Unigas PN30 Operating & Maintenance Instructions

Technical DocumentationCIB Unigas - Campodarsego (PD)

MANUAL OF

- INSTALLATION

- OPERATION

- MAINTENANCE

HEAVY OIL BURNERS

PN30

SINGLE STAGE VERSION

M03930CC Rev. 02 06/01

NOTICES2

NOTICES

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 OPERA TING 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 knowle-

dge in the field of components for civil or industrial heating
systems, sani tary hot water generation and particularly ser­vice centres authorised by the manufactur er.

! Improper installation may cause injury to people and ani-

mals, 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 - cont act 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 su re that inlet or exhaust gril les 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 qualifi ed personnel only.
Units shall be repaired exclusively by a servicing centre, duly
authorised by the ma nufacturer, with origin al spare parts.
Failure to comply wit h 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 dan-

ger 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 fit-

ted then original accessory equipment only shall be used.

! This unit shall be employed exclusively for the use for

which it is meant. Any other use shall be considered as

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

2) SPECIAL INSTRUCTIONS FOR BURNERS

! The burner should be installed i n a suitable room, with ven-

tilation openings complying with the requirements of the
regulations in force, and sufficie nt f o r good combustion.

! Only burners designed accordi ng to the regula tions 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 t he 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 qual if ied personnel perform the following opera-

tions:
a) set the burner fuel flow rate depending on the heat input of

the appliance ;
b) set the flow rate of the 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 combust ion are operating properl y;
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 re-

setting the unit manually. Contact qualified personnel to

take care of such defects.

! The unit shall be operated and serviced by qualified per-

sonnel only, in compliance with the regulations in force.

NOTICES 3

3) GENERAL INSTRUCTIONS DEPENDING ON FUEL
USED

3a) ELECTRICAL CONNECTION

! For safety reasons the unit must be efficiently earthed and

installed as requi red by current safety regul ations.

! It is vit al that all saftey requir ement s are met. In ca se 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 absorbe d by the uni t.

! No adaptors, multiple outlet sockets and/or extension

cables are permitted to connect the unit to the electric
mains.

! An omnipolar switch shall be provided for connection to

mains, as required by the current safety regulations.

! The use of any power-operated component implies obser-

vance of a few basic rules, for example:

◆ do not touch the unit with wet or damp parts of the body

and/or with bare feet;

◆ do not pull electric cables;

◆ do not leave the equipment exposed to weather (rain,

sun, etc.) unless expressly required to do so;

◆ do not allow children or inexperienced persons to use

equipment;

! The unit input cable shall not be replaced by th e 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, et c.) should be switched off.

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

! The burner shall be installed by qualified personnel and in

compliance with regulations and provisions in force; wrong

installation can cause injuries to people and animals, or

damage to property, for which the manufacturer cannot be

held l iable.

! Before installation, it is recommended that all the fuel sup-

ply system pipes be carefully cleaned inside, to remove

foreign matter that might impair the burner operation.

! Before the burner is commissioned, qualified personnel

should inspect the following:
a) the fuel supply system, for proper sealing;

b) the fuel flow rate, to make sure that it has been set based

on the firing rate required of the burner;
c) the burner firing system, to make sure that it is suppl ied for

the designed fuel type;
d) the fuel supply pressure, to make sure that it is included in

the range shown on the rating plate;
e) the fuel supply system, to make sure that the system

dimensions are adequate to the burner firing rate, and that

the system is equipped with all the safety and control devi-

ces required by the regulations in force.

! When the burner is to remain idle for some time, the fuel

supply tap or taps should be closed.

SPECIAL INSTRUCTIONS FOR USING GAS

Have qualified personnel inspect the installation to ensure
that:

a) the gas delivery line and train are in compliance with the

regulations and provisions in force;
b) all gas connections are tight;
c) the boiler room ventilation openings are such that they

ensure the air supply flow required by the current regula-

tions, and in any case are sufficient for proper combustion.

! Do not use gas pipes to earth electri cal equipment.
! Never leave the burner conn ected 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 likel y 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 inst alled, to avo id dangerous conditions

such as the development of toxic or explosiv e mixtures.

PART I: INSTALLATION MANUAL4

TECHNICAL DATA

BURNER MODEL IDENTIFICATION

Burners are identified by burner type and model. Burner model identification is described here following.

Type: PN30 Model: N-. TN. S. IT. A.

(1) (2) (3) (4) (5) (6)
(1) BURNER TYPE
(2) FUEL N - Heavy oil, viscosity up to 7° E at 50° C

E - Eco heavy oil (environmental friendly) , vi scosity 12 °E at 50°C

D - Heavy oil, viscosity up to 50° E at 50° C
(3) OPERATION Available versions AB - Double stage
(4) BLAST TUBE LENGHT (See overall dimensions)

Available versions S - Standard

L - Long
(5) DESTINATION COUNTRY * - see data plate
(6) SPECIAL VERSIONS A - Standard E - with junction box

Y - SpecialeM - Wall mountin g electrical board

G - Floor standing electrical board and junction box

BURNER PN30

Input min. kcal/h 140.000

max. kcal/h 300.000

min. kW 163

max. kW 349

Oil rate min. Kg/h 14

max. Kg/h 30
Fuel heavy oil
Power supply V 230/400
Frequency Hz 50
Motor 2800 rpm kW 0.74
Pre-heater resis tor kW 2.4
Total electrical power kW 3.65
Weight Kg 60
Operation single stage
Destination country *

PART I: INSTALLATION MANUAL

PART I: INSTALLATION MANUAL 5

OVERALL DIMENSIONS

Fig. 4

PERFORMANCE CURVE

ABBLCCLDEFGKZVWM

PN30 520 160 350 680 870 270 450 720 131 400 160 155 219 M10

BACKPRESSURE IN

COMBUSTION CHAMBER mbar

PN30

kW

-1.5

-1

-0.5

0

0.5

1

1.5

2

2.5

3

140 160 180 200 220 240 260 280 300 32 0 340 360 380

PART I: INSTALLATION MANUAL6

MOUNTINGS AND CONNECTIONS
Imballo

The burners are despat ched in wodden crates of dimensions 10070 x 740 x 840 (W x H x D).
Packing cases of this type are affected by humidity and are not suitable for stacking. The following are placed in each packing

case:
1 burner
2 flexible light oi l tubes;
1 oil filter;
1 this manual, the test certificate and the compl iance declaration.
To get rid of the burner’s packing and in t he event of scrapping of the latter, follow the procedures laid down by current laws on

disposal of materials.

Matching the burner to the boiler

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.

The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably­sized spacer to move the burner backwards.

! 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 t ube bundle plate.

Fitting burner to the boiler

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

5 Burner
6 Fixing nut
7 Washer
8 Seal
9 Stud bolt
10Sightglass cleaning tube
11Blast tube

Fig. 5

PART I: INSTALLATION MANUAL 7

ELECTRICAL CONNECTIONS

! Remove the front panel of the electrical board on the burner.

Carry out the connections in the power supply electrical board as shown in Fig. 6; verify the fan motor direction and refit the
electrical board front panel.

! For a complete key of electrical diagrams see on page 22.

Fan motor direction

After completing the electrical connection of the burner, remember to check the rotation of the fan motor. The motor should
rotate in an anti-clockwise direction looking at cooling fan. In the event of incorrect rotation reverse the three-phase supply and
check again the rotation of the motor.

ATTENTION: the burners are supplied 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, replace the thermal overload relay and
modify the resistors connections.

WARNING: The burner is fitted with an electrical bridge between terminals 6 and 7, in the event of connecting the
high/low flame thermostat remove this bridge before connecting the thermostat.

IMPORTANT: In connecting elec tric sup ply wires to burn er teminal block be sure that ground wire sho uld be longer
than phase and neutral ones.

Fig. 6

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.

Pre-heater resistors

2.4 - 4.5 kW

Electrical motor terminal block

Fig. 7a Fig. 7b

230V 400V

230V 400V

PART I: INSTALLATION MANUAL8

HYDRAULIC DIAGRAMS 3ID0010 E 3ID0012 - Complete key

1 Oil storage tank
2 Foot valve
3 Oil storage tank pre-heating coils (1)
4 Oil circuit filter (1 mm mesh)
5 Circuit pressure regulator
6 Pressure gauge scale 0 - 10 bars
7 Pressure regulator by-pass valve (5)
8 Gate valve
9 Oil circuit pre ssure regulator pump
10 Pump pressure regul ator (9)
11 One-way valve
12 Oil buffer tank pre -heater (19)
13 Oil buffer tank thermostat
14 Burner enabling thermostat
15 Thermometer scale 0 - 90° C
16 Oil buffer tank heat er enabling pressure switch
17 Oil buffer tank pre-heating coil (19)
18 Oil buffer tank ai r vent valve
19 Oil buffer tank, capacity 600 l approx.
20 Oil filter (0.3 mm mesh)
21 Fuel cutoff solenoid valve
22 Fuel gate valve
23 Burner pump hoses (24)
24 Burner oil pump
25 Pre-heating tank resistor
26 Pre-heating tank
27 Oil enabling ther mo stat TCN (26)
28 Pre-heating tank resistor safety therm ostat TRS (26)
29 Oil temperature regulator thermostat TN (26)
30 Pre-heating tank (26) filter (0.1 mm mesh)
31 Thermometer 0 - 200° C
32 Check valve, opening 3.5 - 6 bars
33 Solenoid valve EVN1
37 Ignition enabling thermostat TCI
42 Burner enabling thermostat
43 Burner
45 Coils and tubes pre-heating pumps thermosta t
46 Oil buffer tank pre -heating water pump (19)
47 Oil storage tank pre- heating water pump (1)
48 Pre-heating water balance calibration valves
50 Oil pump (diagram 3ID0012 only)
52 Maximum circuit pressure switch (if present)

PART I: INSTALLATION MANUAL 9

OIL SUPPLY PIPING INSTALLATION DIAGRAM

Fig. 8 - Hydraulic diagram 3ID0010 for 1 burner installations

OIL CIRCUIT

PRE-HEATED WATER CIRCUIT

PRE-HEATING 50°C

PRE-HEATING 70°C

LIMIT OF BURNER SUPPLY

PART I: INSTALLATION MANUAL10

Fig. 9 - Hydraulic diagram 3ID0012 for 2 or more burners

OIL CIRCUIT

PRE-HEATED WATER CIRCUIT

PRE-HEATING 50°C

PRE-HEATING 70°C

LIMIT OF

BURNER

SUPPLY

NOTE: PRE-HEATING OF

ENABLING THERMOSTAT

CONNECTION TUBE (16)

BURNER 2

BURNER 1