Unigas PN30, Operating & Maintenance Instructions

Page 1: ...Technical Documentation CIB Unigas Campodarsego PD MANUAL OF INSTALLATION OPERATION MAINTENANCE HEAVY OIL BURNERS PN30 SINGLE STAGE VERSION M03930CC Rev 02 06 01 ...

Page 2: ...ssory equipment only shall be used This unit shall be employed exclusively for the use for which it is meant Any other use shall be considered as improper and therefore dangerous The manufacturer shall not be held liable by agreement or otherwise for damages resulting from improper installation use and failure to comply with the instructions supplied by the manufacturer 2 SPECIAL INSTRUCTIONS FOR ...

Page 3: ...nimals or damage to property for which the manufacturer cannot be held liable Before installation it is recommended that all the fuel sup ply system pipes be carefully cleaned inside to remove foreign matter that might impair the burner operation Before the burner is commissioned qualified personnel should inspect the following a the fuel supply system for proper sealing b the fuel flow rate to ma...

Page 4: ...ons AB Double stage 4 BLAST TUBE LENGHT See overall dimensions Available versions S Standard L Long 5 DESTINATION COUNTRY see data plate 6 SPECIAL VERSIONS A Standard E with junction box Y SpecialeM Wall mounting electrical board G Floor standing electrical board and junction box BURNER PN30 Input min kcal h 140 000 max kcal h 300 000 min kW 163 max kW 349 Oil rate min Kg h 14 max Kg h 30 Fuel hea...

Page 5: ...NS Fig 4 PERFORMANCE CURVE A B BL C CL D E F G K Z V W M PN30 520 160 350 680 870 270 450 720 131 400 160 155 219 M10 BACKPRESSURE IN COMBUSTION CHAMBER mbar PN30 kW 1 5 1 0 5 0 0 5 1 1 5 2 2 5 3 140 160 180 200 220 240 260 280 300 320 340 360 380 ...

Page 6: ...revised consulting the burner manufacturer To cho ose the blast tube lenght follow the instructions of the boiler manufacturer In absence of these consider the following 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 The length of the blast tubes does not always allow this requirement to be...

Page 7: ...ee phase 400 V supply and in the case of three phase 230 V supply it is neces sary to modify the electrical connections inside the terminal box of the electric motor replace the thermal overload relay and modify the resistors connections WARNING The burner is fitted with an electrical bridge between terminals 6 and 7 in the event of connecting the high low flame thermostat remove this bridge befor...

Page 8: ...ent valve 19 Oil buffer tank capacity 600 l approx 20 Oil filter 0 3 mm mesh 21 Fuel cutoff solenoid valve 22 Fuel gate valve 23 Burner pump hoses 24 24 Burner oil pump 25 Pre heating tank resistor 26 Pre heating tank 27 Oil enabling thermostat TCN 26 28 Pre heating tank resistor safety thermostat TRS 26 29 Oil temperature regulator thermostat TN 26 30 Pre heating tank 26 filter 0 1 mm mesh 31 The...

Page 9: ...STALLATION MANUAL 9 OIL SUPPLY PIPING INSTALLATION DIAGRAM Fig 8 Hydraulic diagram 3ID0010 for 1 burner installations OIL CIRCUIT PRE HEATED WATER CIRCUIT PRE HEATING 50 C PRE HEATING 70 C LIMIT OF BURNER SUPPLY ...

Page 10: ... 10 Fig 9 Hydraulic diagram 3ID0012 for 2 or more burners OIL CIRCUIT PRE HEATED WATER CIRCUIT PRE HEATING 50 C PRE HEATING 70 C LIMIT OF BURNER SUPPLY NOTE PRE HEATING OF ENABLING THERMOSTAT CONNECTION TUBE 16 BURNER 2 BURNER 1 ...

Page 11: ...ircuit diagram in Fig 10 To select the nozzle consult Tab 1 To regulate pump pressure see page 12 Further information on oil pump cha racteristics are given in the appendix SINGLE TUBE INSTALLATION The burners leave the factory with two tube fuel supply They can however be converted to single tube fuel supply See appendix for details Oil circuit operating principle Key 1 Filter 2 Pump 3 Pre heatin...

Page 12: ... 70 2 00 12 90 13 20 13 40 2 25 14 50 14 80 15 10 2 50 16 10 16 50 16 80 3 00 19 30 19 70 20 10 3 50 22 50 23 00 23 50 4 00 25 80 26 30 26 80 4 50 29 00 29 60 30 20 5 00 32 20 32 90 33 60 Pressure set in the factory Pump Suntec E4 Suction height 0 5 bar Advised value to prevent air separation from oil 0 35 bar Rated speed max max 3600 g m Operation viscosity from 2 8 to 800 cSt Oil temperature Typ...

Page 13: ...tor safety thermostat Fig 12a The thermostat is set during factory testing at a value of about 190 C This thermostat trips when the operating tempera ture exceeds the set limit Ascertain the cause of the malfunction and reset the thermostat using the PR button TR Resistor thermostat Fig 12a Calibrate this thermostat to the correct value accor ding to the viscosity temperature diagram page 14 and c...

Page 14: ...COSITY vs TEMPERATURE DIAGRAM BEST VISCOSITY RANGE FOR A PROPER ATOMIZATION 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 50 60 70 80 90 100 110 120 130 140 150 160 170 180 TEMPERATURE C VISCOSITY E 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 ...

Page 15: ...uffer tank 19 at this stage the pressure may vary from 3 to 10 bar The pre washing phase is necessary to remove possible fuel residues accumulated during the period of inactivity and comple tely free the piping and nozzle assembly of obstacles During this phase the flow of oil to the nozzles at the ideal temperature for combustion is guaranteed At the end of pre washing the temperature at the nozz...

Page 16: ...MANTLE ANY COMPONENT OF THE MACHINE ONLY OPERATE THE CONTROL SWITCH OF THE BOILER AND WHERE APPLICABLE THE RESET PUSH BUTTON IF THE EQUIPMENT BECOMES LOCKED OUT AGAIN DO NOT CONTINUE TO USE THE RE SET PUSH BUTTON AND CONSULT QUALIFIED PERSONNEL WHO WILL BE ABLE TO ELIMINATE THE OPERATING FAULT WARNING DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST THE HEAT GENERATOR COU PLING FLANGE ARE S...

Page 17: ... Solenoid valve opening indicator light F Maximum input operation indicator light H Ignition transformer operation indicator light I Thermal cutout tripped indicator light L Resistors safety thermostat tripped indicator light M Pre heat resistor light Fig 15b Flame control device reset button on burners PN30 F H L A M D I F B C ...

Page 18: ...s important clean with solvents only Do not use metal implements At the end of maintenance and after replacing the burner light the flame and check the shape If in doubt replace faulty nozzle If the burner is used intensively you are recommended to replace the nozzle at the beginning of the operating season inspect and thoroughly clean the flame detector photoresistor Replace if necessary If in do...

Page 19: ...rodes and combustion head To guarantee efficient ignition the measurements indicated in Fig 18a Fig 18b must be respected Make sure the electrode locking screw is tight before replacing the combustion head Fig 18a Electrodes correct position Fig 18c Fig 18b ...

Page 20: ...range indicated check the electrical contacts cleanliness of the combustion head and position of the photoresistor If necessary replace the photoresistor Fig 19 Minimum current intensity with flame 65 µA 65 µA Maximum current intensity without flame 5 µA 5 µA Maximum current intensity possible with flame 200 µA 200 µA 34 35 SCALE µA DC TERMINAL BLOCK ...

Page 21: ...AIN SWITCH OPEN LINE FUSES BLOWN MAXIMUM THERMOSTAT MALFUNCTION FAN THERMAL CUTOUT TRIPPED AUXILIARY FUSE BLOWN OIL RESISTOR FAULTY OIL ENABLING THERMOSTAT TRIPPED CONTROL UNIT MALFUNCTION PLANT ENABLING THERMOSTAT SMOKY FLAME IGNITION TRANSFORMER FAULTY IGNITION ELECTRODES WRONGLY POSITIONED DIRTY NOZZLE FAULTY OIL VALVE FAULTY OR DIRTY PHOTORESISTOR FAULTY RESISTOR THERMOSTAT LOW OIL PRESSURE OI...

Page 22: ...hutdown indicator light LTA Ignition transformer indicator light LTRS Pre heat TRS shutdown indicator light MA Power terminal board MC Burner components connection terminal board MV Fan motor N Neutral PS Flame control unit reset button RA Auxiliary resistors RP Pre heat resistors ST Series of thermostats or pressure switches STA6B2 41 Berger air damper servo control STA4 5B0 37 63N21L Berger air ...

Page 23: ...PART III MAINTENANCE MANUAL 23 ELECTRICAL DIAGRAM 04 649 ...

Page 24: ...PART III MAINTENANCE MANUAL 24 SPARE PARTS ...

Page 25: ...CLEANING PRE HEATER FILTER DENSE ENVIRONMENTALLY FRIENDLY OIL 2090210 23 CARTRIDGE PRE HEATER FILTER FLUID OIL 2090218 23a PRE HEATER FILTER GASKET 2110036 24 THERMOMETER 2450001 24a THERMOMETER SHEATH 3160002 25 RESISTOR PROTECTION COVER 2210013 25a RESISTOR O RING 2250004 26 RESISTOR THERMOSTAT TR 2560003 27 CHECK VALVE 2190627 28 OIL PRE HEATER RESISTOR 6060011 34 CARTRIDGE RESISTOR 55 W 606001...

Page 26: ...APPENDIX TECHNICAL CHARACTERISTICS 26 LANDIS LIGHT OIL BURNERS AUTOMATIC CONTROLLER LOA24 27 LANDIS OIL BURNERS AUTOMATIC CONTROLLER LOA44 29 SUNTEC PUMPS E SERIE 31 APPENDIX TECHNICAL CHARACTERISTICS ...

Page 27: ...of the socket for mounting To dismantle it only requires gentle pressure with a screw driver in the slot of the mounting guide The base dimensions of the socket are exaclty the same as for types LAB LAI and there is no difference in the diameter of the reset button the two mounting screws and the flange of the burner earth Safety at low voltage levels Safety devices against any reduction in the ma...

Page 28: ...there is a flame signal eg from premature ignition due to a faulty sole noid external light short circuit in the photoresisto or wiring malfunc tion in the flame signal amplifier etc at the end of pre purge and safety time the controller locks out the burner and stops the fuel flow even during safety time Absence of flame If there is no flame at the end of safety time the controller locks out imme...

Page 29: ...ogramme or operation Automatic repetition of programme when power restored Lack of sufficient power 160V Solenoid BV1 de energised sole noid BV2 de energised when flame goes out Lockout which occurs within less than 1 second cuts off power to ter minals 3 8 and 12 terminal 10 still remains live in order to activate the optical lockout indicator The controller can be reset 2 seconds after a lockout...

Page 30: ...6 External fuse max 10 A slow action Contact flow terminal 1 max 5A terminal 3 5A incl consumed cap of motor and pre heater terminals 4 5 6 max 2A terminal 8 max 5A terminal 10 max 1A Permitted temperature operation 20 60 C storage and transport 50 40 C Protection IP40 Mass weight controller socket 140g 80g AGK accessories 12g ...

Page 31: ...lower than the flat flow The cut on and cut off speeds depend on the gear set size and set pressure Bleed Bleeding in two pipe operation is automatic but it could be accelerated by loosening the plug in a pressure gauge port In one pipe operation a pressure port must be opened to bleed the system Technical data Connection threads Cylindrical according to ISO 228 1 Inlet and return G 1 2 Nozzle out...

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