Unigas PG70, PG60, PG81 Manual Of Installation - Use - Maintenance
PG60
PG70
PG81
Progressive / Fully-modulating
Light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -
M039191CA Rel: 0.1 09/2011
ГОРЕЛКИ
CIB UNIGAS - M039191CA
TABLE OF CONTENTS
WARNINGS ................................................................................................................................................................ 3
PART I: INSTALLATION .................................... ....................................................................................................... 5
GENERAL FEATURES ................................................................................................................................................................... 5
How to interpret the burner’s “Performance curve” ............................................... ... ....................................................................... 5
Technical specifications ..................................................................................................................................................................5
Performance curves ........................................................................................................................................................................6
Overall dimensions .........................................................................................................................................................................7
MOUNTINGS AND CONNECTIONS .............................................................................................................................................. 8
Fitting the burner to the boiler .........................................................................................................................................................8
Handling the burner ........................................................................................................................................................................8
Hydraulic diagrams for light oil supplying circuits ...........................................................................................................................9
Installation diagram of light oil pipes .............................................................................................................................................10
About the use of fuel pumps .........................................................................................................................................................11
Light oil pumps ...................................... ... .....................................................................................................................................12
Connecting the light oil flexible hoses ...........................................................................................................................................13
Light oil circuit ..................................................... ..........................................................................................................................14
Light oil nozzles ................... ... ... ....................................... ............................................................................................................15
Electrical connections ...................................................................................................................................................................16
Fan-pump motor rotation ...................... ........................................................................................................................................16
ADJUSTMENTS . .......................................................................................................................................................................... 17
Adjustments - brief description ......................................................................................................................................................17
Adjustment procedure ...................................................................................................................................................................17
Adjustment by the Berger STM30.. actuator .................................................................................................................................18
Adjustment by the Siemens SQL33.. servocontrol .......................................................................................................................21
Fully modulating burners ...............................................................................................................................................................25
Calibration of air pressure switch (when provided)....................................................................................................................... 25
PART II: OPERATION ..................................... ........................................................................................................ 26
OPERATION ................................................................................................................................................................................. 26
Burner control panel .................................... ................................................................ ..................................................................27
PART III: MAINTENANCE...................... ................................................................................................................. 28
ROUTINE MAINTENANCE ........................................................................................................................................................... 28
Light oil filter maintenance ................................................... ... .. ........................................ ............................................................28
Removing the combustion head and the oil gun ...........................................................................................................................29
Removing the oil gun (PG70-PG81) .............................................................................................................................................29
Correct position of electrodes and combustion head ....................................................................................................................30
Replacing the ignition electrodes ..................................................................................................................................................30
Cleaning and replacing the detection photocell ...........................................................................................................................30
Checking the detection current .....................................................................................................................................................31
Seasonal stop.................................. ... .................................. ................................. ....................................................................... 31
Burner disposal ................................................... ..........................................................................................................................31
TROUBLESHOOTING .................................................................................................................................................................. 31
ELECTRICAL WIRING DIAGRAMS .............................................................................................................................................. 32
SPARE PARTS ........................................................................................................................................................................... 43
APPENDIX............................................................................................................................................................... 44
2
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
z The equipment must be installed in compliance with the regulations
in force, following the manufacturer’s instructions, by qualified personnel.
z 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.
z Improper installation may cause injury to people and animals, or
damage to property, for which the manufacturer cannot be held liable.
z 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.
z 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.
z Make sure that inlet or exhaust grilles are unobstructed.
z 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.
z 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.
z 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.
z For all the units that have been modified or have options fitted then
original accessory equipment only shall be used.
z 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
z 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.
z Only burners designed according to the regulations in force should
be used.
z This burner should be employed exclusively for the use for which it
was designed.
z Before connecting the burner, make sure that the unit rating is the
same as delivery mains (electricity, gas oil,
z 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
or other fuel).
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
z Make sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.
z 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.
z 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.
z 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
z For safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.
z 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.
z 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.
z No adaptors, multiple outlet sockets and/or extension cables are per-
mitted to connect the unit to the electric mains.
z An omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.
z 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;
z 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
z 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.
z 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.
z Before the burner is commissioned, qualified personnel should ins-
pect 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.
z 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.
z Do not use gas pipes to earth electrical equipment.
z Never leave the burner connected when not in use. Always shut the
gas valve off.
z 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.
z 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 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE 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/
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/CEE 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 90/396/CEE Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE 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 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE 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
CEE on electromagnetic compatibility
Heavy oil burners
Gas - Light oil burners
Gas - Heavy oil burners
4
CIB UNIGAS - M039191CA
PART I: INSTALLATION
GENERAL FEATURES
Monobloc burners of this series are made in die-cast aluminium housing with relative flange to work on heating generators. The output
range is from 150kW to 1900kW (according to the model).
They can be provided in progressive or fully-modulating version.
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 pass through the nozzle.
The pump main function is to transfer oil from the tank to the nozzle at required quantity and pressure. To adjust pressure, pumps are
provided with a pressure governor (except some models for which a separate adjusting valve is provided). Other pumps are provided
with two pressure governors: one for high and one for low pressure (in double-stage systems with one nozzle).
In the double-stage burners, the electric actuator, that moves the air damper, allows the optimisation of the gas flue values, as to get an
efficient combustion. The position of the combustion head determines the burner output. The air (comburent) and fuel (light oil) are forced into the combustion chamber, as to let the flame light up.
How to interpret the burner’s “Performance curve”
To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed:
z furnace input, in kW or kcal/h (kW = kcal/h / 860);
z backpressure (data are available on the boiler 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.
Camp o di lavo ro bruciato ri
Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65
8
7
6
5
4
3
2
1
combustione mbar
0
Contropressione in camera di
-1
100 200 300 400 500 600 700 800 900
A
Pote nza k W
Fig. 1
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type PG60 Model G-. PR. S. *. A.
(1) (2) (3) (4) (5) (6)
(1) BURNER TYPE
(2) FUEL
(3) OPERATION (Available versions)
(4) BLAST TUBE S - Standard L - Extended
(5) DESTINATION COUNTRY
(6) BURNER VERSION
PG60-PG70-PG81
G - Light oil A - Biodiesel
PR - Progressive MD - Fully modulating
* - see data plate*
A - Standard
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CIB UNIGAS - M039191CA
Technical specifications
BURNERS PG60 PG70 PG81
Output min. -max. kW 151 - 791 291 - 1047 264-1900
Light oil rate min. -max. kg/h 13 - 67 25 - 88 22-160
Fuel Light oil
Viscosity 1.3 °E @20°C
Power supply 400V 3N ~ 50Hz
Electric motor kW 1.1 2.2 3
Total power consumption kW 1.6 2.7 3.5
Approx. weight kg 55 85 85
Operation
Operating temperature °C -10 ÷ +50
Storage temperature °C -20 ÷ +60
Working service * Intermittent
*NOTE ON THE BURNER WORKING SERVICE:
z Burners provided with Siemens LOA24 control box: for safety reasons, one controlled shutdown must take place every 24 hours.
z Burners provided with Si emens LMO24-44 control box: the control box automatically stops after 24h of con tinuous working. The
control box immediately starts up, automatically.
Progressive - Fully modulating
Performance curves
PG60
10
8
6
4
2
BACK PRESSURE IN
BACK PRESSURE IN
0
-2
CCOMBUSTION CHAMBER mbar
0 100 200 300 400 500 600 700 800 900
PG81
14
12
10
8
6
4
2
0
200 400 600 800 1000 1200 1400 1600 1800 2000
CCOMBUSTION CHAMBER mbar
kW
kW
PG70
14
12
10
8
6
4
2
0
-2
200 300 400 500 600 700 800 900 1000 1100 1200
kW
To get the input in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: atmosferic pressure at 1013mbar, ambient temperature at 15°C.
6
OVERALL DIMENSIONS (mm)
P
H
N
P
M
7
ABBLCCLDEFGKH P M N
PG60 760 244 442 1004 1202 270 300 570 153 240 182 190 M10 269
PG70 725 310 460 1035 1185 355 420 775 198 300 228 233 M10 330
PG81 825 340 490 1165 1315 355 420 775 234 300 264 233 M10 330
boiler drilling plate
CIB UNIGAS - M039191CA
CIB UNIGAS - M039191CA
MOUNTINGS AND CONNECTION S
Packing
The burners are dispatched in wooden pakages whose dimensions are:
PG60: 1200 x 670 x 540 mm
PG70-PG81: 1280 x 850 x 760 mm
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing case.
1 burner;
2 light oil flexible hoses;
1 light oil filter;
1 gasket to be inserted between the burner and the boiler;
1 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 the hole of the boiler’s door, according to the burner’s drilling plate 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;
7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture.
8 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).
Handling the burner
ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these operations are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.
To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).
Keys
1 Burner
2 Fixing nut
3Washer
4 Sealing gasket
5 Stud bolt
7Blast tube
8
CIB UNIGAS - M039191CA
Hydraulic diagrams for light oil supplying circuits
Fig. 2 - Gravity circuit
Fig. 3 - Ring circuit
Fig. 4 - Suction circuit
Key
1 Manual valve
2 Light oil filter
3 Light oil feeding pump
4 One way valve
5 Flexible hoses
6 Relief valve
NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n. 4).
9
CIB UNIGAS - M039191CA
Installation diagram of light oil pipes
PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL.
From tank
To tank
Fig. 5 - Double-pipe system
The burner is supplied with filter and flexible hoses, all the parts upstream the filter must be installed by the customer. As far as
the hoses connection, see the related paragraph..
Key
1 Burner
2 Flexible hoses (fitted)
3 Light oil filter (fitted)
4 Automatic interceptor (*)
5 One-way valve (*)
(*) Only for installations with gravity, siphon or forced circulation feed systems. If the device installed
is a sol enoid valve, a timer must b e i nstalled to
delay the valve closing.
The direct connection of the device without a timer
may cause pump breaks.
6 Gate valve
7 Quick-closing gate-valve (outside the tank or boiler rooms)
The provided 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 plug, if provided,
must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer.
Double-pipe system: as for the single pipe system, a pipe that connects the tank to the pump’s inlet is used besides another pipe that
connects the pump’s return port to the tank, as well. The excess of oil goes back to the tank: this installation can be considered self-bleeding. If provided, the inside by-pass plug must be installed to avoid air and fuel passing through the pump.
Burners are factory-set for double-pipe systems. They can be suited for single-pipe system (recommended in the
case of gravity feed) as decribed before.To change from a 1-pipe system to a 2-pipe-system, insert the by-pass plug G (as for ccw-rotation- referring to the pump shaft).
Caution: Changing the direction of rotation, all connections on top and side are reversed.
..
.
Suntec AJ6
Suntec J6
Twin pipe installation
Danfoss RSB30
Single pipe installation
G
G
10
CIB UNIGAS - M039191CA
Suntec TA
Danfoss KSM..L
G
G
Bleed
Bleeding in two-pipe operation is automatic : it is assured by a bleed flat on the piston. In one-pipe operation, the p lug of a pressure
gauge port must be loosened until the air is evacuated from the system.
About the use of fuel pumps
z 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.
z 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.
z After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of the
tank, thus avoiding the possibility that they might be sucked into the pump.
z 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.
z 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.
z Pipes should not con tain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal junc-
tions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of junc-
tions should be kept to a minimum as they are a possible source of leakage.
z Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could depo-
sit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) jun-
ctions if possible.
z An external filter should always be installed in the suction line upstream of the fuel unit.
11
CIB UNIGAS - M039191CA
Light oil pumps
The pumps provided with these burners can be:
z PG60: Suntec AJ6
z PG70: Suntec J6/Danfoss RSB30
z PG81: Suntec TA2 / Danfoss KSM50
PumpSuntec AJ6
Viscosity 2.8 - 75 cSt
Oil temperature 60°C max
Inlet maximum pressure 2 bar
Inlet minimum pressure
Rated speed 3600 rpm max.
Suntec J6 - J7
Oil viscosity 2.8 - 200 cSt
Oil temperature 0 - 90°C
Min. suction pressure - 0,45 barto avoid gasing
Max. suction pressure 1.5 bar
Max. return pressure 1.5 bar
Rotation speed 3600 rpm max.
- 0.45 bar to avoid gasing
Key
1 Pressure governor
2 Pressure gauge
3 Vacuum gauge
5 Nozzle
7 Suction
8 Return
Danfoss RSB
Oil viscosity 2,5 ÷ 200 cSt
Oil temperature -10 ÷ 120°C
Inlet maximum pressure 4 bar
Maximum return pressure 4 bar
Minimum inlet pressure
- 0,45 to avoid gasing
Rotation speed max. 3600 rpm
Key
1 Pressure governor
2 Pressure gauge
3 Suction
4 To nozzle
5 Return
12
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Suntec TA..
Oil viscosity 4 - 450 cSt
Oil temperature 0 - 140°C
Min. suction pressure - 0.45 barto avoid gasing
Max. suction pressure 5 bar
Max. return pressure 5 bar
Rotation speed 3600 rpm max.
Danfoss KSM..
Oil viscosity 2,5 ÷ 450 cSt
Oil temperature -10 ÷ 160 °C
Max. suction pressure 4 bar
Min. suction pressure -0,45 to avoid gasing
Max. return pressure 4 bar
Rotation speed 3450 rpm max
Key
1 Pressure governor
2 Pressure /vacuum gauge port to measure inlet pressure/vacuum
3 Pressure gauge port
5 Suction
7 To nozzle
8 Return
Connecting the light oil flexible hoses
To connect the flexible light oil hoses to the pump, proceed as follows, according to the pump provided:
1 remove the closing nuts A and R on the inlet and return connections of the pump;
2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the inlet and return lines: see
the arrows marked on the pump that show the inlet and the return (see prevoius paragraph).
Suntec AJ6 Suntec J6 Danfoss RSB30
A
A
A
R
R
R
Danfoss KSM Suntec TA
A
R
A
R
13
CIB UNIGAS - M039191CA
Light oil circuit
The fuel is pushed into the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor. The solenoid valve 2 set the
fuel immission into the combustion chamber. The part of fuel that is not burnt goes back to the tank through the return circuit. The fuel
amount to be burnt is adjusted by means of the burner actuator according to the adjustments set (see pag. 22).
Fig. 6 - Stand-by
Fig. 7 - Prepurge
Fig. 8 - Low flame
Fig. 9 - High flame
14
Key
1 Light oil pump
2 Light oil solenoid valve
3 Nozzle
4 Servocontrol
5 Adjusting cam
6 pressure gauge
7 Pressure regulator
8 One-way valve
CIB UNIGAS - M039191CA
Light oil nozzles
The light oil fl ow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation’s output and setting the delivery and
return pressure values according to the values quoted on diagram on Fig. 9.
NOZZLE
NOZZLE
SUPPLY PRESSURE
bar
HIGH FLAME
RETURN PRESSURE
bar
LOW FLAME
RETURN PRESSURE
bar (recommended)
BERGONZO A3 20 11 ÷ 13 5 (recommended)
Example (Bergonzo): if a 220kg/h flow rate BERGONZO nozzle is provided, set the return pressure at 11bar, supply at 20bar on the
delivery to get a 220kg/h flow rate. If the return pressure needed is 5bar, instead, act on the V adjusting screw on the pressure gover-
nor (see chapter on page 18). The flow rate will then be about 95kg/h (see the example showed on the Bergonzo diagram).
Fig. 10
15
CIB UNIGAS - M039191CA
Electrical connections
RESPECT THE BASIC SAFETY RULES. MAKE SURE OF THE CONNECTION TO THE EARTHING SYSTEM. DO NOT
REVERSE THE PHASE AND NEUTRAL CONNECTIONS. FIT A DIFFERENTIAL THERMAL MAGNET SWITCH ADEQUATE FOR CONNECTION TO THE MAINS. STRICTLY OBSERVE THE DATA PLATE.
z Remove the cover from the burner electrical panel.
z Execute the electrical connections to the power supply terminal board as shown, check the direction of the fan-pump motor (see
next paragraph) and replace the electrical panel cover.
WARNING: The burner is provided with a jumper between terminals 6 and 7; in the event of connecting the high/low
flame thermostat remove this jumper before connecting the thermostat.
IMPORTANT: while connecting electric supply wires to burner’s teminal block be sure that ground wire should be
longer than phase and neutral ones.
Progressive burners
Fig. 11
Fully-modulating burners
Fig. 13
Probes connection
(**) Probes connection, see Fig. 12
Fig. 12
Fan-pump motor rotation
Once the burner electrical connection is accomplished, remember to check the motor rotation.
Motor mu st rotate in the direction showed on the casi ng. In the event of wron g rotation, reverse the three-p hase supp ly and che ck
again the motor rotation.
NOTE: Burners are provided for three-phase 400 V supply, and in the case of three-phase 230 V supply it is necessary to modify the
electrical connections inside the terminal box of the electric motor and replace the thermal cutout relay.
16
ADJUSTMENTS
Adjustments - brief description
ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open. Be sure that the mains
switch is closed.
Before starting up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.
.ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation
of carbon monoxide); if this should happen, make the gas decrease slowly until the normal combustion values are achieved.
IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:
CIB UNIGAS - M039191CA
Recommended combustion parameters
Fuel
Recommended (%) CO2 Recommended (%) O2
Light oil 11.5 ÷ 13 2.9 ÷ 4.9
Adjust the air and fuel flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respectively.
z Check that the combustion parameters are in the suggested limits.
z Check the oil flow rate.
z Then, adjust the combustion values corresponding to th e points between maximum and minimum: set the foil shape of the ad ju-
sting cam. The adjusting cam sets the air/fuel ratio in those points, regulating the opening-closing of the fuel governor.
z Set, now, the low flame output, acting on the low flame microswitch of the actuator in order to avoid the low flame output increasing
too much or that the flues temperature gets too low to cause condensation in the chimney.
Adjustment procedure
To change the burner setting during the testing in the plant, follow the next procedure, according to the actuator model provided (mod.
Berger STM30.. or mod. Siemens SQL..).
z PG60: Berger STA12..
z PG70-PG81: Berger STM30.. / Siemens SQL33..
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