Unigas RG1025, RG1030, RG1040 Manual Of Installation, Use And Maintenance

RG1025
RG1030
RG1040

Light oil burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

M039144CD Rel. 3.2 09/2010

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,
 Observe caution w

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

ith hot burner components. These are, usually,

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

 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:

- 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

- Directiv

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

e 2004/108/EC

on electromagnetic compatibility

Heavy oil burners

Gas - Light oil burners

Gas - Heavy oil burners

;

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C.I.B. UNIGAS - M039144CD

PART I: INSTALLATION

10

11

5

7

6

4

32 1

8

9

12

GENERAL FEATURES

This series represents monobloc burners made in die-cast aluminium housing with relative flange to work on heating generators. The
output range is from 2550kW to 13000kW (according to models). They can be provided in progressive or fully-modulating version.

Fig. 1

1 Control panel
2 Electrical panel
3Pump
4 Burner flange
5 Blast tube-combustion head
6 Burner cover
7 Oil pressure governor
8 Adjusting cam
9 Actuator
10 Air inlet
11 Air pressure switch
12 Gun and head adjusting ring nut

The fuel coming from the supply line, is pushed by the pump (11) 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 (11) 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).

In the double-stage burners, the electric servocontrol (12), 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’s output. The air (comburent) and fuel (light
oil) are forced into the combustion chamber, as to let the flame light up.

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C.I.B. UNIGAS - M039144CD

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

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:

 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. 2), 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.

Fig. 2

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 RG1025 Model G-. PR. S. *. A.

(1) (2) (3) (4) (5) (6)

(1) BURNER TYPE RG1025 - RG1030 - RG1040

(2) FUEL G - Light oil

(3) OPERATION (Available versions)

(4) BLAST TUBE S - Standard

(5) DESTINATION COUNTRY * - see data plate

(6) BURNER VERSION A - Standard Y - Special

PR - Progressive
MD - Fully modulating

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C.I.B. UNIGAS - M039144CD

Specifications

BURNERS RG1025 RG1030 RG1040

Output min. - max. kW 2550 - 8700 2550 - 10600 2550 - 13000

Light oil rate min. - max. kg/h 215 - 734 215 - 894 215 - 1096

Fuel Light oil

Viscosity 2 - 7.4 cSt @ 40°C

Density

840 kg/m

Power supply 400V 3N ~ 50Hz

Electric motor kW 18.5 22 30

Pump motor kW 4 4 5.5

Total power consumption kW 22 26.5 36

Approx. weight kg 440 470 500

Operation

Operating temperature °C

Storage Temperature °C

Working service*

Progressive - Fully modulating

-10 ÷ +50

-20 ÷ +60

Intermittent

NOTE: Choosing the nozzle for light oil, consider Hi equal to 42.7 MJ/kg.
*NOTE ON THE BURNER WORKING SERVICE: for safety reasons, one controlled shutdown must be performed after 24 hours

of countinous operation.

3

Performance curves

RG1025

30

20

10

BACK PRESSURE IN

0

2500 3500 4500 5500 6500 7500 8500

CCOMBUSTION CHAMBER mbar

RG1040

20

10

RG1030

30

20

10

0

2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

kW

kW

BACK PRESSURE IN

0

2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

CCOMBUSTION CHAMBER mbar

kW

ìTo 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.

7

Overall dimensions (mm)

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C.I.B. UNIGAS - M039144CD

Burners flange and boiler recommended drilling

template

A(S*) A(L*) AA AB AC AD AE B(S*) B(L*) BB C CC D E F G H K L M N O P RR SS UU W Y Z
RG1025 1896 2090 377 1452 651 25 585 350 544 641 1546 680 1502 680 822 370 410 660 816 M16 651 460 460 265 80 142 1146 379 330
RG1030 1914 2108 377 1452 651 25 585 350 544 657 1564 680 1502 680 822 422 472 660 816 M16 651 460 460 265 80 142 1146 379 330
RG1040 1961 2155 377 1452 651 25 585 386 580 657 1575 680 1502 680 822 671 731** 660 816 M16 651 460 460 265 80 142 1146 412 330

* S: measure referred to burner provided with standard blast tube

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

** Fit a counterflange between burner and boiler

C.I.B. UNIGAS - M039144CD

H

P

L

Eyebolts

SIDE UP

SIDE

DOWN

MOUNTING AND CONNECTIONS

ATTENTION: READ CAREFULLY THE “WARNINGS2 CHATPER AT THE BEGINNIG OF THIS MANUAL.

Packing

The burners are despatched in wooden cages whose dimensions are:

2270 x 1720 x 1360mm (L x P x H)

Packing cases of this kind are affected by humidity and are not suitable for stacking.
In each packing case, you will find:

 burner;
 flexible hoses;
 light oil filter;
 ceramic fibre plait to be inserted between the burner and the boiler;
 envelope containing this manual.

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.

Handling the burner

ATTENTION! the lfting and moving operations must be carried out by
specialised and trained personnel. If these operations are not carried out
perfectly, there is the residual risk of the burner to overturn and fall
down.

As for moving the burner, use means suited for the weight to sustain
(see paragraph “Technical specifications”).

The burner is provided with eyebolts, for handling operations.

The burner is designed to work positioned according to the picture below. For different
installations, please contact the Technical Department.

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

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

The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably-

the combustion chamber.

respect to the tube bundle plate.

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C.I.B. UNIGAS - M039144CD

Keys

1 Burner
2 Fixing nut
3 Washer
4 Ceramic fibre plait
5 Stud bolt
7 Blast tube

4

1

223 4 56

MANUFACTURER

INSTALLER

spacer 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) Length of the flame tube in meters

c) Flame tube firing intensity in MW/m

3

d) Combustion chamber diameter (m)

Fig. 4 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.

Fig. 3

Fitting the burner to the boiler

To perform the installation, proceed as follows:
1 drill the furnace plateas decribed in paragraph (“Overall dimensions”);
2 place the burner towards the furnace plate: lift and move the burner by means of its eyebolts placed on the top side (see”Lifting and

moving the burner”);
3 screw the stud bolts (5) in the plate holes, according to the burner’s drilling plate described on paragraph “Overall dimensions”;
4 place the ceramic fibre plait on the burner flange;
5 install the burner into the boiler;
6 fix the burner to the stud bolts, by means of the fixing nuts, according to the picture below.
7 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).

;

Pilot gas train

Fig. 4

Key

1 Burner
2 Gas valves
3 Minimum gas pressure switch
4 Gas pressure governor with filter
5 Bellow joint
6 Manual cutoff valve

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C.I.B. UNIGAS - M039144CD

connection to the gas supply network

The pilot gas train is already installed into the burner, the connection from the filter with stabiliser to the gas supply network must be
carried out.

Once the gas train in installed, execute the electrical connections for all its items (gas valves group, pressure switch).

ATTENTION: once the gas train is mounted according to the diagram on Fig. 4, the gas proving test mus be performed,
according to the procedure set by the laws in force.

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C.I.B. UNIGAS - M039144CD

From tank

To tank

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.

ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be
sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the
“Electrical connections” section.

WARNING: The burner is provided with an electrical bridge between terminals 6 and 7; when connecting the high/
low flame thermostat, remove this bridge before connecting the thermostat.

IMPORTANT: Connecting electrical supply wires to the burner teminal block MA, be sure that the ground wire is
longer than phase and neutral ones.

To connect the burner, please refer to the wiring diagram.
To execute the electrical connections, proceed as follows:
1 remove the cover from the electrical board, unscrewing the fixing screws;
2 execute the electrical connections to the supply terminal board as shown in the attached wiring diagrams,
3 check the direction of the fan motor and pump motor (see next pargraph)
4 refit the panel cover

CAUTION: adjust the thermal cut-out according to the motor rated current value.

Rotation of fan motor and pump motor

Once the burner’s electrical connection is accomplished, remember to check the rotation of the fan and pump motors. The motor
should rotate in counterclockwise direction looking at motor’s cooling fan. In case of incorrect rotation, reverse the three-phase supply
and check again the rotation of the motor.

Installation diagram of light oil pipes

PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL.

Fig. 5 - Double-pipe system

The burner is supplied with filter and flexible hoses, all the parts upstream the filter and downstream the return flexible hose, 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 (*)
6 Gate valve
7 Quick-closing gate-valve (outside the tank or boiler rooms)

(*) Only for installations with gravity, siphon or forced
circulation feed systems. If the device installed is a
solenoid valve, a timer must be installed to delay the
valve closing.
The direct connection of the device without a timer
may cause pump breaks.

12