RN510 - RN515 RN520 - RN525 Progressive, Fully-modulating Heavy oil Burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039215CB REL. 1.0 02/2011 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 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. 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 integrity. 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 cutout 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 harmless. In case the equipment is to be sold or transferred to another user, or in case the original user should move and leave the unit behind, make sure that these instructions accompany the equipment at all times so that they can be consulted by the new owner and/or the installer. For all the units that have been modified or have options 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, therefore, dangerous. The manufacturer shall not be held liable, by agreement or otherwise, for damages resulting from improper installation, use and failure to comply with the instructions supplied by the manufacturer. 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 combustion efficiency level at least equal to the lower level required by the regulations in force; c check the unit operation for proper combustion, to avoid any harmful or polluting unburnt gases in excess of the limits permitted by the regulations in force; d make sure that control and safety devices are operating properly; e make sure that exhaust ducts intended to discharge the products of 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 instructions 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 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, or other fuel). Observe caution with hot burner components. These are, usually, near to the flame and the fuel pre-heating system, they become hot during the unit operation and will remain hot for some time after the burner has stopped. When the decision is made to discontinue the use of the burner, the user 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 permitted to connect the unit to the electric mains. An omnipolar switch shall be provided for connection to mains, as required by the current safety regulations. The use of any power-operated component implies 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 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. 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS GENERAL The burner shall be installed by qualified personnel and in compliance with regulations and provisions in force; wrong installation can cause injuries to people and animals, or damage to property, for which the manufacturer cannot be held 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 designed fuel type; d the fuel supply pressure, to make sure that it is included in the range shown on the rating plate; e the fuel supply system, to make sure that the system dimensions are adequate to the burner firing rate, and that the system is equipped with all the safety and control 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. Light oil burners 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 - 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 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. Heavy oil burners 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 Gas - Light oil 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. National standards : -UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods Gas - Heavy oil 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. National standards : -UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods 4 PART I: INSTALLATION Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type RN520 (1) Model N-. PR. S. *. A. (2) (3) (4) (5) (6) (1) BURNER TYPE RN510 - RN515 - RN520 - RN525 N - Heavy oil, viscosity 50cSt (7° E) @ 50° C E - Heavy oil, viscosity 110cSt (15°E) @ 50° C D - Heavy oil, viscosity 400cSt (50° E) @ 50° C P - Petroleum, viscosity 89cSt (12° E) @ 50° C (2) FUEL (3) OPERATION (Available versions) PR - Progressive MD - Fully modulating (4) BLAST TUBE S - Standard L - Extended (5) DESTINATION COUNTRY * - see data plate (6) BURNER VERSION A - Standard Technical Specifications BURNER Output min - max kW RN510 RN515 RN520 RN525 1314 - 3953 1628 - 4884 2326 - 6977 2000 - 8000 Heavy oil Fuel See “Burner model identification” table Viscosity Heavy oil rate Oil train inlet pressure min. - max. kg/h 117 - 352 145 - 435 bar 207 - 622 178 - 713 4 max 400V 3N a.c. 50Hz Power supply Total power consumption (Heavy oil) kW 33.1 43 59.7 69.2 Total power consumption (Petroleum) kW 27.1 31 41.7 -- Fan motor kW 7.5 11 15 18.5 Pump motor kW 1.1 1.5 2.2 2.2 Pre-heater resistors (heavy oil) kW 24 30 42 48 Pre-heater resistors (Petroleum) kW 18 18 24 -- 415 430 IP40 Protection Approx. weight kg 320 370 Progressive - Fully modulating Operation Operating temperature °C -10 ÷ +50 Storage Temperature °C -20 ÷ +60 Intermittent Working service* Heavy oil net calorific value (Hi): 40.4 MJ/kg (average value). NOTE ON THE WORKING SERVICE: for safety reasons, one controlled shutdown must take place every 24 hours of continuous working. 5 PRESSURE IN COMBUSTION CHAMBER (mbar) Performance Curves RN510 RN515 24 24 20 20 16 16 12 12 8 8 4 4 0 1000 1800 2600 3400 4200 RN520 PRESSURE IN COMBUSTION CHAMBER (mbar) 0 1200 2800 3600 4400 5200 kW RN525 24 24 20 20 16 16 12 12 8 8 4 4 0 1600 2400 3200 4000 4800 5600 6400 7200 8000 0 1500 kW 2000 kW 2500 3500 4500 5500 6500 7500 8500 kW 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. 6 Overall dimensions (mm) P P H N Boiler recommended boiler drilling template M 7 RN510 RN515 RN520 RN525 A(S*) 1502 1502 1502 1502 A(L*) 1682 1682 1682 1682 AA 221 145 145 145 AB 217 217 207 197 AC 246 246 250 275 AD 35 35 35 35 B(S*) B(L*) 350 530 350 530 350 530 350 530 BB 468 508 508 650 C 1152 1152 1152 1152 CC 571 598 598 598 D 1285 1285 1285 1285 DD** 349 x x x *S = measure referred to standard blast tube *L = measure referred to extended blast tube ** RN515-520-525: as far as these burners, the oil pumping/pre-heating unit is separate. E 643 643 643 643 EE** 556 x x x F 642 642 642 642 G 345 384 422 434 H 385 424 472 484 K 540 540 540 540 L 496 496 496 496 M M14 M14 M14 M14 N 552 552 552 552 O 390 390 390 390 P 390 390 390 390 T UU 37 36 37 36 37 36 37 78 W 897 802 802 844 Y 328 328 328 328 Z 270 270 270 270 INSTALLING THE BURNER Packing Burners are despatched in wooden crates whose dimensions are: RN510-515-520: 1720 x 1500 x 1210 (L x P x H) RN525: 1800 x 1500 x 1300 (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; gasket to be inserted between the burner and the boiler; oil flexible hoses; oil filter; envelope containing this manual. RN515-520-525: as far as these burners, the oil pumping/pre-heating unit is separate. To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials. 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. A B Fitting the burner to the boiler To install the burner into the boiler, proceed as follows: 1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) 2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; 3 place the 4 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”; 4 fasten the 4 stud bolts; 5 place the gasket on the burner flange; 6 install the burner into the boiler; 7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture. 8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material (ceramic fibre cord or refractory cement). Keys 1 Burner 2 Fixing nut 3 Washer 4 Sealing gasket 5 Stud bolt 7 Blast tube 8 MOUNTING POSITION SIDE UP SIDE DOWN Burner is designed to operate with horizontal flame axis. Set the upper side of the burner flange in a horizontal position, in order to obtain the correct inclination of the pre-heating tank. For different installations, please contact the Technical Department. . Key 1 Burner flange (upper side indicated) 1 2 Bracket 3 Pre-heating tank on the burner 2 3 9 Electrical connections Respect the basic safety rules. Make sure of the connection to the earthing system. do not reverse the phase and neutral connections. Fit a differential thermal magnet switch adequate for connection to the mains. ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the “Electrical connections” section. WARNING: The burner is provided with an electrical bridge between terminals 6 and 7; when connecting the high/ low flame thermostat, remove this bridge before connecting the thermostat. IMPORTANT: Connecting electrical supply wires to the burner teminal block MA, be sure that the ground wire is longer than phase and neutral ones. auxiliary contacts are provided (terminals no. 507 and no. 508 of the MA terminal block) to connect an intervention system (alarm/power supply cutoff) in case of fault of the oil resistor contactor (see Fig. 1-Fig. 2). To execute the electrical connections, proceed as follows: 1 remove the cover from the electrical board, unscrewing the fixing screws; 2 execute the electrical connections to the supply terminal board as shown in the following diagrams, 3 check the direction of the motor (see next pargraph) 4 refit the panel cover Probes connection MA Fig. 1 - Progressive burners MA Fig. 2 - Fully modulating burners Fig. 3 (#) Free contact for ”Faulty heater resistor contactor” Probes connection oby means of the 7-pins plug (Fig. 4) - see Fig. 3) for connections. Fig. 4 RN515-520-525: As for the connection of the pump-preheating unit, see wiring diagrams. 10 Fan and pump motors direction Once the electrical connection of the burner is performed, remember to check the rotation of the motor. The motor should rotate in an counterclockwise direction looking at cooling fan. In the event of incorrect rotation reverse the three-phase supply and check again the rotation of the motor. Connecting the oil heating resistors 2.4 - 4.5 kW 8 - 12 kW 400 V R1 R1 L1 R2 L2 L1 230V R1 L1 R1 L2 L1 400 V 230V R6 L2 R2 R6 R2 L2 R2 R3 R3 R5 R5 R3 R3 R4 R4 L3 L3 L3 L3 Fig. 5 Fig. 6 18 - 24 kW ELECTRIC MOTOR CONNECTION 400 V 230V 400 V 230V W2 U2 V2 U1 V1 W1 W2 U2 V2 L1 L1 R1 R6 R1 R2 R5 L2 R3 R2 R6 L2 U1 R3 R5 V1 W1 R4 L3 L3 R4 L1 L2 L3 L1 L2 L3 Fig. 8 Fig. 7 Double-pipe and single-pipe system 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.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 TA G 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. 11 Oil pumps RN510: SUNTEC TA3 RN515: SUNTEC TA4 RN520 - RN525: SUNTEC TA5 Suntec TA.. Oil viscosity Oil temperature 3 ÷ 75 cSt 0 ÷ 150°C Min. suction pressure Max. suction pressure Max. return pressure Rotation speed - 0.45 bar to avoid gasing 5 bar 5 bar 3600 rpm max. 1 2 3 4 5 6 Inlet G1/2 To the nozzle G1/2 Return G1/2 Pressure gauge port G1/4 Vacuum gauge port G1/4 Pressure governor 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 junctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of junctions 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 deposit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) junctions if possible. An external filter should always be installed in the suction line upstream of the fuel unit. 12 Burners with separate pre-heating/pumping unit Follow the scheme in the picture below to connect the burner to the oil pumping unit. The pump sends the oil coming from the tank to the burner. The pressure governor makes the oil reach the nozzle at the required pressure, while the excess of oil goes back to the tank. To change the delivery pressure act on the adjusting screw of the delivery pressure governor. to the burner from burner to oil governor air discharge valve from oil governor to degassing bottle from oil governor 13 discharge cap inlet inlet from pump Connecting the 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 on the inlet (A) and return (R) 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.. R A Connections to the oil gun Gun with the oil nozzle inside 5 4 1 Inlet 2 Return 3 Gun opening 4 Heating wire (only for high density oil burners) 5 Cartdrige-type heater (only for oil with viscosity > 110 cSt) 3 2 1 Oil manifold 5 1 2 3 Recommendations to design heavy oil feeding plants This paragraph is intended to give some suggestions to make feeding plants for heavy oil burners. To get a regular burner operation, it is very important to design the supplying system properly. Here some suggestions will be mentioned to give a brief description. The term “heavy oil” is generic and summarises several chemical-physical properties, above all viscosity. The excessive viscosity makes the oil impossible to be pumped, so it must be heated to let it flow in the pipeline; because of the low-boiling hydrocarbons and dissolved gases, the oil must be also pressurised. The pressurisation is also necessary to feed the burner pump avoiding its cavitation because of the high suction at the inlet. The supplying system scope is to pump and heat oil. The oil viscosity is referred in various unit measures; the most common are: °E, cSt, Saybolt and Redwood scales. Table 3 shows thevarious unit convertions (e.g.: 132 cSt viscosity corresponds to 17.5°E viscosity). The diagram in shows how the heavy oil viscosity changes according to its temperature. Example: an oil with 22°E viscosity at 50°C once heated to 100°C gets a 3 °E viscosity. As far as the pumping capability, it depends on the type of the pump that pushes the oil even if on diagram in a generic limit is quoted at about 100 °E, so it is recommended to refer to the specifications of the pump provided. Usually the oil minimum temperature at the oil pump inlet increases as viscosity does, in order to make the oil easy to pump. Referring to the diagram on Fig. 10, it is possible to realise that to pump an oil with 50°E viscosity at 50°C, it must be heated at about 80°C. 14 Pipe heating system Pipe heating system must be provided, that is a system to heat pipes and plant components to mantain the viscosity in the pumping limits. Higher the oil viscosity and lower the ambient temperature, more necessary the pipe heating system. Inlet minimum pressure of the pump (both for supplying system and burner) A very low pressure leads to cavitation (signalled by its peculiar noise): the pump manifacturer declares the minimum value. Therefore, check the pump technical sheets. By increasing the oil temperature, also the minimum inlet pressure at the pump must increase, to avoid the gassification of the oil lowboiling products and the cavitation. The cavitation compromises the burner operation, it causes the pump to break too. The diagram on Fig. 11 roughly shows the inlet pump pressure according to the oil temperature. Pump operating maximum pressure (both for the supplying system and burner) Remember that pumps and all the system components through which the oil circulates, feature an upper limit. Always read the technical documentation for each component. Schemes on Fig. 13 and Fig. 14 are taken from UNI 9248 "liquid fuel feeding lines from tank to burner" standard and show how a feeding line should be designed. For other countries, see related laws in force. The pipe dimensioning, the execution and the winding dimensioning and other construcitve details must be provided by the installer. Adjusting the supplying oil ring According to the heavy oil viscosity used, in the table below indicative temperature and pressure values to be set are shown. Note: the temperature and pressure range allowed by the supplying ring components must be checked in the specifications table of the components themselves. PIPELINE PRESSURE bar 1- 2 1- 2 1- 2 HEAVY OIL VISCOSITY AT 50 °C cSt (°E) > 50 (7) > 110 (15) < 50 (7) < 110 (15) < 400 (50) PIPELINE TEMPERATURE °C 20 50 65 Tab. 1 Burner adjustments The table below shows indicative values of temperature and pressure to be set on the burner devices, according to the viscosity of the heavy oil used. The oil temperature should be set on TR resistor thermostat in order to get about 1.5°E viscosity at the nozzle.* OIL PRESSURE OIL PRESSURE AFTER AFTER OIL VISCOSITY BURNER PUMP METERING VALVE AT 50 °C (N. 24 in 3ID0023/14) (N. 33 IN 3ID0023/14) min max min max cSt (°E) bar bar < 50 (7) 5 8 0.5 2 > 50 (7) < 110 (15) 5 8 0.5 2 > 110 (15) < 400 (50) 5 8 0.5 2 TEMPERATURE OF THE PRE-HEATING RESISTORS THERMOSTAT TR min max °C 70 95 75 105 100 140 Tab. 2 15 TEMPERATURE OF THE RESISTORS SAFETY THERMOSTAT TRS TEMPERATURE OF THE PLANT ENABLING THERMOSTAT TCI °C 190 190 190 °C 50 60 70 Viscosity units conversion table Cinematics viscosity Centistokes (cSt) Engler Degrees (°E) Saybolt Seconds Universal (SSU) Saybolt Seconds Furol (SSF) Redwood Seconds no.1 (Standard) Redwood Seconds no..2 (Admiralty) 1 1 31 -- 29 -- 2.56 1.16 35 -- 32.1 -- 4.3 1.31 40 -- 36.2 5.1 7.4 1.58 50 -- 44.3 5.83 10.3 1.88 60 -- 52.3 6.77 13.1 2.17 70 12.95 60.9 7.6 15.7 2.45 80 13.7 69.2 8.44 18.2 2.73 90 14.44 77.6 9.3 20.6 3.02 100 15.24 85.6 10.12 32.1 4.48 150 19.3 128 14.48 43.2 5.92 200 23.5 170 18.9 54 7.35 250 28 212 23.45 65 8.79 300 32.5 254 28 87.6 11.7 400 41.9 338 37.1 110 14.6 500 51.6 423 46.2 132 17.5 600 61.4 508 55.4 154 20.45 700 71.1 592 64.6 176 23.35 800 81 677 73.8 198 26.3 900 91 762 83 220 29.2 1000 100.7 896 92.1 330 43.8 1500 150 1270 138.2 440 58.4 2000 200 1690 184.2 550 73 2500 250 2120 230 660 87.6 3000 300 2540 276 880 117 4000 400 3380 368 1100 146 5000 500 4230 461 1320 175 6000 600 5080 553 1540 204.5 7000 700 5920 645 1760 233.5 8000 800 6770 737 1980 263 9000 900 7620 829 2200 292 10000 1000 8460 921 3300 438 15000 1500 13700 -- 4400 584 20000 2000 18400 -- Tab. 3 16 VISCOSITY vs TEMPERATURE DIAGRAM FOR COMBUSTIBLE OILS 1000 PUMPING LIMIT VISCOSITY (°E) 100 10 1 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 TEMPERATURE (°C) LIGHT OIL 1,3°E AT 20°C HEAVY OIL 2,4°E AT 50°C HEAVY OIL 4°E AT 50°C HEAVY OIL 7,5°E AT 50°C HEAVY OIL 10°E AT 50°C HEAVY OIL 13°E AT 50°C HEAVY OIL 22°E AT 50°C HEAVY OIL 50°C HEAVY OIL 47°E AT 50°C HEAVY OIL 70°E AT 50°C HEAVY OIL 200°E AT 50°C Fig. 9 17 Indicative diagram showing the oil temperature at burner pump inlet vs. oil viscosity Example: if the oil has a 400cSt (50°E) @ 50°C viscosity, the oil temperature at the pump inlet should be 80°C (see diagram). OIL TEMPERATURE FOR PUMP FEEDING VISCOSITY (°E a 50°C) 100 10 1 0 10 20 30 40 50 60 70 80 90 TEMPERATURE (°C) Fig. 10 Indicative diagram showing the oil pressure according to its temperature PUMP FEEDING PRESSURE 6 Max. for T and TA pumps PRESSURE (bar) 5 Max. for E ..1069 pimps 4 3 2 1 0 40 60 80 100 120 140 160 TEMPERATURE (°C) Fig. 11 Indicative diagram showing the oil atomising temperature according to its viscosity Example: if the oil has a 50°E @ 50°C viscosity, the oil atomising temperature should be between 145°C and 160°C (see diagram). VISCOSITY vs. TEMPERATURE DIAGRAM 2 VISCOSITY (°E) 1.9 1.8 1.7 1.6 BEST VISCOSITY RANGE FOR A PROPER ATOMIZATION 1.5 1.4 1.3 1.2 50 60 70 3°E AT 50°C 5°E AT 50°C 7°E AT 50°C 12°E AT 50°C 15°E AT 50°C 20°E AT 50°C 50°E AT 50°C 80 90 100 110 120 130 140 150 160 170 180 TEMPERATURE (°C) Fig. 12 18 HYDRAULIC DIAGRAMS Fig. 13 - Hydraulic diagram 3ID0023 - Single burner configuration 19 Fig. 14 - Hydraulic diagram 3ID0014 - Two or more burners configuration 20 Hydraulic Diagram 3ID0014 Hydraulic Diagram 3ID0023 1 Main tank 1 Main tank 2 Bottom valve 2 Bottom valve 3 Main tank pre-heating pipe 3 Main tank pre-heating pipe 4 Oil filter (filtration, 1mm) 4 Oil filter 5 Circuit pressure regulator 5 Circuit pressure regulator 6 Manometer 6 Manometer 7 Pressure regulation by-pass valve 7 Pressure regulation by-pass valve 8 Manual valve 8 Manual valve 9 Oil pump 9 Oil pump 10 Pump pressure regulator 10 Pump pressure regulator 11 Unidirectional valve 11 Unidirectional valve 12 Service tank pre-heating resistor 12 Service tank pre-heating resistor 13 Service tank pre-heating thermostat 13 Service tank pre-heating thermostat 14 Burner consent thermostat 14 Burner consent thermostat 15 Thermometer 15 Thermometer 16 Consent pressure switch for service tank resistor 16 Consent pressure switch for service tank resistor 17 Service tank heating pipe 17 Service tank heating pipe 18 Service tank air drain valve 18 Service tank air drain valve 19 Service tank 19 Service tank 20 Oil filter 20 Oil filter 21 Fuel solenoid valve 21 Fuel solenoid valve 22 Fuel valve 22 Fuel valve 23 Burner pump flexible hoses 23 Burner pump flexible hoses 24 Burner oil pump 24 Burner oil pump 25 Pre-heating tank resistor 25 Pre-heating tank resistor 26 Pre heating tank 26 Pre heating tank 27 Oil consent thermostat 27 Oil consent thermostat 28 Heather safety thermostat 28 Pre-heating tank resistors safety thermostat 29 Thermostat for oil temperature setting 29 Thermostat for oil temperature setting 30 Tank filter 30 Pre-heating tank filter 31 Thermometer 31 Thermometer 32 Check valve 32 Check valve 33 Oil pressure governor 33 Oil pressure governor 35 Oil needle drive piston 35 Oil needle drive piston 36 Oil rate regulator 36 Three way valve for piston drive 37 Burner consent thermostat 37 Burner consent thermostat 42 Burner start consent thermostat 42 Air separation bottle 43 Burner 43 Burner 45 Thermostat for pipes pre-heating pumps 45 Thermostat for pipes pre-heating pumps 46 Water pump for service tank pre-heating (1) 46 Water pump for service tank pre-heating (1) 47 Water pump for main tank pre-heating (19) 47 Water pump for main tank pre-heating (19) 48 Water pre-heating balance setting valve 48 Valves for setting of pre-heating water balance 50 Oil circulation pump 52 Oil ring max. pressure switch 52 Oil ring max. pressure switch 21 Regolazione della portata dell’olio combustibileAdjusting light oil flow rate The light oil flow rate can be adjusted choosing a by-pass 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. 15 (as far as reading the pressure values, see next paragraphs). NOZZLE DELIVERY PRESSURE bar RETURN PRESSURE MAX. bar RETURN PRESSURE MIN. bar FLUIDICS WR2/UNIGAS M3 25 19 - 20 7 - 9 (indicative values) Fig. 15 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 Tab. 4 Pressure at nozzle Pressure at nozzle Atomisation angle Pressure on return Pressure on return Up to 100kg/ Over 100kg/ % Flow rate ---------------Atomisation angle according to the return pressure _________ % Flow rate Example: as for over 100kg/h nozzles, the 80% of the nozzle flow rate can be obtained with a return pressure at about 18bar (see Fig. 15). 22 Oil thermostat adjustment To find the thermostats, remove the cover of the burner switchboard. Adjust them using a screwdriver on the VR screw as shown in the next picture. TCN - Oil enabling thermostat (Fig. 16) Adjust this thermostat to a value 10% lower than that showed in the viscosity-temperature diagram (Fig. 12). TRS - Resistor safety thermostat (Fig. 16) The thermostat is set during factory testing at about 190° C. This thermostat trips when the operating temperature exceeds the set limit. Ascertain the cause of the malfunction and reset the thermostat by means of the PR button. PR VR VR TR - Resistor thermostat (Fig. 16) Adjust this thermostat to the correct value according to the viscosity-temperature diagram (Fig. 12) and check the temperature by using a thermometer mounted on the pre-heating tank. VR Fig. 16 TCI (when provided) - Installation enabling thermostat (Fig. 16) This thermostat is fitted on burners fired with oil at a viscosity of 400cSt (50°E) at 50° C only. Set the thermostat according to data on page 14. Petroleum burners: TCI -Installation enabling thermostat Set this thermostat to about 40° C. TCN - Oil enabling thermostat Adjust this thermostat to a value between 45 and 50°C. Anyway, set TCN to a value possibly lower than the one set for TR (see below). TR - Resistor thermostat Adjust this thermostat to a value between 45 and 50°C. Check the temperature by using a thermometer mounted on the pre-heating tank. TRS - Resistor safety thermostat The thermostat is set during factory testing at about 190° C. This thermostat trips when the operating temperature exceeds the set limit. Ascertain the cause of the malfunction and reset the thermostat by means of the PR button (see picture). CAUTION: even if the adjusting ranges for the TR (Resistor thermostat) and TCN (Oil enabling thermostat) are the same, set TCN to a value lower than the one set for TR. 23 ADJUSTING AIR AND FUEL RATE ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open. Be sure that the mains switch is closed. .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. 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. IMPORTANT! the combustion air excess must be adjusted according to the values in the following chart. Recommended combustion parameters Fuel Recommended (%) CO2 Recommended (%) O2 Heavy oil 50cSt (7° E) @ 50° C 11 ÷ 12 4.2 ÷ 6.2 Heavy oil 50cSt (7° E) @ 50° C 11 ÷ 12.5 4.7 ÷ 6.7 Adjustments - brief description Adjust the air and oil 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. 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. Now set 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 the flues temperature getting too low to cause condensation in the chimney. Now, adjust the burner according to the actuator model provided. Oil Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator 1 Check the fan motor rotation. 2 Prime the oil pump acting on the related contactor (CP - see next picture): check the pump motor rotation (see “Fan and pump motors direction” on page 11) and keep pressing for some seconds until the oil circuit is charged; CP 3 bleed the air from the M pressure gauge port (Fig. 17) by loosing the cap without removing it, then release the solenoid starter. Suntec TA.. M VR 4 5 Fig. 17 Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner operates at the lowest output) to safely achieve the high flame stage. Turn the burner on by means of its main switch A (see next picture): if the burner locks (LED B on in the control panel) press the RESET button (C) on the control panel - see chapter “OPERATION”. 24 B C A 6 7 8 Start the burner up by means of the thermostat series and wait unitl the pre-purge phase comes to end and that burner starts up; drive the burner to high flame stage, by means fo the thermostat TAB (high/low flame thermostat - see Wiring diagrams), as far as fully-modulating burners, see related paragraph. Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion values (see next steps). mensions Dimensions in VI SQM4... V IV III II Actuator cams I II III I High flame Stand-by and Ignition Low flame MAN-AUTO MAN-AUTO Berger STM30 Siemens SQM40 9 the nozzle supply pressure is 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. 18 and act on on the pump adjusting screw VR (see Fig. 17) as to get the nozzle pressure at 25bar (see diagram on page 22). Pressure gauge port PG RP V SV Fig. 18 Fig. 20 10 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge): checking always the combustion parameters, the adjustment is to be performed by means of the SV adjusting cam screw V (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 the rod TR towards the air damper shaft, the air damper opens and consequently the air flow rate increases, moving it far from the 25 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. TR VRA RA 12 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. VB ”MIN” position VRT ”MAX” position Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above. 13 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°); 14 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position (as for fullymodulating burners, refer to the related paragraph); 15 move cam III towards the minimum to make the actuator move 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 showed on diagram on Fig. 15, according to the requested rate. ID RP SC V SV 16 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. 17 The low flame position must never match the ignition position that is why cam III must be set 20°- 30° more than the ignition position. 18 Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps. 26 Adjustment by the Siemens SQL33.. actuator 1 2 Check the fan motor rotation. Prime the oil pump acting on the related contactor (CP - see next picture): check the pump motor rotation (see “Fan and pump motors direction” on page 11) and keep pressing for some seconds until the oil circuit is charged; CP 3 bleed the air from the M pressure gauge port (Fig. 21) by loosing the cap without removing it, then release the contactor. Suntec TA.. M VR Fig. 21 4 5 Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner operates at the lowest output) to safely achieve the high flame stage. Turn the burner on by means of its main switch A (see next picture): if the burner locks (LED B on in the control panel) press the RESET button (C) - see chapter “OPERATION”. B C A 6 7 Start the burner up by means of the thermostat series and wait until the pre-purge phase comes to end and that burner starts up; 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 ID); SQL330.. actuator cams AUTO F = plastic clamp A = cam locking lever S = cam locking lever BF = Low flame cam BF MAN F A S 8 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); 9 set the actuator to the manual mode (MAN) by means of the MAN/AUTO switch (see next pictures). 10 manually drive the adjusting cam SV to the high flame position and set the actuator to the AUTO mode (by means of the related switch - see picture) to lock the adjusting cam. 11 The nozzle supply pressure is 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. 22 and act on on the pump adjusting screw VR (see Fig. 21) as to get the nozzle pressure at 25bar (Fluidics nozzles - see diagramd on pag. 22). 27 Pressure gauge port PG RP V SV Fig. 22 Fig. 23 12 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge): always checking the combustion parameters, the adjustment is to be performed by means of the SV adjusting cam screw V (see picture) when the cam has reached the high flame position. 13 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. TR VRA RA 14 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. VB ”MIN” position VRT ”MAX” position Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above. 15 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 adjusting 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. 16 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; 17 act on the V screw that mathces the bearings referring to the adjusting cam position; 18 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, accor28 19 20 21 22 ding to the combustion values read. Once the cam foil shape is defined, reconnect the TAB thermostat by 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). Turn the burner off then start it up again. Once the pre-purge time comes to end and the burner is on, drive the burner to the high flame stage by the TAB thermostat: check the combustion values; drive the burner to low flame, if necessary adjust the low flame size (output) by inserting a screwdriver on the slot F to move the BF cam. BF FA 23 The low flame position must never match the ignition position that is why cam BF must be set 20°- 30° more than the ignition position. 24 Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps. Calibration of air pressure switch To calibrate the air pressure switch, proceed as follows: Remove the transparent plastic cap. VR Once air and heavy oil 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. Fully-modulating burners 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 or 2 and then CMF=0. CMF = 0 CMF = 1 CMF = 2 CMF = 3 CMF 29 stop at the current position high flame operation low flame operation automatic operation 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). 3 5 6 Fig. 24 - Stand-by 2 4 1 3 5 6 Fig. 25 - Prepurge 2 4 1 3 5 6 Fig. 26 - Low flame 2 4 1 3 Fig. 27 - High flame 5 Key 1 Oil pump 2 Oil solenoid valve 3 Nozzle 4 Adjusting cam 5 Pressure gauge 6 Pressure governor 6 2 1 4 30 PART II: OPERATION LIMITATIONS OF USE 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. 31 OPERATION ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. N.B. be sure the cutoff valves on the delivery and return pipes are OPEN. Turn the burner on by means of its main switch A (see next pictures). Check that the burner is not locked (LED E lights up); if so, reset it by pressing the reset button N. Check that the series of thermostats (or pressure switches) enable the burner to start up. At the beginning of the start-up cycle the servo control drives the air damper to the maximum opening, the fan motor starts and the pre-purge phase begins. During the pre-purge phase the complete opening of the air damper is signalled by the indicator light F on the front panel. At the end of the pre-purge the ignition transformer is energised (signalled by the indicator light C on the panel). Two seconds later, the oil valve opens and the ignition transformer is de-energized (light C off). The burner is now into operation, the servocontrol begins the opening, after few seconds the burner goes to two stages operation and eventually switches to the high flame operation, depending on the needs of the plant (light A, on) or continues with low flame operation (light B, on). As far as fully-modulating burners, see the Siemens RWF40 burner modulator manual. 32 Control panel RN510 A B C CMF E F B A C D E F IRA L N P Q R T D L Q P R N T RN515 - RN520 - RN525 E A B F C D L P P Q Q R N T 33 High flame lamp Low flame lamp Ignition transformer operation Manual operation switch 0= Off 1= High flame 2= Low flame 3= Automatic Fan motor thermal cutout intervention Burner lockout Burner in stand-by Auxiliary resistors wsitch Heavy oil solenoid lamp operation Contrlol box reset pushbutton Heating resistors safety thermostat Pre-heating tank Modulator Main switch PART III: MAINTENANCE At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry 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 Clean and examine the oil filter cartridge and replace it if necessary. Examine the condition of the oil flexible tubing and check for possible leaks. Check and clean if necessary the oil heaters and the tank, according to the fuel type and its use; remove the heaters flange fixing nuts and remove the heaters from the tank: clean by using steam or solvents and not metallic things. Clean and examine the filter inside the oil pump. Filter 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. An external filter should always be installed in the suction line upstream of the fuel unit. Remove and clean the combustion head (page 35). Examine and clean the ignition electrodes, adjust and replace if necessary (see page 35). Examine and clean the detection probe, adjust and replace if necessary (see page 36). Examine the detection current (see page 36). Remove and clean (page 36) the heavy oil nozzle (Important: use solvents for cleaning, not metallic tools) and at the end of the maintenance procedures, after replacing the burner, turn it on and check the shape of the flame; if in doubt replace the nozzle. Where the burner is used intensively it is recommended to replace the nozzle as a preventive measure, at the begin of the operating season. Clean and grease joints and rotating parts. IMPORTANT:Remove the combustion head before checking the ignition electrodes. CAUTION: avoid the contact of steam, solvent and other liquids with the electric terminals of the resistor. On flanged heaters, replace the seal gasket before refitting it. Periodic inspections must be carried out to determine the frequency of cleaning. Self-cleaning filter Fitted only on high viscosity oil burners. Periodically turn the knob to clean the filter. 34 Removing the combustion head Remove the cover H. Slide the photoresistor out of its housing. Unscrew the oil connections E (Fig. 28) connecting the flexible pipes to the gun L and remove the whole assembly as shown in Fig. 28-Fig. 29. 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. 5 H 4 L 1 2 3 1 2 3 5 E 1 Fig. 28 2 Key 1 Inlet 3 2 Return 3 Lance opening 4 Heating wire (only on high density oil burners) 5 Cartdrige-type heater H Cover Fig. 29 L Oil lance E Oil piping connections Removing the oil gun, replacing the nozzle and the electrodes ATTENTION: avoid the electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrodes position after any intervention on the combustion head. To remove the oil gun, proceed as follows: 1 remove the combustion head as described on the prevoius paragraph; 2 loosen the VL screw and remove the oil gun and the electrodes: check the oil gun, replace it fi necessary; 3 after removing the oil gun, unscrew the nozzle and replace it if necessary; 4 in order to replace the electrodes, unscrew the VE fixing screws and remove them: place the new electrodes being careful to observe the measures showed on pag.: reassemlbe following the reversed procedure. VE VL Fig. 30 35 Nozzle and ignition electrodes correct position Place the nozzle according to the combustion head; unscrew VB and move the combustion head. Check the ignition electrodes at the end of the procedure. E N B M N Fig. 31 B C M 3 ÷ 5 mm 3 ÷ 4 mm 10 ÷ 15 mm N E F 10 mm 13 mm 8 mm Checking the detection current To check the flame itensity signal, follow the diagram shown on the next picture. If the measured value is lower than the suggested one, check the photoresistor position, the electrical contacts. Replace the photoresistor if necessary. MA TERMINAL BLOCK 34 35 Siemens LAL2.. control box Minimum detection current @ 230V 8 µA Maximum detection current without flame 0.8 µA Maximum detection current 35 µA SCALE µA DC Fig. 32 Cleaning and replacing the detection photoresistor To clean/replace the photoresistive detector, remove it from its slot. To clean the photoresistor, use a clean cloth, not cleaning sprays. 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”. 36 AUXILIARY FUSE BLOWN OIL RESISTOR FAULTY OIL ENABLING THERMOSTAT TRIPPED CONTROL UNIT MALFUNCTION BURNER STARTS UP WITH COLD OIL GOES OFF AND REPEATS THE CYCLE DURING OPERATION FAN THERMAL CUTOUT TRIPPED GOES TO SHUT DOWN DURING OPERATION MAXIMUM THERMOSTAT MALFUNCTION DOES NOT PASS TO HIGH FLAME LINE FUSES BLOWN DOES NOT IGNITE AND GOES TO SHUT DOWN MAIN SWITCH OFF CONTINUES PREPURGUE CAUSES/TROUBLES DOES NOT START UP TROUBLESHOOTING AIR SERVOCONTROL MALFUNCTION CIRCUIT ENABLING THERMOSTAT SMOKY FLAME IGNITION TRANSFORMER FAULTY IGNITION ELECTRODES WRONGLY POSITIONED DIRTY NOZZLE FAULTY OIL VALVE FAULTY OR DIRTY PHOTORESISTOR FAULTY RESISTOR THERMOSTAT FAULTY HIGH-LOW FLAME THERMOSTAT ACTUATOR CAM NOT CALIBRATED LOW OIL PRESSURE 37 BURNER EXPLODED VIEW ITEM 38 1 2 3 4 5 6 7 8 9.1 9.2 9.3 9.4 9.5 9.5.1 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13.1 9.13.2 10 11 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10.1 DESCRIPTION FLANGE AIR INLET CONE CLOSING PLATE INDEX LABEL RING NUT PLATE PLATE PHOTORESISTOR INDEX LABEL BUSH BUSH ADJUSTING CAM SHAFT ADJUSTING CAM ADJUSTING CAM FOIL ACTUATOR LEVERAGE CAM JOINT BRACKET BRACKET BRACKET PRESSURE GOVERNOR BRACKET EXTENDED BLAST TUBE AIR DAMPER INDEX NET BURNER HOUSING FLANGE CERAMIC FIBRE PLAIT PRESSURE PLUG INLET SCREW INSPECTION GLASS AIR PRESSURE SWITCH PIPE THREADED GAS PIPE ITEM 12.10.2 12.10.3 12.11.1 12.11.2 12.11.3 12.11.4 12.11.5 12.11.6 12.12 12.13.1 12.13.2 12.13.3 13.1 13.2 13.3 14.1 14.2 14.3 14.4 14.5 14.6.1 14.6.2 14.6.3 14.6.4 15.1 15.1.1 15.1.2 18.104.22.168 22.214.171.124 15.2 15.3 15.4.1 15.4.2 15.4.3 15.4.4 DESCRIPTION AIR PRESSURE SWITCH PRESSURE SWITCH BRACKET AIR DAMPER SILENCER AIR INTAKE DAMPER LEVERAGE ROD JOINT JOINT CONNECTOR SPACER SILENCER SILENCER OIL SOLENOID VALVE OIL MANIFOLD CONNECTOR PLUG PLUG OIL PRE-HEATER SHEATH RESISTOR OIL FILTER GASKET GAS BLEEDING VALVE THERMOMETER STANDARD COMPLETE OIL GUN NOZZLE NOZZLE HOLDER OIL MANIFOLD RESISTOR OIL GUN HOLDER COMBUSTION HEAD ADJUSTING PIPE LONG IGNITION ELECTRODE LONG IGNITION ELECTRODE COMBUSTION HEAD IGNITION CABLE ITEM 16.1 16.2 16.3 16.4 17.1 17.2 18.1 18.2 18.3.1 18.3.2 18.3.3 18.3.4 18.3.5 18.3.6 18.3.7 18.3.8 19.1 19.2 DESCRIPTION MOTOR COUPLING PUMP BRACKET FAN WHEEL MOTOR BOARD COVER POWER CONTROLLER FRONT CONTROL PANEL LIGHT LIGHT LOCK-OUT RESET BUTTON PROTECTION SWITCH SWITCH CONTROL BOX IGNITION TRANSFORMER 39 SPARE PARTS CONTROL BOX - SIEMENS LAL DESCRIPTION RN510 2020420 RN515 2020420 RN520 2020420 RN525 2020420 RIGHT ELECTRODE 2080250 2080250 2080250 2080250 LEFT ELECTRODE 2080251 2080251 2080251 2080251 FILTER 2090207 2090207 2090207 2090207 FAN WHEEL 2150010 2150030 2150029 2150029 AIR PRESSURE SWITCH 2160065 2160065 2160065 2160065 2170005 2170005 2170005 2170005 218020601 2180209 2180278 2180289 PUMP MOTOR 2180202 2180223 2180210 2180210 SOLENOID VALVE 2190437 2190437 2190437 2190437 OIL HOSES L = 1500 1”Mx1”F 2340004 2340004 2340004 2340004 OIL GUN HOSES L = 435 3/8” 2340089 2340089 2340089 2340089 ADJUSTING CAM FOIL 2440013 2440013 2440013 - ACTUATOR SIEMENS SQL.. 2480007 2480007 2480007 2480007 IGNITION TRANSFORMER ELECTRIC MOTOR ACTUATOR BERGER STM30 2480090 2480090 2480090 2480090 ACTUATOR SIEMENS SQM40 24800A5 24800A5 24800A5 24800A5 PHOTORESISTOR SIEMENS 2510003 2510003 2510003 2510003 COUPLING 2540019 2540126 2540126 2540126 RESISTOR THERMOSTAT TR-TCN-TCI 2560026 2560026 2560026 2560026 THERMOSTAT TRS 2560028 2560028 2560028 2560028 PRESSURE GOVERNOR - viscosity 110cSt (15°E) @ 50° C 25700C6 25700C7 25700C7 - PRESSURE GOVERNOR - viscosity 400cSt (50°E) @ 50° C 25700A6 25700A7 25700A7 - BURNER MODULATOR (FULLY-MODULATING BURNERS) 2570112 2570112 2570112 2570112 PUMP 2590119 2590120 2590121 2590121 NOZZLE mod. FLUIDICS WR2 50° 2610203 2610203 2610203 2610203 NOZZLE mod. UNIGAS M3 45° 2610230 2610230 2610230 2610230 STANDARD OIL GUN - viscosity 110cSt (15°E) @ 50° C 2700347 2700347 2700347 - EXTENDED OIL GUN - viscosity 110cSt (15°E) @ 50° C 2700337 2700337 2700337 - STANDARD OIL GUN - viscosity 400cSt (50°E) @ 50° C 2700348 2700348 2700348 2700357 EXTENDED OIL GUN - viscosity 400cSt (50°E) @ 50° C 2700338 2700338 2700338 2700358 COMBUSTION HEAD 3060167 3060164 3060169 30601D2 STANDARD BLAST TUBE 30910S4 30910S5 30910S5 30910T2 EXTENDED BLAST TUBE 30910S7 30910S8 30910S9 30910T1 IGNITION CABLE 6050144 6050144 6050144 6050144 NOTE: it is recommended to mention the burner ID number on the spare parts request form. ELECTRICAL WIRING DIAGRAMS See attached wiring diagrams. 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 41 APPENDIX SIEMENS LAL.. CONTROL BOX 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 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 contacts 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 damper 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. 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 «Preconditions for burner startup»): Extraneous light: Lockout during or after completion of the control program Examples: nonextinguished flame, leaking fuel valves faulty flame supervision circuit. Interruption of startup. No OPEN signal at terminal 8 from the changeover 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 pressure check. Air pressure failure after the air pressure check. Defect in the flame supervision circuit. Interruption of the startup sequence. No positioning signal at terminal 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 pressostato R dell’impianto 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». 4 A max., 20 A peak T6,3H250V according to IEC 127 max. 10 A Device 1000 g Plug-in base 165 g Internal fuse External fuse Weight During burner off times, the flame supervision circuit is live. Lockout indication S L Q R C 1 ... H bl SB br sw 23 22 1 1 AS b r1 a-b Startup sequence b-b’ Idle step (with no contact confirmation) b(b’)-a Postpurge program a b I a b ar1 6 7 M1 M2 4 Q R B 1 ... 23 24 22 a r2 V W 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 N 5 a b EK1* a r3 X III a a b V II a b fr2 b IX b X IV fr1 XI FR a R B X II b a IV II X b aa V III b a V a b VI b III a b AR SM b r2 L1 M M E BR A 3 21 1 (3 ) 2 15 16 18 17 19 9 11 1 0 8 SA H AL 20 LR v a M z m LK EK2* Z N BV1 BV2 7 1 5 3 a 0 7 /0 4 9 6 Sequence diagram Control output at terminal A II a b t7 a b III a b I t11 t12 C t6 D 4 12 * 7 t4 19 16 10 9 t3 IV V t1 B 15 t3 n t3" 9 a b t1 6 t5 11 20 VI V II a b V III a b 8 t20 17 IX t2 X a b XI a b X II a b X III a b X IV a b 18 * t10* t13 t8 Lockout position indication T3’ Key t1 Prepurge time with air damper fully open t2 Safety time t3 Preignition time, short («Z» connected to terminal 16) 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 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: firstname.lastname@example.org Note: specifications and data subject to change without notice. Errors and omissions excepted.