 Fig 56 e Refit the rod T Fig 57 e Reassemble the combustion head and tighten the 4 screws V1 V4 Fig 53 28 PART III MAINTENANCE MANUAL Removing the electrodes e Remove the combusti
40. ollows A Prior to start up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pump seal to break Start the burner light up the photoresistor after the opening of the solenoid valve and escape the air from the pressure port The light oil flow rate is adjusted choosing a nozzle of proper dimensions and setting the inlet pump pressure To choose the nozzle refer to the table below Setting the light oil pump Adjust the ignition stage of the pump to a pressure value of 8 10 bar After 10 the safety device switch to the second stage The pump setting must be fixed to 24 bar by means of the adjusting screw see chapter LIGHT OIL PUMPS NOTE The nozzle oil rate at a pressure of 8 bar must be greather than the oil rate at the minimum output EVI NC Regulator high flame EV2 NO Regulator low flame low flame 8 10 bar high flame 24 bar Tab 2 Choice of the oil 221 High low flame burners NOZZLE PUMP PRESSURE bar 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 G P H kg h 0 40 136 1 4 152 1 9 166 1 3 180 1 6 1 92 1 8 204 209 2 15 2 20 225 2 30 2 35 2 40 0 50 170 180 1 90 1 99 2 08 2 17 225 2 33 240 248 255 2 62 2 69 275 282 2 88 2 94 3 00 0 60 204 2 16 2 28
41. on head see Removing the combustion head on page 26 Withdraw the screw VE and remove the electrodes from the support Fig 59 Fig 60 Fig 59 Fig 60 DISASSEMBLY OF THE NOZZLE mod 1 0280 Before disassembly the nozzle measure the real position see Fig 61 and make note the panel below Fig 61 NOZZLE A 60 8 Position A set in the factory mm 45 10 60 T Measurement of real A position mm 45 e Unscrew the V screw that fastens the combustion head and remove the head from the nozzle holder Fig 62 Fig 63 A In order to remove the nozzle it is important to use two wrenches as shown in Fig 63 to avoid damaging the bur ner component plate e Reassemble the combustion head by respecting the position A measured previously making sure to fasten the V screw Fig 62 PART III MAINTENANCE MANUAL 29 Fig 62 Fig 63 Removing the nozzles LO400 Unscrew the Allen screw VT and remove the combustion head TC Unscrew the nozzles using two wrenches 16 and 24 mm as shown in Fig 66 Double stage burners Single stage burners Fig 65 30 PART III MAINTENANCE MANUAL Correct position of electrodes and combustion head To ensure a good ignition respect the measures in Fig 67 Fig 68 Single stage burners mod LO280 LO400 and Double
42. out reset button FS flame signal M burner motor HR auxiliary relay with contacts hr OH oil pre heater OW release contact of oil pre heater QRB photoresistive detector R control pressostat or pressure switch V flame signal amplifer w limit thermostat or pressure switch 2 ignition transformer APPENDIX COMPONENTS SPECIFICATIONS 45 Technical characteristics Voltage 220V 15 240V 10 or 100V 15 110V 10 Frequency 50 60Hz _6 External fuse max 10 A slow action Contact flow terminal 1 max 5A terminal 3 5A incl consumed cap of motor and pre heater terminals 4 5 amp 6 max 2A terminal 8 max 5A terminal 10 max 1A Permitted temperature operation 20 60 C storage and transport 50 40 Protection 40 Mass weight controller socket 1409 80 AGK accessories 12g Key to internal diagram AL Remote optical lockout indicator AR Main relay with contacts ar BV Fuel solenoid BR Lockout relay with contacts br EK Reset button FR Flame relay with contacts fr FS Flame present signal G Burner motor HR Auxiliary relay with contacts hr L Lockout LED incorporated in the reset button OH Fuel pre heater OW All clear contact for pre heater QRB Photo resistor flame detector R Normal thermostat or pressure switch V Flame signal amplifier Safety thermostat pressure switch Z Safety transformer Internal diagram 71281010799 46 APPENDIX COMPONENTS S
43. r 1 Low pressure regulation first stage 2 Manometer 2 Manometer 3 Vacuum gauge 3 Vacuum gauge 4 Solenoid valve 4 Light oil solenoid valve 5 Nozzle 4a High low pressure solenoid valve d Suction 5 To nozzle 8 Return 6 High pressure regulation second stage 7 Suction 8 Return with internal by pass plug 22 PART I INSTALLATION Pumps for mod 10400 Pump Suntec AL65 Viscosity range 2 12 cSt mm s Oil temperature 0 60 C in the pump Inlet pressure 2 bar max 0 45 barto avoid the separation between air and oil Return pressure 2 bar max Rated speed 3600 rpm Minimum inlet pressure suction return and internal by pass plug nozzle outlet pressure gauge port vacuum gauge port pressure adjustement O Q WN Fig 45 ADJUSTING THE COMBUSTION HEAD The burner is set in the factory with the combustion head in the MAX position corresponding to the maximum power combu stion head all forward To operate the burner at a lowest strenght progressively shift back the combustion head toward the MIN position rotating the VRT screw clockwise Fig 47 Fig 46 LO280 PART I INSTALLATION 23 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 CONSIDERED IMPROPER AND THEREFORE DANGEROUS THE USER MUST GUARANTEE THE CORRECT FITTING O
44. ry provided for double stage systems They can be suited for single pipe system recommen ded in the case of gravity feed as decribed before 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 pres sure gauge port must be loosened until the air is evacuated from the system As far as the pipes installation refer to the following values considering as well the plant s needs Syphon twin pipe feed Twin pipe suction feed Fig 28 Fig 29 SUNTEC AL65 AS47 AT2 45 SUNTEC AL65 AS47 AT2 45 H m L m H m L m 06 08 010 012 06 08 910 012 0 14 49 123 150 0 14 49 123 150 0 5 16 55 136 150 0 5 12 44 110 150 1 18 61 150 150 1 10 38 96 150 2 22 73 150 150 2 7 26 66 140 3 25 85 150 150 3 3 13 13 75 4 29 96 150 150 4 0 1 1 15 PART I INSTALLATION 13 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 t
45. stage burners mod LO280 8 10 C r_ B 4 5 6 mm N 2 10 mm 1 6 5 i A NS Fig 67 FRATE Double stage burners mod LO400 8 10 4 5 6 mm C 8 3 nm 28 g oO mx Fig 68 Check the detection current See the diagram in Fig 69 to measure the detection current If the signal doesn t suit the suggested value verify the electric terminal the cleaning of the combustion head and the position of the photoelectric cell replace it if 7 CONNECTOR necessary Minimum current intensity with flame 45 pA Maximum current intensity without flame 5 pA Maximum possible current intensity with 45 pA LOA flame 100 pA LMO PART MAINTENANCE 31 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 BURNER LOCK DURING OPERATION BURNER LOCKS AND REPEATS CYCLE DURING OPERATION MAINS SWITCH OPEN FUSES INTERVENTION MAXIMUM PRESSURE SWITCH FAULT INTERVENTION OF THE FAN MOTOR THERMAL CUTOUT AUXILIARIES RELAY F
46. su jiog 614 LM y v 7 A N O SNOISNIMIA TIVHINO PART I INSTALLATION Performance curves LO280 Single stage LO280 High Low flame ur m 6 54 2 LU 4 um 4 gt 2 lt 3 OL 3 2 z LO ve o9 1 0 100 150 200 250 300 350 0 O 50 100 150 200 250 300 350 kw kw Fig 6 Fig 7 LO400 Single stage LO400 High Low flame 74 Zi 6 7 5 6 DIA 4 5 DI VO 3 4 gt 3 2 2 lt 0 0 m Q 150 200 250 300 350 400 450 100 150 200 250 300 350 400 450 kW kW Fig 8 Fig 9 PART I INSTALLATION 7 How to modify blast tube length mod LO400 To modify blast tube length please read the following instructions 1 Remove combustion head See Removing the combustion head Part III of this user s manual 2 Remove the flanged piece by removing the 4 socket head screws VTF Fig 10 3 Remove the 4 screws which hold the blast tube to the flanged piece Fig 2 4 Extract the blast tube from the flanged piece and assemble it in the other way round as shown in pictures Fig 12 and Fig 13 Now fasten the two pieces using the same screws Fig 14 5 Assemble the whole piece to the burner by caring attention to the indication in picture Fig 15 Fig 12 Short blast tub
47. the programme To ensure correct wiring it is essential to observe local standards and follow the instructions of the burner manufacturer with regard to assembly and start up Program s legend Controller output signals Required input signals Burner start up with light pre heater A Burner start up without light oil pre heater B Flame lit C Normal operation D Normal stop through R tw Oil pre heating time until operational all clear given through contact OW tl Pre purge time t3 Pre ignition time t2 Safety time t8n Post ignition time t4 Interval between the flame lighting and energising of solenoid 2a at terminal 5 Internal layout AL Optical alarm BV Fuel valve EK Reset button FR Flame relay fr Flame relay contacts FS Flame alight signal G Burner motor K Flame relay anchor to delay the 121 command in the event of a premature flame signal or endorse it where the signal is correct OH light oil pre heater OW Operational all clear contact QRB Photo resistant cell flame detector R Thermostat or pressure switch TZ Thermo electric programmer bimetal system tz TZ contacts V Flame signal amplifier w Safety thermostat or pressure switch 2 Ignition transformer The above are safety devices To tamper with them in any way may have unforeseeable conse quences Do not open them 2 a v 890 0000 77 Y BV1 v 2
48. tion of the flame post ignition time after which it is disconnected from the circuit and the corresponding signal light switches off In this way the burner is lit at low flame after 5 or 15 seconds depending on the apparatus installed two stage operation begins and the burner is either automatically brought to high flame light G on or remains burning at low flame light H on depending on the requests received from the system Burner s control panel lt Main switch High flame lamp Low flame lamp Ignition transformer ligh Lockout signalling lamp Fuse High flame solenoid valve operation light Low flame solenoid valve operation light Reset pushbutton Fig 49 WVIOTNMZWIO DI Fig 49 PART Il OPERATION MANUAL 25 At least once a year carry out the maintenance operations listed below In the case of seasonal servicing it is recommended to carry out the maintenance at the end of each heating season in the case of continuous operation the maintenance is carried out every 6 months WARNING All operations on the burner must be carried out with the mains disconnected A PLEASE READ CAREFULLY WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL ROUTINE OPERATIONS e Inspection and cleaning of the light oil filter cartdrige replace it if necessary e Check the overall condition of the flexible light oil hoses and make sure there no signs of leakage e Inspection and cleaning of the
49. tion 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 e In case of repeated burner shut downs do not continue re setting the unit manually Contact qualified personnel to take care of such defects The unit shall be operated and serviced by qualified per sonnel only in compliance with the regulations in force 3 WARNINGS 3 GENERAL INSTRUCTIONS DEPENDING ON FUEL USED 3a ELECTRICAL CONNECTION e For safety reasons the unit must be efficiently earthed and installed as required by current safety regulations e Itis vital that all saftey requirements are met In case of any doubt ask for an accurate inspection of electrics by quali fied personnel since the manufacturer cannot be held lia ble for damages that may be caused by failure to correctly earth the equipment e Qu
50. 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 quali fied personnel at regular intervals following the manufactu rer s instructions When a decision is made to discontinue the use of the equipment those parts likely to constitute sources of dan ger shall be made harmless 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 the units that have been modified or have options fit ted then original accessory equipment only shall be used This unit shall be employed exclusively for the use for which it is meant Any other use shall be considered as improper and 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
51. witch and the fuse Make sure that the apparatus is not in shutdown condition and if so release by using the release button S on the burner cover see Fig 49 Make sure that the set of thermostats or pressure switches triggers burner operation The burner starting cycle begins and the apparatus starts the burner fan while the ignition transformer switches on at the same time At the end of pre ventilation the fuel solenoid valve receives input and the burner switches on The ignition transformer remains switched on for a few seconds after the ignition of the flame post ignition time after which it is disconnected from the circuit Double stage burners Turn on the burner using the switch A on the control panel Fig 48 Make sure that the apparatus is not in shutdown condition and if so release by using the release button S on the burner cover see Fig 49 Make sure that the set of thermostats or pressure switches triggers burner operation The burner starting cycle begins and the apparatus starts the burner fan while the ignition transformer switches on at the same time pre ventilation lasts for 13 or 25 seconds depending on the apparatus provided with the burner At the end of pre ventilation the fuel solenoid valve 1st stage EVG1 receives input as signalled by the illumination of the signal light H on the control panel and the burner starts The ignition transformer remains switched on for a few seconds after the igni

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