IDEA series Light oil burners
Contents
1. 7130a02e 0700 Control sequence LMO14 R A A B D 745 4 tw ay p 8 C OW 77 r A 3 Cu mfy a gt 3 X BV1 zi ay seal p gt 4 a W d t3n QE z 7 74 gt 6 Mi TSA a gt FSi gt lt KD Only with LMO14 113A2 re ignition t3n t3n 5 24 7 6 JE FS 4 SL Lg 7130d02e 0700 12 LMO24 LMO44 poA A B C D w 74 44 1 tw E d y aasma y ow gt 3 Cu xd X BV1 74 A 4 Y pve 17 mem2. 12 Connecting the light Ol flexible NOSOS Y 12 ADJUSTMENT H A 19 Eo uuu 13 Priming the pump and adjusting the burner for single stage burners seii eese enne nnne 14 Priming the pump and adjustments for double stage burners sss 15 POSTING ME COmDUSTON HOQ u u c 16 PARTI OPERATION u E 17 AO 17 00 OTS e Om a sa 17 DUMETS 17 us 18 PART Ill MAINTENANCE ases 19 FIOUTINE MAINTENANCE PON 19 LON Oler UC 19 Removing the combustion head and the oil gun cccccsscccencenccscncnseneneaanenseneneseeasanuenenenansesenenseaeaasaneneesananarcenenseseasanuesessnansetenenaens 20 Removing burner components plate
3. 21 Renova ship COC OG z C 22 IOO TT Nor 22 Checking the COLE CH ON u 23 Cleaning and replacing the detection photoresistor 24 Burner control panel disassembly a 24 Seasonal S OD uuu EE 24 GIS 9 e 24 TROUBLE SOO TING A X OOFO X M aa 25 BURANEREXPLODED VIEW u wen E atresia E 26 SPARE PARTO uuu 28 ELECTRICAL WIRING DIAGRAMS APPENDIX 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 GENERAL INTRODUCTION The equipment must
4. EVG1 FR LINEA TAB 4 eu evs 1 tl N J CONN LINEA 2101 FR j TA 3 z y L MIN 6 3A T MAX 10A T MOTORE VENTIL 450W 0 620W FU2 6 3A F MOTORE VENTIL 370W FU2 10A F FAN MOTOR 450W OR 620W FU2 6 3A F FAN MOTOR 370W FU2 10 F Ve MOTORE VENTILATORE MOTORE VENTILATORE 2 3 0 V FAN MOTOR FAN MOTOR 20W 370W Data id lea Revisione Revisione O4 SEGUE TOTALE 18 049 MIN 104 T MAX 15A T AAA AS a aa ee O ME HE ES AA ucc lcu AA VERSIONE AL TA BASSA FIAMMA AB AB HIGH LOW FLAME VERSION MIN 10A T MAX 15A T FRONTALE QUADRO FRONT CONTROL PANEL SIEMENS LOA24 44 24 111 LM024 255 LM044 255 8 4 5 3 10 Z APPARECCH A APPARECCH B FRONTALE 2 APPARECCH A APPARECCH B TT NT MT M N NT mi 3 Af o lt lt lt lt c ol m m Tip CIRCUITO STAMPATO PRINTED CIRCUIT BOARD COD 6100542 EVG2 TA AUX EVG1 FR STA 174 TUI AT 3 pe EE EVG2 m di mE 1 v A B VERSIONE CON MARTINETTO IDRAULICO WITH HYDRAULIC RAM VERSION S S S STA4 5B0 37 63N30L SQN72 2A4A20 MOTORE VENTILATORE MOTORE VENTILATORE FAN MOTOR FAN MOTOR 20W 370W MOTORE VENTIL 450W O 620W FU2 6 3A F MOTOR
5. LO350 IDEA series Light oil burners MANUAL OF INSTALLATION USE MAINTENANCE DIB UNIGAS BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES M03H122CB TABLE OF CONTENTS WARNING cH P 3 PAFRITITLINSIARKLATIONu u 5 GENERAL FEATURES 5 How to interpret the burner s Performance curve 5 MOINS tk ners sa ae ona sae aes Ds 6 POTION TACO OOS a xu a A a pene ates 6 Qr I u re ee rene rer eee 7 MOUNTINGS AND CONNEC TIONG 8 8 C u us eo A 8 Fling Me TOTNC DONET 8 Igne D A P 9 Installation diagram of light 11 a o Pe ss sn 11 About the use Of fuel pumps Rena 11 8 807
6. Q CTA Z r O E ELA y _ L u BV2 J FS L L l C Lal liii tp v v NERIS UN A 99 O Technical characteristics Voltage 220V 15 240V 10 or 100V 15 110V 10 Frequency External fuse Contact flow terminal 1 terminal 3 Terminal flow terminals 4 5 amp 10 terminals 6 amp 7 terminal 8 Absorbed cap Protection Premitted temp operational transport amp storage Emplacement Mass weight 50 60Hz 6 max 10A slow action 5A 5A incl capacity absorbed by motor and pre heater 1A 2A 5A 3VA IP40 20 60 C 50 60 C any controller 180g socket 50g AGK accessories 12 g 0 4 N r SIEMENS OIL BURNERS AUTOMATIC CONTROLLER SIEMENS LMO14 LMO24 LMO44 The LMO burner controls are designed for the start up and supervision of single or 2 stage forced draught oil burners in intermittent operation Yellow burning flames are supervised with photoresistive detectors QRB blue burning flames with blue flame detectors QRC In terms of housing dimensions electrical connections and flame detectors the LMO are identical to the LOA oil burner controls Preconditions for startup e Burner control is reset e All contacts in the line are closed No undervoltage e Flame detector is darkened no extraneous light Undervoltage e Safety shut down in the operating position takes place shoul
7. BURNER STARTS AND BURNER DOESN T SWITCH TO HIGH FLAME BURNER LOCK DURING OPERATION BURNER LOCKS AND REPEATS CYCLE DURING OPERATION MAINS SWITCH OPEN FUSES INTERVENTION MAXIMUM PRESSURE SWITCH FAULT INTERVENTION OF THE FAN MOTOR THERMAL CUTOUT AUXILIARIES RELAY FUSES INTERVEN TION FLAME CONTROL DEVICE FAULT SERVOCONTROL FAULT SMOKY FLAME IGNITION TRANSFORMER FAULT IGNITION ELECTRODE DIRTY OR BAD POSITION DIRTY NOZZLE FUEL SOLENOID VALVE DEFECTIVE PHORESISTANCE DIRTY OR DEFEC TIVE HIGH LOW FLAME THERMOSTAT DEFECTIVE BAD POSITION OF SERVOCONTROL CAMS FUEL LOW PRESSURE FUEL FILTERS DIRTY 25 9c BURNER EXPLODED VIEW tuwa w PM O e O CO OO O PM O ITEM DESCRIPTION 9 0 uwa IGNITION CABLE QOOcc16 0W SVOINN ATO C I B UNIGAS M039122CCC d _ y a v e k y E go va 4 hx 23 w E m _ Y RES p z JA Gi m y BS i vu Vue P c f Tu P T UJ O 12 q fi 4 P gt let _ ea 7 2 gh MA Ae A wu g lt 27
8. 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 instruc tions is available in the boiler room Incase of a burner shut down reser the control box by means of the RESET pushbutton If a second shut down takes place call the Technical Service without trying to RESET further 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 safety reasons the unit must be efficiently earthed and installed as required by current safety regulations Itis 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 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 No adaptors multiple outlet sockets and or extension cables are per mitted to c
9. 2 91519 T 6 5 4 LAMPADA SEGNALAZIONE BLOCCO BRUCIATORE LAMPADA SEGNALAZIONE BASSA FIAMMA BRUCIATORE INDICATOR LIGHT FOR OPENING OF ELECTRO VALVE EVG2 OAU UL LMO2U 1 20 255 425 APPARECCHIATURA CONTROLLO FIAMMA LAMPADA SEGNALAZIONE TRASFORMATORE DI ACCENSIONE TA4 580 37 63N301 PULSANTE INNESCO SECONDO STADIO BRUCIATORE 1 STAGE BURNER START BUTTON TRASFORMATORE DI ACCENSIONE TERMOSTATO PRESSOSTATO DI SICUREZZA B4 B5 B6 falo a B1 B2 B3 oo OJFR 2 1 TA VN MV ole 57 3 1 1 2 Doto 13 10 2004 PREPS 2 SEGUE TOTALE o 18 049 SIEMENS OIL BURNERS AUTOMATIC CONTROLLER LOA24 Use LOA safety devices are intended for use solely with QRB photoresi stors for lighting and controlling low capacity forced air light oil burners with max capacity 30 kg h in accordance with standard DIN 4787 The One or two flamess are lit through electrical connections with or without post ignition To replace LAI AND LAB WITH LOA LOA models can be used as replacement for LAI and LAB controllers by means of the adapter KF8819 and without the need to change the electrical wiring Because the LOA is smaller in dimensions when it is used with the adapter the external dimensions are almost identical which means that there is no need to move the reset button Performance The controllers just need plugging in so they can be mounted in almost any position on the burner on the
10. and adjustments for double stage burners Before carrying out the adjustment it is necessary to start up the fuel pump proceeding as follows 1 remove the burner cover 2 remove the solenoid valve coil B connector on pump Fig 15 to avoid the light oil to get into the combustion chamber 3 start the burner up by means of the control panel switch switch to ON Fig 20 and by means of the thermostatsW pressure switches series when the EVG lamp turns to on see chapter page 17 remove the phtoresistor FR Fig 17 from its slot and light it up bleed the air from the M pressure gauge port of the pump slightly loosing the cap and without removing it Fig 15 turn the burner off replace the photoresistor FR Fig 17 into its slot reconnect the B coil on the pump Fig 15 light the burner if the burner locks press the unlock pushbutton placed on the upper side of the burner and repeat the steps above 10 when the flame lights up press the P1 pushbutton see Fig 16 for a while to fill the second nozzle pipe NOTE The oil flow rate depends on the choosen nozzle The air rate can be adjusted by means of the air damper actuator cams see picture below 11 The that enables the second stage solenoid valve to open EVG2 valve must be set between the other two cams 12 drive the burner to high flame by means of the thermostat TAB if TAB is not present insert a bridge between T6 and T8 contacts on the related connector
11. apparatus Wiring diagram of the programme To ensure correct wiring it is essential to observe local standards and fol low the instructions of the burner manufacturer with regard to assembly and start up Program s legend Emp Controller output signals Required input signals A Burner start up with light oil pre heater OH A Burner start up without light oil pre heater B Flame lit C Normal operation D Normal stop through R tw Oil pre heating time until operational all clear given through contact OW tl Pre purge time t3 Pre ignition time t2 Safety time tn Post ignition time t4 Interval between the flame lighting and energising of solenoid 2a at terminal 5 Internal layout AL Optical alarm BV Fuel valve EK Reset button FR Flame relay fr Flame relay contacts FS Flame alight signal G Burner motor K Flame relay anchor to delay the 121 command in the event of a premature flame signal or endorse it where the signal is correct OH light oil pre heater OW Operational all clear contact QRB Photo resistant cell flame detector H Thermostat or pressure switch TZ Thermo electric programmer bimetal system tz TZ contacts V Flame signal amplifier W Safety thermostat or pressure switch Z Ignition transformer The above are safety devices To tamper with them in any way may have unforeseeable conse quences Do not open them A A B C D mp Ao ooo nmm mmm OH gt G gt
12. be installed in compliance with the regulations in force following the manufacturer s instructions by qualified per sonnel 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 Improper installation may cause injury to people and animals or damage to property for which the manufacturer cannot be held lia ble Remove all packaging material and inspect the equipment for inte grity 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 chil dren as they may prove harmful Before any cleaning or servicing operation disconnect the unit from the mains by turning the master switch OFF and or through the cut out devices that are provided e Make sure that inlet or exhaust grilles are unobstructed Incase 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 efficie
13. proper sealing b the fuel flow rate to make sure that it has been set based on the firing rate required of the burner the burner firing system to make sure that it is supplied for the desi gned fuel type d the fuel supply pressure to make sure that it is included in the range shown on the rating plate e thefuel 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 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 all gas connections are tight 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 not use gas pipes to earth electrical equipment Never leave the burner connected when not in use Always shut the gas valve off e 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 a
14. see page 9 13 adjust the high flame air flow rate acting on the related cam in order to get the right combustion values 14 drive the burner to low flame by means of the thermostat TAB or remove the bridge between T6 and T8 contacts on the related connector see page 9 15 adjust the low flame air flow rate acting on the related cam in order to get the right combustion values 16 Replace the actuator and burner covers o Suntec AL Fig 16 Pushbutton for second nozzle priming on two stage burners As for the setting refer to this correspondence table Berger STA4 5 Siemens SQN72 AUTO MAN Refer to the next table for cams functions red Air in low flame Stand by Ignition cam ny camer opening consom o second shake H Web e Berger STA12 this actuator is not provided with the manual control of the air damper The adjustment of the cams is carried out by means of a screwdriver by twisting the VS screw located inside the cam e Siemens SQN72 a key is provided to move cams and IV the other cams be moved by means of screws On the Siemens actuator the AUTO MAN mode is provided see picture Air adjustment in high flame cam 15 C I B UNIGAS M039122CC Adjusting the combustion head The burner is set in the factory with the combustion head in the MAX position corresponding to the maximum power combustion head all forward To ope
15. 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 Overall dimensions mm A S LO550 G AB x xx A 843 S STANDARD BLAST TUBE L EXTENDED BLAST TUBE EAS CIT IAN m oas 353 soo 426 175 241 274 187 182 QOOcc16 0W SVOINN ATO C I B UNIGAS M039122CC MOUNTINGS AND CONNECTIONS Packing Burners are dispatched in cardboard pakages whose dimensions are 1030mmx530mmx270mm LxPxH Packing cases of this kind are affected by humidity and are not suitable for stacking The following are pla ced in each packing case 1 burner H 2 light oil flexible hoses 1 light oil filter 1 gasket to be inserted between the burner and the boiler 1 envelope containing this manual To get rid of the burner s packing follow the procedures laid down by current laws on disposal of materials Handling the burner ATTENTION The Ihandling operations must be carried out by specialised and trained personnel If these opera tions are not carried out correctly the residual risk for the burner to overturn and fall down still persists To move the burner use means suitable to support its weight see paragraph Technical specifications Fitting the burner to t
16. 0 e Withdraw the screw VE and remove the electrodes from the support Fig 29 Fig 30 Single stage burners Double stage burners Removing the nozzles e Unscrew the Allen screw VT and remove the combustion head TC Unscrew the nozzles using two wrenches 16 and 24 mm as shown in Fig 31 Fig 32 Single stage burners Double stage burners 22 C I B UNIGAS M039122CC Correct position of electrodes and combustion head ATTENTION avoid the electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the electrodes position after any intervention on the combustion head To ensure a good ignition respect the measures in mm in Fig 34 Fig 35 Single stage burners A 7 9 B 45 6 C 10 D 5 Fig 34 High Low flame burners A 9 11 B 45 6 C 8 D 3 Fig 35 Checking the detection current To measure the detection signal follow the diagram on the next picture If the signal is not in the advised range check the electrical contacts the cleaning of the combustion head the position of the photore sistor and if necessary replace it Minimum current intensity with flame 65 pA CONNECTOR CN7 Maximum current intensity without flame Maximum possible current intensity with flame 200 Fig 36 23 C I B UNIGAS M039122CC Cleaning and replacing the detection photoresistor To clean replace t
17. 1 T xG400 6 3A T MAX 10A T p lt o gt lt gt M T lt 2 xG550 10A T MAX 16A T Fig 7 7 poles and 4 poles connectors Fig 8Electric motor 3 poles connector Key LBF BURNER IN LOW FLAME SIGNALLING LAMP C1 LOW FLAME TIME METER MV FAN MOTOR C2 HIGH FLAME TIME METER ST THERMOSTATS O PRESSURE SWITCHES SERIE FU1 FAN MOTOR LINE FUSE TAB HIGH LOW FLAME THERMOSTAT PRESSURE SWITCH LINE FUSE TS SAFETY THERMOSTAT PRESSURE SWITCH IL BURNER LINE SWITCH CONN MOTORE FAN MOTOR CONNECTOR IM FAN MOTOR LINE SWITCH CONN LINEA BURNER POWER SUPPLY CONNNECTOR KM1 FAN MOTOR CONTACTOR CONN TAB HIGH LOW FLAME CONNECTOR LAF BURNER IN HIGH FLAME INDICATOR LIGHT LB INDICATOR LIGHT FOR BURNER LOCK OUT IF TAB USED REMOVE THE BRIDGE BETWEEN TERMINALS T6 T8 10 C I B UNIGAS M039122CC Installation diagram of light oil pipes AN PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL From tank Totank Fig 9 Double pipe system The burner is supplied with filter and flexible hoses all the parts upstream the filter and downstream the return flexible hose must be installed by the customer As far as the hoses connection see the related paragraph Key Only for installations with gravity siphon or for 1 Burner ced circulation feed systems If the device installed 2 Flexible hoses fitted is a solenoid valv
18. 5 u lis QE z fa gt rs 74 Lot 4 S Bn Bn oe 7 a 7 6 E Fs LA SAT Y lt q 11 7130d03e 0700 Key AL Alarm device kbr BV EK1 EK2 FS FSV K LED M OW t1 t3 t3n Cable link required only when no oil pre heater is used Fuel valve Lock out reset button Remote lock out reset button Flame signal Flame signal amplifier Contacts of control relay 3 colour signal lamps Burner motor Release contact of oil pre heater Pre purge time Pre ignition time Post ignition time Beginning of start up sequence with burners using an oil pre heater Beginning of start up sequence with burners using no oil pre heater Controller output signals Required input signals OH Oil pre heater QRB Photoresistive detector QRC Blue flame detector bl blue br brown sw black R Control thermostat or pressurestat SB Si W Z t4 TSA tw B C D uC 1 uC2 Safety limit thermostat External primary fuse Limit thermostat or pressure switch Ignition transformer Interval from flame signal to release BV2 Ignition safety time Waiting time for oil pre heating Time of flame establishment Operating position Controlled shut down by R Microcontroller 1 Microcontroller 2 Gen
19. E VENTIL 370W FU2 10A F FAN MOTOR 450W OR 620W FU2 6 3A F FAN MOTOR 370W FU2 10A F SE PREVISTO TAB TOGLIERE IL PONTE TRA MORSETTI T6 T8 IF TAB USED REMOVE THE BRIDGE BETWEEN TERMINALS T6 T8 2 GROUND S MIN 6 3A T MAX 10A T SERVOCOMANDO SERRANDA ARIA AIR DAMPER ACTUATOR STA4 5B0 37 63N30L ROSSO RED II SLU IV BLACK Data 13 40 2004 1 18 ALTA FIAMMA HIGH FLAME SOSTA ACCENSIONE BASSA FIAMMA STAND BY IGNITION LOW FLAME APERTURA EVG2 OPEN EVG2 SERVOCOMANDO SERRANDA ARIA ALTERNATIVO AIR DAMPER ACTUATOR AL TERNA TIVE SQN72 2A4 A20 ALTA FIAMMA HIGH FLAME SOSTA ACCENSIONE BASSA FIAMMA STAND BY IGNITION LOW FLAME APERTURA EVG2 OPEN EVG2 SEGUE TOTALE 049 ES C C T S AS A O GB OS A i s M ka SIGLA ITEM Funzione JFNT N O HIGH FLAME TIME COUNTER ELETTROVALVOLA GASOLIO BASSA ELETTROVALVOLA GASOLIO ALTA FIAMMA HIGH FLAME LIGHT OIL SOLENOID VALVE INTERRUTTORE LINEA BRUCIATORE BURNER LINE SWITCH INTERRUTTORE LINEA AUSILIARI AUXILIARY LINE SWITCH INTERRUTTORE LINEA MOTORE VENTILATORE FAN MOTOR LINE SWITCH CONTATTORE MOTORE VENTILATORE FAN MOTOR CONTACTOR LAMPADA SEGNALAZIONE ALTA FIAMMA BRUCIATORE BURNER IN HIGH FLAME INDICATOR LIGHT LAMPADA SEGNALAZIONE BLOCCO BRUCIATORE INDICATOR LIGHT FOR BURNER LOCK OUT B FRONTALE 1 FRONTALE
20. General requirements 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 Gas Light oil 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 National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Heavy oil 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 National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods C I B UNIGAS M039122CC GENERAL FEATURES These burners are characterised by high performa
21. OF PART OF THE BURNER NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE OPERATE ONLY THE MAIN SWITCH WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH AND ON THE RESET BUTTON IN CASE OF A BURNER SHUT DOWN RESET THE CONTROL BOX BY MEANS OF THE RESET PUSHBUTTON IF A SECOND SHUT DOWN TAKES PLACE CALL THE TECHNICAL SERVICE WITHOUT TRYING TO RESET FURTHER WARNING DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR COUPLING FLANGE CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT OPERATION ATTENTION before starting the burner up be sure that the manual cutoff valves are open and check that the pres sure upstream the gas train complies the value quoted on paragraph Technical specifications ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL Single stage burners e Set Switch E on the burner control panel to ON position e Make sure that the control box is not in shutdown condition if so release by means of the release button F in Fig 19 on the bur ner control panel e Make sure that the set of thermostats or pressure switches enables burner operation e The burner starting cycle begins and the control box starts the burner fan while the ignition transformer switches on at the same time e Atthe end of pre purge the fuel solenoid valve is energised and the burner switches on e The ignition t
22. R LINE FUSE BURNER LINE SWITCH FAN MOTOR LINE SWITCH AUXILIARY RELAY AUXILIARY RELAY FAN MOTOR CONTACTOR DELAYED RELAY BURNER IN HIGH FLAME INDICATOR LIGHT SIEMENS CONTROL BOX SIEMENS CONTROL BOX INDICATOR LIGHT FOR BURNER LOCK OUT BURNER IN LOW FLAME INDICATOR LIGHT INDICATOR LIGHT FOR OPENING OF ELECTRO VALVE EVG1 IGNITION TRANSFORMER INDICATOR LIGHT FAN MOTOR LOCK OUT RESET BUTTON WITH LOA44 AND LMO ONLY SATRONIC DKO976 DKW976CONTROL BOX SATRONIC DKW972 CONTROL BOX SATRONIC TF976 ST SW1 TA TAB TS CONTROL BOX SERIES OF THERMOSTATS OR PRESSURE SWITCHES II STAGE BURNER START BUTTON IGNITION TRANSFORMER HIGH LOW THERMOSTAT PRESSURE SWITCHES SAFETY THERMOSTAT OR PRESSURE SWITCH IF TAB USED REMOVE THE BRIDGE BETWEEN TERMINALS 6 8 WARNING 1 Electrical supply 230V 50 60Hz 1N a c 2 Do not reverse phase with neutral 3 Ensure burner is properly earthed 29 A 117 ee E MS TRAS TS s E ME A MEAR cao re VERSIONE MONDS ALTHO TN FRONT CONTROL PANEL EN SINGLESS TAGE VERSION SIEMENS LOA24 44 24 111 LM024 255 LM044 255 APPARECCH A APPARECCH B FRONTALE 2 APPARECCH A APPARECCH B TT NT MT f N NT M f mf o lt lt m o wa m m OE hse enl AAA z eee Ee sed sl CIRCUITO STAMPATO PRINTED CIRCUIT BOARD am uno Slam 1 COD 6100542
23. SPARE PARTS C I B UNIGAS M039122CC Desription Code LO550 TN LO550 AB COVER 1011801 1011801 CONTROL BOX SIEMENS LOA 2020445 2020445 CONTROL BOX SIEMENS LMO 2020453 2020453 SHORT IGNITION ELECTRODE 2080259 2080259 LONG IGNITION ELECTRODE 2080260 FUEL FILTER 2090025 2090025 GASKET 2110056 2110056 FAN WHEEL 2150049 2150049 IGNITION TRANSFORMER FIDA 2170302 IGNITION TRANSFORMER COFI 2170139 IGNITION TRANSFORMER DANFOSS 2170231 ELECTRIC MOTOR 2180711 2180711 SOLENOID VALVE 2190638 FLEXIBLE HOSE 2340001 2340001 ACTUATOR mod BERGER 2480057 ACTUATOR mod SIEMENS 24800A3 PHOTORESISTOR mod SIEMENS QRB 2510033 2510033 PUMP mod SUNTEC 2590170 2590170 NOZZLE 0 75 6 00GPH 45 2610002 NOZZLE 0 75 6 00GPH 60 2610004 2610004 NOZZLE 6 50 11 00GPH 60 2610017 NOZZLE 6 50 35 00 GPH 45 2610016 COMBUSTION HEAD 3060199 3060198 BLAST TUBE standard 30900F5 30900F5 BLAST TUBE extended 30900F6 30900F6 IGNITION CABLES 6050153 6050153 PRINTED CIRCUIT BOARD 6100542 6100542 28 C I B UNIGAS M039122CC WIRING DIAGRAMS Keys C1 C2 EVG FR FU1 FU2 FU3 IL IM KA2 3 KA2 4 KM1 1 KT2 4 LAF LMO 24 44 LOA24 44 LB LBF LEVG1 LTA MV PS LOW FLAME TIME METER HIGH FLAME TIME METER LIGHT OIL ELECTRO VALVE PHOTORESISTOR FLAME DETECTOR FAN MOTOR LINE FUSE LINE FUSE BURNE
24. THE BURNER WORKING SERVICE e Burners provided with Siemens LOA24 control box for safety reasons one controlled shutdown must take place every 24 hours e Burners provided with Siemens LMO24 44 control box the control box automatically stops after 24h of continuous working The control box immediately starts up automatically A CAUTION in case the fuel requested is biodiesel come components must be replaced Please contact our Technical Dept for further details Performance curves LO550 Single stage LO550 Double stage 84 8 or 7 gt 6 uz 5 tr lt 5 5 am 7 O 4 4 2 3 zo 5 EET 2 2 2 m 1 1 S 0 0 150 200 250 300 350 400 450 500 550 600 100 150 200 250 300 350 400 450 500 550 600 kW kW Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 C NOTE The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests but does not represent the regulation range of the machine On this diagram the maximum output point is usually reached by 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
25. ces and width in the performance curves when the pressure in the combustion chamber is high They are also characterised for other important functional features there are plugs which can be easily connected to the boiler and to the detecting probes a pressure plug in the combustion chamber all mechanical components are mounted on a plate which can be quickly taken off for maintenance The head is adjustable through a graduated screw The gas train can be mounted either on the right side or on the left side 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 pass through the nozzle The pump main function is to transfer oil from the tank to the nozzle at required quantity and pressure To adjust pressure pumps are provided with a pressure governor The electric actuator moves the air damper and allows the optimisation of the gas flue values as to get an efficient combustion The position of the combustion head determines the burner output The air comburent and fuel light oil are forced into the combustion chamber as to let the flame light up How to interpret the burner s Performance curve To check
26. ck out The repetition count is restarted each time controlled switching by R W SB takes place Operation Lock out reset button EK is the key operating element for resetting the burner control and for activating deactivating the diagnostic functions The multicolour LED is the key indicating element for both visual diagnosis and interface diagnosis Red 1 Yellow Green Colour code table Status Colour code Colour Oil pre heater heats it Yellow waiting time tw SMO prase NOMIC ie Yellow off controlled Operation flame o k 000000000000 Green Operation flame not o k omomomomomo Green off Undervoltage 15151515161 Yellow red Fault alarm SSSSSSSSSSS Red Output of fault code refer to Fault code table smsmsmsmsm Hed off Extraneous light prior to burner start up Interface diagnosis SSSSSSSSSSSSSS Red flicker light Key m Off l Yellow Green S Hed Diagnosis of cause of fault After lock out the red fault signal lamp remains steady on In that condition the visual diagnosis of the cause of fault according to the error code table can be activated by pressing the lock out reset button for more than 3 seconds Error code table Possible cause Blink code 2 blinks No establishment of flame at the end of TSA e Faulty or soiled fuel valves e Faulty or soiled flame detector e Poor adjustment of burner no fue
27. d make sure there are no signs of leakage e check and clean the filter on the fuel pump bilter 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 e disassemble check and clean of the combustion head When re assembling carefully observe the measures quoted in Fig 35 e check and clean the ignition electrodes and respective ceramic insulators clean adjust and replace if necessary e Disassemble and clean the light oil nozzles AN IMPORTANT cleaning must be performed using solvent not metal tools At the end of maintenance operations after first reassembling the burner light the flame and check its shape replacing the nozzle whe never a questionable flame shape appears Whenever the burner is used intensely we recommend preventively replacing the nozzle at the start of each heating season Inspect and thoroughly clean the flame detection photoresistor and replace if necessary In case of doubt check the detection cur rent after first starting the burner by following the procedure illustrated in Fig 36 e Clean and grease levers and rotating parts Light oil filter maintenance For correct and proper servicing proceed as follows 1 shut off fuel in the
28. d the mains voltage drop below about AC 165 V e Restart is initiated when the mains voltage exceeds about AC 175 V Time supervision oil pre heater If the oil pre heater s release contact does not close within 10 minutes Commands in the event of operational interference Stray light premature ignition During pre purge and or pre ignition there should be no flamesignal If there is a flame signal eg from premature ignition due to a faulty solenoid external light short circuit in the photoresisto or wiring malfunction 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 diately Absence of flame during operation If there is no flame during operation the controller cuts off the supply of fuel and automatically initiates a fresh start up programme at the end of t4 the start up programme ends Whenever there is a safety stop terminals 3 8 and 11 are de energised in less than 1 second at the same time a remote lockout signal is transmit ted through terminal 10 The controller can be reset after c 50 seconds the burner control will initiate lock out Controlled intermittent operation After no more than 24 hours of continuous operation the burner control will initiate an automatic safety shut down followed by a restart Co
29. e a timer must be installed to 3 Light oil filter fitted delay the valve closing mE 4 Automatic interceptor The direct connection of the device without a timer may cause pump breaks 5 One way valve 6 Gate valve 7 Quick closing gate valve outside the tank or boiler rooms The provided pumps 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 plug 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 pump 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 are factory set for double pipe systems They can be suited for single pipe system recommended in the case of gravity feed as decribed before pep TH 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 directi
30. e manual cutoff valves are open 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 fuel decrease slowly until the normal combustion values are achieved IMPORTANT the combustion air excess must be adjusted according to the in the following chart Recommended combustion parameters Recommended CO Recommended O Light oil 11 5 13 Adjusting the fuel flow rate The fuel rate is setting choosing properly sized nozzles and adjusting the fuel pressure at the pump inlet see the diagram Fig 10 and Fig 11 To choose the nozzles refer to Tab 2 for pump pressure regulation see pag 12 Note all pumps are set to 12 bar The nozzle rate must be higher than the rate referred to the minimum burner N output Key EV Fuel solenoid valve EVG1 Fuel solenoid valve low flame p M EVG2 Fuel solenoid valve high flame only hi lo flame burners M Manometer P Pum ui EV Fig 10 Single stage burners Fig 11 Double stage burners 13 C I B UNIGAS M039122CC Choosing the light oil nozzles single stage burners PUMP PRESSURE bar Tab 1 Choosing the light oil nozzles double s
31. e plant s switch to OFF and be sure that the burner s main switch is in 0 position OFF too Read carefully the chapter WARNINGS and the Electrical connections section To execute the electrical connections proceed as follows 1 find the plug or the plugs according to the model e 7 poles plug for the power supply for all models e 4 poles plug double stage burners e 3 poles plug 2 execute the electrical connections to the plugs according to hte burner model see next paragraph 3 once all the connections are accomplished check the fan motor direction sse next paragraphs 4 now the burner is ready to start up Identification of linking connectors Burner mains supply connector Fig 5 Fig 7 HIGH LOW flame connector progressive burners Fig 7 Fan motor connector Fig 6 Fig 8 C I B UNIGAS M039122CC e Single stage burner connectors CONNETTORE 3 POLI MOT VENTILATORE 3 PINS FAN MOTOR CONNECTOR CONNETTORE LINEA 7 POLI 7 PINS SUPPLY CONNECTOR e m MIN 6 3A T MAX 10A T xG400 MIN 6 3A T MAX 10A T xG550 10A T MAX 16A T Fig 5 7 poles connector Fig 6 Electric motor 3 pole connector Double stage burner connectors CONNETTORE LINEA 7 POLI CONNETTORE 4 POLI TAB CONNETTORE 3 POLI MOT VENTILATORE 7 PINS SUPPLY CONNECTOR 4 PINS CONNECTOR PINS FAN MOTOR CONNECTOR cole o in Z a c la N PE L
32. ecting the burner make sure that the unit rating is the same as delivery mains 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 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 e Make sure that the burner has on installation been firmly secured to the appliance so that the flame is generated inside the appliance firebox 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 setthe flow rate of the combustion supporting air to obtain a combu stion 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
33. electrical panel or on the control panel The casing is made of robust heat resistant plastic and contains e the thermic programmer operating a multiple switch control system with ambient temperature compensator e flame signal amplifier with flame relay e warning light indicating lockout and associated sealed reset button The plug in socket also made of robust heat resistant plastic contains the 12 terminals and also e 3neutral terminals ready wired up to terminal 2 e 4earth terminals for earthing the burner e 2 supplementary terminals numbered 31 and 32 The socket has two openings at the bottom for the leads 5 others with threaded connection for cable holders PG11 or 3 4UNP for non metallic sleeves are located on a mobile stuffing box one on either side and 3 on the front There are two flexible metal tongues on the sides of the socket for moun ting 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 mains voltage operate on a special electronic circuit which in the event of the power supply falling below 165V stops the burner switching on without releasing the fuel and locks out the
34. eral unit data Mains voltage AC 230 V 10 15 96 AC 120 V 10 15 Mains frequency 50 60 Hz 6 External primary fuse Si 6 3A slow Power consumption 12 VA Mounting orientation optional Weight Degree of protection Perm cable lengths approx 200 g 40 to be ensured through mounting max 3m at line capacitance of 100 pF m Detector cable laid separately 10m Remote reset laid separately 20m LMO14 LMO24 LMO44 Terminal 1 5A 5A 5A Terminals 3 and 8 3A 5A 5A Terminals 4 5 and 10 1A 1A 1A Terminals 6 1A 1A 2A Flame supervision with QRB and QRC QRB QRC Min detector current required with flame 45 70 Min detector current permitted without flame 5 5 pA 5 5 yA Max possible with flame tipically 100 yA 100 pA Measurement circuit for detector current 11 12 LMO 11 12 1 LMO bl SW di bl sw br 7130v02 0700 uA DC uA DC MC Key DC DC microamperometer with an internal resistance of 5 max bl Blue SW Black br Brown NIGAS C B UNIGAS C I B UNIGAS S p A Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201 269 web site www cibunigas it e mail cibunigas cibunigas it Note Specifications and and data subject to change Errors and omissions excepted
35. he boiler To install the burner into the boiler proceed as follows make a hole on the closing door of the combustion chamber as described on paragraph Overall dimensions place the burner to the boiler lift it up and handle it according to the procedure described on paragraph Handling the burner place the 4 stud bolts 5 on boiler s door according to the burner s drilling template described on paragraph Overall dimensions fasten the 4 stud bolts place the gasket on the burner flange install the burner into the boiler fix the burner to the stud bolts by means of the fixing nuts according to the next picture 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 CON OOF WBN Keys Burner Fixing nut Washer Sealing gasket Stud bolt Blast tube No BWDP The burner is designed to work positioned according to the picture below For different installations please contact the Technical Department SIDE UP SIDE DOWN C I B UNIGAS M039122CC Electrical connections Respect the basic safety rules make sure of the connection to the earthing system do not reverse the phase and neutral connections fit a differential thermal magnet switch adequate for connection to the mains ATTENTION before executing the electrical connections pay attention to turn th
36. he photoresistor proceed as follows disconnect the system from the electrical power supply shut off the fuel supply remove the photoresistor from its slot clean it using a clean cloth do not use any burner cleansing sprays if necessary replace it insert the photoresistor into its slot O OI WN Burner control panel disassembly A IMPORTANT perform operations on the burner s electrical components only after first disconnecting the apparatus from the mains Sisa 1 Remove the VQ screw that fastens the control panel to the ip burner head support Fig 37 2 Remove the VF1 and VF3 screws from the rubber cable gland the cables will remain in place because they loc 9 ked by the retainer fastened by the VF2 screw Fig 37 3 Remove the rubber and cable gland unit FC from the hou sing Fig 38 4 Connect the control panel to the burner body using the sup ports G provided as shown in Fig 39 Fig 38 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 manual valve of the supply line Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials 24 C I B UNIGAS M039122CC TROUBLESHOOTING BURNER DOESN T START REPETITION OF PRE NOISY FUEL PUMP BURNER DOESN T START AND LOCKS
37. if the burner is suitable for the boiler to which it must be installled the following parameters are needed e furnace input in kW or kcal h KW kcal h 860 e backpressure data are available on the boiler ID plate or in the user s manual Example Furnace input 600kW Backpressure 4mbar In the Performance curve diagram Fig 1 draw a vertical line matching the furnace input value and an horizontal line matching the backpressure value The burner is suitable if the intersection point A is inside the performance curve Campo di lavoro bruciatori 8 7 G TN 5895 E c eo o0 o 3 S1 5 0 14 100 200 300 400 500 600 700 800 900 Potenza kW Fig 1 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 C C I B UNIGAS M039122CC Burner model identification Burners are identified by burner type and model Burner model identification is described as follows LO550 Model G S A 1 2 3 4 5 6 1 BURNER TYPE LO550 2 FUEL G Light oil A Biodiesel 3 OPERATION Available versions TN Single stage AB Double stage BLAST TUBE S Standard L Extended BURNER VERSION A Standard Specifications Light oil rate 18 5 47 wa Operation Operating temperature 10 50 20 60 Intermittent Storage Temperature Working service NOTE ON
38. l e Faulty ignition 3 blinks 4 blinks 5 blinks 6 blinks 7 blinks Xe x Free Extraneous light on burner startup Free Free Too manny losses of fleme during operation limitattion og the number of repetitions e Faulty or soiled fuel valves e Faulty or soiled flame detector e Poor adjustment of burner 8 blinks ke nx xXx 9 blinks kkkkkkkkk 10 blinks kkkkkkkkkk Time supervision oil pre heater Free Wiring error or internal error output contacts During the time the cause of fault is diagnosed the control outputs are deactivated e Burner remains shut down e Fault status signal AL at terminal 10 is activated The diagnosis of the cause of fault is quit and the burner switched on again by resetting the burner control Press lock out reset button for about 1 second 3 seconds Connection diagram and internal diagram LMO14 EK1 ZV uC1 control uC2 b LED YK FSV SB Q R OW QRB 9 o W AE OH EU N QRC Si 1 bl sw MHA vi CEN 7130 01 0700 LMO24 LMO44
39. 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 19 C I B UNIGAS M039122CC Removing the combustion head and the oil gun e Slacken the light oil pipes T1 and T2 from the pump Fig 21 e Disconnect the ignition cables CA1 and CA2 from the tran sformer Fig 22 e Remove the 4 screws V1 V4 shown in Fig 23 ATTENTION the screw V1 is longer than the other and must be replaced in the same position e Withdraw the photoelectric cell FR from its housing Fig 24 AN ATTENTION avoid to withdraw the photoelectric cell drawing its cable e Remove the combustion head from its housing as shown in Fig 25 20 C I B UNIGAS M039122CC Removing burner components plate Hemove the combustion head see page 20 Remove the 6 screws V5 V10 which fasten the component plate Fig 26 Remove the rod T from its housing as shown in Fig 27 Hook the burner components plate as shown in Fig 28 Fig 27 Replacing burner components plate Reassemble burner components plate and tighten the 6 screws V5 V10 Fig 26 Refit the rod T Fig 27 Reassemble the combustion head and tighten the 4 screws V1 V4 Fig 28 21 C I B UNIGAS M039122CC Removing the electrodes e Remove the combustion head page 2
40. n air flow to purge the room C close the gas valves contact qualified personnel 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 o 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 house hold and similar purposes Safety requirements Light oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for house hold and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Heavy oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards CEI EN 60335 1 Household and similar electrical appliances SafetyPart 1
41. ncy and proper operation it is essential that maintenance operations are performed by qualified personnel at regular intervals following the manufacturer s instructions When a decision is made to discontinue the use of the equipment those parts likely to constitute sources of danger shall be made har mless Incase 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 For all the units that have been modified or have options fitted then original accessory 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 there fore 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 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 Only burners designed according to the regulations in force should be used This burner should be employed exclusively for the use for which it was designed Before conn
42. ntrol sequence in the event of fault If lock out occurs the outputs for the fuel valves and the ignition will immediately be deactivated 1 second Cause undervoltage threshold event of a premature faulty ook out at the end of tt Prevention of start up lock out after no more than 40 seconds If the burner does not ignite during Lock out at the end of TSA TSA In the event the flame is lost during Max 3 repetitions followed operation by lock out Oil pre heater s release contact does Lock out not close within 10 min Lock out In the event of lock out the LMO remains locked lock out cannot be changed and the red signal lamp will light up This status is also maintai ned in the case of a mains failure Resetting the burner Whenever lock out occurs the burner control can immediately be reset To do this keep control the lock out reset button depressed for about 1 second lt 3 seconds Ignition program with LMO24 113A2 If the flame is lost during TSA the burner will be reignited but not later In the event of a premature faulty flame signal during tw than at the end of TSAmax This means that several ignition attempts can be made during TSA refer to Program sequence Limitation of repetitions If the flame is lost during operation a maximum of 3 repetitions can be made If the flame is lost for the 4th time during operation the burner will initiate lo
43. on of rotation all connections on top and side are reversed Bleed Bleeding in two pipe operation is automatic it is assured by a bleed flat on the piston In one pipe operation the plug of a pressure gauge port must be loosened until the air is evacuated from the system 11 C I B UNIGAS M039122CC About the use of fuel pumps e 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 e 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 e 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 e 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 e Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical seal junc tions preferred Junction threads elbow joints and couplings sh
44. onnect the unit to the electric mains An omnipolar switch shall be provided for connection to mains as required by the current safety regulations 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 The unit input cable shall not be replaced by the user In case of damage to the cable switch off the unit and contact qualified personnel to replace When the unit is out of use for some time the electric switch supplying all the power driven components in the system i e pumps burner etc should be switched off 3b FIRING WITH GAS LIGHT OIL OR OTHER FUELS GENERAL e The burner shall be installed by qualified personnel and in com pliance 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 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 Before the burner is commissioned qualified personnel should ins pect the following a thefuel supply system for
45. ould be sealed with removable sg component The number of junc tions 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 depo sit on the pump filter or the nozzle reducing efficiency Always use O Rings or mechanical seal copper or aluminium gaskets jun ctions if possible e An external filter should always be installed in the suction line upstream of the fuel unit Oil pump Pump Suntec AL65 Viscosity range 2 12 cSt mm s Oil temperature 0 60 C Inlet pressure 2 bar Minimum inlet pressure 0 45 barto avoid gasing Rated speed 3600 rpm Keys 1 2 3 4 5 6 inlet Suction G1 4 return and internal by pass plug G1 4 outlet to the nozzle G1 8 pressure gauge port G1 8 vacuum gauge port G1 8 pressure adjusting screw Connecting the light oil flexible hoses To connect the flexible light oil hoses to the pump proceed as follows according to the pump provided 1 2 remove the closing nuts A and R on the inlet and return connections of the pump screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the inlet and return lines see the arrows marked on the pump that show the inlet and the return see prevoius paragraph 12 C I B UNIGAS M039122CC ADJUSTMENTS ATTENTION before starting the burner up be sure that th
46. ransformer is on for a few seconds after the ignition of the flame post ignition time after which it is de energised Double stage burners e Set Switch G on the burner control panel in ON position e Make sure that the control box is not in shutdown condition if so release by using the release button F in Fig 19 and H in on the burner control panel e Make sure that the set of thermostats or pressure switches enables burner operation e The burner starting cycle begins and the control box starts the burner fan while the ignition transformer switches on at the same time pre purge lasts for some seconds depending on the control box provided with the burner e Atthe end of pre purge the fuel solenoid valve ist stage EVG1 is energise as signalled signal light on the control panel is on and the burner starts up e The ignition transformer remains switched on for a few seconds after the ignition of the flame post ignition time after which it is de energised and the related signal light switches off e In this way the burner is lit at low flame after some seconds depending on the control box installed two stage operation begins and the burner is either automatically driven to high flame or remains burning at low flame depending on the requests received from the system Operation at high or low flame is signalled by the switchingon off of the related signalling lights A and F on the 17 C I B UNIGAS M039122CC control panel
47. rate the burner at a lowest strenght progressively shift back the combustion head toward the MIN position rotating the VRT screw clockwise Fig 18 SEU LI S VE lt NA da i a p al yat NM 1 i TDS Ik 1 x P E P H Fig 18 Attention if it is necessary to change the head position repeat the air and gas adjustments described above 16 C I B UNIGAS M039122CC 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
48. signalling light F showes the opening of the solenoid valve that supplies the 2nd stage nozzle high flame Burner control panel Fig 19 Single stage burner Fig 20 Double stage burner 18 6100833 19 M 00 e o Burner operation signalling lamp Ignition transformer operation signalling light Lockout signalling lamp Light oil solenoid valve operation signalling light Mains switch Reset pushbutton for flame con trol box High flame operation signalling light Low flame operation light Ignition transformer operation signalling light Lockout signalling lamp Low flame solenoid valve opera tion signalling light High flame solenoid valve opera tion signalling light Mains switch Reset pushbutton for flame con trol box C I B UNIGAS M039122CC 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 ROUTINE MAINTENANCE e Inspection and cleaning of the light oil filter cartdrige replace it if necessary Check the overall condition of the flexible light oil hoses an
49. tage burners w me T We 35 48948 53 5000650 450600 400600 _ 59 550750 0700 450650 _ Tab 2 Prior to start up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pump seal to break Priming the pump and adjusting the burner for single stage burners 1 remove the burner cover 2 remove the solenoid valve coil B on pump Fig 13 to avoid the light oil to get into the combustion chamber 3 start the burner up by means of the control panel switch switch to ON Fig 20 and by means of the thermostats pressure switches series 4 when the EVG lamp turns to on see chapter page 17 remove the phtoresistor FR Fig 12 from its slot and light it up 5 bleed the air from the M pressure gauge port of the pump slightly loosing the cap and without removing it Fig 13 6 turn the burner off 7 replace the photoresistor FR Fig 12 into its slot 8 reconnect the B coil on the pump Fig 13 9 light the burner if the burner locks press the unlock pushbutton placed on the upper side of the burner and repeat the steps above 10 The oil flow rate depends on the choosen nozzle 11 Checking the combustion values adjust the air flow rate by means of the VSB Fig 14 screw to decrease the air rate or unscrew to increase it 12 Replace the burner cover Suntec AL 14 C I B UNIGAS M039122CC Priming the pump
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