CIB UNIGAS TN 1050 Manual Of Installation - Use - Maintenance

TN1030

TN1050

Heavy oil

Industrial Burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

M039208CA REV. 0 03/2008

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 repeated burner shut-downs, do not continue re-setting the unit manually. Contact qualified personnel to take care of such defects.

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

3

the power-driven components in the system (i.e. pumps, burner, etc.) should be switched off.

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

GENERAL 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 90/396/CEE - Gas Appliances;

- Directive 2006/95/EC on low voltage ;

- Directive 2004/108/CEE 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 ;





- 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 90/396/CEE Gas Appliances;




-UNI EN 676 Gas Burners






Gas - Heavy oil burners


- Directive 90/396/CEE - Gas Appliances;




-UNI EN 676 (Gas Burners;






4

CIB UNIGAS - M039208CA

PART I: INSTALLATION MANUAL

GENERAL FEATURES

This series of industrial burners is designed for all those applications that require big-sized air fans or air-flue heat exchangers to be installed in sound-proof areas to reduce noise. They can be provided with built-in or separately-mounted control panel (console or wallmounted.

8

7

1

2

3

6

5

4

Fig. 1

1 Combustion head

2 Blast tube

3 Burner flange

4 Adjusting cam

5 Actuator

6 Air inlet flange

7 Oil gun

8 Ignitor gas train

The fuel coming from the supply line, is pushed by the pump to the nozzle and then into the combustion chamber, where the mixture between fuel and air takes place and consequently the flame.

In the burners, the mixture bertween fuel and air, to perform clean and efficient combustion, is activated by atomisation of oil into very small particles. This process is achieved making pressurised oil passing through the nozzle.

The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pressure, pumps are provided with a pressure regulator (except for some models for which a separate regulating valve is provided). Other pumps are provided with two pressure regulators: one for the high and one for low pressure (in double-stage systems with one nozzle).

In the double-stage burners, the electric actuator (5), that moves the air damper, allows the optimisation of the gas flue values, as to get an efficient combustion. The position of the combustion head determines the burner’s output. The air (comburent) and fuel (light oil) are forced into the combustion chamber, as to let the flame light up.

How to choose the burner

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

To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed: z fuel furnace input, in kW or kcal/h (kW = kcal/h / 860); boiler type; combustione head type (reverse flame or three phase)’ temperature or pressure of the thermal carrier fluid

Comburent air temperature

Air duct positioning

Pressure in the combustion chamber

Elevation (altitude) of burner installation

Gas train (only for gas burners)

Pumping unit (only for light-oil or heavy-oil burners)

Air fan

Bilt-in or separated control panel

5

CIB UNIGAS - M039208CA z backpressure (data are available on the boiler ID plate or in the user’s manual).

Burners provided with built-in control panel are designed for IP40 index of protection. For other values of IP, please contact the CIB

UNIGAS Technical Dpt.

Power output diagram at 15àC air temperature

TP1030

TP1050

TP525A

0

TP520A

TP515A

TP512A

TP93A

TP92A

TP91A

TP90A

2000 4000 6000 8000

Burner performance range

10000 12000 14000 16000 z z z

Data requested: z furnace input; z z z air temperature altitude generator pressure or temperature

Example: furnace input: 9600kW air temperature: 15°C altitude: 0m

Fig. 2

See the diagram in Fig. 2, as to find the burners that better suite the power range requested in the exmple (9600kW). Once the models are founded out, the choice regards technical and economical features. Technical features can be summarised in a higher modulation ratio (fewer start-ups, less consumption, fewer swigings in the generator temperature and pressure values.

Burner model identification

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

Type TN1030 Model N.

PR.

S. *.

G.

(1)

(1) BURNER TYPE

(2) FUEL

(3) OPERATION

(4) BLAST TUBE

(5) DESTINATION COUNTRY

(6) BURNER VERSION

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

TN1030

N - Heavy oil, standard viscosity <= 7° E @ 50° C

D - Heavy oil, high viscosity <= 50° E @ 50° C

E - Ecological heavy oil, viscosity between 7°E and 15°E @ 50° C

PR - Progressive

MD - Fully-modulating

S - standard

* - see data plate

G - Control panel and junction box

6


Specifications

Note: Output values are valid for comburent air temperature lower than 50°C.

Output

Fuel

Oil viscosity

Flow rate

Power supply

Electrical power consumption

Pump motor

Pre-heater resistors

Index of protection

Approx. weight

Operation

Operating temperature

Storage temperature

Working service * kW

°E, 50 °C kg/h kW kW kW kg

°C

°C

TN 1030 TN 1050

2550 - 13000

Heavy oil

3500 - 15500

50

227 - 1158 312 - 1381

400V 3Na.c. 50Hz

54

5.5

24 + 24

IP40

200

Progressive - Fully modulating

-10 / +50

-20 / +60

Intermittent

* NOTE ON THE BURNER WORKING SERVICE: for safety reasons, one controlled shutdown must be performed every 24 hours of continuous operation.

WARNING: the ignitor operates with natural gas or LPG and its working service is intermittent. For further information, see paragraph “Ignitor gas train”.

Performance Curves

TN1030

2000

TN1050

4000 6000 8000 10000 12000 14000 kW

2000 4000 6000 8000 10000 12000 14000 16000 kW

Performance range

To get the input in kcal/h, multiply value in kW by 860. Data are referred to standard conditions: 1013mbar, 15°C

7

Overall dimensions (mm) (TN1030)

460

460

65

1

Ø472

M16

600

Boiler drilling plate and burner flange

70

570

470

370

270

100

Q 10

610

640

Air inlet flange

MOUNTING AND CONNECTING THE BURNER

Packing


1

1

1

2

The burners are despatched in wooden crates whose dimensions are:

2280 x 1730 x 1360mm (L x P x H)

Packing cases of this kind are affected by humidity and are not suitable for stacking. In each packing case, you will find: burner; flexible hoses; light oil filter; gasket to be inserted between the burner and the boiler;

1 envelope containing this manual.

Packing cases of this type are affected by humidity and are not suitable for stacking.

The following are placed in each packing case:

Handling the burner

H

P

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

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

The burner is provided with eyebolts, for handling operations.

L

Eyebolts

Fitting the burner to the boiler

To perform the installation, proceed as follows:

1 drill the furnace plateas decribed in paragraph (“Overall dimensions”);

2 place the burner towards the furnace plate: lift and move the burner by means of its eyebolts placed on the top side (see”Lifting and moving the burner”);

3 screw the stud bolts (5) in the plate holes, according to the burner’s drilling plate described on paragraph “Overall dimensions”;

4 place the gasket on the burner’s flange;

5 install the burner into the boiler;

6 fix the burner to the stud bolts, by means of the fixing nuts, according to the picture below.

;

7 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material (ceramic fibre cord or refractory cement).

Keys

4

1 Burner

2 Fixing nut

3 Washer

4 Ceramic fibre plait

5 Stud bolt

7 Blast tube

Installing the fan

Pay attention when designing the air duct: dimensioning must be performed according to the flow rate, the temperature, the distance between the fan and the burner and according to the fan features as well.

ATTENTION!

The bellows unit provided is made of canvas and is provided with blocking spacers to avoid breaking it during installation: first place the bellows unit between flanges, then remove the spacers.

9


Matching the burner to the boiler

The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in diameter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with respect of the application involved. To correctly match the burner to the boiler verify the necessary input and the pressure in combustion chamber are included in the burner performance curve; otherwise the choice of the burner must be revised consulting the burner manufacturer. To choose the blast tube lenght follow the instructions of the boiler manufacturer. In absence of these consider the following: z z

Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than 100 mm into the combustion chamber.

Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in respect to the tube bundle plate.

The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably-sized spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).

Burner ignitor

Execute the burner ignitor connections as follows:

MANIFACTURER INSTALLER

LPG

1 2 3 4

5

Legenda

1 Gas valve

2 Gas filter

3 Manual cutoff valve

4 Pressure reducer

5 Tank

Gas supply: LPG

Gas pressure: 100 mbar

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

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

10


H

y

draulic 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 p lu g, 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 p ’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 doublepipe systems. They can be suited for single-pipe system (recommended in the case of gravity feed) as decribed before.

The bypass plug inserted beween high pressure and shaft seal is only intended to change the pump rotation, check the presence of this plug with a 4 mm Allen key in the pressure outlet of the pump.

Caution: changing the direction of pump rotation involves changing of all pump connections.

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.

pipeline length in meters.

Key

3

5

6

1

2

A

B

Oil under suction

Oil under pressure

To the pressure adjustment valve

Vacuum gauge port

Pressure gauge port

Suction (from the tank)

By-pass plug inserted

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.

Suntec T pump

Viscosity

Oil temperature

Minimum suction pressure

4 - 800 cSt

0 - 140 °C

- 0,45bar to prevent gasing

Maximum suction pressure 5 bar

2

3

4

Rated speed

Key

1 To pressure adjusting valve G3/4

3600 rpm max.

Pressure/vacuum gauge port to measure the inlet pressure/vacuum G1/4

Pressure gauge port G1/4

Inlet G3/4

11


Suntec TV Pressure governor

Pressure adjustment

Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase pressure, twist adjusting screw 3 clockwise.

To decrease the pressure, twist screw counterclockwise. Tight the lock nut 4, refit the gasket 2 and the cap nut 1.

3

4

5

Key

1

2

Cap nut

Gasket

Adjusting screw

Lock nut

Gasket

Connections to the oil gun

1 Inlet

2 Return

3 Gun opening

4 Heating wire (only for high density oil burners)

5 Cartdrige-type heater

(only for Ecoden or high density oil burners)

Gun with the oil nozzle inside

5

3 2

4

1

Oil manifold

1

2

3

5

Fig. 3

12

Connecting the burner to the light oil pumping unitConnecting the burner to the oil pumping unit

Follow the scheme in the picture below to connect the burner to the oil pumping unit. The pump sends the oil coming from the tank to the burner. The pressure governor makes the oil reach the nozzle at the required pressure, while the excess of oil goes back to the tank. To change the delivery pressure act on the adjusting screw of the delivery pressure governor.

To the burner

Electric panel

Comb filter

Thermometer

Air drain cock

To plug

From the tank

Pressure gauge

Pump

Pressure governor

Pre-heater drain plug

Filter

Return from burner


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.

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 ADE-

QUATE FOR CONNECTION TO THE MAINS. STRICTLY OBSERVE THE DATA PLATE.

As far as electrical connections, see the “ELECTRICAL WIRING DIAGRAMS” chapter.

Once the burner electrical connection is accomplished, remember to check the rotation of the motors.

Motors must rotate in the direction showed on their casing. In the event of wrong rotation, reverse the three-phase supply and check again the motor rotation.

Rotation of fan motor and pump motor

Once the electrical connection of the burner is executed, remember to check the rotation of the motors. The motor should rotate according to the indication on the body. In the event of wrong rotation, reverse the three-phase supply and check again the rotation of the motor.

Connecting the oil heating resistors

18 - 24 kW

400 V 230V

PUMP MOTOR CONNECTION

W2

400 V 230V

U2 V2 W2 U2 V2

L1

R6

R5

R1

L3

R4

R2

L2

R3

L1

R1

R6

R2

L2

R3

R5

R4

L3

L1

U1

L2

V1

L3

W1

U1

L1

V1

L2

W1

L3

Connecting the fan motor

In case of star-delta start-up, connect all the 6 wires, according to the sequence shown in the “Electrical wiring diagrams” chapter. If the start-up is performes by means of inverter, follow the instructions on the related manual.

14


Guidelines for the appropriate use of heavy oil

For a correct operation of heavy oil or dual fuel burners (gas - heavy oil), the supply plant must be correctly build and it must ensure two fundamental conditions: z z

CONSTANT PRESSURE

CONSTANT TEMPERATURE z z

Here below we explain why it is essential to heat the oil and keep it under pressure.

Consider, as an example, a fuel oil with the following properties:

Fuel oil BTZ (low sulphur rate)

Viscosity from 3 to 5 °E at 50 °C

Such a fuel (see curve n. 3 in Fig. 4), at a temperature of 20° C, changes its viscosity from 3 - 5 °E to 15-20 °E and, at 10° C the viscosity exceeds 40° E.

In such conditions, obviously, the fuel couldn’t be carried from the tank to the burner.

Once the oil has been heated, it can’t be sucked by the burner pump, unless you keep it in pressure. In fact, as per drawing in Fig. 6, the pump manufacturer states that the minimum feeding pressure must be 1 bar at 40 °C temperature.

Should you try to suck the heated oil directly from the tank, you could get cavitation. The burner pump would constantly loose pressure as long as you heat the fuel. In this way you bring the nozzle pressure to values different from the one stated by the nozzle manufacturer. In such way the atomization would result incorrect.

From the diagram in Fig. 5, you get the pre-heating temperature of the oil according to viscosity and, from diagram in Fig. 6, you get the pump feeding pressure according to temperature.

Therefore, it is necessary in order to set up a suitable oil circuit, look at the diagrams in Fig. 8 and Fig. 9, taken from UNI 9248 “FEE-

DING LINES FOR LIQUID FUELS TRANSPORT FROM TANK TO BURNER”.

In any case, whatever is the choosen solution to realise the oil circuit, you must act according to what is mentioned here above (constant pressure and constant temperature).

After setting up the feeding circuit, you have to decide the temperature and pressure values to be set up in the components of the feeding pipeline and of the burner.

Please find here below, a set up table regarding several types of fuels.

FUEL

Fluid BTZ

(ecoflu)

High viscosity BTZ

(Ecoden)

High viscosity

VISCOSITY

AT 50 °C

°E

3 7

7

15

15

PIPELINE

PRESSURE bar

1- 2

1- 2

PIPELINE

TEMPERATURE*

°C

20

PUMP SUPPLY

TEMPERATURE

(DIAGRAM IN Fig. 12)

°C

30

50

50 1- 2

Tab. 1 - Supply pipeline

65

50

80

FUEL

VISCOSITY

AT 50 °C

NOZZLE

PRESSURE

MEASURED IN

THE GUN

Fluid BTZ

(ecoflu)

High viscosity

BTZ

(Ecoden)

High viscosity

3

7

15

°E

7

15

50 bar

25

25

25

RETURN

NOZZLE

PRESSURE min.

max.

bar

TEMPERATURE ON

THE PRE-HEATING

RESISTORS

THERMOSTAT

TR* min.

max.

°C

TEMPERATURE

OF THE

RESISTORS

SAFETY

THERMOSTAT

TRS

TEMPERATURE

ON THE OIL

ENABLING

THERMOSTAT

TCN

TEMPERATURE

ON THE PLANT

ENABLING

THERMOSTAT

TCI

°C °C °C

7-97 20 100 115 170 80 50 - 60

7-9

7-9

20

20

125

145

140

160

190

190

100

110

60 - 80

70 - 90

Tab. 2 - Burner

* The temperature in the pre-heater must be set to get a viscosity in the nozzle from 1.4 to 1.6 °E.

15


Cinematics

Engler

(Degrees) °E

15.6

17.0

18.5

19.9

21.3

22.7

24.2

25.6

9.24

9.95

10.7

11.4

12.1

12.8

13.5

14.2

27.0

28.4

34.1

39.8

45.5

51

57

71

85

99

5.15

5.44

5.72

6.28

6.85

7.38

7.95

8.51

2.95

3.21

3.49

3.77

4.04

4.32

4.59

4.88

Cinematics

(Centistokes) cSt

119.2

120.9

140.7

151.3

162.3

173.2

184.0

194.8

70.4

75.8

81.2

86.6

92.0

97.4

102.8

108.2

346

390

433

541

206

216

260

303

650

758

38.7

41.0

43.2

47.5

51.9

56.2

60.6

64.9

20.60

23.00

25.3

27.5

29.8

32.1

34.3

36.5

VISCOSITY UNITS CONVERSION TABLE

Cinematics

(Centipoises) cps

Saybolt

Universal

(Seconds)

S.S.U.

Saybolt

Furol

(Seconds)

S.S.F.

20.60

23.00

25.3

27.5

100

110

120

130

29.8

32.1

34.3

36.5

38.7

41.0

43.2

47.5

140

150

160

170

180

190

200

220

51.9

56.2

60.6

64.9

70.4

75.8

81.2

86.6

240

260

280

300

325

350

375

400

23

25.3

27.0

28.7

30.5

32.5

35.0

37.2

92.0

97.4

102.8

108.2

119.2

120.9

140.7

151.3

425

450

475

500

550

600

650

700

49

51

56

61

39.5

42.0

44.2

47.0

162.3

173.2

184.0

194.8

206

216

260

303

750

800

850

900

950

1000

1200

1400

86

91

96

100

66

71

76

81

346

390

433

541

650

758

1600

1800

2000

2500

3000

3500

200

250

300

350

212

141

160

180

Tab. 3

Redwood n. 1

(Seconds)

R.S.I

Redwood n. 2

(Seconds)

R.S.II

661

705

749

793

485

529

573

617

375

397

419

441

287

309

331

353

837

882

1058

1234

1411

1587

1703

2204

2646

3087

158.8

167.5

176.4

194.0

212

229

247

265

88.4

97.1

105.9

114.8

123.6

132.4

141.1

150.0

104

122

138

153

170

215

255

300

16


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. 4

The burners must be feeded with fuel with a minimum temperature at the pump inlet, as a function of the oil viscosity, as showed ondiagrmas in Fig. 4, Fig. 5 and Fig. 7.

17


Minimum feeding temperature vs. oil viscosity

OIL TEMPERATURE FOR PUMP FEEDING

100

10

1

0 10 20 30 40 50 60


70 80 90

Fig. 5

6

5

4

3

2

1

0

40

PUMP FEEDING PRESSURE

Max. for T and

TA pumps

Max. for E ..1069 pimps

60 80 100 120


140 160

Pumps operating range

Fig. 6

The use of heavy oil forces to feed the burner to a pressure strictly related to the oil temperature. This avoids damage to the pump caused by gassification.

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. 7

18


HYDRAULIC DIAGRAMS

Fig. 8 - Hydraulic diagram 3ID0023 - Single burner configuration

19


Fig. 9 - Hydraulic diagram 3ID0014 - Two or more burners configuration

20


-

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

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 regulator

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

21


OIL NOZZLES

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 s (as far as reading the pressure values, see next paragraphs).

NOZZLE

FLUIDICS WR2

BERGONZO B

BERGONZO C

NOZZLE SUPPLY

PRESSURE bar

25

25

25

HIGH FLAME

RETURN PRESSURE bar

20

20

20

LOW FLAME

RETURN PRESSURE bar

7 (recommended)

7 (recommended)

7 (recommended) z FLUIDICS nozzles

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

Pressure at nozzle 25bar

Pressure on return

Up to 100kg/h

Over 100kg/h

Pressure at nozzle 357psi

Atomisation angle

Pressure on return

Fig. 10

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

_________ % Flow rate

% Flow rate

Tab. 4

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.

10).

22

z BERGONZO NOZZLES


Fig. 11

23


Fig. 12

24


Fig. 13

25


Fig. 14

26


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. 15)

Adjust this thermostat to a value 10% lower than that showed in the viscosity-temperature diagram (Fig. 4).

TRS - Resistor safety thermostat (Fig. 15)

The thermostat is set during factory testing at about 190° C.

This thermostat trips when the operating temperature exceeds the set limit. Ascertain the cause of the malfunction and reset the thermostat by means of the PR button.

PR

VR VR VR

TR - Resistor thermostat (Fig. 15)

Adjust this thermostat to the correct value according to the viscosity-temperature diagram (Fig. 4) and check the temperature by using a thermometer with a scale of up to 200° C mounted on the pre-heating tank.

Fig. 15

TCI - Installation enabling thermostat (Fig. 15)

This thermostat is fitted on burners fired with oil at a viscosity of 50° E at 50° C only. Set the thermostat to a temperature about 40° C lower than the TR.

27


ADJUSTMENTS

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”. Be sure that the mains switch is closed.

Before starting up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would cause the pump seal to break.

.

ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide); if this should happen, make the gas decrease slowly until the normal combustion values are achieved.

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

Fuel

Recommended combustion parameters

Recommended (%) CO

2

Recommended (%) O

2

Heavy oil <=7°E a 50 °C

Heavy oil >=7°E a 50 °C

11 ÷ 12

11 ÷ 12.5

4.2 ÷ 6.2

4.7 ÷ 6.7

Adjusting the gas ignitor

To change the pilot gas valve flow rate, proceed as follows:

1 remove the protection on the bottom of the valve, moving it counterclockwise (see next figure);

2 rotate clockwise the nut 1 as shown in to close the valve or counterclockwise to open.

To perform a finest adjustment, act directly on the pressure stabiliser as follows (see next figure):

3 remove the cap T : to increase the gas pressure at the outlet use a screwdriver on the screw TR as shown in the next picture. Screw to increase the pressure, unscrew to decrease; once the regulation is performed, replace cap T .

T

TR

1

Brahma gas valve EGR*12

Pressure stabiliser

28


Adjustments - brief description

z z

Adjust the air and fuel flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respectively.

z Check that the combustion parameters are in the suggested limits.

z

Check the nozzle flow rate.

Then, adjust the combustion values corresponding to the points between maximum and minimum: set the shape of the adjusting cam foil. The adjusting cam sets the air/fuel ratio in those points, regulating the opening-closing of the fuel governor.

Set, now, the low flame output, acting on the low flame microswitch of the actuator in order to avoid the low flame output increasing too much or that the flues temperature gets too low to cause condensation in the chimney.

Adjustment procedure

1 Check the fan motor rotation.

2 With the electrical panel open, prime the oil pump acting directly on the related CP contactor (see next picture): check the pump motor rotation and keep pressed for some seconds until the oil circuit is charged;

CP

3 bleed the air from the M pressure gauge port (Fig. 16) by loosing the cap without removing it, then release the contactor.

Suntec T..

M

VR

Fig. 16

1 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 achieve safely the high flame stage;

2 cam IV (stroke limitation cam) must be set a little higher than the cam III to limit the output during the first seconds the flame appears;

NOTE: cam IV must shift according to cam III.

3 Turn the burner on by means of its main switch: if the burner locks press the RESET button on the control panel - see chapter

“OPERATION” on page 25.

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

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

6 Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion values and eventually adjust the oil pressure (see next step).

29

MAN

AUTO


I II III IV

Actuator cams

I

II

High flame

Stand-by and Ignition

III Low flame

IV Stroke limitation

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 showed on Fig. 17 and act on on the pump adjusting screw VR

(see Fig. 16 and page 11) as to get the nozzle pressure at 25bar (Fluidics/Bergonzo nozzles - see diagram on page 22).

PG

Pressure gauge port

RP

V

SV

Fig. 17 Fig. 18

8 In order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge (see picture above): always checking the combustion parameters, the adjustment is to be performed by means of the SV adjusting cam screw (see picture above) 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.

VRA

RA

10 Only if necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when the adjustment is accomplished.

VB

VRT

“MAX” head position “MIN” head position

Attention!

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

30


11 the air and oil rate are now adjusted at the maximum output stage, go on with the point to point adjustement on the SV (Fig. 18) adjusting cam as to reach the minimum output point.

12 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°);

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

14 move cam III (low flame) towards the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw that refers to a lower position: screw V to increase the rate, unscrew to decrease, in order to get the pressure as showed on diagrams on page 16, according to the nozzle provided and the requested rate.

15 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.

NOTE: remembern that cam IV must shift according to cam III (see step 2).

16 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.

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

18 Now adjust the air pressure switch (see next paragraph).

Calibration of air pressure switch

z z

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

Remove the transparent plastic cap.

Once air and fuel 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 (to increase the adjusting pressure) 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 chapter “ELECTRICAL WIRING DIA-

GRAMS”), 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=2; to drive it to the low-flame stage, set

CMF=1.

To move the adjusting cam set CMF=1 and then CMF=0.

CMF = 0 stop

CMF = 1 low flame operation

CMF = 2 high flame operation

CMF = 3 automatic operation

For further details, see the burner modulator reference guide.

31


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 THE EVENT OF REPEATED LOCKOUTS, DO NOT PERSIST WITH THE RESET BUTTON AND CONTACT QUALIFIED PER-

SONNEL WHO WILL PROCEED TO ELIMINATE THE MALFUNCTION.

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”.

1 Set to the ON position the main switch on the burner control panel.

2 Check the control box is not in the lockout position; in such a case reset it by the reset pushbutton.

3 Check that the series of thermostats (or pressure switches) enable the burner to operate.

4 The startup sequence begins: the control box ignites the fan and pump motors and energises the ignition transformer as well.

5 At the end of the pre-purge stage, the light oil solenoid valve EVG is energised and the burner is on.

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

7 After the ignition the actuator moves to the high flame position for some seconds, then the operation begins and the burner switches to high flame or to low flame, according to the plant demand.

32

4

3


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

ROUTINE MAINTENANCE

z Check and clean the ignitor gas filter cartdrige, replace if necessary.

Check and clean the fuel filter cartdrige, replace if necessary.

Check and clean the filter inside the light 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.

Check the fuel hoses for possible leaks.

Remove, clean and check the combustion head (see Fig. 21).

Check and clean the ignition electrode on the pilot burner, adjust and, if necessary, replace it (page 35).

Check and clean the detection photoresistor, adjust and, if necessary, replace it (Fig. 23).

z z

Remove and clean the fuel nozzle (Important: cleaning must be performed using solvent, not metal tools!

).

At the end of maintenance operations after the burner reassembly, light the flame and check its shape, replacing the nozzle whenever a questionable flame shape appears. Whenever the burner is used intensely, we recommend preventively replacing the nozzle at the start of each heating season.

Clean and grease levers and rotating parts.

Maintenance of the governor with filter (ignitor gas train)

figura sottofigura sottoBefore disassmbling the device, be sure that there is no pressurised gas inside it.

To check the filtering part (1) on threaded bodies (see ): z remove the bottom cover, unscrewing the fixing screws; z z z remove the filtering part (1), clean it with water and soap, blow it with compressed air or replace it if necessary; reassemble the filtering part in its initial position checking that it is placed in its own slots (see ); reassemble the bottom cover (3), being sure that the main bolt is centered in the bottom cover slot.

To check the filtering part (1) on flanged bodies (see ): z z z remove the bottom cover, unscrewing the fixing screws; remove the filtering part (1), clean it with water and soap, blow it with compressed air or replace it if necessary; reassemble the filtering part in its initial position checking that it is placed in its own slots (see );

NOTE: pay attention that the teflon ring (5): while reassembling the cover (3), it must be placed inside the proper bell/slot (6).

filter slots

1

2

33


Light oil filter maintenance

For correct and proper servicing, proceed as follows:

1 shut off fuel in the line section being serviced;

2 unscrew the tray;

3 remove the filter cartridge from its support and wash it with petrol or replace if necessary; check seal O-Ring, replace if necessary;

4 reassemble the tray and restore fuel flow.

Removing the combustion head

z z

Remove the top cover C; remove the photoresistor from its seat; z unscrew the revolving connectors (E in Fig. 20) on the fuel pipes (use 2 spanners to avoid loosening the connections attached to the distributor block); z loosen the screw VRT to free the threaded rod AR, then screw out the 2 screws V holding the washer R and the screw VRT in position; z remove the whole assembly as shown in Fig. 19.

Note: to replace the combustion head reverse the procedure described above.

C

AR

VRT

R

Fig. 19

Removing the gun

1 Remove the combustion head, as described on the previous paragraph;

2 slacken the screw VB

3 remove the lance with the nozzle holder

4 to replace the combustion head reverse the procedure described above.

VB

E

Fig. 20

34


Electrode position setting

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

To guarantee a good ignition, the masures below (in mm) must be observed (Fig. 21).

A

B

C

A= 8 mm

B= 3 mm

C= 8 mm

Fig. 21

Replacing the ignition electrode

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

To replace the ignition electrode, proceed as follows:

1 remove the burner cover

2 disconnect the electrode cable

3 remove the combustion head (see par. “Removing the combustion head”);

4 loose the screw that fasten the ignition electrode to the burner pilot;

5 remove the electrode and replace it, referring to the values quoted on Fig. 21;

Cleaning and replacing the detection photoresistor

To clean/replace the detection photoresistor proceed as follows:

1 Disconnect the system from the electrical power supply.

2 Shut off the fuel supply

3 remove the photoresistor from its slot;

4 clean it using a clean cloth;

5 if necessary, replace it;

6 insert the photoresistor into its slot.

35


Checking the detection current

To measure the detection signal follow the diagram in Fig. 22 - Fig. 23.

If the signal is not in the advised range, check the electrical contacts, the cleaning of the combustion head, the position of the photoresistor and if necessary replace it.

Control box

Siemens LAL

Minimum current intensity with flame-

Minimum detection signal

6.5µA

Fig. 22

Flame detector

Krom Schroeder IFW15

Minimum detection signal

1µA

Fig. 23

Seasonal stop

To stop the burner in the seasonal stop, proceed as follows:

1 turn the burner’s main switch to 0 (Off position)

2 disconnect the power mains

3 close the fuel cock of the supply line

Burner disposal

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

36

TROUBLESHOOTING


MAIN SWITCH OPEN

LINE FUSE INTERVENTION

MAX. PRESSURE SWITCH FAULT

FAN THERMAL CUTOUT INTERVENTION

AUXILIARY RELAIS FUSES INTERVENTION

CONTROL BOX FAULT

SERVOCONTROL FAULT

SMOKEY FLAME

IGNITION TRANSFORMER FAULT

IGNITION ELECTRODE DIRTY OR BADLY

POSITIONED

DIRTY NOZZLE

FUEL SOLENOID VALVE DEFECTIVE

PHOTORESISTOR DIRTY OR DEFECTIVE

HI-LO FLAME THERMOSTAT DEFECTIVE

WRONG POSITION OF SERVOCONTROL

CAMS

FUEL PRESSURE TOO LOW

DIRTY FUEL FILTERS 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

37


SPARE PARTS

Desription

FLAME DETECTOR mod.KROM-SCHROEDER IFW15

CONTROL BOX mod.SIEMENS LAL2..

PILOT DETECTION ELECTRODE

PILOT IGNITION ELECTRODE

OIL FILTER

AIR PRESSURE SWITCH

IGNITOR GAS PRESSURE SWITCH

IGNITION TRANSFORMER

PUMP MOTOR

3-WAYS SOLENOID VALVE mod. SIRAI

GAS SOLENOID VALVE mod. BRAHMA EG*R12

OIL FLEXIBLE HOSES L = 600

OIL FLEXIBLE HOSES 3/8” L=385

GAS FLEXIBLE HOSES 1/2”M

OIL FLEXIBLE HOSES L=347

OIL FLEXIBLE HOSES L=485

ADJUSTING CAM FOIL

ACTUATOR (SIEMENS SQM10)

DETECTION PHOTORESISTOR (SIEMENS RAR)

PRESSURE GOVERNOR

PRESSURE GOVERNOR (SUNTEC TV40)

MODULATOR (SIEMENS RWF40)

PUMP (SUNTEC T4)

NOZZLE (specify angle and rate when ordering) mod. BERGONZO B

GAS GOVERNOR WITH FILTER

COMBUSTION HEAD

BLAST TUBE

OIL RESISTOR (24kW)

IGNITION CABLE

OIL RESISTOR CARTRIDGE (80W )

234FX31

2440014

2480004

2510009

2570008

2570036

2570112

2590148

2610210

2800085

30601A5

30910L5

6060008

6050157

6060010

TN1030

2020114

2020420

2080115

2080258

2090209

2160085

2160086

2170136

2180257

2190437

2190502

2340059

2340088

234FX07

234FX24

38

SIEMENS LAL.. CONTROL BOX z z

Use 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) z Universally applicable for multistage or modulating burners z z z

Housing and plug-in base z Made of impact-proof and heat-resistance black plastic

Lockout reset button with viewing window; located behind it:

Lockout warning lamp z

Lockout indicator coupled to the spindle of the sequence switch and visible in the transparent lockout reset button uses easy-to-remember symbols to indicate the type of fault and the point in time lockout occurred z 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 z Auxiliary terminals «31» and «32»

3 earth terminals terminating in a lug for earthing the burner

3 neutral conductor terminals prewired to terminal 2

14 knockout holes for cable entry by means of cable glands

8 at the side

6 in the bottom of the base

6 lateral threaded knockout holes for cable entry glands Pg11 or M20

Operation

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

Pre-conditions for burner startup z z

Burner control is not in the lockout position

Sequence switch is in its start position (with LAL2 voltage is present at terminals 11 and 12.

z z

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

Contact of the limit thermostat or pressure switch «W» and the contacts of any other switching devices in the control loop between terminals 4 and 5 must be closed e.g. a control contact for the oil preheater’s temperature z Normally closed contact of the air pressure switch must be closed.

Startup sequence z z z z

Start command by «R»:

«R» closes the start control loop between terminals 4 and 5 z The sequence switch starts to run

Only prepurging, fan motor at terminal 6 receives power

Pre- and postpurging, fan motor or flue gas fan at terminal 7 receives power on completion of «t7» z 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.

APPENDIX 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».

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

Absorption

Mounting position

50 Hz -6 %...60 Hz +6 %

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 ar1 a

4

W

I b a r2

6 7 V

2 2

F R

B

R

IX fr1 a

5 b

N

M 1 M 2 fr2

L 1

3

A L

X I b a

X III a

X II b

2 1

A R b r2

E

A

M

B R

1 (3 )

2

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 11 1 0 a

M z 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

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

KROM-SCHROEDER IFW15 FLAME DETECTOR z z z z z z z

For flame detection

For multi-flame control for intermittent operation in conjunction with the flame control units IFS

Ionisation or UV control

Potential-free change-over contacts

Integrated flame control signal

APPLICATION

For the detection and signalling of the presence of a flame by means of ionisation or UV control. The flame detector is intended for use in conjunction with the flame control units IFS 110 IM, IFS 111 IM, IFS 410 or IFS

414. It can also be used where there is no fully automatic control required.

FEATURES

- Flame control with ionisation electrode or UV probe

- For intermittent operation

- Potential-free contacts for flame detection (1 normally closed, 1 normally open)

Function

The flame detector is ready for operation as soon as the mains voltage is applied to it. When the flame is established, the d.c. current energises a relay. The contacts of this relay can be used for control functions according to the application.

In a multi-flame control system (Fig. 2), several burners may be controlled at the same time. A flame control unit (e.g. IFS 110 IM) is used for the entire control functions and this also controls the first burner (only in the case of ionisation control). All remaining burners of this group are each controlled by an IFW 15 flame detector.

Should the flame controlled by a flame detector be extinguished during operation, the flame signal to the control unit is interrupted and an emergency cut-off occurs. This also occurs if a flame is simulated prior to ignition.

Load of the flame control unit per output: 1A, total current: 2 A.

Decoupling relays must be provided if the currents exceed these values.

Ionisation line: Max. 50 m; condition: well away from mains cable and sources of radiated noise - no electrical interference.

Several ionisation lines may be laid together in one plastic conduit. Avoid metal conduits wherever possible. Use high-voltage cables, non-screened.

Fig. 1

Technical data

Mains voltage:

IFW 15: 220/240 VAC -15/+10%, 50/60 Hz for earthed mains

IFW 15T: 110/120 VAC -15/+10%, 50/60 Hz or

220/240 VAC -15/+10%, 50/60 Hz for earthed or non-earthed mains

Consumption: 12 VA

Output voltage for ionisation electrode: 230 VAC

Ionisation current: > 1 µA

Output signal:

Potential-free contacts (1 normally closed, 1 normally open)

Contact load: max. 2 A

Connection terminals: 2 x 1.5 mm2

Flame detection: Lamp in the device

Ambient temperature: 20 °C to +60 °C

Fitting position: Arbitrary

Weight: 370 g

Construction: Housing made of impact-resistant plastic.

Plug-in upper housing with amplifying stage and green lamp for flame detection.

Plug socket with terminals, earthing strip and neutral bar 5 openings for

Pg 9 cable gland provided.

Project planning information

Multi-flame control: No more than 5 flame detectors should be used per flame control unit since it must be guaranteed that all burners are ignited within the flame control unit’s safety period (3 s, 5 s or 10 s).

Very long gas pipes may possibly lead to delayed ignition of a burner and to switchoff of the entire system. This is why the pilot gas valves should be installed directly on the burners. In the case of ionisation control, one of the burners can be monitored by the flame control unit.

In the case of UV control, one IFW 15 flame detector must be used per burner. A diode of type EM 513 must be fitted as shown on the wiring diagram (Fig. 4).

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.

CIB UNIGAS TN 1050 Manual Of Installation - Use - Maintenance

Heavy oil

Industrial Burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

GENERAL FEATURES

How to choose the burner

Burner model identification

Specifications

Performance Curves

Overall dimensions (mm) (TN1030)

MOUNTING AND CONNECTING THE BURNER

Packing

Handling the burner

Fitting the burner to the boiler

Installing the fan

Matching the burner to the boiler

Burner ignitor

H

draulic system

Bleed

Suntec T pump

Suntec TV Pressure governor

Connections to the oil gun

Connecting the burner to the light oil pumping unitConnecting the burner to the oil pumping unit

About the use of fuel pumps

Electrical connections

Rotation of fan motor and pump motor

Guidelines for the appropriate use of heavy oil

PUMP FEEDING PRESSURE

HYDRAULIC DIAGRAMS

OIL NOZZLES

Oil thermostat adjustment

ADJUSTMENTS

Adjusting the gas ignitor

Brahma gas valve EGR*12

Pressure stabiliser

Adjustments - brief description

Adjustment procedure

M

VR

Calibration of air pressure switch

Fully modulating burners

OPERATION

ROUTINE MAINTENANCE

Maintenance of the governor with filter (ignitor gas train)

Light oil filter maintenance

Removing the combustion head

Removing the gun

Electrode position setting

Replacing the ignition electrode

Cleaning and replacing the detection photoresistor

Checking the detection current

Seasonal stop

Burner disposal

TROUBLESHOOTING

SPARE PARTS

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***Brahma gas valve EGR*12***