Unigas PN91, PN92, PN93 Manual Of Installation - Use - Maintenance

PN91 - PN92 - PN93

PN510 - PN515

PN520 - PN525

Progressive, Fully-modulating

Heavy oil Burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

M039196CC Rel. 2.

2

05/2010

TABLE OF CONTENTS

WARNINGS ............................................................................................................................................................... 5

PART I: INSTALLATION ........................................................................................................................................... 5

Burner model identification ............................................................................................................................................................. 5

Technical Specifications ................................................................................................................................................................. 5

Performance Curves ....................................................................................................................................................................... 7

INSTALLING THE BURNER ........................................................................................................................................................... 8

Packing ........................................................................................................................................................................................... 8

Handling the burner ........................................................................................................................................................................ 8

Fitting the burner to the boiler ......................................................................................................................................................... 9

Electrical connections ................................................................................................................................................................... 10

Fan motor direction ....................................................................................................................................................................... 11

Connecting the oil heating resistors .............................................................................................................................................. 11

Double-pipe and single-pipe system ............................................................................................................................................. 11

Oil pumps ...................................................................................................................................................................................... 12

About the use of fuel pumps ......................................................................................................................................................... 12

Connecting the oil flexible hoses .................................................................................................................................................. 13

Connections to the oil gun ............................................................................................................................................................ 13

Recommendations to design heavy oil feeding plants .................................................................................................................. 13

Pipe heating system ...................................................................................................................................................................... 14

Inlet minimum pressure of the pump (both for supplying system and burner) .............................................................................. 14

Pump operating maximum pressure (both for the supplying system and burner) ........................................................................ 14

Adjusting the supplying oil ring ..................................................................................................................................................... 14

Burner adjustments ....................................................................................................................................................................... 14

HYDRAULIC DIAGRAMS ............................................................................................................................................................. 18

Adjusting light oil flow rate ............................................................................................................................................................ 21

Oil thermostat adjustment ............................................................................................................................................................. 22

Thermostat adjustment for petroleum burners .............................................................................................................................. 22

ADJUSTING AIR AND FUEL RATE ............................................................................................................................................. 23

Adjustments - brief description ...................................................................................................................................................... 23

Oil Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator ....................................................................... 24

Adjustment by the Siemens SQL33.. actuator .............................................................................................................................. 26

Calibration of air pressure switch .................................................................................................................................................. 28

Fully-modulating burners .............................................................................................................................................................. 28

Oil circuit ....................................................................................................................................................................................... 29

PART II: OPERATION ............................................................................................................................................. 30

OPERATION ................................................................................................................................................................................. 30

Control panel ................................................................................................................................................................................. 31

PART III: MAINTENANCE ....................................................................................................................................... 32

ROUTINE MAINTENANCE ........................................................................................................................................................... 30

Self-cleaning filter ......................................................................................................................................................................... 32

Removing the combustion head ................................................................................................................................................... 32

Removing the oil gun, replacing the nozzle and the electrodes .................................................................................................... 33

Nozzle and electrodes correct position......................................................................................................................................... 34

Checking the detection current ..................................................................................................................................................... 34

Cleaning and replacing the detection photoresistor...................................................................................................................... 34

Seasonal stop ............................................................................................................................................................................... 34

Burner disposal ............................................................................................................................................................................. 34

TROUBLESHOOTING .................................................................................................................................................................. 35

BURNER EXPLODED VIEW ........................................................................................................................................................ 36

SPARE PARTS ............................................................................................................................................................................. 38

ELECTRICAL WIRING DIAGRAMS ............................................................................................................................................. 39

APPENDIX

2

WARNINGS

THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE

USER.

INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO-

DUCT 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 z

The equipment must be installed in compliance with the regulations in force, following the manufacturer’s instructions, by qualified personnel.

z 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.

z

Improper installation may cause injury to people and animals, or damage to property, for which the manufacturer cannot be held liable.

z 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.

z

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.

z Make sure that inlet or exhaust grilles are unobstructed.

z

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.

z When a decision is made to discontinue the use of the equipment, those parts likely to constitute sources of danger shall be made harmless.

z

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.

z For all the units that have been modified or have options fitted then original accessory equipment only shall be used.

z

This unit shall be employed exclusively for the use for which it is meant. Any other use shall be considered as improper and, therefore, dangerous.

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

2) SPECIAL INSTRUCTIONS FOR BURNERS z

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.

z Only burners designed according to the regulations in force should be used.

z

This burner should be employed exclusively for the use for which it was designed.

z Before connecting the burner, make sure that the unit rating is the same as delivery mains (electricity, gas oil, or other fuel).

z

Observe caution with hot burner components. These are, usually, near to the flame and the fuel pre-heating system, they become hot during the unit operation and will remain hot for some time after the burner has stopped.

When the decision is made to discontinue the use of the burner, the user shall have qualified personnel carry out the following operations: a Remove the power supply by disconnecting 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 z Make sure that the burner has, on installation, been firmly secured to the appliance, so that the flame is generated inside the appliance firebox.

z

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.

z

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 .

z 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 z

For safety reasons the unit must be efficiently earthed and installed as required by current safety regulations.

z 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.

z

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.

z No adaptors, multiple outlet sockets and/or extension cables are permitted to connect the unit to the electric mains.

z

An omnipolar switch shall be provided for connection to mains, as required by the current safety regulations.

z 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; z

The unit input cable shall not be replaced by the user.

In case of damage to the cable, switch off the unit and contact qualified personnel to replace.

When the unit is out of use for some time the electric switch supplying all the power-driven components in the system (i.e. pumps, burner, etc.) should be switched off.

3

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

GENERAL z 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.

z

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.

z 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.

z 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.

z

Do not use gas pipes to earth electrical equipment.

z Never leave the burner connected when not in use. Always shut the gas valve off.

z

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.

z

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

/E

C

- Gas Appliances;

- Directive 2006/95/EC on low voltage ;

- Directive 2004/108/E

C

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


Directive 2006/95/EC on low voltage ;

- Directive 2004/108/E C on electromagnetic compatibility




- 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

Heavy oil burners


Directive 2006/95/EC on low voltage ;



-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.



Gas - Light oil burners


- Directive 2009 / 142 /E C Gas Appliances;




-UNI EN 676 Gas Burners






Gas - Heavy oil burners


- Directive 2009 / 142 /E C - Gas Appliances;




-UNI EN 676 (Gas Burners;






4

C.I.B. UNIGAS - M039196CC

PART I: INSTALLATION

Burner model identification

Burners are identified by burner type and model. Burner model identification is described as follows.

Type PN91 Model N-. PR. S. *. A.

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

(1) BURNER TYPE

(2) FUEL

(3) OPERATION

(

Available versions)

(4) BLAST TUBE

(5) DESTINATION COUNTRY

(6) BURNER VERSION

PN91 - PN92 - PN93 - PN510 - PN515 - PN520 - PN525

N - Heavy oil, viscosity

≤

50cSt (7° E) @ 50° C

E - Heavy oil, viscosity

D - Heavy oil, viscosity

≤

110cSt (15°E) @ 50° C

≤

400cSt (50° E) @ 50° C

P - Petroleum, viscosity 89cSt (12° E) @ 50° C

PR - Progressive MD - Fully modulating

S - Standard L - Extended

* - see data plate

A - Standard

Technical Specifications

BURNER

Output

Fuel

Oil viscosity

Heavy oil rate

Power supply

Total power consumption (Heavy oil)

Total power consumption (Petroleum)

Fan motor

Pre-heater resistors (heavy oil)

Pre-heater resistors (Petroleum)

Protection

Approx. weight

Operation

Operating temperature

Storage Temperature

Working service* min - max kW min. - max. kg/h kW kW kW kW kW kg

°C

°C

PN91

698 - 2093

PN92

849 - 2558

Heavy oil

PN93

550 - 4100

See “Burner model identification” table

62 - 187 76- 228 49- 365

22.5

12.5

4

18

8

230/400V 3N a.c. 50Hz

24

18

5.5

18

12

32

26

7.5

24

18

240

IP40

280

Progressive - Fully modulating

-10 ÷ +50

290

-20 ÷ +60

Intermittent

Heavy oil net calorific value (Hi): 40.4 MJ/kg (average value).

z z

Burners provided with Siemens LMO44 control box: the control box automatically stops after 24h of continuous working. The control box immediately starts up, automatically.

Burners provided with Siemens LAL25 control box: for safety reasons, one controlled shutdown must take place every 24 hours of continuous working .

5


BURNER

Output

Fuel

Oil viscosity

Heavy oil rate

Power supply

Total power consumption (Heavy oil)

Total power consumption (Petroleum)

Fan-pump motor

Fan motor

Pump motor

Pre-heater resistors (heavy oil)

Pre-heater resistors (Petroleum)

Protection

Approx. weight

Operation

Operating temperature

Storage Temperature

Working service* min - max kW min. - max. kg/h kW kW kW kW kW kW kW kg

°C

°C

PN510 PN515 PN520 PN525

1314 - 3953

117 - 352

1628 - 4884 2326 - 6977

Heavy oil

2000 - 8000

See “Burner model identification” table

145 - 435 207 - 622

230/400V 3N a.c. 50Hz

178 - 713

400V 3N a.c. 50Hz

32

26

7.5

-

41.5

29.5

11

-

59.7

41.7

-

15

69.2

57.2

-

18.5

-

24

18

-

30

18

2.2

42

24

2.2

48

36

IP40

320 370 415 430

Progressive - Fully modulatingProgressive - Fully modulating

-10 ÷ +50

-20 ÷ +60

Intermittent

Heavy oil net calorific value (Hi): 40.4 MJ/kg (average value).

z z

Burners provided with Siemens LMO44 control box: the control box automatically stops after 24h of continuous working. The control box immediately starts up, automatically.

Burners provided with Siemens LAL25 control box: for safety reasons, one controlled shutdown must take place every 24 hours of continuous working .

6


Performance Curves

PN91

8

6

4

2

18

16

14

12

10

0

400 800 1200 1600 2000

PN93

8

6

4

2

0

500

18

16

14

12

10

1000 1500 2000 2500 3000 3500 4000 4500

PN92

2400 kW

18

16

14

12

10

8

6

4

2

0

400 800 1200 1600 2000 2400 2800 kW

PN510

24

20

16

12

8

4

0

1000 1800 2600 3400

PN520

24

20

16

12

8

4

0

1600 2400 3200 4000 4800 5600 6400 7200 8000 kW

PN515

24

20

16

12

8

4

0

1200

4200 kW

PN525

24

20

16

12

8

4

0

1500 kW

2000 2800 3600 4400 5200

2500 3500 4500 5500 6500 7500

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.

kW

8500 kW

NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine. On this diagram the maximum output point is usually reached by adjsuting the combustion head to its “MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is reached setting the combustion head to its “MIN” position. During the first ignition, the combustion head is set in order to find a compromise between the burner output and the generator specifications, that is why the minimum output may be different from the Performance curve minimum.

7

Overall dimensions (mm)

Y


Type

PN91

PN92

PN93

PN510

PN515

PN520

PN525

B = standard blast tube

BL = extended blast tube

A

1017

1017

1017

1050

1050

1050

1050

B

298

301

301

340

340

340

340

BL

488

491

491

520

520

520

520

C CL

1315 1505

1318 1508

1318 1508

1390 1570

1390 1570

1390 1570

1390 1600

D

532

532

532

550

550

650

650

E

520

520

520

560

560

670

670

F

1052

1052

1052

1110

1110

1320

1320

G

262

292

292

345

384

422

434

K

464

464

464

650

650

650

650

H M P Y

292 M12 295 228

322 M12 295

322 M12 295

2

28

2

28

385 M14 390 328

424 M14 390

328

472 M14 390 3

28

484 M14 390 3 40 z z z z z

INSTALLING THE BURNER

Packing

Burners are despatched in wooden crates whose dimensions are:

PN91-92-93

PN510-515-520-525

1730mm x 1280mm x 1020mm (L x P x H)

1730mm x 1430mm x 1130mm(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.

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.

8

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’s 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

Set the upper side of the burner flange in a horizontal position, in order to obtain the correct inclination of the pre-heating tank

Key

1 Burner flange (upper side indicated)

2 Bracket

1

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.

CAUTION: 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 fan-pump motor (see next pargraph)

4 refit the panel cover.

Probes connection

MA

Fig. 1 Progressive burners

MA

Fig. 2 - Fully modulating burners

(#) Free contact for ”Faulty heater resistor contactor”

(**) Probes connection (see Fig. 3)

Probes connection oby means of the 7-pins plug (Fig. 4) - see Fig. 3 for connections.

Fig. 4

10

Fig. 3


Fan motor direction ( and pump motor direction only for PN520 - PN525)

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

400 V 230V

L1

R1

L2

R2

L1

R1

L2

R2

R3

L3

R3

L3

Fig. 5

18 - 24 kW

400 V 230V

L1

R6

R1

R2

L2

R5 R3

L3

R4

L1

R1

R6

R2

L2

R5

L3

R4

R3

Fig. 7

8 - 12 kW

400 V 230V

L1

R1

R6

R5

R4

R2

L2

R3

L3

Fig. 6

L1

R6

R5

R4

L3

R1

R3

R2

L2

W2

ELECTRIC MOTOR CONNECTION

400 V 230V

U2 V2 W2 U2 V2

U1 V1 W1

L1 L2 L3

U1 V1 W1

L1 L2 L3

Fig. 8

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.

Danfoss KSM..

Suntec TA

G

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

PN91: SUNTEC TA2 / DANFOSS KSM50

PN92/93/510: SUNTEC TA3 / DANFOSS KSM70

PN515: SUNTEC TA4 / DANFOSS KSM100

PN520/525: SUNTEC TA5 / DANFOSS KSM140

Danfoss KSM..

Oil viscosity

Oil temperature

Max. suction pressure

Min. suction pressure

Max. return pressure

Rotation speed

2.5 ÷ 450 cSt

-10 ÷ 160 °C

4 bar

-0.45 bar to avoid gasing

4 bar

3450 rpm max

Keys

3

5

1

2

7

Pressure regulator

Pressure/Vacuum gauge port to measure inlet pressure/vacuum

Pressure gauge port

Suction

To the nozzle

8 Return

Suntec TA..

Oil viscosity

Oil temperature

Min. suction pressure

Max. suction pressure

Max. return pressure

Rotation speed

3 ÷ 75 cSt

0 ÷ 150°C

- 0.45 bar to avoid gasing

5 bar

5 bar

3600 rpm max.

3

4

1

2

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

z z z z z z z z

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


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 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..

Danfoss KSM..

A R

A R

Connections to the oil gun

1 Inlet

2 Return

3 Gun opening

4 Heating wire (only for oil viscosity > 50Cst @ 50°C)

5 Cartdrige-type heater

(only for oil viscosity >

50Cst @ 50°C)

Gun with the oil nozzle inside

5

3 2

4

1

Oil manifold

1

5

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 Fig. 9 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 Fig. 9 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.

13


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.

HEAVY OIL VISCOSITY AT 50 °C

> 50 (7) cSt (°E)

< 50 (7)

< 110 (15)

> 110 (15) < 400 (50)

PIPELINE

PRESSURE bar

1- 2

1- 2

1- 2

PIPELINE

TEMPERATURE

°C

20

50

65

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.

VISCOSITY

AT 50 °C cSt (°E)

< 50 (7)

> 50 (7) < 110 (15)

> 110 (15) 400 (50)

NOZZLE

PRESSURE

MEASURED IN

THE GUN bar

25

25

25

RETURN

NOZZLE

PRESSURE min.

max.

bar

7-9 19-20

7-9 19-20

7-9 19-20

TEMPERATURE ON

THE PRE-HEATING

RESISTORS min.

100

125

145

°C max.

115

140

160

TEMPERATURE

OF THE

RESISTORS

SAFETY

THERMOSTAT

TRS

°C

170

190

190

TEMPERATURE

ON THE OIL

ENABLING

THERMOSTAT

TCN

TEMPERATURE

ON THE PLANT

ENABLING

THERMOSTAT

TCI

°C

80

100

110

°C

50 - 60

60 - 80

70 - 90

Tab. 1 - Fluidics WR2 nozzle

*

VISCOSITY

AT 50 °C cSt (°E)

< 50 (7)

> 50 (7) < 110 (15)

> 110 (15) 400 (50)

NOZZLE

PRESSURE

MEASURED IN

THE GUN bar

20

20

20

RETURN

NOZZLE

PRESSURE min.

max.

bar

5-7 11-13

5-7 11-13

5-7 11-13

TEMPERATURE ON

THE PRE-HEATING

RESISTORS min.

100

125

145

°C max.

115

140

160

TEMPERATURE

OF THE

RESISTORS

SAFETY

THERMOSTAT

TRS

°C

170

190

190

TEMPERATURE

ON THE OIL

ENABLING

THERMOSTAT

TCN

TEMPERATURE

ON THE PLANT

ENABLING

THERMOSTAT

TCI

°C

80

100

110

°C

50 - 60

60 - 80

70 - 90

Tab. 2 - Bergonzo A3 nozzle

14

Viscosity units conversion table

Cinematics viscosity

Centistokes (cSt)

880

1100

1320

1540

1760

1980

2200

3300

4400

330

440

550

660

154

176

198

220

20.6

32.1

43.2

54

65

87.6

110

132

1

2.56

4.3

7.4

10.3

13.1

15.7

18.2

Engler Degrees

(°E)

117

146

175

204.5

233.5

263

292

438

584

20.45

23.35

26.3

29.2

43.8

58.4

73

87.6

3.02

4.48

5.92

7.35

8.79

11.7

14.6

17.5

1

1.16

1.31

1.58

1.88

2.17

2.45

2.73


2500

3000

4000

5000

6000

7000

8000

9000

500

600

700

800

900

1000

1500

2000

10000

15000

20000

Tab. 3

200

250

300

400

80

90

100

150

Saybolt

Seconds

Universal

(SSU)

31

35

40

50

60

70

Saybolt

Seconds

Furol (SSF)

400

500

600

700

800

900

1000

1500

2000

71.1

81

91

100.7

150

200

250

300

15.24

19.3

23.5

28

32.5

41.9

51.6

61.4

--

12.95

13.7

14.44

--

--

--

--

Redwood

Seconds no.1

(Standard)

Redwood Seconds no..2 (Admiralty)

3380

4230

5080

5920

6770

7620

8460

13700

18400

592

677

762

896

1270

1690

2120

2540

85.6

128

170

212

254

338

423

508

29

32.1

36.2

44.3

52.3

60.9

69.2

77.6

737

829

921

--

--

368

461

553

645

64.6

73.8

83

92.1

138.2

184.2

230

276

10.12

14.48

18.9

23.45

28

37.1

46.2

55.4

--

--

5.1

5.83

6.77

7.6

8.44

9.3

15


1000

VISCOSITY vs TEMPERATURE DIAGRAM FOR COMBUSTIBLE OILS

PUMPING LIMIT

100

10

1

-10 0 10 20 30 40 50 60

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 50°C




70 80 90 100 110 120 130 140 150 160

TEMPERATURE (°C)

Fig. 9

16


Indicative diagram showing the oil temperature at burner pump inlet vs. oil viscosity

Example: if the oil has a 50°E @ 50°C viscosity, the oil temperature at the pump inlet should be 80°C (see diagram).

OIL TEMPERATURE FOR PUMP FEEDING

100

10

1

0 10 20 30 40 50 60


70 80 90

Fig. 10

Indicative diagram showing the oil pressure according to its temperature

6

PRESSION D’ALIMENTATION POMPE

PUMP FEEDING PRESSURE

Max. for T and

TA pumps

5

Max. for E ..1069 pimps

4

3

2

1

0

40 60 80 100 120


140 160

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

1.9

1.8

1.7

1.6

1.5

1.4

1.3

1.2

50

BEST VISCOSITY RANGE FOR A

PROPER ATOMIZATION

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

Fig. 12

17


HYDRAULIC DIAGRAMS

Fig. 13 - Hydraulic diagram 3ID0023 - Single burner configuration

18


Fig. 14 - Hydraulic diagram 3ID0014 - Two or more burners configuration

19


Hydraulic Diagram 3ID0014

1 Main tank

2 Bottom valve

3 Main tank pre-heating pipe

4 Oil filter (filtration, 1mm)

5 Circuit pressure regulator

6 Manometer

7 Pressure regulation by-pass valve

8 Manual valve

9 Oil pump

10 Pump pressure regulator

11 Unidirectional valve

12 Service tank pre-heating resistor

13 Service tank pre-heating thermostat

14 Burner consent thermostat

15 Thermometer

16 Consent pressure switch for service tank resistor

17 Service tank heating pipe

18 Service tank air drain valve

19 Service tank

20 Oil filter

21 Fuel solenoid valve

22 Fuel valve

23 Burner pump flexible hoses

24 Burner oil pump

25 Pre-heating tank resistor

26 Pre heating tank

27 Oil consent thermostat

28 Heather safety thermostat

29 Thermostat for oil temperature setting

30 Tank filter

31 Thermometer

32 Check valve

33 Return pressure governor

35 Oil needle drive piston

36 Oil rate regulator


42 Burner start consent thermostat

43 Burner

45 Thermostat for pipes pre-heating pumps

46 Water pump for service tank pre-heating (1)

47 Water pump for main tank pre-heating (19)

48 Water pre-heating balance setting valve

50 Oil circulation pump

52 Oil ring max. pressure switch

Hydraulic Diagram 3ID0023

1 Main tank

2 Bottom valve

3 Main tank pre-heating pipe

4 Oil filter

5 Circuit pressure regulator

6 Manometer

7 Pressure regulation by-pass valve

8 Manual valve

9 Oil pump

10 Pump pressure regulator

11 Unidirectional valve

12 Service tank pre-heating resistor

13 Service tank pre-heating thermostat


15 Thermometer

16 Consent pressure switch for service tank resistor

17 Service tank heating pipe

18 Service tank air drain valve

19 Service tank

20 Oil filter

21 Fuel solenoid valve

22 Fuel valve

23 Burner pump flexible hoses

24 Burner oil pump

25 Pre-heating tank resistor

26 Pre heating tank

27 Oil consent thermostat

28 Pre-heating tank resistors safety thermostat

29 Thermostat for oil temperature setting

30 Pre-heating tank filter

31 Thermometer

32 Check valve

33 Return pressure governor

35 Oil needle drive piston

36 Three way valve for piston drive


42 Air separation bottle

43 Burner

45 Thermostat for pipes pre-heating pumps

46 Water pump for service tank pre-heating (1)

47 Water pump for main tank pre-heating (19)

48 Valves for setting of pre-heating water balance

52 Oil ring max. pressure switch

20


Adjusting 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 25 19-20 7 - 9 (recommended)

Fig. 15

DIMENSIONS

40

50

60

70

80

90

100

115

130

145

160

180

200

225

250

275

300

330

360

400

450

500

550

600

650

700

750

800

FLOW RATE kg/h

Min Max

13

16

20

23

26

30

33

38

43

48

53

59

66

74

82

91

99

109

119

132

148

165

181

198

214

231

250

267

40

50

60

70

80

90

100

115

130

145

160

180

200

225

250

275

300

330

360

400

450

500

550

600

650

700

750

800

Tab. 4

Pressure at nozzle 25bar

Pressure on return

Up to 100kg/h

Over 100kg/h

---------------Atomisation angle according to the return pressure

_________ % Flow rate

Pressure at nozzle 357psi

Atomisation angle

Pressure on return

% 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.

15Fig. 15).

21


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.

NOTE: thermostat TCI is provided on burners fired with fuel oil having a 50° E at 50° C viscosity only.

TCN - Oil enabling thermostat (Fig. 16)

Adjust this thermostat to a value 10% lower than that showed in the viscosity-temperature diagram ().

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.

TR - Resistor thermostat (Fig. 16)

Adjust this thermostat to the correct value according to the viscosity-temperature diagram (page 13) and check the temperature by using a thermometer mounted on the pre-heating tank.

TCI - Installation enabling thermostat (Fig. 16)

This thermostat is fitted on burners fired with oil at a viscosity of 400cSt at 50° C only. Set the thermostat according to data on page 13.

VR

PR

Fig. 16

VR VR

Thermostat adjustment for petroleum burners

To find the thermostats, remove the burner switchboard cover. Adjust them using a screwdriver on the VR screw as shown in the next picture.

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.

22


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.

Fuel

Heavy oil

Recommended combustion parameters

Recommended (%) CO

2

11 ÷ 12.5

Recommended (%) O

2

4.7 ÷ 6.7

Adjustments - brief description

z 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.

z z

Check that the combustion parameters are in the suggested limits.

z 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.

23


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

1 with the electrical panel open, prime the oil pump acting on the related contactor (see next picture): check the pump motor rotation

(page 11) and keep pressing for some seconds until the oil circuit is charged;

2 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..

Danfoss KSM..

M

VR

M

VR

Fig. 17

3 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.

4 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”.

B

C

A

5 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;

6 drive the burner to high flame stage, by means fo the thermostat TAB .

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

I

II

III

Actuator cams

High flame

Stand-by and Ignition

Low flame

MAN-AUTO

Berger STM30

MAN-AUTO

Siemens SQM40

7 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 (Fluidics nozzles - see diagram on page 21).

24


PG Pressure gauge port

Pressure gauge port

RP

V

SV

Fig. 18 Fig. 20

8 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.

9 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

RA

VRA

10 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

Attention!

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

11 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°);

12 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position;

13 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.

14 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.

15 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.

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

25


Adjustment by the Siemens SQL33.. actuator

1 with the electrical panel open, prime the oil pump acting directly on the related contactor (see next picture): check the pump motor rotation (see “Fan-pump motor direction” on page 10) and keep pressed for some seconds until the oil circuit is charged;

2 bleed the air from the M pressure gauge port (Fig. 21) by loosing the cap without removing it, then release the contactor.

Suntec TA..

Danfoss KSM..

M

VR

M

VR

Fig. 21

3 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.

4 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

5 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;

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 ID );

AUT

MAN

BF

SQL33.. actuator cams

AB = High flame

BF = Low flame

B = plastic cam

G = cam locking lever

AB B G

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 to 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 means of the related switch - see picture) to lock the adjusting cam.

26


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 showed 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. 21).

Pressure gauge port

PG

Pressure gauge port

RP

V

SV

Fig. 22 Fig. 23

10 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.

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 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

RA

VRA

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

Attention!

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

13 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.

14 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;

15 act on the V screw that mathces the bearings referring to the adjusting cam position;

16 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, according to the combustion values read.

17 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).

27


18 Turn the burner off then start it up again.

19 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;

20 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

F

21 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.

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

Calibration of air pressure switch

(only for PN520 - PN525) z z

To calibrate the air pressure switch, proceed as follows: z z z

Remove the transparent plastic cap.

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.

VR

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 stop at the current position

CMF = 1 high flame operation

CMF = 2 low flame operation

CMF = 3 automatic operation

CMF

28


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

6

5

2

Fig. 24 - Stand-by

4

1

2

3

4

6

5

Fig. 25 - Prepurge

1

2

3

4

6

5

Fig. 26 - Low flame

1

1

2

3

4

6

5

Fig. 27 - High flame

Key

1 Oil pump

2 Oil solenoid valve

3 Nozzle

4 Adjusting cam

5 Pressure gauge

6 Pressure governor

29


PART II: OPERATION

LIMITATIONS OF USE

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CON-

NECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSI-

DERED 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 AUTHORI-

SED 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

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.

z z

Turn the burner on by means of its main switch

Check that the burner is not locked (LED E

A (see next pictures).

lights up); if so, reset it by pressing the reset button N .

z z

Check that the series of thermostats (or pressure switches) enable the burner to start up.

z

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.

30


Control panel

PN91 - PN92 - PN93 - PN510

E

A B C

D

F

Q

P

N

L

R

A

B

High flame lamp

Low flame lamp

C Ignition transformer operation

CMF Manual operation switch

0= Off 1= High flame

2= Low flame 3= Automatic

D Fan motor thermal cutout intervention

F Burner in stand-by

IRA Auxiliary resistors wsitch

L

N

P

Heavy oil solenoid lamp operation

Contrlol box reset pushbutton

Heating resistors safety thermostat

R Modulator

T Main switch

T

PN515 - PN520 - PN525

E

F

A B C

D

P

P

Q

Q

N

L

T

R

31


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..

z z z z z z z

ROUTINE MAINTENANCE z Clean and examine the oil filter cartridge and replace it if necessary.

z

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 32).

z

Examine and clean the ignition electrodes, adjust and replace if necessary (see page 33).

Examine and clean the detection probe, adjust and replace if necessary (see page 34).

Examine the detection current (see page 34).

Remove and clean (page 34) 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 for oil viscosity >110 cSt @ 50 °C. Periodically turn the knob to clean the filter.

Removing the combustion head

z z z

Remove the cover H.

Slide the UV photoelectric cell out of its housing.

Unscrew the oil connections E (Fig. 28) connecting the flexible pipes to the lance L and remove the whole assembly as shown in

Fig. 28-Fig. 29. z 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.

32


H

5 4

L

1 2 3 1 2 3

5

E

Fig. 25

Key

1 Inlet

2 Return

3 Lance opening

4 Heating wire (only for oil viscosity > 110 cSt @ 50 °C)

5 Cartdrige-type heater

H Cover

L Oil lance

E Oil piping connections

Fig. 26

1

2

3

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 previous paragraph;

2 loosen the VU screw and remove the oil gun: 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 VB fixing screws and remove them: place the new electrodes being careful to observe the measures shown on next paragraph: reassemlbe following the reversed procedure.

Caution : adjust the nozzle position, by means of the VU screw.

VB

VU

Fig. 27

33


Nozzle and 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. Quotes are referred in mm.

VB

Fig. 28

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.

PN91-PN92 - PN93: LMO44

PN510-PN515-PN520-PN525: LAL2.

MA TERMINAL BLOCK 34 35

Control box

LMO44

LAL2..

Minimum detection signal

45 µA

95µA SCALE µA DC

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.

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”.

34


TROUBLESHOOTING

CAUSES/TROUBLES

MAIN SWITCH OFF

LINE FUSES BLOWN

MAXIMUM THERMOSTAT MALFUNCTION

FAN THERMAL CUTOUT TRIPPED

AUXILIARY FUSE BLOWN

OIL RESISTOR FAULTY

OIL ENABLING THERMOSTAT TRIPPED

CONTROL UNIT MALFUNCTION

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 z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z

35

BURNER EXPLODED VIEW

ITEM

3.5

4.1

4.2

4.3

3.3.1.4

3.3.2

3.3.3

3.4

3.1.2

3.1.3

3.1.4

3.2

3.3

3.3.1.1

3.3.1.2

3.3.1.3

4.4

5.1

5.2.1

2.1.5

2.1.6

2.1.7

2.1.8

2.2

2.3

2.4

3.1.1

1.1

1.2

1.3

1.4

2.1.1

2.1.2

2.1.3

2.1.4

DESCRIPTION

NIPPLE

ELBOW

NIPPLE

PUMP

POWER CONTROLLER

FRONT CONTROL PANEL

LIGHT

LIGHT

LOCK-OUT RESET BUTTON

PROTECTION

SWITCH

SWITCH

BRACKET

BOARD

COVER

LONG IGNITION ELECTRODE

LONG IGNITION ELECTRODE

COMBUSTION HEAD

IGNITION CABLE

GUN TERMINAL

STANDARD COMPLETE OIL GUN

NIPPLE

RESISTOR FIXING SCREW

OIL MANIFOLD

RESISTOR

NOZZLE

NOZZLE HOLDER

OIL GUN HOLDER

COMBUSTION HEAD ADJUSTING PIPE

SPACER

FAN WHEEL

MOTOR

GAUGE RING

STRAIGHT UNION

OIL FILTER

ITEM

7.9

7.10

7.11

7.12

7.13

8.1.1

8.1.2

8.1.3

7.5

7.6

7.7

7.8

7.1

7.2

7.3

7.4

8.1.4

8.1.5

8.2

6.4

6.5

6.6

6.7

5.7

6.1

6.2

6.3

5.3

5.4

5.5

5.6

5.2.2

5.2.3

5.2.4

5.2.5

DESCRIPTION

GASKET

GAS BLEEDING VALVE

THERMOMETER

MUFF

COVER

REDUCTION

OIL PRE-HEATER

SHEATH

RESISTOR

NIPPLE

STRAIGHT JOINT

UNION ELBOW

OIL SOLENOID VALVE

REDUCTION

OIL MANIFOLD

CONNECTOR

UNION ELBOW

STRAIGHT UNION

UNION ELBOW

SCREW

ADJUSTING ROD

REDUCTION

WASHER

BUSH

BEARING

PRESSURE GOVERNOR

BRACKET

BRACKET

SPACER

BUSH

ACTUATOR

ACTUATOR SHAFT

BRACKET

NET

ITEM

16.1

16.2

16.3

16.4

16.5

16.6

16.7

17

18

19

12

13

14

15

9.2

10

11

11.1

8.10.2

8.10.3

8.10.4

8.10.5

8.10.6

8.10.7

8.10.8

9.1

8.3

8.4

8.5

8.6

8.7

8.8

8.9

8.10.1

DESCRIPTION

AIR INTAKE DAMPER

AIR INTAKE DAMPER

AIR INTAKE

LOUVER SHAFT

LOUVER SHAFT

ADJUSTING CAM SHAFT

ADJUSTING CAM

SCREW

SCREW

SPACER

CAM

LEVERAGE

ROD

JOINT

JOINT

FAIRLEAD

FAIRLEAD

AIR INLET CONE

BURNER HOUSING

COVER

GENERATOR GASKET

RING NUT

INSPECTION GLASS

PHOTORESISTOR

PIN

ELASTIC RING

ELASTIC RING

HALF-COUPLING

HALF-COUPLING

HALF-COUPLING

HALF-COUPLING

BRACKET

RESISTOR

STANDARD BLAST TUBE


SPARE PARTS

DESCRIPTION

CONTROL BOX SIEMENS LMO

RIGHT ELECTRODE

LEFT ELECTRODE

FILTER FOR OIL VISCOSITY > 50 cSt @ 50°C

SELF-CLEANING PRE-HEATER FILTER

GASKET

FAN WHEEL

IGNITION TRANSFORMER

ELECTRIC MOTOR

SOLENOID VALVE

OIL HOSES

OIL GUN HOSES

OIL GUN HOSES

OIL GUN HOSES

ADJUSTING CAM FOIL

ACTUATOR mod. SIEMENS SQL..

ACTUATOR mod. BERGER STM30

ACTUATOR mod. SIEMENS SQM40

PHOTORESISTOR SIEMENS

COUPLING

RESISTOR THERMOSTATTR-TCN-TCI

THERMOSTAT TRS

PRESSURE GOVERNOR FOR OIL VISCOSITY < 110 cSt @ 50 °C

PRESSURE GOVERNOR OIL VISCOSITY > 110 cSt @ 50 °C

BURNER MODULATOR (only for fully-modulating burners)

PUMP mod. DANFOSS

PUMP mod. SUNTEC

NOZZLE mod. FLUIDICS WR2 50°

STANDARD OIL GUN FOR OIL VISCOSITY < 110 cSt @ 50 °C

EXTENDED OIL GUN FOR OIL VISCOSITY < 110 cSt @ 50 °C

STANDARD OIL GUN FOR OIL VISCOSITY > 110 cSt @ 50 °C

EXTENDED OIL GUN FOR OIL VISCOSITY > 110 cSt @ 50 °C

COMBUSTION HEAD

STANDARD BLAST TUBE

EXTENDED BLAST TUBE

IGNITION CABLES

PN91 PN92 PN93

2020455 2020455 2020420

2080250 2080250 2080250

2510003

2540121

2560026

2560028

2570054

25700A6

2570112

2590310

2590118

2610203

2700331

2700332

2700339

2700333

3060160

30910E2

3091091

6050144

2080251

2090207

2090212

2110048

2150031

2170005

2180276

2190437

2340004

2340087

2340088

2340091

2440013

2480007

2480090

24800A5

2510003

2540121

2560026

2560028

2570054

25700A6

2570112

2590310

2590118

2610203

2700331

2700332

2700339

2700333

3060161

30910E3

30910A2

6050144

2080251

2090207

2090212

2110048

2150033

2170005

2180277

2190437

2340004

2340087

2340088

2340091

2440013

2480007

2480090

24800A5

2510003

2540134

2560026

2560028

2570077

25700A6

2570112

2590311

2590119

2610203

2700331

2700332

2700339

2700333

3060161

30910E3

30910A2

6050144

2080251

2090207

2090212

2110047

2150032

2170005

2180206

2190437

2340004

2340087

2340088

2340091

2440013

2480007

2480090

24800A5

38


DESCRIPTION

CONTROL BOX SIEMENS LAL

RIGHT ELECTRODE

LEFT ELECTRODE

FILTER FOR OIL VISCOSITY > 50 cSt @ 50°C

SELF-CLEANING PRE-HEATER FILTER

GASKET

FAN WHEEL

IGNITION TRANSFORMER

ELECTRIC MOTOR

ELECTRIC MOTOR

SOLENOID VALVE

OIL HOSES

OIL GUN HOSES

OIL GUN HOSES

OIL GUN HOSES

ADJUSTING CAM FOIL

ACTUATOR mod. SIEMENS SQL..

ACTUATOR mod. BERGER STM30

ACTUATOR mod. SIEMENS SQM40

PHOTORESISTOR SIEMENS

COUPLING

RESISTOR THERMOSTATTR-TCN-TCI

THERMOSTAT TRS

PRESSURE GOVERNOR FOR OIL VISCOSITY < 110 cSt @ 50 °C

PRESSURE GOVERNOR OIL VISCOSITY > 110 cSt @ 50 °C

BURNER MODULATOR (only for fully-modulating burners)

PUMP mod. DANFOSS

PUMP mod. SUNTEC

NOZZLE mod. FLUIDICS WR2 50°

STANDARD OIL GUN FOR OIL VISCOSITY < 110 cSt @ 50 °C

EXTENDED OIL GUN FOR OIL VISCOSITY < 110 cSt @ 50 °C

STANDARD OIL GUN FOR OIL VISCOSITY > 110 cSt @ 50 °C

EXTENDED OIL GUN FOR OIL VISCOSITY > 110 cSt @ 50 °C

COMBUSTION HEAD

STANDARD BLAST TUBE

EXTENDED BLAST TUBE

IGNITION CABLES

ELECTRICAL WIRING DIAGRAMS

Electrical diagram 07-345 - Burners type PN 91 - 92 -93 x-.PR...

Electrical diagram 07-403 - Burners type PN91 - 92 - 93 x-.MD..

Electrical diagram 11-275 - Burners type PN510 x-.PR...

Electrical diagram 11-294 - Burners type PN510 x-.MD...

Electrical wiring diagram 11-276 - Burners type PN515 D-.PR..

Electrical wiring diagram 11-277 - Burners type PN520 D-.PR...

Electrical wiring diagram 11-295 -Burners type PN515 D-.MD...

Electrical wiring diagram 11-296 - Burners type PN520 D-.MD...

PN510

2020420

2080250

2080251

2090207

2090212

2110047

2150032

2170005

2180206

-

2190437

2340004

2340087

2340088

2340089

2440013

2480007

2480090

24800A5

2510003

2540122

2560026

2560028

2570077

25700A6

2570112

2590311

2590119

2610203

2700347

2700337

2700348

2700338

3060167

30910E4

30910A3

6050144

PN515

2020420

2080250

2080251

2090207

2090212

2110047

2150035

2170005

2180209

-

2190437

2340004

2340087

2340088

2340089

2440013

2480007

2480090

24800A5

2510003

2540122

2560026

2560028

25700B2

25700A7

2570112

2590312

2590120

2610203

2700347

2700337

2700348

2700338

3060164

30910E5

30910A4

6050144

PN525

2020420

2080250

2080251

2090207

2090212

2110047

2150029

2170005

2180289

2180210

2190437

2340004

2340087

2340088

2340089

2440013

2480007

2480090

24800A5

2510003

2540126

2560026

2560028

25700A7

25700A7

2570112

2590313

2590121

2610203

2700244

-

2700245

-

30601C9

30910L9

-

6050144

PN520

2020420

2080250

2080251

2090207

2090212

2110047

2150029

2170005

2180278

2180210

2190437

2340004

2340087

2340088

2340089

2440013

2480007

2480090

24800A5

2510003

2540126

2560026

2560028

25700B2

25700A7

2570112

2590313

2590121

2610203

2700347

2700337

2700348

2700338

3060165

30910E6

30910A5

6050144

39

APPENDIX

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

SIEMENS OIL BURNERS AUTOMATIC CONTROLLER SIEMENS

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.

z z z

Preconditions for startup z Burner control is reset

All contacts in the line are closed

No undervoltage

Flame detector is darkened, no extraneous light

Undervoltage z Safety shut-down in the operating position takes place should the mains voltage drop below about AC 165 V z 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

After a mains failure Restart

Response

After voltage has fallen below the undervoltage threshold

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

Restart

Lock-out at the end of «t1»

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

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

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.

Lock-out at the end of TSA

Max. 3 repetitions, followed by lock-out

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

E K

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

s l o

Status

Oil pre-heater heats, waiting time «tw»

Ignition phase, ignition controlled

Operation, flame o.k.

oooooooooooo

Operation, flame not o.k.

omomomomomo

Undervoltage lslslslslsl

Fault, alarm sssssssssss

Output of fault code (refer to Fault code table) smsmsmsmsm

Extraneous light prior to burner start-up

Interface diagnosis osososososo ssssssssssssss

Key m l o s

Red

Yellow

Green

Off

Yellow

Green

Red

Colour

Yellow

Yellow-off

Green

Green-off

Yellow-red

Red

Red-off

Green-red

Red flicker light

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.

Blink code

2 blinks **

3 blinks ***

4 blinks ****

5 blinks *****

6 blinks ******

7 blinks *******

8 blinks ********

9 blinks *********

10 blinks ********** z z z

Colour code table

Colour code lllllllllll lmlmlmlmlml

Error code table

Possible cause

No establishment of flame at the end of TSA z Faulty or soiled fuel valves

Faulty or soiled flame detector

Poor adjustment of burner, no fuel

Faulty ignition

Free

Extraneous light on burner startup

Free

Free

Too manny losses of fleme during operation

(limitattion og the number of repetitions) z z z

Faulty or soiled fuel valves

Faulty or soiled flame detector

Poor adjustment of burner

Time supervision oil pre-heater

Free

Wiring error or internal error, output contacts

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

z Burner remains shut down z 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

EK1 μC1 μC control

LED

SB

R

K3

1 2 10

W

AL

K1

8

8

N

K2 kbr

OW

3

3

OH

Si

L

N

7130a01e/0700

6

M Z

μC2

7 4

BV1

5 9

1

11 12 bl

QRC sw br

FSV

EK2

QRB

LMO24 - LMO44

EK1 µC 1 µC control µC 2

LED

K2

SB

1 2

K3

10

R

W

AL

Si

L

N

7130a02e/0700

Control sequence

LMO14

K1

8 kbr

3

8

O W

3

O H

N

M Z

6 7 4 5

K4

9

BV1

BV2

FSV

11 12

EK2

Q R B

1

Q R C bl sw br

R

W

SB

A´

OH tw

OW

M

A B

BV1

Z t1 t3

FS

Only with LMO14.113A2: re-ignition

Z

FS t3n

7130d02e/0700 t3n

TSA t3n

C D

1

8

3

3

4

6

11

12

6

11

12

LMO24 - LMO44

R

W

SB

A ´

O H tw

A

O W

M

BV1

BV2

Z t1 t3

FS

B t3n

Z

FS

7130d03e/0700 t3n

TSA t3n

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´

A

Beginning of start-up sequence with burners using an oil preheater

Beginning of start-up sequence with burners using no oil preheater

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

W

External primary fuse

Limit thermostat or pressure switch

Z t4

Ignition transformer

Interval from flame signal to release «BV2»

TSA Ignition safety time tw Waiting time for oil pre-heating

B

C

Time of flame establishment

Operating position

D Controlled shut-down by «R»

µC1 Microcontroller 1

µC2 Microcontroller 2

C D

3

3

1

8

4

5

6

11

12

6

11

12

General unit data

Mains voltage

Mains frequency

External primary fuse

Power consumption

Mounting orientation

Weight

Degree of protection

Perm. cable lengths

AC 230 V +10 % / -15 %

AC 110 V +10 % / -15 %

50...60 Hz ±6 %

(Si) 5 A (slow)

12 VA optional approx. 200 g

IP 40 max. 3 m at a line capacitance of 100 pF/ m

Detector cable laid separately 20 m

Remote reset 20m

Max perm. amperage at cos

ϕ≥

0.6

LMO14

Terminal 1

Terminals 3 and 8

Terminals 4, 5, 6 and 10

5 A

3 A

1 A

LMO24-LMO44

5 A

5 A

1 A

Flame supervision with QRB and QRC

Min. detector current required (with flame)

QRB QRC

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

Key

µA DC bl sw br

11 bl

QRB...

12 sw

+

LMO...

7130v01/0700

µA DC bl

11 12 sw

+ br

1

µA DC

QRC1...

DC microamperometer with an internal resistance of 5 k

Blue

Black

Brown

Ω

max.

LMO...

7130v02/0700

SIEMENS LAL.. CONTROL BOX

Use z z z z

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 z z z z

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 z uses easy-to-remember symbols to indicate the type of fault and the point in time lockout occurred z z z z z

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

z 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 z z

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 z Burner control is not in the lockout position z Sequence switch is in its start position (with LAL2 voltage is present at terminals 11 and 12.

z Air damper is closed; end switch «z» for the CLOSED position must feed power from terminal 11 to terminal8.

z z

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»: z z

«R» closes the start control loop between terminals 4 and 5 z The sequence switch starts to run z Only prepurging, fan motor at terminal 6 receives power z z

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 z z

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 ensured.

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.

|

A

Flame signa has been lost during operation.

Consenso all’avviamento (ad esempio tramite il termostato o il pressostato R dell’impianto

Operating position of the burner B

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».

Absorption

Mounting position

AC 3.5 VA optional

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

External fuse

Weight

T6,3H250V according to IEC 127

max. 10 A

Device 1000 g

Plug-in base 165 g

L

S

Q R C 1 ...

H

S B

1 b l

22 s w

2 3 b r

1

A S

E K 1 *

N b r1 a b a

I b ar1

4

W a r2

6 7

2 2

V

F R

B

R

IX fr1 a

5 b

N

M 1 M 2 fr2

L 1

X I b a

X III a

X II b

A R b r2

E

A

M

B R

3 2 1

1 (3 )

2

A L

H

E K 2 *

IV

1 5

Z b

II X a a

V III b a b a

V b

1 6 1 8 1 7 1 9 9

S A

B V 1 B V 2 v

V I

L R

2 0 a

M z

11 1 0 m a

X IV b a a

V II b b a r3

III a b

7 1 5 3 a 0 7 /0 4 9 6

S M

M

8

Q R B 1 ...

2 3 2 4

L K

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

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 %

Sequence diagram

I

II

III

IV

V

V I

V II

V III

IX

X

X I

X II

X III

X IV a b a b a b a b a b a b a b a b a b a b a b t7

*

A t1 6 t1 1 t10 * t3 " t1

Lockout position indication t8 t1 2 t3 t2 t4 t3 n t5

B C t2 0

Control output at terminal t6

D

4 1 2

*

7

1 9

16

10

9

15

9

11

20

8

17

1 8 t1 3

T3’ t3n t4 t5

Key t1 t2 t3 t6 t7 t8 t10 t11 t12 t13 t16 t20

Prepurge time with air damper fully open

Safety time

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

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

Postignition time («Z» connected to terminal 15)

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

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

Postpurge time (with «M2»)

Interval between start command and voltage at terminal 7 (start delay time for «M2»)

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

Interval from startup to the beginning of the air pressure check

Air damper running time to the OPEN position

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

Permissible afterburn time

Interval to the OPEN command for the air damper

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: [email protected]

Note: specifications and data subject to change without notice. Errors and omissions excepted.

Unigas PN91, PN92, PN93 Manual Of Installation - Use - Maintenance

Progressive, Fully-modulating

Heavy oil Burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

TABLE OF CONTENTS

Burner model identification

Technical Specifications

Performance Curves

Overall dimensions (mm)

Packing

Handling the burner

Fitting the burner to the boiler

Electrical connections

Fan motor direction ( and pump motor direction only for PN520 - PN525)

Connecting the oil heating resistors

Double-pipe and single-pipe system

Bleed

Oil pumps

About the use of fuel pumps

Connecting the oil flexible hoses

Connections to the oil gun

Recommendations to design heavy oil feeding plants

Pipe heating system

Inlet minimum pressure of the pump (both for supplying system and burner)

Pump operating maximum pressure (both for the supplying system and burner)

Adjusting the supplying oil ring

Burner adjustments

PUMP FEEDING PRESSURE

Adjusting light oil flow rate

Oil thermostat adjustment

Thermostat adjustment for petroleum burners

Adjustments - brief description

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

Adjustment by the Siemens SQL33.. actuator

Calibration of air pressure switch

Fully-modulating burners

Oil circuit

Control panel

Self-cleaning filter

Removing the combustion head

Removing the oil gun, replacing the nozzle and the electrodes

Nozzle and electrodes correct position

Checking the detection current

Cleaning and replacing the detection photoresistor

Seasonal stop

Burner disposal

BURNER EXPLODED VIEW

ϕ≥

Ω

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