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Summary of Contents for Unigas PN91
- Page 1 PN91 - PN92 - PN93 PN510 - PN515 PN520 - PN525 Progressive, Fully-modulating Heavy oil Burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039196CC Rel. 2.2 05/2010...
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Page 2: Table Of Contents
TABLE OF CONTENTS WARNINGS ................................5 PART I: INSTALLATION ............................5 Burner model identification ................................5 Technical Specifications ................................. 5 Performance Curves ..................................7 INSTALLING THE BURNER ................................8 Packing ......................................8 Handling the burner ..................................8 Fitting the burner to the boiler ................................. 9 Electrical connections ................................... -
Page 3: Warnings
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;...
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Page 5: Part I: Installation
Burners are identified by burner type and model. Burner model identification is described as follows. Type PN91 Model (1) BURNER TYPE PN91 - PN92 - PN93 - PN510 - PN515 - PN520 - PN525 ≤ N - Heavy oil, viscosity 50cSt (7° E) @ 50° C ≤... - Page 6 C.I.B. UNIGAS - M039196CC BURNER PN510 PN515 PN520 PN525 1314 - 3953 1628 - 4884 2326 - 6977 2000 - 8000 Output min - max kW Heavy oil Fuel See “Burner model identification” table Oil viscosity min. - max. kg/h...
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Page 7: Performance Curves
C.I.B. UNIGAS - M039196CC Performance Curves PN91 PN92 1200 1600 2000 2400 1200 1600 2000 2400 2800 PN93 100 0 1 500 2000 25 00 3000 35 00 4000 45 00 PN510 PN515 1200 2000 2800 3600 4400 5200 1000... -
Page 8: Installing The Burner
C.I.B. UNIGAS - M039196CC Overall dimensions (mm) Type PN91 1017 1315 1505 1052 PN92 1017 1318 1508 1052 PN93 1017 1318 1508 1052 PN510 1050 1390 1570 1110 PN515 1050 1390 1570 1110 PN520 1050 1390 1570 1320 PN525 1050... -
Page 9: Fitting The Burner To The Boiler
C.I.B. UNIGAS - M039196CC Fitting the burner to the 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”;... -
Page 10: Electrical Connections
C.I.B. UNIGAS - M039196CC 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 11: Fan Motor Direction
C.I.B. UNIGAS - M039196CC Fan motor direction ( and pump motor direction only for PN520 - PN525) Once the electrical connection of the burner is performed, remember to check the rotation of the motor. The motor should rotate in an counterclockwise direction looking at cooling fan. -
Page 12: Oil Pumps
C.I.B. UNIGAS - M039196CC Oil pumps PN91: SUNTEC TA2 / DANFOSS KSM50 PN92/93/510: SUNTEC TA3 / DANFOSS KSM70 PN515: SUNTEC TA4 / DANFOSS KSM100 PN520/525: SUNTEC TA5 / DANFOSS KSM140 Danfoss KSM.. Oil viscosity 2.5 ÷ 450 cSt Oil temperature -10 ÷... -
Page 13: Connecting The Oil Flexible Hoses
C.I.B. UNIGAS - M039196CC Connecting the oil flexible hoses To connect the flexible light oil hoses to the pump, proceed as follows, according to the pump provided: remove the closing nuts A and R on the inlet and return connections of the pump;... -
Page 14: Pipe Heating System
C.I.B. UNIGAS - M039196CC Pipe heating system Pipe heating system must be provided, that is a system to heat pipes and plant components to mantain the viscosity in the pumping lim- its. Higher the oil viscosity and lower the ambient temperature, more necessary the pipe heating system. - Page 15 C.I.B. UNIGAS - M039196CC Viscosity units conversion table Saybolt Cinematics Saybolt Redwood Engler Degrees Seconds Redwood Seconds viscosity Seconds Seconds no.1 (°E) Universal no..2 (Admiralty) Centistokes (cSt) Furol (SSF) (Standard) (SSU) 2.56 1.16 32.1 1.31 36.2 1.58 44.3 5.83 10.3 1.88...
- Page 16 C.I.B. UNIGAS - M039196CC VISCOSITY vs TEMPERATURE DIAGRAM FOR COMBUSTIBLE OILS 1000 PUMPING LIMIT TEMPERATURE (°C) LIGHT OIL 1,3°E AT 20°C HEAVY OIL 2,4°E AT 50°C HEAVY OIL 4°E AT 50°C HEAVY OIL 7,5°E AT 50°C HEAVY OIL 10°E AT 50°C HEAVY OIL 13°E AT 50°C...
- Page 17 C.I.B. UNIGAS - M039196CC Indicative diagram showing the oil temperature at burner pump inlet vs. oil viscosity Example: if the oil has a 50°E @ 50°C viscosity, the oil temperature at the pump inlet should be 80°C (see diagram). OIL TEMPERATURE FOR PUMP FEEDING TEMPERATURE (°C)
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Page 18: Hydraulic Diagrams
C.I.B. UNIGAS - M039196CC HYDRAULIC DIAGRAMS Fig. 13 - Hydraulic diagram 3ID0023 - Single burner configuration... - Page 19 C.I.B. UNIGAS - M039196CC Fig. 14 - Hydraulic diagram 3ID0014 - Two or more burners configuration...
- Page 20 C.I.B. UNIGAS - M039196CC Hydraulic Diagram 3ID0014 Hydraulic Diagram 3ID0023 1 Main tank 1 Main tank 2 Bottom valve 2 Bottom valve 3 Main tank pre-heating pipe 3 Main tank pre-heating pipe 4 Oil filter (filtration, 1mm) 4 Oil filter...
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Page 21: Adjusting Light Oil Flow Rate
C.I.B. UNIGAS - M039196CC Adjusting light oil flow rate The light oil flow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the chart below and the diagram on Fig. 15 (as far as reading the pressure values, see next paragraphs). -
Page 22: Oil Thermostat Adjustment
C.I.B. UNIGAS - M039196CC Oil thermostat adjustment To find the thermostats, remove the cover of the burner switchboard. Adjust them using a screwdriver on the VR screw as shown in the next picture. NOTE: thermostat TCI is provided on burners fired with fuel oil having a 50° E at 50° C viscosity only. -
Page 23: Adjusting Air And Fuel Rate
C.I.B. UNIGAS - M039196CC ADJUSTING AIR AND FUEL RATE ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open. Be sure that the mains switch is closed. ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide);... -
Page 24: Oil Flow Rate Settings By Means Of Berger Stm30../Siemens Sqm40.. Actuator
C.I.B. UNIGAS - M039196CC Oil Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator with the electrical panel open, prime the oil pump acting on the related contactor (see next picture): check the pump motor rotation (page 11) and keep pressing for some seconds until the oil circuit is charged;... - Page 25 C.I.B. UNIGAS - M039196CC Pressure gauge port Pressure gauge port Fig. 18 Fig. 20 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge): checking always the combu- stion parameters, the adjustment is to be performed by means of the SV adjusting cam screw V (see picture) when the cam has reached the high flame position.
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Page 26: Adjustment By The Siemens Sql33.. Actuator
C.I.B. UNIGAS - M039196CC Adjustment by the Siemens SQL33.. actuator with the electrical panel open, prime the oil pump acting directly on the related contactor (see next picture): check the pump motor rotation (see “Fan-pump motor direction” on page 10) and keep pressed for some seconds until the oil circuit is charged;... - Page 27 C.I.B. UNIGAS - M039196CC The nozzle supply pressure is already factory-set and must not be changed. Only if necessary, adjust the supply pressure as follows (see related paragraph);insert a pressure gauge into the port showed on Fig. 22 and act on on the pump adjusting screw VR (see Fig.
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Page 28: Calibration Of Air Pressure Switch
C.I.B. UNIGAS - M039196CC 18 Turn the burner off then start it up again. 19 Once the pre-purge time comes to end and the burner is on, drive the burner to the high flame stage by the TAB thermostat: check the combustion values;... -
Page 29: Oil Circuit
C.I.B. UNIGAS - M039196CC 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 30: Part Ii: Operation
C.I.B. UNIGAS - M039196CC PART II: OPERATION 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. -
Page 31: Control Panel
C.I.B. UNIGAS - M039196CC Control panel PN91 - PN92 - PN93 - PN510 High flame lamp Low flame lamp Ignition transformer operation CMF Manual operation switch 0= Off 1= High flame 2= Low flame 3= Automatic Fan motor thermal cutout intervention... -
Page 32: Part Iii: Maintenance
C.I.B. UNIGAS - M039196CC 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 33: Removing The Oil Gun, Replacing The Nozzle And The Electrodes
C.I.B. UNIGAS - M039196CC Fig. 25 1 Inlet 2 Return 3 Lance opening 4 Heating wire (only for oil viscosity > 110 cSt @ 50 °C) 5 Cartdrige-type heater H Cover Fig. 26 L Oil lance E Oil piping connections Removing the oil gun, replacing the nozzle and the electrodes ATTENTION: avoid the electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation... -
Page 34: Nozzle And Electrodes Correct Position
To check the flame itensity signal, follow the diagram shown on the next picture. If the measured value is lower than the suggested one, check the photoresistor position, the electrical contacts. Replace the photoresistor if necessary. PN91-PN92 - PN93: LMO44 PN510-PN515-PN520-PN525: LAL2. -
Page 35: Troubleshooting
C.I.B. UNIGAS - M039196CC TROUBLESHOOTING CAUSES/TROUBLES MAIN SWITCH OFF LINE FUSES BLOWN MAXIMUM THERMOSTAT MALFUNCTION FAN THERMAL CUTOUT TRIPPED AUXILIARY FUSE BLOWN OIL RESISTOR FAULTY OIL ENABLING THERMOSTAT TRIPPED CONTROL UNIT MALFUNCTION AIR SERVOCONTROL MALFUNCTION CIRCUIT ENABLING THERMOSTAT SMOKY FLAME... -
Page 36: Burner Exploded View
BURNER EXPLODED VIEW ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION NIPPLE 5.2.2 GASKET AIR INTAKE DAMPER ELBOW 5.2.3 GAS BLEEDING VALVE AIR INTAKE DAMPER NIPPLE 5.2.4 THERMOMETER AIR INTAKE PUMP 5.2.5 MUFF LOUVER SHAFT 2.1.1 POWER CONTROLLER COVER LOUVER SHAFT 2.1.2 FRONT CONTROL PANEL REDUCTION ADJUSTING CAM SHAFT... -
Page 38: Spare Parts
C.I.B. UNIGAS - M039196CC SPARE PARTS DESCRIPTION PN91 PN92 PN93 2020455 2020455 2020420 CONTROL BOX SIEMENS LMO 2080250 2080250 2080250 RIGHT ELECTRODE 2080251 2080251 2080251 LEFT ELECTRODE 2090207 2090207 2090207 FILTER FOR OIL VISCOSITY > 50 cSt @ 50°C 2090212... -
Page 39: Electrical Wiring Diagrams
ELECTRICAL WIRING DIAGRAMS Electrical diagram 07-345 - Burners type PN 91 - 92 -93 x-.PR... Electrical diagram 07-403 - Burners type PN91 - 92 - 93 x-.MD.. Electrical diagram 11-275 - Burners type PN510 x-.PR... Electrical diagram 11-294 - Burners type PN510 x-.MD... -
Page 40: Appendix
APPENDIX The multicolour «LED» is the key indicating element for both visual diagnosis and interface diagnosis. 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 Yellow-burning flames are supervised with photoresistive detectors Green... - Page 41 Connection diagram and internal diagram LMO24 - LMO44 LMO14 A ´ μC control μC1 μC2 t 3n t 3n t 3n 7130a01e/0700 7130d03e/ 0700 LMO24 - LMO44 Alarm device µC cont r ol µC 1 µC 2 kbr... Cable link (required only when no oil pre-heater is used) BV...
- Page 42 6 in the bottom of the base General unit data 6 lateral threaded knockout holes for cable entry glands Pg11 or M20 Mains voltage AC 230 V +10 % / -15 % Operation AC 110 V +10 % / -15 % Mains frequency 50...60 Hz ±6 % Flame detector and flame simulation test are made automatically during...
- Page 43 following burner off time, terminal 11 is live. Absorption AC 3.5 VA Mounting position optional Permissible afterburn time: during «t13», the flame signal input may still receive a flame signal. Protection IP 40 Perm. input current at terminal 1 End of control program: start position AC 5 A max., 20 A peak As soon as the sequence switch has reached the start position –...
- Page 44 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 48 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 data subject to change without notice. Errors and omissions excepted.
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