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

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.

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

;

GENERAL FEATURES

PART I: INSTALLATION

32 1

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.

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

100 200 300 400 500 600 700 800 900

Pote nza kW

Contropressione in camera di

combustione mbar

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

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

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

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.

Performance curves

400 800 1200 1600 2000 2400

400 800 1200 1600 2000 2400 2800

0 500 1000 1500 2000 2500 3000 3500 4000 4500

1000 1800 2600 3400 4200

1200 2000 2800 3600 4400 5200

2000 2800 3600 4400 5200 6000 6800 7600

1500 2500 3500 4500 5500 6500 7500 8500

RG91

PRESSURE IN

COMBUSTION CHAMBER mbar

RG93

PRESSURE IN

COMBUSTION CHAMBER mbar

RG510

RG92

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.

RG525

Overall dimensions (mm)

boiler recommended drilling template

burner flange

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

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

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.

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”).

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

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.

Suntec TA Pumps



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.

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

Assembling 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 TA. Suntec T..

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 stops the fuel immission into the combustion chamber. The fuel flow rate that is not burnt goes back to the tank through the return circuit. The spill-back nozzle is feeded at constant pressure, while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam. The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set (see prevoius paragraph).

Fig. 8 - Stand-by

Fig. 9 - Prepurge

Fig. 10 - Low flame

Fig. 11 - High flame

Key

1 Light oil pump

2 Light oil solenoid valve 3 Nozzle 4 Adjusting cam 5 Pressure gauge 6 Pressure governor

RG525

Oil circuit

Fig. 12 - Stand-by

Fig. 13 - Prepurge

Fig. 14 - Low flame

Fig. 15 - High flame

Key

1Oil pump

2 Oil solenoid valve 3 Nozzle 4 Adjusting cam 5 Pressure gauge 6 Pressure governor

Electrical connections diagram

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.

 Remove the cover of the electrical board mounted on the burner.  Execute the electrical connections to the power supply terminal board as shown here following, check the direction of the fan

motor and the pump motor - see note at the end of page and refit the cover of the electrical board.

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. 16

Fully-modulating burners

Probes connection

Fig. 18

Probes connection by means of the 7-pins plug (Fig. 19) - see Fig. 17 and the ELECTRIC WIRING DIAGRAMS for connections.

Fig. 19

Fig. 17

Fan motor and pump motor rotation

Once the electrical connection of the burner is executed, remember to check the rotation of the motor. The motor should rotate according to the direction shown by the “Arrow” attache to the body. In the event of wrong rotation, reverse the three-phase supply and check again the rotation of the motor.

NOTE (except for motors with “star-delta” start up): 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.

ADJUSTING AIR AND LIGHT OIL FLOW RATE

FLOW RATE kg/h

DIMENSIONS Min Max

40 13 40

50 16 50

60 20 60

70 23 70

80 26 80

90 30 90

100 33 100

115 38 115

130 43 130

145 48 145

160 53 160

180 59 180

200 66 200

225 74 225

250 82 250

275 91 275

300 99 300

330 109 330

360 119 360

400 132 400

450 148 450

500 165 500

550 181 550

600 198 600

650 214 650

700 231 700

750 250 750

800 267 800

Pressure at nozzle 357psi

Pressure on return

Up to 100kg/h

Over 100kg/h

% Flow rate

Pressure at nozzle 25bar

Atomisation angle

Light oil nozzles

The light oil flow rate can be adjusted choosing a nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the chart below and the diagram on Fig. 20 (as far as reading the pressure values, see next paragraphs).

NOZZLE

NOZZLE SUPPLY

PRESSURE (bar)

HIGH FLAME

RETURN PRESSURE (bar)

LOW FLAME

RETURN PRESSURE (bar)

BERGONZO A3 20 11 - 13 5 (recommended))

FLUIDICS WR2/UNIGAS M3 25

19 - 20

7 (recommended)

Example: as far as over 100kg/h nozzle the 80% of the nozzle rated flow rate is achieved with 18bar return pressure (see Fig. 20).

Tab. 1

Fig. 20

---------------Atomisation angle according to the return pressure _________ % Flow rate

Fig. 21

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 fuel decrease slowly until the normal combustion values are achieved.

IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:

Recommended combustion parameters

Fuel

Recommended (%) CO

Recommended (%) O2

Light oil 11.5 ÷ 13 2.9 ÷ 4.9

Adjustments - brief description

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.

 Check that the combustion parameters are in the suggested limits.  Check the nozzle flow rate.  Then, adjust the combustion values corresponding to the points between maximum and minimum: set the shape of the adjusting

cam foil. The adjusting cam sets the air/fuel ratio in those points, regulating the opening-closing of the fuel governor.

 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. Siemens SQM40.., Berger STM30.. or mod. Siemens SQL..).

Oil Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator

1 Check the fan motor rotation (see page 19).

2 with the electrical panel open, prime the oil pump acting directly on the related CP contactor (see next picture): check the pump

motor rotation and keep pressing for some seconds until the oil circuit is charged;

3 bleed the air from the M pressure gauge port (Fig. 22) by loosing the cap without removing it, then release the contactor.

Suntec TA. Suntec T..

Fig. 22

4 Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner ope-

rates at the lowest output) to achieve safely the high flame stage . 5 Turn the burner on by means of its main switch A: if the burner locks (LED B on in the control panel) press the RESET button (C)

on the control panel (see next picture) - see chapter “OPERATION” on page 30.

6 ;start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end;

MAN-AUTO

mensions

Dimensions in

SQM4...

III

VIVI

III

MAN-AUTO

Pressure gauge port

7 drive the burner to high flame stage, by means fo the thermostat TAB (as far as fully-modulating burners, see the related para-

graph). 8 Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion

values and eventually adjusting the oil pressure (see next step).

Actuator cams

I High flame II Stand-by and Ignition III Low flame

Berger STM30

9 the nozzle suplly pressureis already factory-set and must not be changed. Only if necessary, adjust the supply pressure as follows

(see related paragraph); insert a pressure gauge into the port shown on Fig. 23 and act on on the pump adjusting screw VR (see

Fig. 22) as to get the nozzle pressure at 25bar (Fluidics nozzles - see diagram on page 20).

10 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge) without changing the air flow

rate set during the gas operation adjustments (see prevoius paragraph): checking always the combustion parameters, the adjustment is to

be performed by means of the SV adjusting cam screw (see picture) when the cam has reached the high flame position. 11 To adjust the air flow rate in the high flame stage, loose the RA nut and screw VRA as to get the desired air flow rate: moving

Siemens SQM40

Fig. 23 Fig. 24

the rod TR towards the air damper shaft, the air damper opens and consequently the air flow rate increases, moving it far from the

VRA

”MIN” position

”MAX” position

VRT

shaft the air damper closes and the air flow rate decreases.

Note: once the procedure is perfomed, be sure that the blocking nut RA is fasten. Do not change the position of the air damper

rods.

12 Only if necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move

progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when

the adjustment is accomplished.

Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above.

13 the air and oil rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV adjusting

cam as to reach the minimum output point.

14 as for the point-to-point regulation in order to set the cam foil shape, move the low flame microswitch (cam III) a little lower than the

maximum position (90°); 15 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position; 16 move cam III (low flame) towards the minimum to move the actuator towards the low flame until the two bearings find the adjusting

screw that refers to a lower position: screw V to increase the rate, unscrew to decrease, in order to get the pressure as shown on

diagram in Fig. 20, according to the requested rate. 17 Move again cam III towards the minimum to meet the next screw on the adjusting cam and repeat the previous step; go on this way

as to reach the desired low flame point. 18 The low flame position must never match the ignition position that is why cam III must be set 20°- 30° more than the ignition posi-

tion. Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps.

Adjustment by the Siemens SQL33.. actuator

MAN

AUT

1 Check the fan motor rotation (see page 19). 2 owith the electrical panel open, prime the oil pump acting directly on the related CP contactor (see next picture): check the pump

motor rotation and keep pressing for some seconds until the oil circuit is charged;

3 bleed the air from the M pressure gauge port (Fig. 25) by loosing the cap without removing it, then release the contactor.

Suntec TA. Suntec T..

Fig. 25

4 Turn the burner on by means of its main switch A: if the burner locks (LED B on in the control panel) press the RESET button (C)

on the control panel (see next picture) - see chapter “OPERATION” on page 30.

SQL330.. actuator cams

F = plastic clamp A = cam locking lever S = cam locking lever

BF = Low flame cam

5 Start the burner up by means of the thermostat series and wait unitl the pre-purge phase comes to end; 6 the burner starts up with the actuator on the ignition position, set it to the MAN (manual mode), by the MAN/AUTO selector (ignition

position= read on the air damper index ID1 - see picture on page 24); 7 disconnect the TAB thermostat removing the wire from the terminal no. 6 or by setting MAN on the RWF40 modulator or by setting

0 by means of the CMF switch (only for fully-modulating burners); 8 set the actuator on the manual mode (MAN) by means of the MAN/AUTO switch (see next pictures).

9 manually drive the adjusting cam SV to the high flame position and set the actuator to the AUTO mode (by the related switch - see

Pressure gauge port

VRA

”MIN” position

”MAX” position

VRT

picture) to lock the adjusting cam. 10 the nozzle supply pressureis already factory-set and must not be changed. Only if necessary, adjust the supply pressure as fol-

lows (see related paragraph);insert a pressure gauge into the port shown on Fig. 21 and act on on the pump adjusting screw VR

(see Fig. 25) as to get the nozzle pressure at 25bar (Fluidics nozzles - see diagram on page 20).

Fig. 26 Fig. 27

11 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge) without changing the air

flow rate set during the gas operation adjustments (see prevoius paragraph): checking always the combustion parameters, the

adjustment is to be performed by means of the SV adjusting cam screw (see picture) when the cam has reached the high flame

position. 12 To adjust the air flow rate in the high flame stage, loose the RA nut and screw VRA as to get the desired air flow rate: moving

the rod TR towards the air damper shaft, the air damper opens and consequently the air flow rate increases, moving it far from the

shaft the air damper closes and the air flow rate decreases.

Note: once the procedure is perfomed, be sure that the blocking nut RA is fasten. Do not change the position of the air damper

rods.

13 Only if necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move

progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when

the adjustment is accomplished.

Attention! if it is necessary to change the head position, repeat the air and oil adjustments described above.

14 once the air and oil flow rate have been adjusted at the maximum output, go on with the point to point adjustment on the SV adju-

sting cam as to reach the minimum output point: gradually move the adjusting cam in order to adjust each of the V screws as to

describe the cam foil shape.

15 to change the SV position set the actuator on the manual mode (MAN), turn the adjusting cam SV and set again the actuator to the

AUTO mode to lock the adjusting cam; 16 act on the V screw that mathces the bearings referring to the adjusting cam position; 17 to adjust the next screw, set again the actuator mode to MAN, turn the adjusting cam and set the actuator to AUTO mode to lock

the adjusting cam on the next screw; adjust it and go on this way to adjust all the screws in order to set the cam foil shape, accor-

ding to the combustion values read. 18 Once the cam foil shape is defined, reconnect the TAB thermostat reconnecting the wire to the terminal no.6 or setting the RWF40

burner modulator to AUTO or the CMF switch to 3 (only for fully-modulating burner). 19 Turn the burner off then start it up again. 20 Once the pre-purge time comes to end, drive the burner to the high flame stage by the TAB thermostat: check the combustion

values; 21 drive the burner to low flame, if necessary adjust the low flame size (output) by inserting a screwdriver on the slot FA to move the

BF cam.

22 The low flame position must never match the ignition position that is why cam BF must be set 20°- 30° more than the ignition posi-

tion.

NOTE: to change the low flame position, act exclusively on the actuator cam.

Now adjust the pressure switch (see page 28).

Fully modulating burners

CMF

CMF = 0 stop at current position CMF = 1 high flame operation CMF = 2 low flame operation CMF = 3 automatic operation

To adjust the fully-modulating burners, use the CMF switch on the burner control panel (see next picture), instead of the TAB thermostat as described on the previous paragraphs about the progressive burners. Go on adjusting the burner as described before, paying attention to use the CMF switch intead of TAB.

The CMF position sets the oprating stages: to drive the burner to the high-flame stage, set CMF=1; to drive it to the low-flame stage, set CMF=2.

To move the adjusting cam set CMF=1 and then CMF=0. For further information about the regulating modulator, see the attached manual.

Calibration of air pressure switch (when provided)

To calibrate the air pressure switch, proceed as follows:

 Remove the transparent plastic cap.  Once air and gas setting have been accomplished, startup the burner.  During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout,

then read the value on the pressure switch scale and set it to a value reduced by 15%.

 Repeat the ignition cycle of the burner and check it runs properly.  Refit the transparent plastic cover on the pressure switch.

LIMITATIONS OF USE

PART II: OPERATION

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.

THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER.

A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER.

THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER).

NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.

OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON.

IN CASE OF A BURNER SHUT-DOWN, RESET 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.

WARNING: DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR (COUPLING FLANGE) CAN BECOME VERY HOT, AVOID TOUCHING THEM SO AS NOT TO GET BURNT.

OPERATION

EHGF

ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open. Be sure that the mains switch is closed.

1 Set to the ON position the switch A on the control panel of the burner. 2 Check the control box is not in the lockout position (light B must be off); in such a case reset it by the reset pushbutton C. 3 Check that the series of thermostats (or pressure switches) enables the burner to operate. 4 The startup sequence begins: the control box ignites the fan motor and energises the ignition transformer as well (signalled by the

light H on the burner control panel). 5 At the end of the pre-purge stage, the light oil solenoid valve EVG1 is energised (signalled by the lamp G on the control panel) and

the burner is on. 6 The ignition transformer is energized for few seconds after the ignition of the flame (post-ignition time) and at the end of this time is

de-energised (light H off). 7 After the ignition the actuator moves to the high flame position for some seconds, then the operation begins and the burner

switches to high flame or to low flame, according to the plant demand. 8 The high/low flame operation is shown by the F LED turning on/off.

Burner control panel

Keys

A ON-OFF main switch B Lockout signalling lamp C Conreol box release pushbutton D Signalling lamp for light oil solenoid valve opening E Thermal cutout intervention signalling lamp F High flame operation signalling lamp G Low flame operation signalling lamp H Ignition transformer operation signalling lamp P Siemens modulator Q Manual operation mode switch

Fig. 28

At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry

PART III: MAINTENANCE

out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6 months.

WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED!

ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL..

ROUTINE MAINTENANCE

 Check and clean the cartdrige of the fuel filter, replace it if necessary (see next paragraph);  carefully check the fuel flexible hoses for leaks;  check and clean the filter on the fuel pump: bilter must be thoroughly cleaned at least once in a season to ensure correct working of

the fuel unit. To remove the filter, unscrew the four screws on the cover. When reassemble, make sure that the filter is mounted

with the feet toward the pump body. If the gasket between cover and pump housing should be damaged, it must be replaced;

 remove, check and clean the combustion head (page 32); when reassembling, carefully observe the measures on page 33;  check the ignition electrodes and their ceramic insulators, clean, adjust and replace if necessary page 33;  remove and clean the oil nozzles (IMPORTANT: do not clean the nozzles using metallic or sharp utensils, use only solvents or

steam); at the end of maintenance operations, refit the burner, turn it on and check the combustion. If in doubt, replace the defec-

tive nozzle/s. In case of intensive use of the burner, the nozzles must be replaced at the end of the working season;

 check and carefully clean the flame detection photoresistor, if necessary replace it and, if in doubt, check the detection current fol-

lowing the scheme in Fig. 30;

 clean and grease levers and rotating parts.

Light oil filter maintenance

For correct and proper servicing, proceed as follows: 1 shut off fuel in the line section being serviced; 2 unscrew the tray; 3 remove the filter cartridge from its support and wash it with petrol or replace if necessary; check seal O-Ring, replace if necessary; 4 reassemble the tray and restore fuel flow.

Removing the combustion head

VRT

1 Remove the top cover C; 2 remove the photoresistor from its seat; 3 unscrew the revolving connectors (E in figure) on the fuel pipes (use 2 spanners to avoid loosening the connections attached to the

distributor block); 4 loosen VRT screw to free the threaded rod AR, then screw out the 2 screws V holding the washer R and the screw VRT again; 5 remove the whole assembly as shown in figure; 6 clean the combustion head by means of a vacuum cleaner; to scrape off the scale use a metallic brush. Note: to replace the combustion head reverse the procedure described above.

Removing the oil gun

Once the combustion head is removed, as described before, remove the oil gun as foloows: 1 unscrew the connectors from the oil pipes (E in figure) using 2 spanners to avoid loosening the connections attached to the distri-

butor block); 2 loosen the screw VB 3 remove the gun with the light oil nozzle holder. 4 clean the oil gun by means of a vacuum cleaner; to scrape off the scale use a metallic brush 5 replace the oil gun, if necessary.

Note: To re-assemble, follow the procedure above in reversed order.

Correct position of electrodes and combustion head

ATTENTION: avoid the ignition electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head.

To guarantee a good ignition the measures (in mm) shown on the next pictures must be observed. Be sure to tight the screw on the electrodes group before reassembling the combustion head.

series 91-92: 5 series 93-5xx: 8 - 10

Fig. 29

Replacing the ignition electrodes

To replace the ignition electrodes, proceed as follows: 1 remove the burner cover; 2 disconnect the electrodes cables; 3 remove the combustion head (see par. “Removing the combustion head”); 4 loose screw (B) that fasten the ignition electrodes; 5 remove the electrodes and replace them, referring to the values quoted on Fig. 29.

Cleaning and replacing the detection photoresistor

When cleaning the photoresistive detector, always use a clean cloth. If necessary, remove it from its slot to replace it.

Checking the detection current

MC TERMINAL BLOCK

34 35

SCALE

µA DC

To measure the detection signal follow the diagram in Fig. 30. If the signal is not in the advised range, check the electrical contacts, the cleaning of the combustion head, the position of the photoresistor and if necessary replace it.

series 9x: LMO series 5xx: LAL25

Minimum current intensity with flame LMO: 45µA

LAL25: 8µA

Maximum current intensity without flame: LMO: 5.5µA LAL25: 0.8µA

Maximum possible current intensit with flame: LMO: 100µA

Fig. 30

LAL25: 30µA

Seasonal stop

To stop the burner in the seasonal stop, proceed as follows: 1 turn the burner main switch to 0 (Off position) 2 disconnect the power mains 3 close the fuel valve of the supply line

Burner disposal

In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”.

TROUBLESHOOTING

MAIN SWITCH OPEN

LINE FUSE INTERVENTION

MAX. PRESSURE SWITCH FAULT

FAN THERMAL CUTOUT INTERVENTION

AUXILIARY RELAIS FUSES INTERVENTION

CONTROL BOX FAULT

SERVOCONTROL FAULT

SMOKEY FLAME

IGNITION TRANSFORMER FAULT

IGNITION ELECTRODE DIRTY OR WRONG POSITIONED

DIRTY NOZZLE

FUEL SOLENOID VALVE DEFECTIVE

PHOTORESISTOR DIRTY OR DEFECTIVE

HI-LO FLAME THERMOSTAT DEFECTIVE

WRONG POSITION OF SERVOCONTROL CAMS

FUEL PRESSURE TOO LOW

PURGE

THE BURNER

DOESN’T START

REPEATS PRE-

STOPS

AND STOPS

THE BURNER

NOISY FUEL PUMP

DOESN’T START

STARTS AND

THE BURNER

TO HIGH FLAME

DOESN’T SWITCH

OPERATION

THE BURNER

STOPS DURING

RATION

AND REPEATS THE

THE BURNER STOPS

CYCLE DURING OPE-

       







 





DIRTY FUEL FILTERS

 

SPARE PARTS

Desription Code

CONTROL BOX

IGNITION ELECTRODES

FUEL FILTER

GASKET

FAN WHEEL

AIR PRESSURE SWITCH

IGNITION TRANSFORMER

FAN MOTOR

PUMP MOTOR

SOLENOID VALVE

FLEXIBLE HOSESL = 1500 1”MX

FLEXIBLE HOSES L = 335 3/8”

FLEXIBLE HOSES L = 385 3/8”

ADJUSTING CAM FOIL

ACTUATOR mod. SIEMENS SQL..

ACTUATOR mod. BERGER STM30..

ACTUATOR mod. SIEMENS SQM40..

PHOTORESISTOR mod. SIEMENS QRB..

COUPLING

PRESSURE GOVERNOR

BURNER MODULATOR

PUMP mod. SUNTEC

NOZZLE mod. BERGONZO A3

NOZZLE mod. FLUIDICS WR2 50°

NOZZLE mod. UNIGAS M3 45°

OIL GUN (standard)

OIL GUN (extended)

COMBUSTION HEAD

BLAST TUBE (standard)

BLAST TUBE (extended)

IGNITION CABLES

RG91 RG92 RG93

2020455 2020455 2020455

2080206 2080206 2080206

2090018 2090018 2090018

2110048 2110048 2110048

2150031 2150033 2150032

2160065 2160065 2160065

2170302 2170302 2170302

2180276 2180277 2180206

2180202 2180202 2180202

2190403 2190403 2190403

2340004 2340004 2340004

2340087 2340087 2340087

2340088 2340088 2340088

2440013 2440013 2440013

2480040 2480040 2480007

2480090 2480090 2480090

24800A5 24800A5 24800A5

2510003 2510003 2510003

2540019 2540019 2540019

2570054 2570054 2570077

2570112 2570112 2570112

2590118 2590119 2590120

2610202 2610202 -

- - 2610203

- - 2610230

2700217 2700217 27002xx

2700223 2700223 27002xx

3060160 3060161 3060161

30910C5 30910C6 30910C6

3091082 3091084 3091084

6050129 6050129 6050129

NOTE: it is recommended to mention the burner ID number on the spare parts request form.

Desription Code

CONTROL BOX

IGNITION ELECTRODES

FUEL FILTER

FAN WHEEL

AIR PRESSURE SWITCH

IGNITION TRANSFORMER

PUMP MOTOR

FAN MOTOR

SOLENOID VALVE

FLEXIBLE HOSES L = 1500 1”

FLEXIBLE HOSES L = 335 3/8”

FLEXIBLE HOSES L = 385 3/8”

FLEXIBLE HOSES L = 435 3/8”

ADJUSTING CAM FOIL (with BG PRO governor)

ADJUSTING CAM FOIL(with BGH PRO governor)

ACTUATOR mod. SIEMENS SQL..

ACTUATORL mod. BERGER STM30..

ACTUATORL mod. SIEMENS SQM40..

PHOTORESISTOR mod. SIEMENS QRB..

MOTOR-PUMP COUPLING

PRESSURE GOVERNOR

PUMP mod. SUNTEC

NOZZLE mod. FLUIDICS WR2

NOZZLE mod. UNIGAS M3 45°

OIL GUN (standard)

OIL GUN (long)

COMBUSTION HEAD

BLAST TUBE (standard)

BLAST TUBE (extended)

IGNITION CABLES

RG510 RG515 RG520 RG525

2020420 2020420 2020420 2020420

2080206 2080206 2080206 2080291

2090018 2090018 2090018 2090018

2150010 2150030 2150029 2150029

2160065 2160065 2160065 2160065

2170302 2170302 2170302

2180202 2180223 2180223

2180206 2180209 2180278

2170302

2180219

2180289

2190403 2190403 2190437 2190437

2340004 2340004 2340004 2340004

2340087 2340087 2340087 2340087

2340088 2340088 2340088 2340088

- - 2340089 2340089

2440013 2440013 2440013

---

2440013

2440054 2480007 2480007 2480007 2480007

2480090 2480090 2480090 2480090

24800A5 24800A5 24800A5 24800A5

2510003 2510003 2510003 2510003 2540019 2540126 2540126 2540133

25700B9 25700C0 25700C0

2570008 (BG PRO)

25700A7 (BGH PRO)

2590120 2590121 2590121 2590124

2610203 2610203 2610203 2610203

2610230 2610230 2610230 2610230

2700225 2700225 2700253 2700253

2700224 2700224 2700254 2700255

3060163 3060164 3060165 30601D2

30910R8 30910R9 30910S0 30910T2

30910S1 30910S2 30910S3 30910T1

6050144 6050144 6050129 6050112

NOTE: it is recommended to mention the burner ID number on the spare parts request form.

BURNER EXPLODED VIEWД

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

1 FLANGE 10 STANDARD BLAST TUBE 14.2 OIL MANIFOLD

2 AIR INLET CONE 11 AIR DAMPER INDEX 14.3 CONNECTOR

3 CLOSING PLATE 12.1 NET 15.1 LONG IGNITION ELECTRODE

4 INDEX LABEL 12.2 MOTOR 15.2 OIL GUN HOLDER

5 RING NUT 12.3 COUPLING 15.3 COMBUSTION HEAD

6 PLATE 12.4 PUMP 15.4 COMBUSTION HEAD ADJUSTING PIPE

7 PLATE 12.5 BRACKET 15.5 IGNITION CABLE

8 PHOTORESISTOR 13.1 NET 15.6.1 NOZZLE

9.1 INDEX LABEL 13.2 BURNER HOUSING 15.6.2 NOZZLE HOLDER

9.2 BUSH 13.3 FLANGE 15.6.3.1 ONE-WAY VALVE

9.3 BUSH 13.4 CERAMIC FIBRE PLAIT 15.6.3.2 OIL MANIFOLD

9.4 ADJUSTING CAM SHAFT 13.5 PRESSURE PLUG 16.1 FAN WHEEL

9.5 ADJUSTING CAM 13.6 INLET 16.2 MOTOR

9.5.1 ADJUSTING CAM FOIL 13.7 SCREW 17.1 BOARD

9.6 ACTUATOR 13.8 INSPECTION GLASS 17.2 COVER

9.7 LEVERAGE 13.9 AIR PRESSURE SWITCH PIPE 17.3.1 POWER CONTROLLER

9.8 ROD 13.10.1 THREADED GAS PIPE 17.3.2 FRONT CONTROL PANEL

9.9 CAM 13.10.2 AIR PRESSURE SWITCH 17.3.3 LIGHT

9.10 ROD 13.10.3 PRESSURE SWITCH BRACKET 17.3.4 LIGHT

9.11 LEVERAGE 13.11.1 AIR DAMPER SILENCER 17.3.5 LOCK-OUT RESET BUTTON

9.12 PRESSURE GAUGE 13.11.2 AIR INTAKE DAMPER 17.3.6 PROTECTION

9.13 JOINT 13.11.3 ROD 17.3.7 SWITCH

9.14 JOINT 13.11.4 JOINT 17.3.8 SWITCH

9.15 JOINT 13.11.5 JOINT 18.1 CONTROL BOX

9.16 PRESSURE GOVERNOR 13.12.1 SPACER 18.2 CONTROL BOX SOCKET

9.17 BRACKET 13.12.2 SILENCER 18.3 IGNITION TRANSFORMER

9.18 BRACKET 13.12.3 SILENCER

9.19 BRACKET 14.1 OIL SOLENOID VALVE

ELECTRICAL WIRING DIAGRAMS

WIRING DIAGRAMS - Complete key

CMF Operation manual switch

CO Time counter (optional) EVG Light oil solenoid valve EVG1/2 Light oil solenoid valves FR Photoresistor FU Fuses FU1.0 Burner line fuse FU1.1 Oil pump line fuses FU1.2 Auxiliary fuse IG Main switch IL Auxiliary line switch KA2.2 Auxiliary relay KA3.2 Auxiliary relay KM1.8 Fan motor contactor KM1.9 Oil pump motor contactor KM2.6 Fan motor contactor (line) KM2.6D Fan motor contactor (delta) KM2.7S Fan motor contactor (star) KM2.8 Pump motor contactor KT2.7 Star/delta delayed relay LAF Burner in high flame signalling lamp LB Flame lockout signalling lamp LBF Burner in low flame signalling lamp LEVG EVG opening signalling lamp LS Burner stand-by signalling lamp LT Thermal cutout intervention signalling lamp LTA Ignition transformer signalling lamp MP Pump motor MV Fan motor PA Air pressure switch PS Control box reset pushbutton Pt100 Pt100 temperature probe SD-0/4÷20mA Probe connection with signal 0÷20mA / 4÷20mA SD-0÷10V Probe connection with signal 0÷10V SD-PRESS. Pressure probe SD-TEMP. Temperature probe SIEMENS LAL2.25 SIEMENS control box SIEMENS RWF40 ** SIEMENS modulator SQM/STM/SQL Air damper actuator ST Thermostats or pressure switches serie TA Ignition transformer TAB High-low flame thermostat (if fitted remove the connection between terminals 6 and 7 on terminal block MA) TC Thermocoupling connection TP Pump motor thermal cutout TV Fan motor thermal cutout

0) stop - 1) high flame - 2) low flame - 3) automatic

* The modulator includes a limit switch (terminals Q13 and Q14), it stops the burner if the work parameter overcomes set differential.

ATTENTION:

1 - Electric supply 230/400V 50Hz 3N a.c. 2 - Don't reverse phase and neutral 3 - Make sure that the burner is properly hearted

Wiring diagram 07-475 - Burners progressive - RG91 - RG92 - RG93 Wiring diagram 07-479 - Burners fully modulating - RG91 - RG92 - RG93 Wiring diagram 11-272 - Burners progressive - RG510 - RG515 - RG520 Wiring diagram 11-293 - Burners fully modulating - RG510 - RG515 - RG520 Wiring diagram 11- 344 - Burners progressive - RG525 Wiring diagram 11- 356 - Burners fully modulating - RG525

SIEMENS OIL BURNERS AUTOMATIC CONTROLLER SIEMENS

APPENDIX

LMO14 - LMO24 - LMO44

The LMO... burner controls are designed for the start-up and supervision of single- or 2-stage forced draught oil burners in intermittent operation. Yellow-burning flames are supervised with photoresistive detectors QRB..., blue-burning flames with blue-flame detectors QRC...

In terms of housing dimensions, electrical connections and flame detectors, the LMO... are identical to the LOA... oil burner controls.

Preconditions for startup

 Burner control is reset  All contacts in the line are closed  No undervoltage  Flame detector is darkened, no extraneous light

Undervoltage

 Safety shut-down in the operating position takes place should the

mains voltage drop below about AC 165 V

 Restart is initiated when the mains voltage exceeds about

AC 175 V

Time supervision oil pre-heater

If the oil pre-heater’s release contact does not close within 10 minutes, the burner control will initiate lock-out.

Controlled intermittent operation

After no more than 24 hours of continuous operation, the burner control will initiate an automatic safety shut-down followed by a restart.

Control sequence in the event of fault

If lock-out occurs, the outputs for the fuel valves and the ignition will immediately be deactivated (< 1 second).

Cause Response

After a mains failure Restart

After voltage has fallen below the undervoltage threshold

In the event of a premature, faulty flame signal during «t1»

In the event of a premature, faulty flame signal during «tw»

If the burner does not ignite during «TSA»

In the event the flame is lost during operation

Oil pre-heater’s release contact does not close within 10 min.

Restart

Lock-out at the end of «t1»

Prevention of start-up, lockout after no more than 40 seconds

Lock-out at the end of TSA

Max. 3 repetitions, followed by lock-out

Lock-out

In the event of lock-out, the LMO... remains locked (lock-out cannot be changed), and the red signal lamp will light up. This status is also maintained in the case of a mains failure.

Resetting the burner

Whenever lock-out occurs, the burner control can immediately be reset. To do this, keep control the lock-out reset button depressed for about 1 second (< 3 seconds).

Ignition program with LMO24.113A2

If the flame is lost during «TSA», the burner will be reignited, but not later than at the end of «TSAmax.». This means that several ignition attempts can be made during TSA (refer to «Program sequence»).

Limitation of repetitions

If the flame is lost during operation, a maximum of 3 repetitions can be made. If the flame is lost for the 4th time during operation, the burner will initiate lock-out. The repetition count is restarted each time controlled switching on by «R-W-SB» takes place.

Operation

Lock-out reset button «EK...» is the key operating element for resetting the burner control and for activating / deactivating the diagnostic functions.

The multicolour «LED» is the key indicating element for both visual diagnosis and interface diagnosis.

s Red l Yellow o Green

Colour code table

Status Colour code Colour Oil pre-heater heats,

waiting time «tw»

Ignition phase, ignition controlled

Operation, flame o.k.

Operation, flame not o.k.

Undervoltage

Fault, alarm

Output of fault code (refer to Fault code table)

Extraneous light prior to burner start-up

Interface diagnosis

lllllllllll Yellow

lmlmlmlmlml Yellow-off oooooooooooo Green

omomomomomo Green-off lslslslslsl Yellow-red sssssssssss Red

smsmsmsmsm Red-off

osososososo Green-red ssssssssssssss Red flicker light

Key

Off

m l Yellow o Green s Red

Diagnosis of cause of fault

After lock-out, the red fault signal lamp remains steady on. In that condition, the visual diagnosis of the cause of fault according to the

error code table can be activated by pressing the lock-out reset button for more than 3 seconds.

Error code table

Blink code Possible cause

2 blinks **

No establishment of flame at the end of TSA

 Faulty or soiled fuel valves  Faulty or soiled flame detector  Poor adjustment of burner, no fuel  Faulty ignition

3 blinks *** Free

4 blinks **** Extraneous light on burner startup

5 blinks ***** Free

6 blinks ****** Free 7 blinks *******

Too manny losses of fleme during operation (limitattion og the number of repetitions)

 Faulty or soiled fuel valves  Faulty or soiled flame detector  Poor adjustment of burner

8 blinks ******** Time supervision oil pre-heater

9 blinks ********* Free

10 blinks ********** Wiring error or internal error, output contacts

During the time the cause of fault is diagnosed, the control outputs are deactivated.

 Burner remains shut down  Fault status signal «AL» at terminal 10 is activated

The diagnosis of the cause of fault is quit and the burner switched on again by resetting the burner control.

Press lock-out reset button for about 1 second (< 3 seconds).

Connection diagram and internal diagram

LMO14

10 11 12

L N

ZBV1

QRB

QRC

bl sw

7130a01e/0700

EK2

EK1

μC control

FSV

μC2

LED

kbr

μC1

10 11 12

L N

ZBV1

QRB

QRC

bl sw

7130a02e/0700

EK2

EK1

µC con trol

BV2

LED

kbr

FSV

µC 2

µC 1

R W SB

BV1

A´

AB C

t3n

TSA

7130d02e/0700

Only with LM O14.113A2: re -ignition

t3n

R W SB

BV2

A´

AB C

t3n

TSA

7130d03e/0700

t3n

BV1

LMO24 - LMO44

Control sequence

LMO14

LMO24 - LMO44

Key

AL Alarm device kbr... Cable link (required only when no oil pre-heater is used) BV... Fuel valve EK1 Lock-out reset button EK2 Remote lock-out reset button FS Flame signal FSV Flame signal amplifier K... Contacts of control relay LED 3-colour signal lamps M Burner motor OW Release contact of oil pre-heater t1 Pre-purge time t3 Pre-ignition time t3n Post-ignition time A´ Beginning of start-up sequence with burners using an oil pre-

heater

A Beginning of start-up sequence with burners using no oil pre-

heater Controller output signals

Required input signals OH Oil pre-heater QRB Photoresistive detector QRC Blue-flame detector bl = blue br = brown sw = black R Control thermostat or pressurestat SB Safety limit thermostat Si External primary fuse W Limit thermostat or pressure switch Z Ignition transformer t4 Interval from flame signal to release «BV2» TSA Ignition safety time tw Waiting time for oil pre-heating B Time of flame establishment C Operating position D Controlled shut-down by «R» µC1 Microcontroller 1 µC2 Microcontroller 2

General unit data

LMO...

µA DC

QRB...

7130v01/0700

Mains voltage AC 230 V +10 % / -15 %

AC 120 V +10 % / -15 % Mains frequency 50...60 Hz ±6 % External primary fuse (Si) 6.3A (slow) Power consumption 12 VA Mounting orientation optional Weight approx. 200 g Degree of protection IP40 (to be ensured through mounting) Perm. cable lengths max. 3m at line capacitance of 100 pF/m Detector cable laid separately 10 m Remote reset laid separately 20m

LMO14 LMO24 LMO44 Terminal 1 5 A 5 A 5 A Terminals 3 and 8 3 A 5 A 5 A Terminals 4, 5 and 10 1 A 1 A 1A Terminals 6 1 A 1 A 2A

Flame supervision with QRB and QRC

QRB QRC

Min. detector current required (with flame) 45 µA 70 µA Min detector current permitted (without flame) 5.5 µA 5.5 µA Max. possible with flame (tipically) 100 µA 100 µA

Measurement circuit for detector current

1211

µA DC

QRC1...

LMO...

7130v02/0700

Key

µA DC DC microamperometer with an internal

resistance of 5 k

max.

bl Blue sw Black br Brown

 6 in the bottom of the base  6 lateral threaded knockout holes for cable entry glands Pg11 or M20

Operation

Flame detector and flame simulation test are made automatically during burner off times and the prepurge time «t1». If loss of flame occurs during operation, the burner control will initiate lockout. If automatic repetition of the startup sequence is required, the clearly marked wire link on the plugin section of the LAL... must be cut away.

Pre-conditions for burner startup

 Burner control is not in the lockout position  Sequence switch is in its start position (with LAL2 voltage is present at

terminals 11 and 12.

 Air damper is closed; end switch «z» for the CLOSED position must

feed power from terminal 11 to terminal8.

 Contact of the limit thermostat or pressure switch «W» and the con-

tacts of any other switching devices in the control loop between terminals 4 and 5 must be closed e.g. a control contact for the oil preheater’s temperature

 Normally closed contact of the air pressure switch must be closed.

Startup sequence

Start command by «R»: «R» closes the start control loop between terminals 4 and 5

 The sequence switch starts to run  Only prepurging, fan motor at terminal 6 receives power  Pre- and postpurging, fan motor or flue gas fan at terminal 7 receives

power on completion of «t7»

 On completion of «t16», the control command for opening the air dam-

per is delivered via terminal 9

 Terminal 8 receives no power during the positioning time  The sequence switch continues to run only after the air damper has

fully closed.

t1 Prepurge time with air damper fully open:

 The correct functioning of the flame supervision circuit is checked

during «t1»

 The burner control will initiate lockout if correct functioning is not ensu-

red.

With LAL2: Shortly after the beginning of «t1», the air pressure switch must change

over from terminal 13 to terminal 14 otherwise, the burner control will initiate lockout start of the air pressure check.

t3 Short preignition time: «Z» must be connected to terminal 16, release of fuel via terminal 18.

LAL.. CONTROL BOX FOR OIL BURNERS

Use

 Control and supervision of oil atomization burners  For burners of medium to high capacity  For intermittent operation (at least one controlled shutdown every 24

hours)

 Universally applicable for multistage or modulating burners

Housing and plug-in base

 Made of impact-proof and heat-resistance black plastic  Lockout reset button with viewing window; located behind it:  Lockout warning lamp  Lockout indicator coupled to the spindle of the sequence switch and

visible in the transparent lockout reset button

 uses easy-to-remember symbols to indicate the type of fault and the

point in time lockout occurred

Base and plug-in section of the LAL... are designed such that only burner controls of the LAL... family can be plugged in.

 24 connection terminals  Auxiliary terminals «31» and «32»  3 earth terminals terminating in a lug for earthing the burner  3 neutral conductor terminals prewired to terminal 2  14 knockout holes for cable entry by means of cable glands  8 at the side

br1

ar1

fr1

aab

XIII

XII

br2

IIXVIII

baababab

III

ar3

VII

XIV

fr2

ar2

QRB1...

810

919

1615

EK1*

EK2*

1 (3)

BV1

BV2

7153a07/0496

QRC1...

t3’ Long preignition time: «Z» connected to terminal 15. t3n Postignition time:

- «Z» must be connected to terminal 15

- With short preignition, «Z» remains on until «TSA» has elapsed connection to terminal 16.

t4 Interval «BV1 – BV2» or «BV1 - LR»: On completion of «t4», voltage is present at terminal 19. The voltage is required to power «BV2» connected to auxiliary switch «v» in the actuator.

t5 Interval: On completion of «t5», terminal 20 receives power. At the same time, control outputs 9 to 11 and input 8 are galvanically separated from the LAL...’s control section.

LAL... is now protected against reverse voltages from the load control circuit. With the release of «LR» at terminal 20, the startup sequence of

the LAL... ends. After a few idle steps (steps with no contact position changes), the sequence switch switches itself off.

B Operating position of the burner

B-C Burner operation: during burner operation, «LR» drives the air damper to the nominal load or low-fire position, depending on heat demand; the release of the nominal load takes place via auxiliary switch «v» in the actuator and in the event of loss of flame during operation, the LAL... will initiate lockout. For automatic start repetition, the clearly marked wire link «B» on the plugin section of the LAL... must be cut away.

C Controlled shutdown: in the case of controlled shutdown, «BV...» will immediately be closed. At the same time, the sequence switch is started to program «t6»

C-D Sequence switch travels to start position «A» t6 Postpurge time: fan «M2» connected to terminal 7. Shortly after the

start of «t6», terminal 10 receives power and the air damper is driven to the MIN position. Full closing of the air damper starts only shortly before «t6» has elapsed initiated by the control signal at terminal 11. During the following burner off time, terminal 11 is live.

t13 Permissible afterburn time: during «t13», the flame signal input may still receive a flame signal.

D-A End of control program: start position As soon as the sequence switch has reached the start position – having

thereby switched itself off – the flame detector and flame simulation test will start again.

During burner off times, the flame supervision circuit is live.

Lockout and indication of the stop position

Whenever a fault occurs, the sequence switch stops and with it the lockout indicator. The symbol appearing above the reading mark indicates the type of fault:

No start. One of the contacts is not closed (also refer to «Precondi-

tions for burner startup»): Extraneous light: Lockout during or after completion of the control program Examples: nonextinguished flame, leaking fuel valves faulty flame super-

vision circuit.

Interruption of startup. No OPEN signal at terminal 8 from the chan-

geover end switch «a». Terminals 6, 7 and 15 are live until fault has been corrected

P Lockout. No air pressure indication at the beginning of the air pres-

sure check. Air pressure failure after the air pressure check.

Defect in the flame supervision circuit. Interruption of the startup sequence. No positioning signal at termi-

nal 8 from the auxiliary switch «m» for the low-fire position. Terminals 6, 7 and 15 are live until fault has been corrected. 1 Lockout. No flame signal at the end of the safety time.

| Flame signa has been lost during operation.

A Consenso all’avviamento (ad esempio tramite il termostato o il

B Operating position of the burner

C Controlled shutdown: in the case of controlled shutdown, «BV...» will immediately be closed. At the same time, the sequence switch is started to program «t6» C-D Sequence switch travels to start position «A».

During burner off times, the flame supervision circuit is live.

pressostato R dell’impianto

Lockout indication

a-b Startup sequence b-b’ Idle step (with no contact confirmation) b(b’)-a Postpurge program

Burner control can immediately be reset after lockout: Do not press the lockout reset button for more than 10 seconds The sequence switch always travels to the start position first After resetting After rectification of a fault that led to shutdown After each power failure During this period of time, power is only fed to terminals 7 and 9...11.

Then, the LAL.... will program a new burner startup sequence

Specifications

Power supply AC 230 V -15 / +10 % for LAL2... on request AC 100 V -15 %...AC 110 V +10 % Frequency 50 Hz -6 %...60 Hz +6 % Absorption AC 3.5 VA Mounting position optional Protection IP 40 Perm. input current at terminal 1

AC 5 A max., 20 A peak

Perm. current rating of control terminals 3, 6, 7, 9...11, 15...20

4 A max., 20 A peak Internal fuse T6,3H250V according to IEC 127 External fuse max. 10 A Weight Device 1000 g

Plug-in base 165 g

Sequence diagram

Control output at terminal

Lockout position indication

III

VII

VIII

XII

XIII

XIV

a b

t11

t16

t3"

t12

t3n

t20

t13t10*

Key

t1 Prepurge time with air damper fully open

t2 Safety time

t3 Preignition time, short («Z» connected to terminal 16)

T3’ Preignition time, long («Z» connected to terminal 15)

t3n Postignition time («Z» connected to terminal 15)

t4 Interval between voltage at terminals 18 and 19 («BV1-BV2»)

t5 Interval between voltage at terminals 19 and 20 («BV2» load

controller)

t6 Postpurge time (with «M2»)

t7 Interval between start command and voltage at terminal 7 (start

delay time for «M2»)

t8 Duration of startup sequence (excluding «t11» and «t12»)

t10 Interval from startup to the beginning of the air pressure check

t11 Air damper running time to the OPEN position

t12 Air damper running time to the low-fire position (MIN)

t13 Permissible afterburn time

t16 Interval to the OPEN command for the air damper

t20 For self-shutdown of the sequence switch

Note: Specifications and and data subject to change. Errors and omissions excepted.

C.I.B. UNIGAS S.p.A.

Via L.Galvani, 9 - 35011 Campodarsego (PD) - ITALY

Tel. +39 049 9200944 - Fax +39 049 9200945/9201269

web site: www.cibunigas.it - e-mail: cibunigas@cibunigas.it

Unigas RG515, RG93, RG520, RG525, RG510 Manual Of Installation - Use - Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual