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Unigas PN510, Manual Of Installation - Use - Maintenance

The Unigas PN510 user manual is your go-to guide for the proper installation, use, and maintenance of this high-quality product. Download the comprehensive manual for free from 88.208.23.73:8080, ensuring you have all the necessary information to maximize your Unigas PN510 experience.

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TABLE OF CONTENTS

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

Burner model identification  ............................................................................................................................................................. 5
Technical Specifications  ................................................................................................................................................................. 5
Performance Curves  ....................................................................................................................................................................... 7

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

Packing ........................................................................................................................................................................................... 8
Handling the burner  ........................................................................................................................................................................ 8
Fitting the burner to the boiler  ......................................................................................................................................................... 9
Electrical connections  ................................................................................................................................................................... 10
Fan motor direction  ....................................................................................................................................................................... 11
Connecting the oil heating resistors .............................................................................................................................................. 11
Double-pipe and single-pipe system ............................................................................................................................................. 11
Oil pumps ...................................................................................................................................................................................... 12
About the use of fuel pumps  ......................................................................................................................................................... 12
Connecting the oil flexible hoses  .................................................................................................................................................. 13
Connections to the oil gun  ............................................................................................................................................................ 13
Recommendations to design heavy oil feeding plants .................................................................................................................. 13
Pipe heating system ...................................................................................................................................................................... 14
Inlet minimum pressure of the pump (both for supplying system and burner)  .............................................................................. 14
Pump operating maximum pressure (both for the supplying system and burner)  ........................................................................ 14
Adjusting the supplying oil ring  ..................................................................................................................................................... 14
Burner adjustments ....................................................................................................................................................................... 14

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

Adjusting light oil flow rate  ............................................................................................................................................................ 21
Oil thermostat adjustment  ............................................................................................................................................................. 22
Thermostat adjustment for petroleum burners .............................................................................................................................. 22

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

Adjustments - brief description ...................................................................................................................................................... 23
Oil Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator  ....................................................................... 24
Adjustment by the Siemens SQL33.. actuator  .............................................................................................................................. 26
Calibration of air pressure switch .................................................................................................................................................. 28
Fully-modulating burners  .............................................................................................................................................................. 28
Oil circuit  ....................................................................................................................................................................................... 29

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

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

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

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

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

Self-cleaning filter  ......................................................................................................................................................................... 32
Removing the combustion head  ................................................................................................................................................... 32
Removing the oil gun, replacing the nozzle and the electrodes .................................................................................................... 33
Nozzle 

and electrodes 

correct position.........................................................................................................................................  34

Checking the detection current  ..................................................................................................................................................... 34
Cleaning and replacing the detection photoresistor......................................................................................................................  34
Seasonal stop  ............................................................................................................................................................................... 34
Burner disposal  ............................................................................................................................................................................. 34

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

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

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

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

APPENDIX

Summary of Contents for PN510

Page 1: ...ANUAL OF INSTALLATION USE MAINTENANCE PN91 PN92 PN93 PN510 PN515 PN520 PN525 M039196CC Rel 2 2 05 2010 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive Fully modulating Heavy oil Burners ...

Page 2: ...ng oil ring 14 Burner adjustments 14 HYDRAULIC DIAGRAMS 18 Adjusting light oil flow rate 21 Oil thermostat adjustment 22 Thermostat adjustment for petroleum burners 22 ADJUSTING AIR AND FUEL RATE 23 Adjustments brief description 23 Oil Flow Rate Settings by means of Berger STM30 Siemens SQM40 actuator 24 Adjustment by the Siemens SQL33 actuator 26 Calibration of air pressure switch 28 Fully modula...

Page 3: ...ains 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 Rem...

Page 4: ... of toxic 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...

Page 5: ...Heavy oil viscosity 110cSt 15 E 50 C D Heavy oil viscosity 400cSt 50 E 50 C P Petroleum viscosity 89cSt 12 E 50 C 3 OPERATION Available versions PR Progressive MD Fully modulating 4 BLAST TUBE S Standard L Extended 5 DESTINATION COUNTRY see data plate 6 BURNER VERSION A Standard BURNER PN91 PN92 PN93 Output min max kW 698 2093 849 2558 550 4100 Fuel Heavy oil Oil viscosity See Burner model identif...

Page 6: ...2326 6977 2000 8000 Fuel Heavy oil Oil viscosity See Burner model identification table Heavy oil rate min max kg h 117 352 145 435 207 622 178 713 Power supply 230 400V 3N a c 50Hz 400V 3N a c 50Hz Total power consumption Heavy oil kW 32 41 5 59 7 69 2 Total power consumption Petroleum kW 26 29 5 41 7 57 2 Fan pump motor kW 7 5 11 Fan motor kW 15 18 5 Pump motor kW 2 2 2 2 Pre heater resistors hea...

Page 7: ...osition During the first ignition the combustion head is set in order to find a compromise between the burner output and the generator specifications that is why the minimum output may be different from the Per formance curve minimum PRESSURE IN COMBUSTION CHAMBER mbar PN91 kW PN92 kW PRESSURE IN COMBUSTION CHAMBER mbar PN93 kW PRESSURE IN COMBUSTION CHAMBER mbar PN510 kW PN515 kW PRESSURE IN COMB...

Page 8: ... inserted into the A anb B ways Remove the stirrup only once the burner is installed to the boiler Type A B BL C CL D E F G K H M P Y PN91 1017 298 488 1315 1505 532 520 1052 262 464 292 M12 295 228 PN92 1017 301 491 1318 1508 532 520 1052 292 464 322 M12 295 228 PN93 1017 301 491 1318 1508 532 520 1052 292 464 322 M12 295 228 PN510 1050 340 520 1390 1570 550 560 1110 345 650 385 M14 390 328 PN515...

Page 9: ...en the 4 stud bolts 5 place the gasket on the burner flange 6 install the burner into the boiler 7 fix the burner to the stud bolts by means of the fixing nuts according to the next picture 8 After fitting the burner to the boiler ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement Set the upper...

Page 10: ...r s main switch is in 0 position OFF too Read carefully the chapter WARNINGS and the Electrical connections section WARNING The burner is provided with an electrical bridge between terminals 6 and 7 when connecting the high low flame thermostat remove this bridge before connecting the thermostat IMPORTANT Connecting electrical supply wires to the burner teminal block MA be sure that the ground wir...

Page 11: ... used besides another pipe that connects the pum s return port to the tank as well The excess of oil goes back to the tank this installation can be considered self ble eding If provided the inside by pass plug must be installed to avoid air and fuel passing through the pump Burners come out from the factory provided for double stage systems They can be suited for single pipe system recommended in ...

Page 12: ...ion line to bleed To avoid damages inject some lubrication oil into the vacuum inlet z 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 z Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical seal junc tions preferred J...

Page 13: ... pressurised The pressurisation is also necessary to feed the burner pump avoiding its cavitation because of the high suction at the inlet The supplying system scope is to pump and heat oil The oil viscosity is referred in various unit measures the most common are E cSt Saybolt and Redwood scales Table 3 shows the various unit convertions e g 132 cSt viscosity corresponds to 17 5 E viscosity The d...

Page 14: ...g the supplying oil ring According to the heavy oil viscosity used in the table below indicative temperature and pressure values to be set are shown Note the temperature and pressure range allowed by the supplying ring components must be checked in the specifications table of the components themselves Burner adjustments The table below shows indicative values of temperature and pressure to be set ...

Page 15: ... 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 16: ...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 17: ...atomising temperature should be between 145 C and 160 C see diagram 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 10 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 11 PRESSION D ALIMENTATION POMPE VISCOSITY vs TEMPERATURE DIAGRAM BEST VISCOSITY RANG...

Page 18: ...C I B UNIGAS M039196CC 18 HYDRAULIC DIAGRAMS Fig 13 Hydraulic diagram 3ID0023 Single burner configuration ...

Page 19: ...C I B UNIGAS M039196CC 19 Fig 14 Hydraulic diagram 3ID0014 Two or more burners configuration ...

Page 20: ... 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 10Pump pressure regulator 11Unidirectional valve 12Service tank pre heati...

Page 21: ...5 NOZZLE DELIVERY PRESSURE bar RETURN PRESSURE MAX bar RETURN PRESSURE MIN bar FLUIDICS WR2 25 19 20 7 9 recommended Tab 4 Fig 15 Atomisation angle according to the return pressure _________ Flow rate FLOW RATE kg h DIMENSIONS Min Max 40 13 40 50 16 50 60 20 60 70 23 70 80 26 80 90 30 90 100 33 100 115 38 115 130 43 130 145 48 145 160 53 160 180 59 180 200 66 200 225 74 225 250 82 250 275 91 275 3...

Page 22: ... C This thermostat trips when the operating temperature exceeds the set limit Ascertain the cause of the malfunction and reset the ther mostat by means of the PR button see picture CAUTION even if the adjusting ranges for the TR Resistor thermostat and TCN Oil enabling thermostat are the same set TCN to a value lower than the one set for TR TCN Oil enabling thermostat Fig 16 Adjust this thermostat...

Page 23: ...easing too much or the flues temperature getting too low to cause condensation in the chimney Now adjust the burner according to the actuator model provided ATTENTION before starting the burner up be sure that the manual cutoff valves are open Be sure that the mains switch is closed ATTENTION During commissioning operations do not let the burner operate with insufficient air flow danger of formati...

Page 24: ...the RESET button C on the control panel see chapter OPERATION 5 Start the burner up by means of the thermostat series and wait unitl the pre purge phase comes to end and that burner starts up 6 drive the burner to high flame stage by means fo the thermostat TAB Then move progressively the microswitch to higher values until it reaches the high flame position always check the combustion values see n...

Page 25: ...the adjustment is accomplished Attention if it is necessary to change the head position repeat the air and gas adjustments described above 11 as for the point to point regulation in order to set the cam foil shape move the low flame microswitch cam III a little lower than the maximum position 90 12 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low...

Page 26: ...rol panel press the RESET button C see chapter OPERATION 5 Start the burner up by means of the thermostat series and wait until the pre purge phase comes to end and that burner starts up 6 the burner starts up with the actuator on the ignition position set it to the MAN manual mode by the MAN AUTO selector ignition position read on the air damper index ID 7 disconnect the TAB thermostat removing t...

Page 27: ...VB screw and move pro gressively back the combustion head towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment is accomplished Attention if it is necessary to change the head position repeat the air and gas adjustments described above 13 once the air and oil flow rate have been adjusted at the maximum output go on with the point to point adjustment on ...

Page 28: ...up the burner z 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 z Repeat the ignition cycle of the burner and check it runs properly z Refit the transparent plastic cover on the pressure switch Fully modulating burners To adjust t...

Page 29: ...back nozzle is feeded at constant pressure while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see prevoius paragraph Fig 24 Stand by Fig 25 Prepurge Fig 26 Low flame Fig 27 High flame Key 1 Oil pump 2 Oil solenoid v...

Page 30: ...ET 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 N B be sure the cutoff valves on the delivery and return pipes are OPEN z Turn the burner on by means of its main switch A see next pictures z Check that the burner is not locked LED E lights up if so reset it by pressi...

Page 31: ... High flame 2 Low flame 3 Automatic D Fan motor thermal cutout intervention E Burner lockout F Burner in stand by IRA Auxiliary resistors wsitch L Heavy oil solenoid lamp operation N Contrlol box reset pushbutton P Heating resistors safety thermostat Q Pre heating tank R Modulator T Main switch PN515 PN520 PN525 A B C D E L P Q N R F T R A B C D E F L N P P Q Q T ...

Page 32: ...essary see page 34 z Examine the detection current see page 34 z Remove and clean page 34 the heavy oil nozzle Important use solvents for cleaning not metallic tools and at the end of the maintenance procedures after replacing the burner turn it on and check the shape of the flame if in doubt replace the nozzle Where the burner is used intensively it is recommended to replace the nozzle as a preve...

Page 33: ...remove them place the new electrodes being careful to observe the measures shown on next paragraph reassemlbe following the reversed procedure Caution adjust the nozzle position by means of the VU screw Fig 27 Fig 25 Key 1 Inlet 2 Return 3 Lance opening 4 Heating wire only for oil viscosity 110 cSt 50 C 5 Cartdrige type heater H Cover L Oil lance E Oil piping connections Fig 26 ATTENTION avoid the...

Page 34: ... photoresistor if necessary PN91 PN92 PN93 LMO44 PN510 PN515 PN520 PN525 LAL2 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 c...

Page 35: ...AXIMUM THERMOSTAT MALFUNCTION z FAN THERMAL CUTOUT TRIPPED z AUXILIARY FUSE BLOWN z OIL RESISTOR FAULTY z z OIL ENABLING THERMOSTAT TRIPPED z z CONTROL UNIT MALFUNCTION z z z z z z AIR SERVOCONTROL MALFUNCTION z CIRCUIT ENABLING THERMOSTAT z z SMOKY FLAME z z IGNITION TRANSFORMER FAULTY z IGNITION ELECTRODES WRONGLY POSITIONED z DIRTY NOZZLE z z FAULTY OIL VALVE z z FAULTY OR DIRTY PHOTORESISTOR z...

Page 36: ...3 1 1 LONG IGNITION ELECTRODE 6 7 CONNECTOR 9 1 FAIRLEAD 3 1 2 LONG IGNITION ELECTRODE 7 1 UNION ELBOW 9 2 FAIRLEAD 3 1 3 COMBUSTION HEAD 7 2 STRAIGHT UNION 10 AIR INLET CONE 3 1 4 IGNITION CABLE 7 3 UNION ELBOW 11 BURNER HOUSING 3 2 GUN TERMINAL 7 4 SCREW 11 1 COVER 3 3 STANDARD COMPLETE OIL GUN 7 5 ADJUSTING ROD 12 GENERATOR GASKET 3 3 1 1 NIPPLE 7 6 REDUCTION 13 RING NUT 3 3 1 2 RESISTOR FIXING...

Page 37: ...C I B UNIGAS M039196CC 37 ...

Page 38: ...S SQM40 24800A5 24800A5 24800A5 PHOTORESISTOR SIEMENS 2510003 2510003 2510003 COUPLING 2540121 2540121 2540134 RESISTOR THERMOSTATTR TCN TCI 2560026 2560026 2560026 THERMOSTAT TRS 2560028 2560028 2560028 PRESSURE GOVERNOR FOR OIL VISCOSITY 110 cSt 50 C 2570054 2570054 2570077 PRESSURE GOVERNOR OIL VISCOSITY 110 cSt 50 C 25700A6 25700A6 25700A6 BURNER MODULATOR only for fully modulating burners 257...

Page 39: ...088 2340088 2340088 OIL GUN HOSES 2340089 2340089 2340089 2340089 ADJUSTING CAM FOIL 2440013 2440013 2440013 2440013 ACTUATOR mod SIEMENS SQL 2480007 2480007 2480007 2480007 ACTUATOR mod BERGER STM30 2480090 2480090 2480090 2480090 ACTUATOR mod SIEMENS SQM40 24800A5 24800A5 24800A5 24800A5 PHOTORESISTOR SIEMENS 2510003 2510003 2510003 2510003 COUPLING 2540122 2540122 2540126 2540126 RESISTOR THERM...

Page 40: ...nd for activating 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...

Page 41: ...ck R Control thermostat 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 ...

Page 42: ...act for the oil preheater s temperature z Normally closed contact of the air pressure switch must be closed Startup sequence Start command by R R closes the start control loop between terminals 4 and 5 z The sequence switch starts to run z Only prepurging fan motor at terminal 6 receives power z Pre and postpurging fan motor or flue gas fan at terminal 7 receives power on completion of t7 z On com...

Page 43: ...r 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 s...

Page 44: ...t terminal 7 start delay time for M2 t8 Duration of startup sequence excluding t11 and t12 t10 Interval from startup to the beginning of the air pressure check t11 Air damper running time to the OPEN position t12 Air damper running time to the low fire position MIN t13 Permissible afterburn time t16 Interval to the OPEN command for the air damper t20 For self shutdown of the sequence switch A t11 ...

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Page 48: ...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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