Cisco Systems PG25 G-SP, PG30 G-TN, G18 G-SP User Manual 2

MANUAL FOR

BURNERS
BRULEURS
BRENNER
QUEMADORES
BRUCIATORI

- 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-out devices that are provided.

* Make sure that inlet or exhaust grilles are unobstructed.
* In case of breakdown and/or defective unit operation,

disconnect the unit. Make no attempt to repair the unit or take
any direct action.

Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly

authorised by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair

the unit’s safety.
To ensure equipment efficiency and proper operation, it is

essential that maintenance operations are performed by
qualified personnel at regular intervals, following the
manufacturer’s instructions.

* 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-heating system,
they become hot during the unit operation and will remain hot
for some time after the burner has stopped.

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

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
operations:

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

b) set the flow rate of the combustion-supporting air to obtain a
combustion efficiency level at least equal to the lower level
required by the regulations in force;

c) check the unit operation for proper combustion, to avoid any
harmful or polluting unburnt gases in excess of the limits
permitted by the regulations in force;

d) make sure that control and safety devices are operating
properly;

e) make sure that exhaust ducts intended to discharge the
products of combustion are operating properly;

f) on completion of setting and adjustment operations, make
sure that all mechanical locking devices of controls have been
duly tightened;

g) make sure that a copy of the burner use and maintenance
instructions is available in the boiler room.

* In case of 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

3B) FIRING WITH GAS, GASOIL OR OTHER FUELS

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-operated component implies
observance of a few basic rules, for example:

- do not touch the unit with wet or damp parts of the body and/
or with bare feet;

- do not pull electric cables;

- do not leave the equipment exposed to weather (rain, sun,
etc.) unless expressly required to do so;

- do not allow children or inexperienced persons to use
equipment;

* The unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact

qualified personnel to replace.
* When the 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.

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.

3FOREWORD

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 firin g rate kg/h m in. 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

ABBLCCLDEGKH P M

G1 8 SP

275 90 200 365 475 340 255 115 230 125 121÷134 M8

Fig. 1

4

INSTALLATION

OVERALL DIMENSIONS

ABBLCCLD EFGKHPM

PG25SP
PG30SP

515 155 345 660 850 267 260 520 133 290 125 155 M10

PERFORMANCE CURVES

1.8

1.6

1.4

1.2
1

0.8

0.6

0.4

Back pressure in

0.2
0

combustion chamber mbar

6 8 10 12 14 16 18 20

Fig. 1a

Fig. 2

4

3

2

1

0

Back pressure in

-1

combustion chamber mbar

Back pressure in

10 12 14 16 18 20 22 24 26 28 30

3

2.5
2

1.5
1

0.5
0

-0.5

-1

combustion chamber mbar

10 12 14 16 18 20 22 24 26 28 30 32 34

Oil rate Kg/h

Fig. 3

Oil rate Kg/h

Fig. 3a

INSTALLATION

Oil rate Kg/h

5

MOUNTINGS AND CONNECTIONS

The burners are despatched in cardboard packages.

The packaging contains the following items:
1 burner;
2 flexible light oil tubes;
1 light oil filter;
1 gasket to be inserted between the burner and the boiler;
1 this 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

7) Blast tube

Fig. 4a

6

INSTALLATION

G18SP PG25SP PG30TN

Fig. 5 Fig. 5bFig. 5a

Fig. 6

7

SETTINGS

Burners G18SP - PG25SP

These burners are fitted with a double-regulation pump. The flame control device, a twin-stage one, after the pre-purgue stage,
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-up the 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 8-10 bar (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 101112131415161718

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

8

BAR

GP H 1 0 1 2 1 4

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

INSTALLATION