LO550

IDEA series Light oil burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

M039122CC Rel. 2.1 02/2010

M03H122CB

TABLE OF CONTENTS
WARNINGS ................................................................................................................................................................ 3 PART I: INSTALLATION ........................................................................................................................................... 5
GENERAL FEATURES 5 How to interpret the burners Performance curve ......................................................................................................................... 5 Specifications .................................................................................................................................................................................. 6 Performance curves ........................................................................................................................................................................ 6 Overall dimensions ......................................................................................................................................................................... 7 MOUNTINGS AND CONNECTIONS .............................................................................................................................................. 8 Packing ........................................................................................................................................................................................... 8 Handling the burner ........................................................................................................................................................................ 8 Fitting the burner to the boiler ......................................................................................................................................................... 8 Electrical connections ..................................................................................................................................................................... 9 Installation diagram of light oil pipes ............................................................................................................................................. 11 Bleed ............................................................................................................................................................................................. 11 About the use of fuel pumps ......................................................................................................................................................... 11 Oil pump ....................................................................................................................................................................................... 12 Connecting the light oil flexible hoses ........................................................................................................................................... 12 ADJUSTMENTS ........................................................................................................................................................................... 13 Adjusting the fuel flow rate ............................................................................................................................................................ 13 Priming the pump and adjusting the burner for single stage burners ........................................................................................... 14 Priming the pump and adjustments for double stage burners ...................................................................................................... 15 Adjusting the combustion head ..................................................................................................................................................... 16

PART II: OPERATION ............................................................................................................................................. 17

OPERATION ................................................................................................................................................................................. 17 Single stage burners ..................................................................................................................................................................... 17 Double stage burners .................................................................................................................................................................... 17 Burner control panel ..................................................................................................................................................................... 18

PART III: MAINTENANCE ....................................................................................................................................... 19

ROUTINE MAINTENANCE ........................................................................................................................................................... 19 Light oil filter maintenance ............................................................................................................................................................ 19 Removing the combustion head and the oil gun ........................................................................................................................... 20 Removing burner components plate ............................................................................................................................................. 21 Removing the electrodes .............................................................................................................................................................. 22 Removing the nozzles ................................................................................................................................................................... 22 Checking the detection current ..................................................................................................................................................... 23 Cleaning and replacing the detection photoresistor ...................................................................................................................... 24 Burner control panel disassembly ................................................................................................................................................. 24 Seasonal stop ............................................................................................................................................................................... 24 Burner disposal ............................................................................................................................................................................. 24 TROUBLESHOOTING .................................................................................................................................................................. 25 BURNER EXPLODED VIEW ........................................................................................................................................................ 26 SPARE PARTS ............................................................................................................................................................................. 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 PRODUCT INSTALLATION AND MAINTENANCE. THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT. CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
1) z GENERAL INTRODUCTION shall have qualified personnel carry out the following operations: a Remove the power supply by disconnecting the power cord from the mains. b) Disconnect the fuel supply by means of the hand-operated shut-off valve and remove the control handwheels from their spindles. Special warnings z Make sure that the burner has, on installation, been firmly secured to the appliance, so that the flame is generated inside the appliance firebox. z Before the burner is started and, thereafter, at least once a year, have qualified personnel perform the following operations: a set the burner fuel flow rate depending on the heat input of the appliance; b set the flow rate of the combustion-supporting air to obtain a combustion efficiency level at least equal to the lower level required by the regulations in force; c check the unit operation for proper combustion, to avoid any harmful or polluting unburnt gases in excess of the limits permitted by the regulations in force; d make sure that control and safety devices are operating properly; e make sure that exhaust ducts intended to discharge the products of combustion are operating properly; f on completion of setting and adjustment operations, make sure that all mechanical locking devices of controls have been duly tightened; g make sure that a copy of the burner use and maintenance instructions is available in the boiler room. z In case of 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. z The unit shall be operated and serviced by qualified personnel only, in compliance with the regulations in force. 3) 3a) z z GENERAL INSTRUCTIONS DEPENDING ON FUEL USED ELECTRICAL CONNECTION For safety reasons the unit must be efficiently earthed and installed as required by current safety regulations. It is vital that all saftey requirements are met. In case of any doubt, ask for an accurate inspection of electrics by qualified personnel, since the manufacturer cannot be held liable for damages that may be caused by failure to correctly earth the equipment. 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 permitted to connect 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;

The equipment must be installed in compliance with the regulations in force, following the manufacturers instructions, by qualified personnel. z Qualified personnel means those having technical knowledge in the field of components for civil or industrial heating systems, sanitary hot water generation and particularly service centres authorised by the manufacturer. z Improper installation may cause injury to people and animals, or damage to property, for which the manufacturer cannot be held liable. z Remove all packaging material and inspect the equipment for integrity. In case of any doubt, do not use the unit - contact the supplier. The packaging materials (wooden crate, nails, fastening devices, plastic bags, foamed polystyrene, etc), should not be left within the reach of children, as they may prove harmful. z Before any cleaning or servicing operation, disconnect the unit from the mains by turning the master switch OFF, and/or through the cutout devices that are provided. z Make sure that inlet or exhaust grilles are unobstructed. z In case of breakdown and/or defective unit operation, disconnect the unit. Make no attempt to repair the unit or take any direct action. Contact qualified personnel only. Units shall be repaired exclusively by a servicing centre, duly authorised by the manufacturer, with original spare parts. Failure to comply with the above instructions is likely to impair the units safety. To ensure equipment efficiency and proper operation, it is essential that maintenance operations are performed by qualified personnel at regular intervals, following the manufacturers instructions. z When a decision is made to discontinue the use of the equipment, those parts likely to constitute sources of danger shall be made harmless. z In case the equipment is to be sold or transferred to another user, or in case the original user should move and leave the unit behind, make sure that these instructions accompany the equipment at all times so that they can be consulted by the new owner and/or the installer. z For all the units that have been modified or have options fitted then original accessory equipment only shall be used. z This unit shall be employed exclusively for the use for which it is meant. Any other use shall be considered as improper and, therefore, dangerous. The manufacturer shall not be held liable, by agreement or otherwise, for damages resulting from improper installation, use and failure to comply with the instructions supplied by the manufacturer. 2) z SPECIAL INSTRUCTIONS FOR BURNERS

z z

The burner should be installed in a suitable room, with ventilation openings complying with the requirements of the regulations in force, and sufficient for good combustion. z Only burners designed according to the regulations in force should be used. z This burner should be employed exclusively for the use for which it was designed. z Before connecting the burner, make sure that the unit rating is the same as delivery mains (electricity, gas oil, or other fuel). z Observe caution with hot burner components. These are, usually, near to the flame and the fuel pre-heating system, they become hot during the unit operation and will remain hot for some time after the burner has stopped. When the decision is made to discontinue the use of the burner, the user 3

- do not leave the equipment exposed to weather (rain, sun, etc.)

unless expressly required to do so;

- do not allow children or inexperienced persons to use equipment;

z The unit input cable shall not be replaced by the user. In case of damage to the cable, switch off the unit and contact qualified personnel to replace. When the unit is out of use for some time the electric switch supplying all the power-driven components in the system (i.e. pumps, burner, etc.) should be switched off.

3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS GENERAL z The burner shall be installed by qualified personnel and in compliance with regulations and provisions in force; wrong installation can cause injuries to people and animals, or damage to property, for which the manufacturer cannot be held liable. z Before installation, it is recommended that all the fuel supply system pipes be carefully cleaned inside, to remove foreign matter that might impair the burner operation. z Before the burner is commissioned, qualified personnel should inspect the following: a the fuel supply system, for proper sealing; b the fuel flow rate, to make sure that it has been set based on the firing rate required of the burner; c the burner firing system, to make sure that it is supplied for the designed fuel type; d the fuel supply pressure, to make sure that it is included in the range shown on the rating plate; e the fuel supply system, to make sure that the system dimensions are adequate to the burner firing rate, and that the system is equipped with all the safety and control devices required by the regulations in force. z When the burner is to remain idle for some time, the fuel supply tap or taps should be closed. SPECIAL INSTRUCTIONS FOR USING GAS Have qualified personnel inspect the installation to ensure that: a the gas delivery line and train are in compliance with the regulations and provisions in force; b all gas connections are tight; c the boiler room ventilation openings are such that they ensure the air supply flow required by the current regulations, and in any case are sufficient for proper combustion. z Do not use gas pipes to earth electrical equipment. z Never leave the burner connected when not in use. Always shut the gas valve off. z In case of prolonged absence of the user, the main gas delivery valve to the burner should be shut off. Precautions if you can smell gas a do not operate electric switches, the telephone, or any other item likely to generate sparks; b immediately open doors and windows to create an air flow to purge the room; c close the gas valves; d contact qualified personnel. z Do not obstruct the ventilation openings of the room where gas appliances are installed, to avoid dangerous conditions such as the development of toxic or explosive mixtures.

DIRECTIVES AND STANDARDS Gas burners European directives: - Directive 90/396/CEE - Gas Appliances; - Directive 2006/95/EC on low voltage; - Directive 2004/108/CEE on electromagnetic compatibility Harmonised standards : -UNI EN 676 (Gas Burners; -CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements; - EN 50165 (Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements. Light oil burners 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 household 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: 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

PART I: INSTALLATION

GENERAL FEATURES
These burners are characterised by high performaces 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 burners Performance curve To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed: furnace input, in kW or kcal/h (kW = kcal/h / 860); z backpressure (data are available on the boiler ID plate or in the users 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.
z

Campo di lavoro bruciatori Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65

8 Contropressione in camera di combustione mbar 7 6 5 4 3 2 1 0 -1 100 200 300 400 500 Potenza kW 600 700 800 900

Fig. 1 Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15C

C.I.B. UNIGAS - M039122CC

Burner model identification

Burners are identified by burner type and model. Burner model identification is described as follows. Type LO550 Model G-. AB. S. *. A. (1) (1) BURNER TYPE (2) FUEL (3) OPERATION(Available versions) (4) BLAST TUBE (5) DESTINATION COUNTRY (6) BURNER VERSION (2) (3) (4) (5) (6) LO550 G - Light oil A - Biodiesel TN - Single-stage S - Standard * - see data plate A - Standard

AB - Double-stage L - Extended

Specifications
BURNERS Output Fuel Light oil rate Viscosity Oil train inlet pressure Power supply Electric motor Total power consumption Index of protection Approx. weight Operation Operating temperature Storage Temperature Working service* C C kg kW kW min. -max. kg/h cSt @ 20 C bar 17 - 47 2 - 7.4 1 max 230V 1N ~ 50Hz 0.62 0.92 IP40 50 Single stage Double stage -10 +50 -20 +60 Intermittent min. -max. kW LO550 G-.TN.x.xx.A 200 - 560 Light oil 13.5 - 47 LO550 G-.AB.x.xx.A 160 - 560

*NOTE ON THE BURNER WORKING SERVICE: z Burners provided with Siemens LOA24 control box: for safety reasons, one controlled shutdown must take place every 24 hours. z 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. 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
PRESSURE IN COMBUSTION CHAMBER mbar
9 8 7 6 5 4 3 2 1 0 150 200 250 300 350 400 450 500 550 600

LO550 Double stage

9 8 7 6 5 4 3 2 1 0 100 150 200 250 300 350 400 450 500 550 600

kW

kW

Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15C 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 adjsuting the combustion head to its MAX position (see paragraph Adjusting the combustion head); the minimum output point is reached setting the combustion head to its MIN position. During the first ignition, the combustion head is set in order to find a compromise between the burner output and the generator specifications, that is why the minimum output may be different from the Performance curve minimum.

Overall dimensions (mm)

C.I.B. UNIGAS - M039122CCC

A(S*) LO550 LO550 G-.TN.x.xx.A G-.AB.x.xx.A 843 843

A(L*) 943 943

B(S*) 253 253

B(L*) 353 353

C 590 590

F 426 426

G 141 141

H 175 175

K 241 241

L 384 384

M M10 M10

N 247 274

Omin 157 157

Omax 192 192

P 174 174

T 69 69

X 533 533

Y 155 155

* S = STANDARD BLAST TUBE * L = EXTENDED BLAST TUBE

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 placed in each packing case. 1 burner; 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 burners packing, follow the procedures laid down by current laws on disposal of materials.

Handling the burner

ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these operations 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 the boiler

To install the burner into the boiler, proceed as follows: 1 make a hole on the closing door of the combustion chamber as described on paragraph Overall dimensions) 2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph Handling the burner; 3 place the 4 stud bolts (5) on boilers door, according to the burners drilling template described on paragraph Overall dimensions; 4 fasten the 4 stud bolts; 5 place the gasket on the burner flange; 6 install the burner into the boiler; 7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture. 8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material (ceramic fibre cord or refractory cement). Keys 1 Burner 2 Fixing nut 3 Washer 4 Sealing gasket 5 Stud bolt 7 Blast tube

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 the plants switch to OFF and be sure that the burners main switch is in 0 position (OFF) too. Read carefully the chapter WARNINGS, and the Electrical connections section.

WARNING: the burner is fitted with a bridge between terminals T6 and T8 on CN2-TAB connector (external side link, male connector); remove this bridge before thermostat connection.

To execute the electrical connections, proceed as follows: 1 find the plug or the plugs, according to the model: z 7 poles plug for the power supply (for all models); z 4 poles plug (double-stage burners); z 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)

Fig. 2

HIGH/LOW flame connector (progressive burners, Fig. 7)

Fig. 3

Fan motor connector (Fig. 6 - Fig. 8) Fig. 4

IMPORTANT: before operating the burner, be sure all connectors are linked as shown in the diagrams.

C.I.B. UNIGAS - M039122CC z

Single stage burner connectors:

Fig. 5 - 7-poles connector

z

Fig. 6 - Electric motor 3-pole connector

Double-stage burner connectors:

Fig. 7 7-poles and 4-poles connectors

Key C1 C2 FU1 FU3 IL IM KM1 LAF LB LBF LOW FLAME TIME METER HIGH FLAME TIME METER FAN MOTOR LINE FUSE LINE FUSE BURNER LINE SWITCH FAN MOTOR LINE SWITCH FAN MOTOR CONTACTOR BURNER IN HIGH FLAME INDICATOR LIGHT INDICATOR LIGHT FOR BURNER LOCK-OUT ($) MV ST TAB TS

Fig. 8Electric motor 3-poles connector

BURNER IN LOW FLAME SIGNALLING LAMP FAN MOTOR THERMOSTATS O PRESSURE SWITCHES SERIE HIGH LOW FLAME THERMOSTAT/PRESSURE SWITCH SAFETY THERMOSTAT/PRESSURE SWITCH

CONN-MOTORE FAN MOTOR CONNECTOR CONN-LINEA BURNER POWER SUPPLY CONNNECTOR CONN-TAB HIGH-LOW FLAME CONNECTOR IF "TAB" USED REMOVE THE BRIDGE BETWEEN TERMINALS T6T8

10

C.I.B. UNIGAS - M039122CC

Installation diagram of light oil pipes

PLEASE READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL.

From tank To tank

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 1 Burner 2 Flexible hoses (fitted) 3 Light oil filter (fitted) 4 Automatic interceptor (*) 5 One-way valve (*) 6 Gate valve 7 Quick-closing gate-valve (outside the tank or boiler rooms) (*) Only for installations with gravity, siphon or forced circulation feed systems. If the device installed is a solenoid valve, a timer must be installed to delay the valve closing. The direct connection of the device without a timer may cause pump breaks.

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 pumps 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 pumps 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 pumps inlet is used besides another pipe that connects the pumps return port to the tank, as well. The excess of oil goes back to the tank: this installation can be considered self-bleeding. If provided, the inside by-pass plug must be installed to avoid air and fuel passing through the pump. Burners 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.

To change from a 1-pipe system to a 2-pipe-system, insert the by-pass plug G (as for ccw-rotation- referring to the pump shaft). Caution: Changing the direction of rotation, all connections on top and side are reversed.

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.

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C.I.B. UNIGAS - M039122CC

About the use of fuel pumps

z z z z z z

Make sure that the by-pass plug is not used in a single pipe installation, because the fuel unit will not function properly and damage to the pump and burner motor could result. Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth, thus obstructing them. After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of the tank, thus avoiding the possibility that they might be sucked into the pump. On initial commissioning a "dry" operation is foreseen for a considerable length of time (for example, when there is a long suction line to bleed). To avoid damages inject some lubrication oil into the vacuum inlet. Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the joint, noise and overloading the gears. Pipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal junctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of junctions should be kept to a minimum as they are a possible source of leakage. Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could deposit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) junctions if possible. An external filter should always be installed in the suction line upstream of the fuel unit.

Oil pump

Pump Suntec AL65 Viscosity range Oil temperature Inlet pressure Minimum inlet pressure Maximum return pressure Rated speed Keys 1 inlet (suction) G1/4 2 return and internal by-pass plug G1/4 3 outlet to the nozzle G1/8 4 pressure gauge port G1/8 5 vacuum gauge port G1/8 6 pressure adjusting screw

2 12 (cSt) mm2/s 0 60 C 2 bar - 0,45 barto avoid gasing 2 bar 3600 rpm

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 remove the closing nuts A and R on the inlet and return connections of the pump; 2 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).

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ADJUSTMENTS
ATTENTION: before starting the burner up, be sure that the 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 Fuel Light oil Recommended (%) CO2 11.5 13 Recommended (%) O2 2.9 4.9

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 output. Key EV EVG1 EVG2 M P Fuel solenoid valve Fuel solenoid valve - low flame Fuel solenoid valve - high flame (only hi-lo flame burners) Manometer Pump

Fig. 10 - Single-stage burners

EVG2 P M

EVG1

Fig. 11 - Double-stage burners

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C.I.B. UNIGAS - M039122CC

Choosing the light oil nozzles - single stage burners

PUMP PRESSURE (bar) 10 NOZZLE (G.P.H.) 4,00 4,50 5,00 5,50 6,00 6,50 7,00 7,50 8,30 9,50 15,19 17,09 18,99 20,89 22,79 24,69 26,59 28,49 31,53 36,09 12 FUEL RATE kg/h 16,64 18,72 20,81 22,89 24,97 27,05 29,13 31,21 34,54 39,53 17,98 20,23 22,47 24,72 26,97 29,21 31,46 33,71 37,30 42,70 14

Tab. 1 Choosing the light oil nozzles - double stage burners

FLOW RATE kg/h 30 35 40 45 50 kcal/h 306.300 357.350 408.400 459.450 510.500 OUTPUT kW 356 416 475 534 594 10bar 3.50+4.50 4.00+5.00 4.50+6.00 5.00+6.50 5.50+7.50 PUMP PRESSURE bar 12bar 3.00+4.00 3.50+5.00 4.00+5.50 4.50+6.00 5.00+7.00 14bar 3.00+3.50 3.50+4.00 4.00+5.00 4.00+6.00 4.50+6.50

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 2 3 remove the burner cover; remove the solenoid valve coil B on pump (Fig. 13) to avoid the light oil to get into the combustion chamber; 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

B
FR

M VR
VBS

Fig. 12

Fig. 13

Fig. 14

14

C.I.B. UNIGAS - M039122CC

Priming the pump 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 thermostats\pressure switches series; 4 when the EVG lamp turns to on (see chapter page 17) remove the phtoresistor FR (Fig. 17) 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. 15); 6 turn the burner off; 7 replace the photoresistor FR (Fig. 17) into its slot; 8 reconnect the B coil on the pump (Fig. 15); 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 ;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 cam 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 (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. Suntec AL

B M VR
P1

FR

Fig. 15

Fig. 16 - Pushbutton for second nozzle priming on two-stage burners

Fig. 17

As for the setting, refer to this correspondence table.

Berger STA4.5 Siemens SQN72

I II III IV

II I AUTO/MAN

VS
Refer to the next table for cams functions.
BERGER STA

Siemens SQN72 I (red) II (blue) IV (black)

Air adjustment in high flame cam Air adjustment in low flame - Stand-by - Ignition cam Auxiliary cam for the opening consent to the second fuel valve
z z

I II III

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. Siemens SQN72: a key is provided to move cams I and IV, the other cams can be moved by means of screws. On the Siemens actuator the AUTO/MAN mode is provided (see picture).

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 operate the burner at a lowest strenght, progressively shift back the combustion head, toward the "MIN" position, rotating the VRT screw clockwise (Fig. 18).

MIN MAX VRT

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

PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED 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 AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER. A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATORS CONTROL AND SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER. THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER). NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE. OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON. IN 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 pressure 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

z z z z z z

Set Switch E on the burner control panel to ON position. 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 burner control panel. Make sure that the set of thermostats (or pressure-switches) enables burner operation. The burner starting cycle begins and the control box starts the burner fan while the ignition transformer switches on at the same time. At the end of pre-purge, the fuel solenoid valve is energised and the burner switches on. The ignition transformer is on for a few seconds after the ignition of the flame (post-ignition time) after which it is de-energised.

Double stage burners

z z z z z z z

Set Switch G on the burner control panel in ON position. 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. Make sure that the set of thermostats (or pressure-switches) enables burner operation. 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. At the end of pre-purge, the fuel solenoid valve (1st stage, EVG1) is energise as signalled (signal light on the control panel is on) and the burner starts up. 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. 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; signalling light F showes the opening of the solenoid valve that supplies the 2nd stage nozzle (high flame).

Burner control panel

C
Keys A B C D 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 control box

B E

E F

Fig. 19 - Single stage burner

Key A

D
B C D

High flame operation signalling light Low flame operation light Ignition transformer operation signalling light Lockout signalling lamp Low flame solenoid valve operation signalling light High flame solenoid valve operation signalling light Mains switch Reset pushbutton for flame control box

E F G H

F H

Fig. 20 - Double stage burner

18

C.I.B. UNIGAS - M039122CC

PART III: MAINTENANCE At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6 months. WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED! ATTENTION: READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL..

ROUTINE MAINTENANCE
z z z

z z z

Inspection and cleaning of the light oil filter cartdrige; replace it if necessary; Check the overall condition of the flexible light oil hoses and make sure there are no signs of leakage; 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; disassemble, check and clean of the combustion head. When re-assembling carefully observe the measures quoted in Fig. 35; check and clean the ignition electrodes and respective ceramic insulators: clean, adjust, and replace if necessary; Disassemble and clean the light oil nozzles. 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 whenever a questionable flame shape appears. Whenever the burner is used intensely, we recommend preventively replacing the nozzle at the start of each heating season; z Inspect and thoroughly clean the flame detection photoresistor and replace if necessary. In case of doubt, check the detection current after first starting the burner by following the procedure illustrated in Fig. 36; z 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 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

z z z

Slacken the light oil pipes T1 and T2 from the pump (Fig. 21). Disconnect the ignition cables CA1 and CA2 from the transformer (Fig. 22). 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! z Withdraw the photoelectric cell FR from its housing (Fig. 24). ATTENTION: avoid to withdraw the photoelectric cell drawing its cable! z Remove the combustion head from its housing as shown in Fig. 25.

T1 Fig. 21

T2

V1 CA1

V2

CA2 V4 V3

Fig. 22

Fig. 23

FR

Fig. 24

Fig. 25

20

C.I.B. UNIGAS - M039122CC

Removing burner components plate

z z z z

Remove 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. V10

V5 V6

V9

V7 V8

Fig. 26

Fig. 27

Fig. 28

Replacing burner components plate

z z z

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

z z

Remove the combustion head (page 20). Withdraw the screw VE and remove the electrodes from the support (Fig. 29 - Fig. 30).

Single stage burners VE

Double stage burners VE

Fig. 29

Fig. 30

Removing the nozzles

z z

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 VT TC

Double stage burners VT

TC Fig. 31 Fig. 32 Fig. 33

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 B C D 79 4,5 6 10 5

B A

D
Fig. 34 High-Low flame burners A B C D 9 11 4,5 6 8 3

C A D B
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 photoresistor and if necessary replace it.

Minimum current intensity with flame Maximum current intensity without flame Maximum possible current intensity with flame

65 A 5 A 200 A

CONNECTOR CN7 1 SCALE A DC 2

Fig. 36

23

C.I.B. UNIGAS - M039122CC

Cleaning and replacing the detection photoresistor

To clean/replace the photoresistor, proceed as follows: 1 disconnect the system from the electrical power supply; 2 shut off the fuel supply; 3 remove the photoresistor from its slot; 4 clean it using a clean cloth; do not use any burner cleansing sprays; 5 if necessary, replace it; 6 insert the photoresistor into its slot.

Burner control panel disassembly

IMPORTANT: perform operations on the burner's electrical components only after first disconnecting the apparatus from the mains! 1 Remove the VQ screw that fastens the control panel to the 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 are locked by the retainer fastened by the VF2 screw (Fig. 37). 3 Remove the rubber and cable gland unit FC from the housing (Fig. 38). 4 Connect the control panel to the burner body using the supports G provided as shown in Fig. 39. VF1 VF2 VF3

VQ

Fig. 37

G FC

Fig. 39 Fig. 38

Seasonal stop
To stop the burner in the seasonal stop, proceed as follows: 1 turn the burners 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 STARTS AND LOCKS

REPETITION OF PREPURGE

MAINS SWITCH OPEN FUSES INTERVENTION MAXIMUM PRESSURE SWITCH FAULT INTERVENTION OF THE FAN MOTOR THERMAL CUTOUT AUXILIARIES RELAY FUSES INTERVENTION 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 DEFECTIVE HIGH - LOW FLAME THERMOSTAT DEFECTIVE BAD POSITION OF SERVOCONTROL CAMS FUEL LOW PRESSURE FUEL FILTERS DIRTY

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

25

BURNER LOCKS AND REPEATS CYCLE DURING OPERATION

BURNER LOCK DURING OPERATION

BURNER DOESNT START AND LOCKS

NOISY FUEL PUMP

BURNER DOESNT START

BURNER DOESNT SWITCH TO HIGH FLAME

BURNER EXPLODED VIEW

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
26

DESCRIPTION BLAST TUBE PUMP COVER FIXING SCREW AIR DAMPER ASSEMBLY AIR INTAKE PRESSURE PLUG BRACKET COVER FAIRLEAD PIPE BURNER HOUSING MOTOR SUPPORT PLATE BURNER HOUSING HINGE PLATE FLANGE GASKET FAN WHEEL MOTOR AIR FLAP WASHER WASHER SCREW CONNECTING ROD ROD BRACKET TRANSFORMER ACTUATOR

ITEM 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

DESCRIPTION BRACKET BRACKET PANEL EARTH PLATE PRINTED BOARD CIRCUIT CONTACTOR PUSHBUTTON PROTECTION SWITCH FUSE CONTROL BOX + SOCKET FLANGE SHORT IGNITION ELECTRODE LONG IGNITION ELECTRODE SOLENOID VALVE PLATE PLATE ROD NOZZLE NOZZLE NOZZLE HOLDER UNIT FOR PIPE CONNECTION COMBUSTION HEAD PIPE PIPE PIPE IGNITION CABLE
C.I.B. UNIGAS - M039122CCC

C.I.B. UNIGAS - M039122CCC

27

C.I.B. UNIGAS - M039122CC

SPARE PARTS

Desription COVER CONTROL BOX (SIEMENS LOA..) CONTROL BOX (SIEMENS LMO..) SHORT IGNITION ELECTRODE LONG IGNITION ELECTRODE FUEL FILTER GASKET FAN WHEEL IGNITION TRANSFORMER (FIDA) IGNITION TRANSFORMER (COFI) IGNITION TRANSFORMER (DANFOSS) ELECTRIC MOTOR SOLENOID VALVE FLEXIBLE HOSE ACTUATOR (mod. BERGER) ACTUATOR (mod. SIEMENS) PHOTORESISTOR (mod. SIEMENS QRB..) PUMP (mod. SUNTEC) NOZZLE - 0.75-6.00GPH 45 NOZZLE - 0.75-6.00GPH 60 NOZZLE - 6.50-11.00GPH 60 NOZZLE - 6.50-35.00 GPH 45 COMBUSTION HEAD BLAST TUBE (standard) BLAST TUBE (extended) IGNITION CABLES PRINTED CIRCUIT BOARD LO550 TN 1011801 2020445 2020453 2080259 2090025 2110056 2150049 2170302 2180711 2340001 2510033 2590170 2610004 2610017 3060199 30900F5 30900F6 6050153 6100542

Code LO550 AB 1011801 2020445 2020453 2080259 2080260 2090025 2110056 2150049 2170139 2170231 2180711 2190638 2340001 2480057 24800A3 2510033 2590170 2610002 2610004 2610016 3060198 30900F5 30900F6 6050153 6100542

28

C.I.B. UNIGAS - M039122CC

WIRING DIAGRAMS
Keys
C1 LOW FLAME TIME METER C2 HIGH FLAME TIME METER EVG LIGHT OIL ELECTRO-VALVE FR PHOTORESISTOR FLAME DETECTOR FU1 FAN MOTOR LINE FUSE FU2 LINE FUSE FU3 BURNER LINE FUSE IL BURNER LINE SWITCH IM FAN MOTOR LINE SWITCH KA2.3 AUXILIARY RELAY KA2.4 AUXILIARY RELAY KM1.1 FAN MOTOR CONTACTOR KT2.4 DELAYED RELAY LAF BURNER IN HIGH FLAME INDICATOR LIGHT LMO 24/44 SIEMENS CONTROL BOX LOA24/44 SIEMENS CONTROL BOX LB INDICATOR LIGHT FOR BURNER LOCK-OUT LBF BURNER IN LOW FLAME INDICATOR LIGHT LEVG1 INDICATOR LIGHT FOR OPENING OF ELECTRO-VALVE [EVG1] LTA IGNITION TRANSFORMER INDICATOR LIGHT MV FAN MOTOR PS LOCK-OUT RESET BUTTON (WITH LOA44 AND LMO.. ONLY) SATRONIC DKO976 - DKW976CONTROL BOX SATRONIC DKW972 CONTROL BOX SATRONIC TF976 CONTROL BOX ST SERIES OF THERMOSTATS OR PRESSURE SWITCHES SW1 II STAGE BURNER START BUTTON TA IGNITION TRANSFORMER TAB HIGH-LOW THERMOSTAT/PRESSURE SWITCHES TS SAFETY THERMOSTAT OR PRESSURE SWITCH ($) IF "TAB" USED REMOVE THE BRIDGE BETWEEN TERMINALS T6-T8

WARNING 1 - Electrical supply 230V 50/60Hz 1N a.c. 2 - Do not reverse phase with neutral 3 - Ensure burner is properly earthed

29

APPENDIX
SIEMENS OIL BURNERS AUTOMATIC CONTROLLER LOA24 Use LOA... safety devices are intended for use solely with QRB... photoresistors, 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 LAl... AND LAB.. WITH LOA... LOA... models can be used as replacement for LAl... 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 electrical panel or on the control panel. The casing is made of robust heat-resistant plastic and contains: z the thermic programmer operating a multiple switch control system with ambient temperature compensator z flame signal amplifier with flame relay z 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: z 3 neutral terminals, ready wired up to terminal 2 z 4 earth terminals for earthing the burner z 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 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 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 apparatus. Wiring diagram of the programme To ensure correct wiring it is essential to observe local standards and follow the instructions of the burner manufacturer with regard to assembly and start-up. Program's legend: Controller output signals Required input signals A A B C D tw Burner start up with light oil pre-heater OH Burner start-up without light oil pre-heater Flame lit Normal operation Normal stop through R Oil pre-heating time until operational all clear given through contact OW tl Pre-purge time t3 Pre-ignition time t2 Safety time t3n Post-ignition time t4 Interval between the flame lighting and energising of solenoid 2a at terminal 5 Internal layout AL BV. EK FR fr FS G K Optical alarm Fuel valve Reset button Flame relay Flame relay contacts Flame alight signal Burner motor Flame relay anchor to delay the tzl 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) R 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 consequences! Do not open them!

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 &10 terminals 6&7 terminal 8 Absorbed cap Protection Premitted temp: operational transport & 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...+60C -50...+60C any controller 180g, socket 50g, AGK accessories 12 g.

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 immediately. 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 transmitted 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. Control 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 After a mains failure After voltage has fallen below the undervoltage threshold 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 z Burner control is reset z All contacts in the line are closed z No undervoltage z Flame detector is darkened, no extraneous light Undervoltage z Safety shut-down in the operating position takes place should the mains voltage drop below about AC 165 V z Restart is initiated when the mains voltage exceeds about AC 175 V Time supervision oil pre-heater If the oil pre-heaters release contact does not close within 10 minutes, In the event of a premature, faulty flame signal during t1 In the event of a premature, faulty flame signal during tw If the burner does not ignite during TSA In the event the flame is lost during operation Oil pre-heaters release contact does 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 maintained 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 (< 3 seconds). Ignition program with LMO24.113A2 If the flame is lost during TSA, the burner will be reignited, but not later Restart Restart Lock-out at the end of t1 Prevention of start-up, lockout after no more than 40 seconds Lock-out at the end of TSA Max. 3 repetitions, followed by lock-out Lock-out Response

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 lock-out. The repetition count is restarted each time controlled switching on by R-W-SB takes place. Operation
EK

During the time the cause of fault is diagnosed, the control outputs are deactivated. z Burner remains shut down z 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

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.

EK1 LED

C1

C control

C2

s l o

Red Yellow Green

SB

K1 K3 1 2 10 8 8 R

K2

FSV

kbr

3 3

11

12

Colour code table Status Oil pre-heater heats, waiting time tw Ignition phase, ignition controlled Operation, flame o.k. Undervoltage Fault, alarm Colour code lllllllllll lmlmlmlmlml oooooooooooo lslslslslsl sssssssssss Colour

OW AL N OH

EK2

QRB

Yellow
Si

QRC 1 M Z BV1
bl br sw

Yellow-off Green Green-off Yellow-red Red Red-off Green-red Red flicker light
EK1

L N
7130a01e/0700

Operation, flame not o.k. omomomomomo

LMO24 - LMO44

Output of fault code (refer smsmsmsmsm to Fault code table) Extraneous light prior to burner start-up Interface diagnosis Key m l o s Off Yellow Green Red osososososo ssssssssssssss

C 1 LED

C cont r ol

C 2

K2 K1 K3 1 SB 8 R W AL N Si L N
7130a02e/ 0700

FSV K4

10

3 kbr 3 OW OH

11

12

EK2 BV2

Q RB

Q RC 1 M Z BV1
bl br sw

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 No establishment of flame at the end of TSA z Faulty or soiled fuel valves z Faulty or soiled flame detector z Poor adjustment of burner, no fuel z Faulty ignition Free Extraneous light on burner startup Free Free Too manny losses of fleme during operation (limitattion og the number of repetitions) z Faulty or soiled fuel valves z Faulty or soiled flame detector z Poor adjustment of burner Time supervision oil pre-heater Free Wiring error or internal error, output contacts

Control sequence LMO14

Blink code 2 blinks **

R A W SB OH OW M BV1

A tw

D 1 8 3 3 4

3 blinks *** 4 blinks **** 5 blinks ***** 6 blinks ****** 7 blinks *******

t1 Z t3 FS Only with LMO14.113A2: re-ignition Z FS

7130d02e/0700

t3n 6 TSA 11 12 t3n t3n 6 11 12

8 blinks ******** 9 blinks ********* 10 blinks **********

LMO24 - LMO44
R W SB OH OW M BV1 BV2 t 1 Z t 3 FS 12 t 3n Z t 3n 6 11 FS
7130d03e/ 0700

A t w

D 1 8 3 3 4 5

General unit data Mains voltage Mains frequency External primary fuse (Si) Power consumption Mounting orientation Weight Degree of protection Perm. cable lengths Detector cable laid separately Remote reset laid separately

t 3n 6 TSA 11

AC 230 V +10 % / -15 % AC 120 V +10 % / -15 % 50...60 Hz 6 % 6.3A (slow) 12 VA optional approx. 200 g IP40 (to be ensured through mounting) max. 3m at line capacitance of 100 pF/m 10 m 20m LMO14 5A 3A 1A 1A LMO24 5A 5A 1A 1A LMO44 5A 5A 1A 2A

Terminal 1 Terminals 3 and 8 Terminals 4, 5 and 10 Terminals 6

12

Flame supervision with QRB and QRC Min. detector current required (with flame) Min detector current permitted (without flame) Max. possible with flame (tipically) Measurement circuit for detector current
11 bl 12 sw + LMO...
7130v01/0700

Key Alarm device 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 preheater A Beginning of start-up sequence with burners using no oil preheater 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 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 C1 Microcontroller 1 C2 Microcontroller 2 AL kbr... BV... EK1 EK2 FS FSV K... LED M OW t1 t3 t3n A

QRB 45 A 5.5 A 100 A

QRC 70 A 5.5 A 100 A

11 bl

12 sw +

1 br

LMO...
7130v02/0700

A DC

A DC

QRB...

QRC1...

Key A DC bl sw br

DC microamperometer with an internal resistance of 5 k max. Blue Black Brown

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
Note: Specifications and and data subject to change. Errors and omissions excepted.