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Unigas RG1025 Manual Of Installation, Use And Maintenance

Light oil burners
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RG1025
RG1030
RG1040
Light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039144CD Rel. 3.2 09/2010

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Summary of Contents for Unigas RG1025

  • Page 1 RG1025 RG1030 RG1040 Light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039144CD Rel. 3.2 09/2010...
  • Page 3 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.
  • Page 4 DIRECTIVES AND STANDARDS 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS Gas burners GENERAL European directives:  The burner shall be installed by qualified personnel and in com- - Directive 2009/142/EC - Gas Appliances; pliance with regulations and provisions in force; wrong installation Directive 2006/95/EC on low voltage;...

  • Page 5: General Features

    C.I.B. UNIGAS - M039144CD PART I: INSTALLATION GENERAL FEATURES This series represents monobloc burners made in die-cast aluminium housing with relative flange to work on heating generators. The output range is from 2550kW to 13000kW (according to models). They can be provided in progressive or fully-modulating version.

  • Page 6: Burner Model Identification

    Burners are identified by burner type and model. Burner model identification is described as follows. Type RG1025 Model (5) (6) (1) BURNER TYPE RG1025 - RG1030 - RG1040 (2) FUEL G - Light oil PR - Progressive (3) OPERATION (Available versions)
  • Page 7 C.I.B. UNIGAS - M039144CD Specifications BURNERS RG1025 RG1030 RG1040 Output min. - max. kW 2550 - 8700 2550 - 10600 2550 - 13000 Light oil rate min. - max. kg/h 215 - 734 215 - 894 215 - 1096 Fuel...
  • Page 8 Overall dimensions (mm) Burners flange and boiler recommended drilling template A(S*) A(L*) AA AC AD AE B(S*) B(L*) BB RR SS UU RG1025 1896 2090 377 1452 25 585 1546 1502 822 370 660 816 M16 651 460 460 265 80 142 1146 379 330...

  • Page 9: Mounting And Connections

    C.I.B. UNIGAS - M039144CD MOUNTING AND CONNECTIONS ATTENTION: READ CAREFULLY THE “WARNINGS2 CHATPER AT THE BEGINNIG OF THIS MANUAL. Packing The burners are despatched in wooden cages whose dimensions are: 2270 x 1720 x 1360mm (L x P x H) Packing cases of this kind are affected by humidity and are not suitable for stacking.
  • Page 10 C.I.B. UNIGAS - M039144CD spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer). a) Heat output in kW b) Length of the flame tube in meters c) Flame tube firing intensity in MW/m d) Combustion chamber diameter (m) Fig.
  • Page 11 C.I.B. UNIGAS - M039144CD The pilot gas train is already installed into the burner, the connection from the filter with stabiliser to the gas supply network must be carried out. connection to the gas supply network Once the gas train in installed, execute the electrical connections for all its items (gas valves group, pressure switch).
  • Page 12 C.I.B. UNIGAS - M039144CD 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.
  • Page 13 C.I.B. UNIGAS - M039144CD Hydraulic diagrams for light oil supplying circuits Fig. 6 - Gravity circuit Fig. 7 - Ring circuit Fig. 8 - Suction circuit Manual valve Light oil filter Light oil feeding pump One way valve Flexible hoses Relief valve NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n.

  • Page 14: Oil Pumps

    C.I.B. UNIGAS - M039144CD tion- referring to the pump shaft). Caution: Changing the direction of rotation, all connections on top and side are reversed. pipeline length in meters. Suntec T 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.
  • Page 15 C.I.B. UNIGAS - M039144CD Suntec TV Pressure governor Pressure adjustment Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase pressure, twist adjusting screw 3 clockwise. To decrease the pressure, twist screw counterclockwise. Tight the lock nut 4, refit the gasket 2 and the cap nut 1.
  • Page 16 C.I.B. UNIGAS - M039144CD Oil circuit The fuel is pushed into the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor. The solenoid valve 2 stops the fuel immission into the combustion chamber. The fuel flow rate that is not burnt goes back to the tank through the return circuit. The spill-back nozzle is feeded at constant pressure, while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam.
  • Page 17 C.I.B. UNIGAS - M039144CD Light oil nozzles The fuel rate is adjusted by choosing a properly dimensioned nozzle (spill-back type) and adjusting the inlet and return pressure fol- lowing the directions showed in the next table. NOZZLE HIGH FLAME LOW FLAME...
  • Page 18 C.I.B. UNIGAS - M039144CD  BERGONZO NOZZLES Fig. 15...
  • Page 19 C.I.B. UNIGAS - M039144CD Fig. 16...
  • Page 20 C.I.B. UNIGAS - M039144CD Fig. 17...
  • Page 21 C.I.B. UNIGAS - M039144CD Fig. 18...
  • Page 22 C.I.B. UNIGAS - M039144CD ADJUSTMENTS Adjustments - brief description 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.
  • Page 23 C.I.B. UNIGAS - M039144CD Turn the burner on by means of its main switch A: if the burner locks (LED B on in the control panel) press the RESET button (C) on the control panel (see next picture) - see chapter “OPERATION” on page 28.
  • Page 24 C.I.B. UNIGAS - M039144CD mensions Dimensions in SQM4... III IV Actuator cams High flame Stand-by and Ignition AUTO Low flame Stroke limitation MAN-AUTO Siemens SQM10 Siemens SQM40 the nozzle supply pressureis already factory-set and must not be changed. Only if necessary, adjust the supply pressure as fol- lows (see related paragraph);insert a pressure gauge into the port shown on Fig.
  • Page 25 C.I.B. UNIGAS - M039144CD 13 as for the point-to-point regulation in order to set the cam foil shape, move the oil low flame microswitch (cam III) a little lower than the maximum position (90°); 14 set the TAB thermostat to the minimum (as far as fully-modulating burners, see related paragraph) in order that the actuator moves progressively towards the low flame position;...
  • Page 26 C.I.B. UNIGAS - M039144CD Adjusting the combustion head To let the burner operate at a lower output, loose the VB screw and move progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when the adjustment is accomplished.
  • Page 27 C.I.B. UNIGAS - M039144CD PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNEC- TED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDE- RED IMPROPER AND THEREFORE DANGEROUS.

  • Page 28: Operation

    C.I.B. UNIGAS - M039144CD OPERATION ATTENTION: before starting the burner up, be sure that the manual cutoff valves. Check that the mains switch is closed. Check that the burner is not in shutdown condition (light E, on), if so, release by pressing the reset button N on the burner control panel.

  • Page 29: Routine Maintenance

    C.I.B. UNIGAS - M039144CD 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.
  • Page 30 C.I.B. UNIGAS - M039144CD Light oil filter maintenance For correct and proper servicing, proceed as follows: shut off fuel in the line section being serviced; unscrew the tray; remove the filter cartridge from its support and wash it with petrol or replace if necessary; check seal O-Ring, replace if necessary;...
  • Page 31 C.I.B. UNIGAS - M039144CD Removing the oil gun remove the combustion head, as described on the previous paragraph; slacken the screw VB remove the gun with the nozzle holder to rreassemble follow the procedure above in the reversed order. Fig. 24 Electrode and nozzle position setting ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boi-...
  • Page 32 C.I.B. UNIGAS - M039144CD Replacing the ignition electrode ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boi- ler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head.

  • Page 33: Troubleshooting

    C.I.B. UNIGAS - M039144CD TROUBLESHOOTING  MAIN SWITCH OPEN  LINE FUSE INTERVENTION   MAX. PRESSURE SWITCH FAULT  FAN THERMAL CUTOUT INTERVENTION  AUXILIARY RELAIS FUSES INTERVENTION      CONTROL BOX FAULT  SERVOCONTROL FAULT ...

  • Page 34: Spare Parts

    C.I.B. UNIGAS - M039144CD SPARE PARTS Desription RG1025 RG1030 RG1040 2020420 2020420 2020420 CONTROL BOX mod.SIEMENS LAL2.25 IGNITION ELECTRODE 2080254 2080254 2080258 2090018 2090018 2090018 LIGHT OIL FILTER 2090101 2090101 2090101 GAS FILTER 2150063 2150058 2150058 FAN WHEEL PILOT GAS PRESSURE SWITCH...
  • Page 35 APPENDIX t3’ Long preignition time: «Z» connected to terminal 15. SIEMENS LAL.. CONTROL BOX FOR OIL BURNERS Postignition time: - «Z» must be connected to terminal 15  Control and supervision of oil atomization burners - With short preignition, «Z» remains on until «TSA» has elapsed connec- ...
  • Page 36 During burner off times, the flame supervision circuit is live. Lockout indication Startup sequence b-b’ Idle step (with no contact confirmation) b(b’)-a Postpurge program Burner control can immediately be reset after lockout: Do not press the lockout reset button for more than 10 seconds The sequence switch always travels to the start position first After resetting After rectification of a fault that led to shutdown...
  • Page 37 Sequence diagram Control output at terminal t3" t3 n t1 6 V II V III X II t10* X III X IV Lockout position indication Prepurge time with air damper fully open Safety time Preignition time, short («Z» connected to terminal 16) T3’...
  • Page 40 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.

This manual is also suitable for:

Rg1030Rg1040

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