Cisco Systems G18 G-.SP User Manual

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B U R N E R S B R U L E U R S B R E N N E R QUEMADORES BRUCIATORI

MANUAL FOR

-INSTALLATION

-OPERATION

-MAINTENANCE

LIGHT OIL BURNERS

G18 G-.SP

PG25 G-.SP

PG30 G-.TN

M03978CA Rev. 00 10/99

 

FOREWORD

Page 2

PARTE I:

INSTALLATION

Page 4

PARTE II:

OPERATION

Page 11

PARTE III: MAINTENANCE

Page 12

 

APPENDIX

Page 18

Complying with

EMC 89/336/CEE

LV 73/23/CEE

Technical Documentation CIB Unigas S.p.a. - Campodarsego (PD)

PREFACE

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 INFORMATIONS ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION OF THIS MANUAL. WE HIGHLY COMMEND 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 instructions, by qualified personnel.

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.

* 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 children, as they may prove harmful.

*Before any cleaning or servicing operation, disconnect the unit from the mains by turning the master switch OFF, and/or through the cut-outdevices 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.

*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.

*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

*The burner should be installed in a suitable room, with ventilation openings complying with the requirements of the regulations in force, and sufficient for good combustion.

*Only burners designed according to the regulations in force should be used.

*This burner should be employed exclusively for the use for which it was designed.

*Before connecting the burner, make sure that the unit rating is the same as delivery mains (electricity, gas oil, or other fuel).

*Observe caution with hot burner components. These are, usually, near to the flame and the fuel pre-heatingsystem, they become hot during the unit operation and will remain hot for some time after the burner has stopped.

* When the decision is made to discontinue the use of the burner, the user shall have qualified personnel carry out the following operations:

a)Remove the power supply by disconnecting the power cord from the mains.

b)Disconnect the fuel supply by means of the hand-operatedshut-offvalve 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 operations:

a)set the burner fuel flow rate depending on the heat input of the appliance;

b)set the flow rate of the combustion-supportingair 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 repeated burner shut-downs,do not continue resetting the unit manually. Contact qualified personnel to take care of such defects.

*The unit shall be operated and serviced by qualified personnel only, in compliance with the regulations in force.

2

FOREWORD

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, ask for an accurate inspection of electrics by qualified personnel, since the manufacturer cannot be held liable for damages that may be caused by failure to correctly earth the equipment.

*Qualified personnel must inspect the system to make sure that it is adequate to take the maximum power used by the equipment shown on the equipment rating plate. In particular, make sure that the system cable cross section is adequate for the power absorbed by the unit.

*No adaptors, multiple outlet sockets and/or extension cables are 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-operatedcomponent 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 unit is out of use for some time the electric switch supplying all the power-drivencomponents in the system (i.e. pumps, burner, etc.) should be switched off.

3B) FIRING WITH GAS, GASOIL 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 property, for which the manufacturer cannot be held liable.

*Before installation, it is recommended that all the fuel supply system pipes be carefully cleaned inside, to remove foreign matter that might impair the burner operation.

*Before the burner is commissioned, qualified personnel should 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 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 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.

FOREWORD

3

PART I: INSTALLATION MANUAL

TECHNICAL DATA

BURNER TYPE

 

G18 SP

PG25 SP

PG30 TN

 

 

 

 

 

Input

min kcal/h

90.300

140.200

140.200

 

max kcal/h

180.000

250.200

300.000

 

min kW

105

163

163

 

max kW

209

291

349

Oil firing rate

kg/h min.

9

14

14

 

kg/h max.

18

25

30

Fuel

 

light oil

light oil

light oil

Electrical supply

 

230V

230V

230V

Frequency

 

50 Hz

50 Hz

50 Hz

Motor 2800 g/1'

kW

0.25

0.37

0.37

A absorbed

A

1.5

2.2

2.2

Total power absorption

kW

0.55

0.87

0.87

Operation

 

Soft start

Soft start

Single

 

stage

 

 

 

 

 

 

 

 

 

BURNER MODEL IDENTIFICATION

Burners are identified by burner type and model. Burner type identification is described as follow:

Type: G18

Model:

G-.

SP.

S.

*.

 

A.

 

 

 

 

 

 

 

(1)

 

 

 

(2)

(3)

(4)

(5)

(6)

 

 

 

 

 

 

(1)

BURNER TYPE

 

 

 

G18 SP - PG25 SP - PG30 TN

 

 

 

 

 

(2)

FUEL

 

 

 

G = Light oil (Viscosity at 20°C 5 cSt)

 

 

 

 

(3)

ADJUSTMENT

 

 

 

SP = Soft Start

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TN = Single Stage

 

 

 

 

 

 

 

 

(4)

BLAST TUBE LENGHT (See overall dimensions)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S = Standard

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L = Long

 

 

 

 

 

 

 

 

 

(5)

DESTINATION COUNTRY

 

* see data plate

 

 

 

 

 

 

 

 

(6)

SPECIAL VERSIONS

 

A = Standard

 

 

 

 

 

 

 

 

 

OVERALL DIMENSIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

B

BL

C

CL

D

E

G

K

H

P

M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G18SP

 

275

90

200

365

475

 

340

255

115

230

125

121÷134

M8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 1

4

INSTALLATION

OVERALL DIMENSIONS

 

A

B

BL

C

CL

D

E

F

G

K

H

P

M

PG25SP

515

155

345

660

850

267

260

520

133

290

125

155

M10

PG30SP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PERFORMANCE CURVES

Back pressure in combustion chamber mbar

Fig. 1a

1.8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

8

10

12

14

16

18

20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Oil rate Kg/h

Back pressure in combustion chamber mbar

Back pressure in combustion chamber mbar

4

3

2

Fig. 3

1

0 -1

1 0

1 2

1 4

1 6

 

 

1 8

 

2 0

2 2

2 4

2 6

 

 

2 8

 

3 0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Oil rate Kg/h

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 3a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-0.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

12

14

16

18

20

22

24

26

28

30

32

34

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Oil rate Kg/h

INSTALLATION

5

MOUNTINGS AND CONNECTIONS

The burners are despatched in cardboard packages.

The packaging contains the following items:

1burner;

2flexible light oil tubes;

1light oil filter;

1gasket to be inserted between the burner and the boiler;

1this manual, the Guarantee Certificate and the test certificate.

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.

FITTING BURNER TO BOILER

G18SP

Attach the flange of the burner to the boiler with the reference as shown in picture. This allows a correct inclination towards the combustion chamber

Fig. 4

PG25SP - PG30TN

After fitting the burner to the boiler see that the space between the blast tube and the refractory lining is sealed with appropriate insulating material (ceramic fibre cord or refractory cement).

Key

1)

Burner

 

2)

Fixing nut

 

3)

Washer

 

4)

Seal

 

5)

Stud bolt

 

6)

Sightglass cleaning tube

Fig. 4a

7)

Blast tube

 

6

INSTALLATION

G18SP

PG25SP

PG30TN

Fig. 5

Fig. 5a

Fig. 5b

Fig. 6

7

R:ANT

SETTINGS

Burners G18SP - PG25SP

These burners are fitted with a double-regulationpump. The flame control device, atwin-stageone, after thepre-purguestage, energized the valve EV1 and the burner starts up.

After few seconds, the intervention of the second stage caused the energizing of the valve EV2, so the burner is feeded with a maximum pressure of about 18 bar.

Burner PG30TN

Before carry out the settings, start-upthe light oil pump proceeding as follows:

- start up the burner, light the photoresistor after the solenoid valve opening and leak the air from the manometer gauge. Before starting up the burner, be sure that the return pipe to the tank is not obstructed; any obstruction would cause the pump seal to break.

Light oil flow rate setting

The light oil rate is adjusted by chosing a nozzle with appropriate dimensions and setting the inlet pump pressure; to chose the nozzle, refer to the tables below.

LIGHT OIL PUMP SETTINGS

Burners G18SP - PG25SP

Adjust the pump for the ingnition, to a pressure value of about 8-10bar (see fig. 7).

After 10”, the safety device drives the second stage; set the pump to a pressure value of 18 bar, by means of the regulation screw.

Burner PG30TN

Set the pump to a pressure value from 10 to 14 bar, depending by the nozzle fitted (see table 2).

SELECTING THE OIL NOZZLE

Table 1 - Burners G18SP - PG25SP

 

 

 

 

 

 

 

 

 

 

BAR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GPH

8

9

10

 

11

12

 

13

 

14

 

15

16

17

18

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.75

6.02

6.38

6.73

7.05

7.37

 

7.67

 

7.96

 

8.24

8.51

8.77

9.02

 

2.00

6.88

7.29

7.69

8.06

8.42

 

8.77

 

9.10

 

9.42

9.72

10.02

10.31

 

2.25

7.74

8.20

8.65

9.07

9.47

 

9.86

 

10.23

 

10.59

10.94

11.28

11.60

 

2.50

8.59

9.12

9.61

10.08

10.53

 

10.96

 

11.37

 

11.77

12.16

12.53

12.89

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.00

10.31

10.94

11.53

12.09

12.63

 

13.15

 

13.64

 

14.12

14.59

15.03

15.47

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.50

12.03

12.76

13.45

14.11

14.74

 

15.34

 

15.92

 

16.48

17.02

17.54

18.05

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.00

13.75

14.59

15.37

16.13

16.84

 

17.53

 

18.19

 

18.83

19.45

20.05

20.63

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.50

15.47

16.41

17.30

18.14

18.95

 

19.72

 

20.47

 

21.18

21.88

22.55

23.21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.00

17.19

18.23

19.22

20.16

21.05

 

21.91

 

22.74

 

23.54

24.31

25.06

25.78

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 2 - Burner PG30TN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BAR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GPH

 

10

 

 

12

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.50

 

13.45

 

14.74

 

15.92

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.00

 

15.37

 

16.84

 

18.19

 

 

 

 

 

 

 

 

 

 

 

4.50

 

17.30

 

18.95

 

20.47

 

 

 

 

 

 

 

 

 

 

 

5.00

 

19.22

 

21.05

 

22.74

 

 

 

 

 

 

 

 

 

 

 

5.50

 

21.14

 

23.16

 

25.01

 

 

 

 

 

 

 

 

 

 

 

6.00

 

23.06

 

25.26

 

27.29

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.50

 

24.98

 

27.37

 

29.56

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7.00

 

26.91

 

29.47

 

31.84

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

INSTALLATION

LIGHT OIL PUMPS

SUNTEC AS57C

Suction height:

Advised value to prevent air separation from oil:

Rated speed: Operation viscosity: Inlet pressure:

DELTA VM2RL2

Suction height:

Advised value to prevent air separation from oil:

Rated speed: Operation viscosity: Inlet pressure:

Key

1Pressure regulator

2Manometer

3Vacuum gauge

4Solenoid valve

5Nozzle

6Supply to nozzle

7Suction

8Return

0.5 bar

0.35 bar

max. 2850 rpm from 2 to 12 cSt max. 2 bar

0.5 bar

0.35 bar

max. 3500 rpm from 1.5 to 50 cSt 0.7 - 1.5 bar

SUNTEC AT2 45C

 

Suction height:

0.45 bar

Advised value to prevent

 

air separation from oil:

0.35 bar

Rated speed:

max. 3600 rpm

Operation viscosity:

from 2 to 12 cSt

Inlet pressure:

max. 2 bar

1Low pressure regulation (first stage)

2Manometer

3Vacuum gauge

4Lockoout solenoid valve

4a High-lowpressure solenoid valve

5To nozzle

6High pressure regulation (second stage)

7Suction

8Return (with internal by-passplug)

Fig. 7

Fig. 8

Fig.

INSTALLATION

9

AIR FLOW ADJUSTMENT

-

VBS

+

Fig. 10

Fig. 11

VBS

COMBUSTION HEAD ADJUSTMENT

Burner G18SP

Loose the screw VBS and rotate the air damper in the desired position, to set the air flow.

At the end of settings, tight the screw VBS.

Burners PG25SP - PG30TN

Loose the screw VBS and set the air flow, working directly on the air damper.

At the end of settings, tight the screw VBS.

The burner is factory-adjustedwith the combustion head in the “max” position (maximum output). Move back the combustion head towards the “MIN” position, turning the screw VRT clockwise.

G18SP

Fig. 12

Fig. 12

PG25SP - PG 30TN

Fig. 12a

10

INSTALLATION

PART II: OPERATION MANUAL

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 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).

DO NOT EVER 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 RE-SETBUTTON.

IN THE EVENT OF REPEATED LOCKOUTS, DO NOT PERSIST WITH THE RE-SETBUTTON 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.

OPERATION

11

PART III: MAINTENANCE

At least once a year carry out the following maintenance procedures.

If servicing is on a seasonal basis, it is recommended at the end of the season; routine sevice should be carried out every months.

Note: Any operation on the burner must be carried out with the main electricity switched off.

PERIODICAL SERVICING

-Clean and examine the oil filter cartridge and replace it if necessary;

-Examine the condition of the oil flexìble pipeworks and check for possible leaks;

-Clean and examine the filter inside the oil pump;

-Dismantle, examine and clean the combustion head. When reassembling respect the measures reported in table 3.

-Examine the ignition electrodes and their ceramic insulators, adjust and replace if necessary (fig. 13);

-Dismantle and clean the oil nozzle (important: use solvents for cleaning and not metal utensils).

At the end of the maintenence procedures replace the burner, light it and check the shape of the flame:if in doubt replace the nozzle(s);

where the burner is used intensively it is recommended to replace the nozzles at the beginning of the operating season;

- Examine and carefully clean the flame detector photoelectric cell and replace if necessary. If in doubt light the burner and then check the detector circuit as shown in Fig. 14.

Correct position of electrodes and combustion head (G18SP)

Prepare a stable surface where lying the burner during maintenance.

To gain access to the combustion head and to the nozzles, loose the screw which lock the blast tube and remove it from the part that remains fixed to the boiler.

To guarantee a good ignition, respect the measures indicated in table 3.

Be sure to lock the screw that fix the electrodes group, before reassembly the burner.

Removal of the combustion head (PG25SP - PG30TN)

-Remove the cap C;

-Take out the photoresistance from its housing;

-Unscrew the floating pipe-fittingE from the oil pipe, using 2 spanners, to avoid to loose the pipefirrings from the distribution block;

-Remove the screws V and unscrew the screw VRT until the threaded rod AR is free;

Remove the complete assembly as shown in figure 13a.

Note: To re-assemblereverse the order of procedures descibed above.

Fig. 13

 

 

 

 

 

Table 3

 

 

 

 

 

 

 

 

A

B

C

D

 

G18SP

60°

6

4

4

6

 

45°

10

5

4

6

 

 

 

 

 

 

 

 

 

 

PG28SP

60°

8

4

4

6

 

45°

12

5

4

6

 

 

 

 

 

 

 

 

 

 

PG30TN

60°

8

4

4

6

 

45°

12

5

4

6

 

 

 

 

 

 

 

 

 

C

AR

VRT

R

Fig. 13a

C

V

12

MAINTENANCE

CHECK OF THE IONIZATION CURRENT

To check the detector signal follow the prcedure shown in fig. 14.

If the signal is not within the prescribed range, check the electrical contacts; check also that the combustion head is clean and the photoelectric sensor is correctly positioned. Replace it if necessary.

Minimum current

TERMINAL BLOCK MC

Scale µA DC

Fig. 14

13

ELECTRICAL DIAGRAM code 01-369BURNER G18SP

1 - Electric supply 230V 50Hz 2N a.c.

2 - Don't reverse Phase and Neutral

3 - Make sure that the burner is properly hearted

CO

Time counter

EVG1

Light oil solenoid valve Ist stage

EVG2

Light oil solenoid valve IInd stage

F

Fuse

FR

Photoresistor

IL

Main switch

L1

Phase

LF

Burner operation light

LB

Burner lockout light

LOA24/BOA64 Flame monitor device

MA

Power supply terminal block

MV

Fan motor

N

Neutral

ST

Thermostats or pressure switches

TA

Ignition transformer

TS

Boiler thermostat or pressure switch

ELECTRICAL DIAGRAM code 04-575BURNER PG25SP

 

EVG1

Light oil solenoid valve

 

F

Fuse

 

FR

Photoresistor

 

IL

Main switch

 

L

Phase

 

LFA

Burner operation light

 

LB

Burner lockout light

 

LEVG1 Opening of EVG1 signalization light

 

LOA24/BOA64 Flame monitor device

 

LTA

Ignition transformer signalization light

 

MA

Power supply terminal block

 

MC

Terminal block for burner components connection

1 - Electric supply 230V 50Hz 2N a.c.

MV

Fan motor

2 - Don't reverse Phase and Neutral

N

Neutral

3 - Make sure that the burner is properly hearted

ST

Thermostats or pressure switches

 

TA

Ignition transformer

14

MAINTENANCE

ELECTRICAL DIAGRAM code 04-574BURNER PG30TN

1 - Electric supply 230V 50Hz 2N a.c.

2 - Don't reverse Phase and Neutral

3 - Make sure that the burner is properly hearted

EVG1

Light oil solenoid valve Ist stage

EVG2

Light oil solenoid valve IInd stage

F

Fuses

FR

Photoresistor

IL

Main switch

L

Phase

LF

Burner operation light

LB

Burner lockout light

LEVG1

EVG1 opening signalization light

LEVG2 EVG2 opening signalization light

LOA24/BOA64 Flame monitor device

MA

Power supply terminal block

MC

Terminal block for burner components connection

LTA

Ignition transformer light

MV

Fan motor

N

Neutral

ST

Thermostats or pressure switches

TA

Ignition transformer

MAINTENANCE

15

SPARE PARTS BURNER G18SP

POS.

DESCRIPTION

CODE

POS.

DESCRIPTION

CODE

1

HOUSING

3010019

19

BLAST TUBE

3090055

2

CONDENSER

6030004

20

COMBUSTION HEAD

3060115

3

MOTOR

2180009

21

ELECTRODE SUPPORT

2280016

4

FLAME CONTROL DEVICE LOA24

2020445

22

GASKET

2110031

5

SOCKET FOR LOA24

2030409

23

FLANGE

2100011

6

SUPPORT BRACKET

2430004

24

DISTRIBUTION MOVING BLOCK

2320012

7

TRANSFORMER

2170106

25

LIGHT OIL PIPE

2220125

8

BURNER CASING

2050228

27

CONNECTOR

6200008

9

FAN

2150004

28

SUNTEC AT2 45C PUMP

2590147

10

COMPLETE JOINT

254…

29

FILTER

2090016

13

ATOMIZER

3020020

30

FLEXIBLE HOSE

2340001

14

NOZZLE

261..

31

SOLENOID VALVE COIL

2580402

15

ATOMIZER SUPPORT

2280006

32

AIR DAMPER

1010702

16

BOTTOM

2010102

33

PHOTORESISTOR QRB1B

2510008

17

IGNITION CABLES

6050122

34

ADJUSTING SCREW

2320011

18

IGNITION ELECTRODE

2080203

 

 

 

16

MAINTENANCE

SPARE PARTS BURNERS PG25SP - PG30TN

POS.

DESCRIPTION

PG25SP

PG30TN

 

 

 

 

1

ELECTRIC BOARD

6100086

6100086

2

THERMAL RELAY

---

---

3

SOCKET FOR FLAME CONTROL DEVICE

2030415

2030415

4

FLAME CONTROL DEVICE

2020445

2020445

5

CONTACTOR

---

---

6

IGNITION TRANSFORMER

2170107

2170107

7

TOP COVER

2210103

2210103

8

LANDIS PHOTORESISTOR

2510003

2510003

9

GASKET

2110004

2110004

10

IGNITION CABLES

6050109

6050109

11

LONG ELECTRODE

---

---

12

SHORT ELECTRODE

2080208

2080208

13

STANDARD BLAST TUBE

3090033

3090033

13

LONG BLAST TUBE

3090035

3090035

14

DIFFUSER

3060179

3060179

15

NOZZLE

261…

261…

16

STANDARD NOZZLE SUPPORT

3020009

3020009

16

LONG NOZZLE SUPPORT

3020017

3020017

17

STANDARD LIGHT OIL PIPE

3071003

3071003

17

LONG LIGHT OIL PIPE

3071021

3071021

22

COIL FOR SUNTEC PUMP

2580402

2580402

22

COIL FOR DELTA PUMP

---

2580406

23

SUNTEC PUMP

2590147

2590144

23

DELTA PUMP

---

2590009

24

LIGHT OIL FILTER

2090016

2090016

25

FLEXIBLE HOSES

2340001

2340001

26

AIR DAMPER

2140005

2140005

30

COMPLETE JOINT FOR SUNTEC PUMP

2540109

2540109

30

COMPLETE JOINT FOR DELTA PUMP

---

2540103

33

FAN

2150006

2150006

34

BURNER CASING

2050117

2050117

35

HEAD ADJUSTING SCREW

2320503

2320503

36

ELECTRIC MOTOR

2180704

2180704

 

 

 

 

MAINTENANCE

17

APPENDIX: COMPONENTS CHARACTERISTICS

 

 

 

FLAME CONTROL DEVICE LANDIS LOA24

Page 18

LIGHT OIL PUMPS

Page 19

LANDIS AUTOMATIC CONTROLLER LOA24 FOR LIGHT OIL BURNERS

Use

LOA... safety devices are intended for use in conjunction with QRB... photoresistors, for lighting and controlling low capacity forced air diesel burners with max. capacity 30 kg/h in accordance with standard DIN 4787.

TheOneortwoflamesarelit,dependingonelectricalconnections, with or without post-ignition.

Performance

The controllers just need plugging in, so they can be mounted in almost any position: on the burner, on the electrical panel or on the control panel. The casing is made of robust heat-resistantplastic and contains:

-the thermic programmer operating a multiple switch control system with ambient temperature compensator

-flame signal amplifier with flame relay

-warning light indicating lockout and associated sealed reset button.

The plug-insocket, also made of robustheat-resistantplastic, contains the 12 terminals and also:

-3 neutral terminals, ready wired up to terminal 2

-4 earth terminals for earthing the burner

-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-metallicsleeves 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 exaclty the same as for types LAB/LAI and there is no difference in the diameter of the reset button, the two mounting screws and the flange of the burner earth.

Safety at low voltage levels

Safety devices against any reduction in the mains voltage operate on a special electronic circuit which, in the event of the power supply falling below 165V~, stops the burner switching on without releasing the fuel and locks out the apparatus.

Wiring diagram of 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 key:

 

Controller output signals

 

Required input signals

A’

Burner start up with diesel pre-heaterOH

ABurner start-upwithout dieselpre-heater

BFlame lit

CNormal operation

DNormal stop through R

tw

Oil pre-heatingtime until operational all clear given

 

through contact OW

tl

Pre-purgetime

t3

Pre-ignitiontime

t2

Safety time

t3n

Post-ignitiontime

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

KFlame relay anchor to delay the tzl command in the event of a premature flame signal or endorse it where the signal is correct.

OH

diesel pre-heater

OW

Operational all-clearcontact

QRB

Photo-resistantcell (flame detector)

R

Thermostat or pressure switch

TZ

Thermo-electricprogrammer (bimetal system)

tz..

TZ contacts

VFlame signal amplifier

WSafety thermostat or pressure switch

ZIgnition transformer

These are safety devices

To tamper with them in any way may have unforeseeable consequences !

Do not open them!

18

APPENDIX

Technical characteristics

Voltage

220V-15%..240V+10%or 100V

 

-15%...110V+10%

Frequency

50...60Hz +/- 6%

External fuse max.10A slow action

Contact flow:

 

 

- terminal 1

5A

 

- terminal 3

5A (incl.capacity absorbed by motor and pre-

 

heater)

Terminal flow:

 

 

- terminals 4, 5 &10

1A

- terminals 6&7

2A

- terminal 8

 

5A

Absorbed cap

 

3VA

Protection

 

IP40

Premitted temp:

 

operational

 

-20...+60°C

transport & storage

-50...+60°C

Emplacement

 

any

Mass (weight)

 

controller 180 g

 

 

socket 50 g

 

 

AGK accessories 12 g

Commands in the event of operational interference

- Stray light/premature ignition

During pre-purgeand/orpre-ignitionthere should be no flame signal. If there is a flame signal, eg from premature ignition due to a faulty solenoid, external light, short circuit in the photoresistor or wiring, malfunction in the flame signal amplifier, etc., at the end ofpre-purgeand 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-upprogramme: at the end of t4 thestart-upprogramme ends.

Whenever there is a safety stop, terminals 3-8and 11 are deenergised 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.

DELTA “VM” PUMPS

In the VM series of DELTA pumps the pressurised flow of oil P is shut off by a built in solenoid and may therefore be switched on for startup of the motor pre-purge)or off before the motor itself switches off (flame goes out instantly when the spray from the nozzle stops).

Oil pressure is regulated and kept constant by the piston valve which is activated when the light comes on to signify that the oil discharged exceeds nozzle capacity and is being returned to the tank (twin-pipesystem) or being returned to the suction pipe through a bypass in the pipe(single-pipesystem).

In this model both the single-pipeandtwin-pipeversions have automatic priming. It is recommended that in eiether case a standard external filter be installed.

All twin-pipemodels can be used assingle-pipesystems with the simple removal of a nylon plug and by closing the return pipe.

Technical data

 

Oil viscosity

1,5÷50 cSt

Oil temperature

50°C

Pressure range

2÷10 bars

 

4÷15 bars

 

8÷20 bars

 

10÷125 bars

Suction vacuum

max.0,5 bars

Suction pressure

max.0,7 bars

Return pressure

max.1,5 bars

Rotational speed

max.3500 rpm

Filter

stainless steel mesh 110 micron, 20 cm2

Mounting

Hub 32, shaft 8 (DIN 24220)

 

On request: flange, hub 54, shaft 7/16"

Hydraulic connections

Return suction

1/8"G 1/4"G (1/8"G only Vl,V2)

Delivery

1/8"G vacuum gauge 1/8"G

Rate

VMl, VM2: max.0,1 Nm; VM3: 0,18 Nm

APPENDIX

19

SUNTEC AS oil pumps

-Oil

-Flow up to 75 1/h (c.600,000 kcal/h - 700 kW)

-Twin-pipesystem

-Single-pipesystem

Technical data

Mounting

On flange or hub in acccordance with

 

standards DIN 24220 and ISO/TC 109 SC

 

3 DP 5062F

Threads

round-headedin accordance with ISO R

 

228-NFE03005(DIN2S9)

Supply and return

R 1/4"

Delivery

R 1/8"

Pressure

R 1/8"

On cover

R 1/8"

Valve function

Pressure control and cut out

Filter

area 34 cm2, 120 micron

Shaft

8 mm in acc. with DIN 24220

Plug

Inserted

By-pass

Insert for twin-pipe,remove for single-

 

pipe system

Weight

1,8 kg - hub-mounted

1,9 kg - flange-mountedRotation and delivery position (view from shaft side)

A - clockwise rotation/RH delivery

C - anticlockwise rotation/LH delivery

Hydraulic data

 

Operational pressure range

 

 

7-14bars adjustable

 

9-15bars adjustable (for AS67)

Calibration

9 bars at factory

Viscosity at 20°C

2-12mm2/s(cSt)

Supply pressure

max.2 bars

Return pressure

max.2 bars

Suction

max. vacuum 0,5 bars;

 

recommended 0,35 bars to

 

avoid separation of oil and gas

Rotational speed

2850 rpm

Max. oil temperature

70°C

Torque

1,0cm - daN

Absorbed capacity

see motor curves

Electrical data

 

Solenoid voltage

20V +10%-15%;50/60Hz

Absorbed capacity

9VA

Length of coil cable

600mm

Length of plug cable

600mm

Cable

Ø6 mm with cross section of

 

0,75 mm2

A

Closed solenoid valve

6

Escape valve

B

Open solenoid valve (NO)

7

Shaft seal

C

Closed return

8

Vacuum gauge port

1

Solenoid valve

9

By-passplug “P”

2

Pressure regulating valve

10

Gear set

3

Pressure adjustment

11

Inlet

4

To nozzle

12

Return

5

Pressure gauge port

13

Back to suction

Oil under suction

Oil under pressure

By-passedoil returned to tank or to suction

Twin pipe installation

Single pipe installation (remove the by-passplug “P”)

20

APPENDIX

Operation

The gear-setdraws oil from the tank through thebuilt-infilter and transfers it to the valve that regulates the oil pressure or tne nozzle line. All oil which does not go through the nozzle line will be dumped through the valve back to the return line or, if it is aone-pipeinstallation, back to the suction port in thegear-set.

The hydraulic valve has a cut-offfunction besides regulating the nozzle pressure. Contrary to the AN pump, the valve has no bleed slot. The function of the bleed slot is taken over by the solenoid valve. When the solenoid valve isnon-activated,theby-passchannel between the pressure and return sides of the valve is open. No pressure will then be built up to open the valve. It does not matter which speed the gear set has. When the solenoid is activated, thisby-passchannel will be closed and because of the full speed of the gear set, the pressure necessary to open the valve will be built up very rapidly which gives a very sharpcut-onfunction.

When the burner stops, the solenoid opens the by-passat the same moment which drains all the oil down to the return and the nozzle valve closes immediately. This gives a very sharpcut-offfunction.

The cut-onand off can be regulated regardless of motor speed and has an extremely fast response. The torque requirement is low up to full motor speed.

SUNTEC AT oil pumps

-Oil

-Twin-pipesystem

-Single-pipesystem

-Twin feed

Technical data

Mounting

On hub Ø 32mm, in acccordance with

 

standards DIN 24220

Threads

round-headedin accordance with ISO R

 

228-NFE03005 (DIN259)

Supply and return

R 1/4"

Delivery

R 1/8"

Pressure

R 1/8"

On cover

R 1/8"

Valve function

Pressure regulation

Filter

Area 34 cm2, mesh 120 micron

Shaft

Ø 8 mm in acc. with DIN 24220

By-pass

Insert for twin-pipe,remove for single-

 

pipe system

Weight

1,3 kg

Rotation and delivery position (viewed from shaft side)

D - counterclockwise rotation/right delivery C - counterclockwise rotation/left delivery

Hydraulic data

Operational pressure range to the nozzle

 

4 - 25 bar

Calibration

22 bars at factory

Viscosity at 20°C

2-12mm2/s(cSt)

Supply pressure

max.2 bars

Return pressure

max.2 bars

Suction

max. vacuum 0,35 bars,

 

recommended to

 

avoid separation of oil and gas

Rotational speed

3600 rpm

Max. oil temperature

70°C

Torque

1,0 cm - daN

Electrical data

 

Solenoid voltage

220V +10%-15%;50/60Hz

Absorbed capacity

9VA

Protection

IP50

Max. pressure

25 bar

Approved by

TUV n.1 x 23985S

PUMP OPERATING PRINCIPLE

The gear set draws oil from the tank through the built-infilter and transfers it to the nozzle line via the cut off solenoid valve. Pressure regulation is assured by two spool valves, one for each pressure mode.

In one pipe operation, oil which is not required at the nozzle is returned directly to the gear inlet via the pressure regulating valves and the suction line flow is equal to the nozzle flow.

In two pipe operation, the by-passplug must be fitted in the return port, which ensures that the oil dumped by the regulating valves is returned to the tank and the suction line flow is equal to the gear set capacity.

Purging on 2 pipe installations is assured by a bleed flat on the pistons. On 1 pipe installations, a high pressure connection must be loosened until the air is evacuated from the system.

Switching between low and high pressure is assured by a normally open by-passsolenoid valve. When this solenoid is non activated, aby-passchannel is open, allowing the normal operation of the low pressure valve which sets the nozzle pressure. When this solenoid is activated, theby-passchannel is closed, thus pressure will build up on both sides of the low pressure valve eliminating its effect and the high pressure valve now determines the nozzle pressure.

The blocking solenoid valve is of the normally closed type and is situated in the nozzle line.

This design ensures extremely fast response and the switching can be selected according to the burner operating sequence independently from the motor speed.

When the solenoid is non-activated,the valve is closed and all oil pressurised by the gear set passes through the regulators to suction or the return line, depending upon the pipe arrangement.

As soon as the solenoid is activated, oil passes to the nozzle line at the pressure set by the pressure regulating valve.

APPENDIX

21

A

Closed by-passsolenoid valve

4

Return to suction

B

Opened by-passsolenoid valve

5

By-passplug

C

Opened cut-offsolenoid valve

6

Return (twin pipe installation)

D

Closed cut-offsolenoid valve

7

Suction (twin pipe installation)

1

Manometer plug

8

Vacuum gauge plug

2

To nozzle

9

Gear

3

Shaft seal

10

Hi-pressureregulator with control screw

 

 

11

Lo-pressureregulator with control screw

Oil under suction

Oil under pressure

By-passedoil returned to tank or to suction

Twin pipe installation

Single pipe installation (remove the

 

by-passplug “P”)

22

APPENDIX

23

Via C. Colombo, 9 - 35011 Campodarsego (PD) Italy Tel. +39-049-9200944- Fax+39-049-9200945-9201269Internet: www.cibunigas.it - E mail: cibunigas@cibunigas.it