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Unigas PBY70, Manual Of Installation - Use - Maintenance

The Unigas PBY70, a versatile heating system, comes with a comprehensive Manual of Installation – Use – Maintenance. This essential manual can be easily downloaded for free from our website, ensuring users have all the necessary information to efficiently operate and maintain their Unigas PBY70.

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TABLE OF CONTENTS

WARNINGS ................................................................................................................................................................ 3

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

Burner model identification  ............................................................................................................................................................. 5
Technical Specifications  ................................................................................................................................................................. 5
Performance Curves  ....................................................................................................................................................................... 6
Overall dimensions  ......................................................................................................................................................................... 7

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

Packing ........................................................................................................................................................................................... 8
Handling the burner ........................................................................................................................................................................  8
Fitting the burner to the boiler  ......................................................................................................................................................... 8
Electrical connections  ................................................................................................................................................................... 10
Fan motor and pump motor direction  ........................................................................................................................................... 10
Connecting the oil heating resistors .............................................................................................................................................. 11
Reccomendations to design heavy oil feeding plant ..................................................................................................................... 11
Pipe heating system ...................................................................................................................................................................... 11
Inlet minimum pressure of the pump (both for supplying system and burner)  .............................................................................. 11
Pump operating maximum pressure (both for the supplying system and burner)  ........................................................................ 11
Adjusting the supplying oil ring  ..................................................................................................................................................... 11
Burner adjustments ....................................................................................................................................................................... 12

HYDRAULIC DIAGRAMS .............................................................................................................................................................  16

Ignitor burner assembly  ................................................................................................................................................................ 20
Heavy oil pumps  ........................................................................................................................................................................... 21
Suntec TV Pressure governor ....................................................................................................................................................... 21
Connecting the oil flexible hoses to the burner  ............................................................................................................................. 22
Connecting the compressed air hoses........................................................................................................................................... 22

ADJUSTING AIR AND FUEL RATE  ............................................................................................................................................. 24

Oil thermostat adjustment  ............................................................................................................................................................. 24
Adjusting the ignitor gas flow rate: gas valve Brahma EG12*R and pressure governor ............................................................... 24
Adjustments - brief description ...................................................................................................................................................... 25
Oil Flow Rate Settings  .................................................................................................................................................................. 25
Calibration of air pressure switch  ................................................................................................................................................. 28
EVL air valve for gun cleaning  ...................................................................................................................................................... 28

PART II: OPERATION .............................................................................................................................................  29

OPERATION ................................................................................................................................................................................. 29

PART III: MAINTENANCE.......................................................................................................................................  31

ROUTINE MAINTENANCE ........................................................................................................................................................... 31

Maintenance of the gas governor with filter (ignitor gas train) ...................................................................................................... 31
Removing the combustion head  ................................................................................................................................................... 32
Removing the oil gun, replacing/adjusting the nozzle and the ignition electrode .......................................................................... 32
Checking the detection current  ..................................................................................................................................................... 33
Cleaning and replacing the detection photoresistor ...................................................................................................................... 33
Seasonal stop  ............................................................................................................................................................................... 33
Burner disposal .............................................................................................................................................................................  33

TROUBLESHOOTING..................................................................................................................................................................  34

SPARE PARTS ............................................................................................................................................................................. 35

BURNER EXPLODED VIEW  ........................................................................................................................................................ 35

ELECTRICAL WIRING DIAGRAMS  ............................................................................................................................................. 38

APPENDIX

Summary of Contents for PBY70

Page 1: ...MANUAL OF INSTALLATION USE MAINTENANCE PBY70 M039241CB Rel 1 0 06 2010 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Double stage Heavy oil Burners ...

Page 2: ...il pumps 21 Suntec TV Pressure governor 21 Connecting the oil flexible hoses to the burner 22 Connecting the compressed air hoses 22 ADJUSTING AIR AND FUEL RATE 24 Oil thermostat adjustment 24 Adjusting the ignitor gas flow rate gas valve Brahma EG12 R and pressure governor 24 Adjustments brief description 25 Oil Flow Rate Settings 25 Calibration of air pressure switch 28 EVL air valve for gun cle...

Page 3: ...s electricity gas oil or other fuel Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stopped When the decision is made to discontinue the use of the burner the user shall have qualified personnel carry out the following operations a Remove t...

Page 4: ...c or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 2009 142 EC Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric applian...

Page 5: ... H AB S A 1 2 3 4 5 6 1 BURNER TYPE PBY70 2 FUEL H heavy oil high viscosity 4000cSt 530 E 50 C 3 OPERATION Available versions AB Double stage 4 BLAST TUBE S Standard L Extended 5 DESTINATION COUNTRY see data plate 6 BURNER VERSION A Standard BURNER PBY70 Output min max kW 290 1300 Fuel Heavy oil Oil viscosity see Burner model identification Heavy oil rate min max kg h 26 116 Gas pressure max mbar ...

Page 6: ... of the machine On this diagram the maximum output point is usually reached by adj suting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is rea ched 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...

Page 7: ...C I B UNIGAS M039241CB 7 Overall dimensions mm boiler recommended drilling template ...

Page 8: ...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 b...

Page 9: ...C I B UNIGAS M039241CB 9 Key 1 Burner flange upper side indicated 2 Bracket 3 Pre heating tank on the burner SIDE UP SIDE DOWN 1 2 3 ...

Page 10: ...minal box of the electric motor and replace the thermal cutout relay 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...

Page 11: ...e provided that is a system to heat pipes and plant components to mantain the viscosity in the pumping lim its 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 valu...

Page 12: ...INE TEMPERATURE cSt E bar C 50 7 1 2 20 50 7 110 15 1 2 50 110 15 400 50 1 2 65 400 50 4000 530 1 2 100 VISCOSITY AT 50 C OIL PRESSURE AFTER BURNER PUMP N 2 in 3I2D 01 OIL PRESSURE AFTER OIL METERING VALVE N 14 IN 3I2D 01 TEMPERATURE OF THE PRE HEATING RESISTORS THERMOSTAT TR TEMPERATURE OF THE RESISTORS SAFETY THERMOSTAT TRS TEMPERATURE OF THE PLANT ENABLING THERMOSTAT TCI min max min max min max...

Page 13: ... 1 4 48 150 19 3 128 14 48 43 2 5 92 200 23 5 170 18 9 54 7 35 250 28 212 23 45 65 8 79 300 32 5 254 28 87 6 11 7 400 41 9 338 37 1 110 14 6 500 51 6 423 46 2 132 17 5 600 61 4 508 55 4 154 20 45 700 71 1 592 64 6 176 23 35 800 81 677 73 8 198 26 3 900 91 762 83 220 29 2 1000 100 7 896 92 1 330 43 8 1500 150 1270 138 2 440 58 4 2000 200 1690 184 2 550 73 2500 250 2120 230 660 87 6 3000 300 2540 27...

Page 14: ...0 30 40 50 60 70 80 90 100 110 120 130 140 150 160 TEMPERATURE C VISCOSITY E LIGHT OIL 1 3 E AT 20 C HEAVY OIL 2 4 E AT 50 C HEAVY OIL 4 E AT 50 C HEAVY OIL 7 5 E AT 50 C HEAVY OIL 10 E AT 50 C HEAVY OIL 13 E AT 50 C HEAVY OIL 22 E AT 50 C HEAVY OIL 50 C HEAVY OIL 47 E AT 50 C HEAVY OIL 70 E AT 50 C HEAVY OIL 200 E AT 50 C ...

Page 15: ...ature at the pump inlet should be 80 C see diagram Indicative diagram showing the oil pressure according to its temperature OIL TEMPERATURE FOR PUMP FEEDING 1 10 100 0 10 20 30 40 50 60 70 80 90 TEMPERATURE C VISCOSITY E a 50 C Fig 6 PUMP FEEDING PRESSURE Max for E 1069 pimps Max for T and TA pumps 0 1 2 3 4 5 6 40 60 80 100 120 140 160 TEMPERATURE C PRESSURE bar Fig 7 ...

Page 16: ...C I B UNIGAS M039241CB 16 HYDRAULIC DIAGRAMS Fig 8 Hydraulic diagram 3ID0024 ...

Page 17: ...ressure gauge 9 High pressure switch PO MAX DAILY TANK 10 Daily tank 11 Heating device 12 Electrical resistor 13 Pressure gauge 14 High pressure switch PO MAX 15 Low pressure switch PO MIN 16 Low thermostat TCN 17 Thermometer 18 High thermostat TRS 19 Thermostat TR 20 Manual valve 21 Manual valve PRESSURE GOVERNOR UNIT 22 Pressure gauge 23 Manual valve 24 Pressure governor 25 Needle valve ...

Page 18: ...C I B UNIGAS M039241CB 18 Fig 9 Hydraulic diagram 3I2D 01 ...

Page 19: ...uator 9 Low thermostat TCI 38 Draught fan with electromotor 10 High thermostat TRS 39 Pressure switch PA 11 Electrical preheater tank STEAM TRAIN OPTIONAL 12 Thermometer 40 Manual valve 13 Pneumatic valve 41 Filter 14 Metering valve 42 Pressure switch 15 Main burner 43 Water separator COMPRESSED AIR TRAIN 44 Water discharger 16 Pressure governor with filter 45 Flow indicator 17 Solenoid valve 46 P...

Page 20: ...lready installed into the burner the connection from the gas governor with filter to the gas supply network must be carried out 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 Fig 10 the gas proving test must be performed according to the procedure set by the la...

Page 21: ...re 5bar Min Inlet Pressure 0 4bar For further details see the manifacturer documentation Suntec TV Pressure governor Pressure adjustment Remove cap nut 1 and the gasket 2 unscrew the lock nut 4 To increase pressure twist adjusting screw 3 clockwise To decrease the pressure twist screw counterclockwise Tight the lock nut 4 refit the gasket 2 and the cap nut 1 Key 1 Cap nut 2 Gasket 3 Adjusting scre...

Page 22: ...ows marked on the pump Connecting the oil flexible hoses to the burner To connect the flexible oil hoses to the pump proceed as follows according to the pump provided 1 remove the closing nuts A on the heater and R on the oil pressure governor 2 screw the rotating nut of the two flexible hoses on the burner being careful to avoid exchanging the inlet and return lines see the arrows marked that sho...

Page 23: ...C I B UNIGAS M039241CB 23 Hydraulic connections Key G Gas A Air O Oil CA Cleaning air Fig 12 G G O A CA A O CA ...

Page 24: ...re 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 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 f...

Page 25: ...ing on the related contactor CP see next picture check the pump motor rotation see Fan motor and pump motor direction on page 10 and keep pressing for some seconds until the oil circuit is charged 2 bleed the air from the SA port by loosing the cap T without removing it then release the contactor and fasten cap T 3 Before starting the burner up drive the high flame actuator microswitch matching th...

Page 26: ...ided to move cams I and IV the other cams can be moved by means of screws On the BERGER STA actuator the manual air damper control is not provided On the Siemens actuator the AUTO MAN mode is provi ded see picture 7 During high fire operation oil pressure is about 4 4 5 bar read on oil pressure gauge Fig 15 8 Set the atomising air pressure switch PA Fig 16 at 0 5 bar Berger STA6 B2 41 6 Siemens SQ...

Page 27: ...an blow off 12 To adjust the comburent 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 blockin...

Page 28: ...itch proceed as follows 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 ...

Page 29: ... 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 Turn the burner on by means of its main switch S1 see next pictures Check that the burner is not locked LE...

Page 30: ...esistors safety thermostat lamp M Plant enabling thermostat lamp N Oil pump in operation O Ignitor solenoid valve lamp PL Light oil operation lamp PH Heavy oil operation lamp Q Ignitor gas pressure switch R Reset pushbutton for control box S Pre heating in operation lamp S1 Burner main switch S2 Pump operation selector MAN AUTO S3 Heavy oil light oil operation selector S4 Auxiliary resistors switc...

Page 31: ...d intensively it is recommended to replace the nozzle as a preventive measure at the begin of the opera ting season Clean and grease joints and rotating parts IMPORTANT Remove the combustion head before checking the ignition electrode Remove and clean the compressed air regulator A in Fig 24 Remove and clean the oil regulator B in Fig 24 Fig 24 Maintenance of the gas governor with filter ignitor g...

Page 32: ...y 3 in order to replace the electrode unscrew the fixing screw and remove it place the new electrode being careful to observe the measures in mm shown on next pictures and reassemble following the reversed procedure To adjust the nozzle position unscrew the fixing screw move the nozzle backwards or forwards then fix the screw on the new position In the example from 1 to 2 see picture below Fig 25 ...

Page 33: ...r and if necessary replace it 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 di...

Page 34: ... FUSES BLOWN MAXIMUM THERMOSTAT MALFUNCTION FAN THERMAL CUTOUT TRIPPED AUXILIARY FUSE BLOWN OIL RESISTOR FAULTY OIL ENABLING THERMOSTAT TRIPPED FAULTY CONTROL BOX AIR ACTUATOR MALFUNCTION CIRCUIT ENABLING THERMOSTAT SMOKY FLAME FAULTY IGNITION TRANSFORMER IGNITION ELECTRODE WRONGLY POSITIONED DIRTY NOZZLE FAULTY OIL VALVE FAULTY OR DIRTY PHOTORESISTOR FAULTY RESISTOR THERMOSTAT FAULTY HIGH LOW FLA...

Page 35: ...OSES L 300 2340040 FLEXIBLE HOSES L 385 3 8 2340088 FLEXIBLE HOSES L 365 234FX13 FLEXIBLE HOSES L 385 1 4 234FX35 ADJUSTING CAM FOIL 2440014 ACTUATOR mod BERGER STA6 2480041 ACTUATOR mod SIEMENS SQN72 24800A3 PHOTORESISTOR SIEMENS QRB1B 2510008 RESISTOR THERMOSTATTR TCN TCI 2560026 THERMOSTAT TRS 2560028 PRESSURE GOVERNORSUNTEC TV 2570068 OIL METERING VALVE HAUCK 25700xx PUMP CUCCHI FMG25 2590218 ...

Page 36: ...ZLE 10 PHOTORESISTOR 17 3 LOUVER SHAFT 20 1 MOTOR 11 STANDARD BLAST TUBE 17 4 AIR INTAKE DAMPER 20 2 FAN WHEEL 12 AIR PRESSURE SWITCH 17 5 AIR INTAKE DAMPER 21 1 CONTROL PANEL 13 1 OIL MANIFOLD 17 6 1 CAM 21 2 1 LIGHT 13 2 MANUAL VALVE 17 7 ACTUATOR SHAFT 21 2 2 LIGHT 13 3 PRESSURE GAUGE 17 8 1 ACTUATOR 21 2 3 SWITCH 13 4 OIL SOLENOID VALVE 17 8 2 ACTUATOR SHAFT 21 2 4 LOCK OUT RESET BUTTON 13 5 C...

Page 37: ...C I B UNIGAS M039241CB 37 ...

Page 38: ...order to ensure the burner stops if IRxx switcesh are open When the three phase power supply is interrupted the auxiliary single phase power supply must be interrupted as well WARNING 1 Power supply 400V 50Hz 3N AC with neutral 2 Don t reverse phase with neutral 3 Ensure the burner is properly earthed ...

Page 39: ... deactivating the diagnostic functions The multicolour LED is the key indicating element for both visual diagnosis and interface diagnosis s Red l Yellow o Green Key m Off l Yellow o Green s Red Diagnosis of cause of fault After lock out the red fault signal lamp remains steady on In that condition the visual diagnosis of the cause of fault according to the error code table can be activated by pre...

Page 40: ...tat or pressurestat SB Safety limit thermostat Si External primary fuse W Limit thermostat or pressure switch Z Ignition transformer t4 Interval from flame signal to release BV2 TSA Ignition safety time tw Waiting time for oil pre heating B Time of flame establishment C Operating position D Controlled shut down by R µC1 Microcontroller 1 µC2 Microcontroller 2 1 2 6 7 4 5 10 11 12 W SB R L N M Z BV...

Page 41: ...id separately 20m LMO14 LMO24 LMO44 Terminal 1 5 A 5 A 5 A Terminals 3 and 8 3 A 5 A 5 A Terminals 4 5 and 10 1 A 1 A 1A Terminals 6 1 A 1 A 2A Flame supervision with QRB and QRC QRB QRC Min detector current required with flame 45 µA 70 µA Min detector current permitted without flame 5 5 µA 5 5 µA Max possible with flame tipically 100 µA 100 µA Measurement circuit for detector current Key µA DC DC...

Page 42: ......

Page 43: ......

Page 44: ...a subject to change without notice Errors and omissions excepted C I B UNIGAS S p A Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it ...

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