Unigas G6, G10, G18 Manual Of Installation - Use - Maintenance

MANUAL OF INSTALLATION - USE - MAINTENANCE

G6 - G10 - G18

24 Vdc voltage supplied

single stage burners

M039223CC Rel. 2.2 09/2012

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

WARNINGS

THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE
USER.

INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO­DUCT INSTALLATION AND MAINTENANCE.

THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION
OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.

CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.

1) GENERAL INTRODUCTION

 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 inte-

grity.
In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devices, plastic

bags, foamed polystyrene, etc), should not be left within the reach of 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 har-

mless.
 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, there-

fore, dangerous.
The manufacturer shall not be held liable, by agreement or otherwise, for
damages resulting from improper installation, use and failure to comply

with the instructions supplied by the manufacturer.

2) SPECIAL INSTRUCTIONS FOR BURNERS

 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

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 combu-

stion 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 instruc-

tions is available in the boiler room.
 In case of a burner shut-down, reser the control box by means of the

RESET pushbutton. If a second shut-down takes place, call the

Technical Service, without trying to RESET further.
 The unit shall be operated and serviced by qualified personnel only,

in compliance with the regulations in force.

3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED

3a) ELECTRICAL CONNECTION

 For safety reasons the unit must be efficiently earthed and installed

as required by current safety regulations.
 It is vital that all saftey requirements are met. In case of any doubt,

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 per-

mitted 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:

the hand-operated shut-off

- 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.

3

3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS

GENERAL

 The burner shall be installed by qualified personnel and in com-

pliance with regulations and provisions in force; wrong installation
can cause injuries to people and animals, or damage to property, for
which the manufacturer cannot be held liable.

 Before installation, it is recommended that 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 desi-

gned 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.

DIRECTIVES AND STANDARDS

Gas burners

European directives:

- Directive 2009/142/EC - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC on electromagnetic compatibility

Harmonised standards :

-UNI EN 676 (Gas Burners;

-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;

- EN 50165 (Electrical equipment of non-electric appliances for house­hold and similar purposes. Safety requirements.

Light oil burners

European directives:

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC on electromagnetic compatibility

Harmonised standards

CEI EN 60335-1(Household and similar electrical appliances - Safety.

­Part 1: General requirements;

- EN 50165 (Electrical equipment of non-electric appliances for house­hold and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

European directives:

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC on electromagnetic compatibility

Harmonised standards :

-CEI EN 60335-1 Household and similar electrical appliances - SafetyPart
1: General requirements;

- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

European directives:

- Directive 2009/142/EC - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC on electromagnetic compatibility

Harmonised standards :

-UNI EN 676 Gas Burners

-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;

- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

European directives:

- Directive 2009/142/EC - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC on electromagnetic compatibility

Harmonised standards :

-UNI EN 676 (Gas Burners;

-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;

- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

:

Heavy oil burners

Gas - Light oil burners

Gas - Heavy oil burners

4

GENERAL FEATURES

PART I: INSTALLATION

4

2

1

3

5

This series represents monobloc gas burners made in die-cast aluminium housing, the combustion head position can be adjuste­dwhich allows a good performance.

Fig. 1

1 Gas valve group
2 Blast tube-Combustion head ass.y
3 Burner flange
4 Burner cover

The fuel coming from the supply line, is pushed by the pump to the nozzle and then into the combustion chamber, where the mixture
between fuel and air takes place and consequently the flame.

In the burners, the mixture bertween fuel and air, to perform clean and efficient combustion, is activated by atomisation of oil into very
small particles. This process is achieved making pressurised oil passing through the nozzle.

The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pressure,
pumps are provided with a pressure regulator (except for some models for which a separate regulating valve is provided). Other pumps
are provided with two pressure regulators: one for the high and one for low pressure (in double-stage systems with one nozzle).

The adjustable combustion head can improve the burner performance. The combustion head determines the energetic quality and the
geometry of the flame. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion cham­ber).

How to interpret the burner “Performance curve”

To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed:

 furnace input, in kW or kcal/h (kW = kcal/h / 860);
 backpressure (data are available on the boiler’s ID plate or in the user’s manual).

Example:
Furnace input: 600kW
Backpressure: 4mbar
In the “Performance curve” diagram (Fig. 1), draw a vertical line matching the furnace input value and an horizontal line matching the

backpressure value. The burner is suitable if the intersection point A is inside the performance curve.

5

Fig. 2

Campo di lavoro bruciatori

Tipo P60 Mod. M-x x.x.IT.A.0.50 - M-.x x.x.IT.A.0.65

-1

0

1

2

3

4

5

6

7

8

100 200 300 400 500 600 700 800 900

Pote nza kW

Contropressione in camera di

combustione mbar

A

Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C

Matching the burner to the boiler

The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose
dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in dia­meter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with
respect of the application involved. To correctly match the burner to the boiler verify the necessary input and the pressure in combu­stion chamber are included in the burner performance curve; otherwise the choice of the burner must be revised consulting the burner
manufacturer. To choose the blast tube lenght follow the instructions of the boiler manufacturer. In absence of these consider the fol­lowing:

 Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than 100 mm into

the combustion chamber.

 Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in

respect to the tube bundle plate.
The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably­spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).

Key

a) Heat output in kW
b) Lenght of the flame tube in meters

c) Flame tube firing intensity in MW/m

3

d) Combustion chamber diameter (m)

Fig. 3 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.

sized

Fig. 3

6

Burner model identification

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

Type G10 Model G-. TN. S. *. Y.
(1) (2) (3) (4) (5) (6)

(1) BURNER TYPE G6 - G10 - G18
(2) FUEL G - Light oil
(3) OPERATION TN - Single stage
(4) BLAST TUBEBLAST TUBE S - Standard L - Extended
(5) DESTINATION COUNTRY * - see data plate
(6) BURNER VERSION Y - Special version (24Vdc power supply)

Specifications

BURNER TYPE G6 G10 G18

Output min. -max. kW

Fuel

Light oil rate min. - max. kg/h

Light oil viscosity cSt @ 40°C 2 - 7.4

Light oil density

kg/m

3

Power supply

MotorДвигатель W

Total power consumption W

(approx.)Weight kg

Operation

Operating temperature °C

Storage Temperature °C

29 - 70 58 - 116 105 - 209

Light oil

2.5 - 6 5 - 10 9 - 18

0.84

24 Vdc

110 180 180

210 280 280

15.5 17 18

Single-stage

-10 ÷ +50

-20 ÷ +60

NOTE: Choosing the nozzle for light oil, consider Hi equal to 10210 kcal/kg.

* NOTE ON THE WORKING SERVICE: for safety reasons, one controlled shutdown must take place every 24 hours of conti­nuous working.

7

Overall dimensions (mm)

0

0,2

0,4

0,6

0,8

1

1,2

1,4

10 30 50 70 90 110 130 150 170 190 210 230

G6 G10 G18

Burner flange and boiler
recommended drilling tem­plate

AS AL AD B BL C CL D E F G H II K L M N O O P T

min. - max.min. - max.min. - max.min. - max. min. max.

G6 345 455 12 53 - 67 53 - 177 278 - 292 278 - 402 375 65 310 Ø80 Ø101 x 162 187 M8 156 86 138 112 x 80 265

G10

352 472 12 81 201 270 270 375 33 342 Ø88,9 Ø125 Ø105 160 221 M8 170 109 131 120 18 80 311

G18

352 472 12 81 201 270 270 375 33 342 Ø114,3 Ø134 x 160 221 M8 170 109 131 120 18 80 311

min.

*L = measure referred to burner provided with extended blast tube

Performance Curves

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

kW

ZW

To get the input in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C

NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory
tests, but does not represent the regulation range of the machine. On this diagram the maximum output point is usually reached by adj­suting the combustion head to its “MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is rea­ched setting the combustion head to its “MIN” position. During the first ignition, the combustion head is set in order to find a
compromise between the burner output and the generator specifications, that is why the minimum output may be different from the Per­formance curve minimum.

8

MOUNTINGS AND CONNECTIONS

Packing

Burners are despatched in cardboard packages whose dimensions are (mm):
340mm x 415mm x 415mm

Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing case:

 burner with gas train detached;
 gasket to be inserted between the burner and the boiler;
 oil flexible hoses;
 oil filter;
 envelope containing this manual

To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials

Fitting the burner to the boiler

To install the burner into the boiler, proceed as follows:
1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)
2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;
3 place the 4 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;
4 fasten the 4 stud bolts;
5 place the gasket on the burner flange;
6 install the burner into the boiler, moving the blast tube inwards the flange, until it reaches the measure requested by the boiler/utili-

sation;
fasten the screws;
7 fix the burner to the stud bolts, by means of the fixing nuts of the flange.
after fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insu-

lating material (ceramic fibre cord or refractory cement).

9