Unigas RG515, RG93, RG520, RG525, RG510 Manual Of Installation - Use - Maintenance
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MANUAL OF INSTALLATION - USE - MAINTENANCE
RG91 - RG92 - RG93
RG510 - RG515
RG520 - RG525
Progressive - Fully modulating
Light oil burners
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -
ГОРЕЛКИ
M039214CC Rel. 2. 11/2010
TABLE OF CONTENTS
WARNINGS ................................................................................................................................................................ 3
PART I: INSTALLATION ........................................................................................................................................... 5
GENERAL FEATURES ................................................................................................................................................................... 5
How to interpret the burner’s “Performance curve” ......................................................................................................................... 6
Technical specifications .................................................................................................................................................................. 7
Performance curves ........................................................................................................................................................................ 8
Overall dimensions ......................................................................................................................................................................... 9
MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 11
Packing ......................................................................................................................................................................................... 11
Fitting the burner to the boiler ....................................................................................................................................................... 11
Handling the burner ...................................................................................................................................................................... 12
Hydraulic diagrams for light oil supplying circuits ......................................................................................................................... 12
Installation diagram of light oil pipes ............................................................................................................................................. 13
About the use of fuel pumps ......................................................................................................................................................... 14
Light oil pumps .............................................................................................................................................................................. 15
Suntec TV Pressure governor ....................................................................................................................................................... 15
Assembling the light oil flexible hoses .......................................................................................................................................... 16
Oil circuit ....................................................................................................................................................................................... 17
Electrical connections diagram ..................................................................................................................................................... 19
Fan motor and pump motor rotation ............................................................................................................................................. 19
ADJUSTING AIR AND LIGHT OIL FLOW RATE ......................................................................................................................... 20
Light oil nozzles ............................................................................................................................................................................ 20
Adjustments - brief description ...................................................................................................................................................... 22
Adjustment procedure ................................................................................................................................................................... 22
Oil Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator ....................................................................... 22
Adjustment by the Siemens SQL33.. actuator .............................................................................................................................. 25
Fully modulating burners ............................................................................................................................................................... 28
Calibration of air pressure switch .................................................................................................................................................. 28
PART II: OPERATION ............................................................................................................................................. 29
OPERATION ................................................................................................................................................................................. 30
Burner control panel ...................................................................................................................................................................... 30
PART III: MAINTENANCE....................................................................................................................................... 31
ROUTINE MAINTENANCE ........................................................................................................................................................... 31
Light oil filter maintenance ............................................................................................................................................................ 31
Removing the combustion head ................................................................................................................................................... 32
Removing the oil gun .................................................................................................................................................................... 32
Correct position of electrodes and combustion head .................................................................................................................... 33
Replacing the ignition electrodes .................................................................................................................................................. 33
Cleaning and replacing the detection photoresistor ...................................................................................................................... 33
Seasonal stop ............................................................................................................................................................................... 34
Burner disposal ............................................................................................................................................................................. 34
TROUBLESHOOTING.................................................................................................................................................................. 35
SPARE PARTS ............................................................................................................................................................................. 36
BURNER EXPLODED VIEW ......................................................................................................................................................... 38
ELECTRICAL WIRING DIAGRAMS ............................................................................................................................................. 40
APPENDIX
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
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 ca
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
ution with 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/E
C on electromagnetic compatibility
Heavy oil burners
Gas - Light oil burners
Gas - Heavy oil burners
;
4
GENERAL FEATURES
PART I: INSTALLATION
10
11
5
7
6
4
32 1
8
9
12
The burners of this series represent monoblock burners made in die-cast aluminium housing with relative flange to work on heating
generators. The maximum output range is from 2100kW to 8000kW (according to the model).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 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).
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.
5
How to interpret the burner’s “Performance curve”
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
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 RG520 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 * - see data plate*
(6) BURNER VERSION
RG91 - RG92 - RG93 - RG510 - RG515 - RG520 - RG525
G - Light oil
PR - Progressive MD - Fully modulating
A - Standard
6
Technical specifications
BURNERS RG91 RG92 RG93
Output min. -max. kW 698 - 2093 849 - 2558 550 - 4100
Light oil rate min. -max. kg/h 59 - 176 72 - 215 46 - 345
Fuel Light oil
Viscosity cSt @ 40 °C 2 - 7.4
Density
Oil train pressure inlet
Power supply 400V 3N ~ 50Hz
Fan motor kW 4 5.5 7.5
Pump motor kW 1.1 1.1 1.1
Total power consumption kW 5.6 7.0 9.0
Index of protection
Approx. weight kg 220 220 230
Operation
Operating temperature °C -10 ÷ +50
Storage temperature °C -20 ÷ +60
Working service * Intermittent
kg/m
3
840
bar max 4
IP40
Progressive - Fully modulating
BURNERS RG510 RG515 RG520 RG525
Output min. -max. kW 1314 - 3953 1628 - 4884 2326 - 6977 2000 - 8000
Fuel Light oil
Light oil rate min. -max. kg/h 111 - 333 137 - 411 196 - 588 169 - 674
Viscosity cSt @ 40 °C 2 - 7.4
Density
Oil train pressure inlet
kg/m
3
840
bar max 4
Power supply 400V 3N ~ 50Hz
Electric motor kW 7.5 11 15 18.5
Pump motor kW 1.1 1.5 1.5 3
Total power consumption kW 9.1 13 17 22
Operation
Index of protection
Progressive - Fully modulating
IP40
Operating temperature °C -10 ÷ +50
Storage temperature °C -20 ÷ +60
Working service * Intermittent
*NOTE ON THE BURNER WORKING SERVICE: for safety reasons, one controlled shutdown must be performed after 24 hours
of intermittent operation.
NOTE: Choosing the nozzle for light oil, consider Hi equal to 42.8MJ/kg.
7
Performance curves
0
2
4
6
8
10
12
14
16
18
400 800 1200 1600 2000 2400
0
2
4
6
8
10
12
14
16
18
400 800 1200 1600 2000 2400 2800
0
2
4
6
8
10
12
14
16
0 500 1000 1500 2000 2500 3000 3500 4000 4500
0
4
8
12
16
20
24
1000 1800 2600 3400 4200
0
4
8
12
16
20
24
1200 2000 2800 3600 4400 5200
0
4
8
12
16
20
24
2000 2800 3600 4400 5200 6000 6800 7600
0
4
8
12
16
20
24
1500 2500 3500 4500 5500 6500 7500 8500
RG91
PRESSURE IN
COMBUSTION CHAMBER mbar
RG93
PRESSURE IN
COMBUSTION CHAMBER mbar
RG510
kW
kW
RG92
kW
RG515
PRESSURE IN
COMBUSTION CHAMBER mbar
RG520
PRESSURE IN
COMBUSTION CHAMBER mbar
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.
kW
kW
kW
RG525
kW
8
Overall dimensions (mm)
boiler recommended drilling template
burner flange
9
A (AS) A (AL)
RG91 1345 1518 242 820 421 35 380 300 473 419 1045 422 419 434 238 268 360 513 M12 417 280 310 295 698 228 185
RG92 1339 1512 242 820 421 35 380 294 467 419 1045 422 419 434 266 296 360 513 M12 417 280 310 295 698 228 185
RG93 1339 1512 242 820 421 35 380 294 467 460 1045 422 460 434 266 296 360 513 M12 417 280 310 295 698 228 185
*AS/BS: measure referred to burner with standard blast tube provided
*AL/BL: measure referred to burner with extended blast tube provided
AA AB AC AD AE
B (BS) B (BL)
BB C CC E F G H K L M N Omin Omax P W Y Z
10
recommended boiler drilling
burner flange
A (AS) A (AL)
RG510 1451 1671 219 217 246 35 310 530 468 1141 571 1313 671 642 329 369 540 496 M14 552 390 390 x 766 328 270
RG515 1451 1671 219 217 246 35 310 530 508 1141 571 1323 681 642 350 390 540 496 M14 552 390 390 x 766 328 270
RG520 1451 1671 219 207 250 35 310 530 508 1141 571 1323 681 642 370 410 540 496 M14 552 390 390 114 880 328 270
RG525 1511 1691 219 197 275 35 350 530 650 1161 571 1341 698 642 434 484 540 496 M14 552 390 390 172 938 434 270
*AS/BS: measure referred to burner with standard blast tube provided
*AL/BL: measure referred to burner with extended blast tube provided
AA AB AC AD
B (BS) B (BL)
BB C CC D E F G H K L M N O P UU W Y Z
MOUNTINGS AND CONNECTIONS
H
P
L
Keys
1 Burner
2 Fixing nut
3Washer
4 Ceramic fibre plait
5 Stud bolt
7Blast tube
SIDE UP
SIDE
DOWN
Packing
The burners are dispatched in wooden packages whose dimensions are:
series 9x: 1720 mm x 1270 mm x 1020 mm (L x P x H)
series 5xx: 1800 mm x 1500 mm x 1300 mm (L x P x H)
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing case.
burner;
light oil flexible hoses;
light oil filter;
gasket to be inserted between the burner and the boiler;
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), according to the burner’s drilling plate described on paragraph “Overall dimensions”;
4 fasten the 4 stud bolts;
5 place the ceramic fibre plait 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).
The burner is designed to work positioned according to the picture below. For different installations, please contact the Technical
Department.
11
Handling the burner
A
B
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”).
The unpacked burner must be lifted and moved only by means of a fork lift truck.
The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck: the forks must be inserted into the A
anb B ways. Remove the stirrup only once the burner is installed to the boiler.
Hydraulic diagrams for light oil supplying circuits
Fig. 3 - Gravity circuit
Fig. 4 - Ring circuit
12
Fig. 5 - Suction circuit
From tank
To tank
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 - Fig. 6).
Installation diagram of light oil pipes
PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL.
Fig. 6 - 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 (*)
(*) 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.
6 Gate valve
7 Quick-closing gate-valve (outside the tank or boiler rooms)
The pumps that are used 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 pulg, 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 pum’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 come out from the factory provided for double-stage systems. They can be suited for single-pipe system (recommended in the
case of gravity feed) as decribed before.
13
Suntec TA Pumps
G
G
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 T Pump
The bypass plug inserted between the pressure-side and shaft seal is only intended to change the pump rotation, check the presence
of this plug by means of a 4 mm Allen key in the pressure outlet of the pump.
Caution: changing the direction of pump rotation involves changing of all pump connections.
Bleed
Bleeding in two-pipe operation is automatic : it is assured by a bleed flat on the piston. In one-pipe operation, the plug of a pressure
gauge port must be loosened until the air is evacuated from the system.
About the use of fuel pumps
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.
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.
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.
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.
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.
Pipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal jun-
ctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of jun-
ctions should be kept to a minimum as they are a possible source of leakage.
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.
An external filter should always be installed in the suction line upstream of the fuel unit.
14
Light oil pumps
The pumps provided with these burners are Suntec TA (except mod. RG525).
RG525: Suntec T pump and Suntec TV pressure governor are provided.
Suntec TA..
Oil viscosity 3 ÷ 75 cSt
Oil temperature 0 ÷ 150°C
Min. suction pressure - 0.45 bar to avoid gasing
Max. suction pressure 5 bar
Max. return pressure 5 bar
Rotation speed 3600 rpm max.
1 Inlet G1/2
2 To the nozzle G1/2
3 Return G1/2
4 Pressure gauge port G1/4
5 Vacuum gauge port G1/4
6 Pressure governor
Suntec T..
Viscosity 3 - 75 cSt
Oil temperature 0 - 150 °C
Minimum suction pressure - 0.45 bar to prevent gasing
Maximum suction pressure 5 bar
Rated speed 3600 rpm max.
Key
1 Inlet G3/4
2 Pressure gauge port G1/4
3 Vacuum gauge port to measure the inlet vacuum G1/4
4 To pressure adjusting valve G3/4
"Note: pump with “C” rotation.
Suntec TV Pressure governor
Pressure adjustment
Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase pressure,
twist adjusting screw 3 clockwise.
To decrease the pressure, twist screw counterclockwise. Tight the lock nut 4, refit the
gasket 2 and the cap nut 1.
Key
1Cap nut
2 Gasket
3 Adjusting screw
4 Lock nut
5 Gasket
Fig. 7
15
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