Unigas RN510 Manual Of Installation - Use - Maintenance
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Unigas RN510 Manual Of Installation - Use - Maintenance

Progressive, fully-modulating heavy oil burners
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RN510 - RN515
RN520 - RN525
Progressive, Fully-modulating
Heavy oil Burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039215CB REL. 1.1 02/2014

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Summary of Contents for Unigas RN510

  • Page 1 RN510 - RN515 RN520 - RN525 Progressive, Fully-modulating Heavy oil Burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039215CB REL. 1.1 02/2014...

  • Page 2: General Introduction

    DANGERS, WARNINGS AND NOTES OF CAUTION 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.

  • Page 3: Directives And Standards

    do not leave the equipment exposed to weather (rain, sun, etc.) DIRECTIVES AND STANDARDS unless expressly required to do so; Gas burners do not allow children or inexperienced persons to use equipment; European directives: - Directive 2009/142/EC - Gas Appliances; The unit input cable shall not be replaced by the user.

  • Page 4: Symbols Used

    -EN 55014-1Electromagnetic compatibility - Requirements for household appliances, electric tools and similar apparatus. -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.

  • Page 5: Burner Model Identification

    Burners are identified by burner type and model. Burner model identification is described as follows. Type RN520 Model (1) BURNER TYPE RN510 - RN515 - RN520 - RN525 ≤ N - Heavy oil, viscosity 50cSt (7° E) @ 50° C ≤...

  • Page 6: Performance Curves

    Performance Curves RN510 RN515 1200 2000 2800 3600 4400 5200 1000 1800 2600 3400 4200 RN520 RN525 1600 2400 3200 4000 4800 5600 6400 7200 8000 1500 2500 3500 4500 5500 6500 7500 8500 To get the input in kcal/h, multiply value in kW by 860.
  • Page 7 Overall dimensions (mm) Boiler recommended boiler drilling template A(S*) A(L*) B(S*) B(L*) DD** EE** 1502 1682 1152 1285 RN510 1502 1682 1152 1285 RN515 1502 1682 1152 1285 RN520 1502 1682 1152 1285 RN525 *S = measure referred to standard blast tube *L = measure referred to extended blast tube ** RN515-520-525: as far as these burners, the oil pumping/pre-heating unit is separate.

  • Page 8: Installing The Burner

    Packing Burners are despatched in wooden crates whose dimensions are: RN510-515-520: 1720 x 1500 x 1210 (L x P x H) RN525: 1800 x 1500 x 1300 (L x P x H) Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing case: burner;...

  • Page 9: Mounting Position

    MOUNTING POSITION SIDE UP SIDE DOWN Burner is designed to operate with horizontal flame axis. Set the upper side of the burner flange in a horizontal position, in order to obtain the correct inclination of the pre-heating tank. For different installations, please contact the Technical Department. 1 Burner flange (upper side indicated) 2 Bracket 3 Pre-heating tank on the burner...

  • Page 10: Electrical Connections

    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 plant’s switch to OFF and be sure that the burner’s main switch is in 0 position (OFF) too.
  • Page 11 Fan and pump motors direction 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. In the event of incorrect rotation reverse the three-phase supply and check again the rotation of the motor.

  • Page 12: Oil Pumps

    Oil pumps RN510: SUNTEC TA3 RN515: SUNTEC TA4 RN520 - RN525: SUNTEC TA5 Suntec TA.. Oil viscosity 3 ÷ 75 cSt Oil temperature 0 ÷ 150°C Min. suction pressure - 0.45 bar to avoid gasing Max. suction pressure 5 bar Max.
  • Page 13 Burners with separate pre-heating/pumping unit Follow the scheme in the picture below to connect the burner to the oil pumping unit. The pump sends the oil coming from the tank to the burner. The pressure governor makes the oil reach the nozzle at the required pressure, while the excess of oil goes back to the tank.
  • Page 14 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 on the inlet (A) and return (R) connections of the pump; screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the inlet and return lines: see the arrows marked on the pump that show the inlet and the return (see prevoius paragraph).
  • Page 15 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. Inlet minimum pressure of the pump (both for supplying system and burner) A very low pressure leads to cavitation (signalled by its peculiar noise): the pump manifacturer declares the minimum value.
  • Page 16 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 52.3 6.77 13.1 2.17 12.95 60.9...
  • Page 17 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 HEAVY OIL 22°E AT 50°C HEAVY OIL 50°C HEAVY OIL 47°E AT 50°C...
  • Page 18 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) Fig.
  • Page 19 HYDRAULIC DIAGRAMS Fig. 13 - 3ID00014 v2 Hydraulic diagram - Two or more burners configuration...
  • Page 20 Горелка n.1 См. P&ID горелки Вход жидкости для подогрева Обратный ход жидкости для подогрева Группа рабочей емкости Насосная группа Fig. 14 - 3ID0023 v2 - Hydraulic diagram - Single burner configuration...
  • Page 21 LEGEND OIL TRAIN Main tank OIL PUMPING UNIT Manual valve Filter Pump coupled to electrical motor Safety valve One-way valve Manual valve Pressure gauge Maximum pressure switch Minimum pressure switch PRESSURE GOVERNOR UNIT Manual valve Pressure governor Needle valve Pressure gauge DAILY TANK Daily tank Electrical resistor...
  • Page 22 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 23 trolled by thyristor. (for details refer to the attached technical documentation) Fig. 16 - Danfoss MCX Fig. 17 - Probe connections (Danfoss MCX) Oil viscosity at 50 °C according to the letter shown in the burner model Menu path 89 cSt <...
  • Page 24 Adjust this thermostat to the correct value according to the viscosity-temperature diagram and check the temperature by using a thermometer with a scale of up to 200° C mounted on the pre-heating tank. Safety resistors thermostat TRS: it is factory preset and sealed.
  • Page 25 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 26 Start the burner up by means of the thermostat series and wait unitl the pre-purge phase comes to end and that burner starts up; drive the burner to high flame stage, by means fo the thermostat TAB (high/low flame thermostat - see Wiring diagrams), as far as fully-modulating burners, see related paragraph.
  • Page 27 shaft the air damper closes and the air flow rate decreases. Note: once the procedure is perfomed, be sure that the blocking nut RA is fasten. Do not change the position of the air dam- per rods. 12 If necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move pro- gressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut.
  • Page 28 Calibration of air pressure switch To calibrate the air pressure switch, proceed as follows: Remove the transparent plastic cap. Once air and heavy oil setting have been accomplished, startup the burner. During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout, then read the value on the pressure switch scale and set it to a value reduced by 15%.
  • Page 29 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 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 31: Operation

    OPERATION ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. N.B. be sure the cutoff valves on the delivery and return pipes are OPEN. Turn the burner on by means of its main switch A (see next pictures).

  • Page 32: Control Panel

    Control panel High flame lamp RN510 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 Burner lockout Burner in stand-by Auxiliary resistors wsitch Heavy oil solenoid lamp operation...

  • Page 33: Routine Maintenance

    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 34 Removing the combustion head Remove the cover H. Slide the photoresistor out of its housing. Unscrew the oil connections E (Fig. 28) connecting the flexible pipes to the gun L and remove the whole assembly as shown in Fig. 28-Fig. 29. clean the combustion head by means of a vacuum cleaner;...
  • Page 35 Nozzle and ignition electrodes correct position Place the nozzle according to the combustion head; unscrew VB and move the combustion head. Check the ignition electrodes at the end of the procedure. Fig. 30 3 ÷ 5 mm 3 ÷ 4 mm 10 ÷ 15 mm 10 mm 13 mm 8 mm...

  • Page 36: Troubleshooting

    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 IGNITION TRANSFORMER FAULTY IGNITION ELECTRODES WRONGLY POSITIONED DIRTY NOZZLE FAULTY OIL VALVE FAULTY OR DIRTY PHOTORESISTOR...
  • Page 37 BURNER EXPLODED VIEW ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION FLANGE 12.10.2 AIR PRESSURE SWITCH 16.1 MOTOR AIR INLET CONE 12.10.3 PRESSURE SWITCH BRACKET 16.2 COUPLING CLOSING PLATE 12.11.1 AIR DAMPER SILENCER 16.3 PUMP INDEX LABEL 12.11.2 AIR INTAKE DAMPER 16.4 BRACKET RING NUT 12.11.3...

  • Page 39: Wiring Diagrams

    WIRING DIAGRAMS Refer to the attached wiring diagrams. WARNING 1 - Electrical supply 230V 50Hz 1 a.c./400V 50Hz 3N a.c. 2 - Do not reverse phase with neutral 3 - Ensure burner is properly earthed...
  • Page 40 APPENDIX t3’ Long preignition time: «Z» connected to terminal 15. Postignition time: SIEMENS LAL.. CONTROL BOX - «Z» must be connected to terminal 15 - With short preignition, «Z» remains on until «TSA» has elapsed connec- Control and supervision of oil atomization burners tion to terminal 16.
  • Page 41 4 A max., 20 A peak Internal fuse T6,3H250V according to IEC 127 During burner off times, the flame supervision circuit is live. External fuse max. 10 A Weight Device 1000 g Lockout indication Plug-in base 165 g Q R C 1 ... Startup sequence b r1 b-b’...
  • Page 42 Postpurge time (with «M2») Interval between start command and voltage at terminal 7 (start delay time for «M2») Duration of startup sequence (excluding «t11» and «t12») Interval from startup to the beginning of the air pressure check Air damper running time to the OPEN position Air damper running time to the low-fire position (MIN) Permissible afterburn time Interval to the OPEN command for the air damper...
  • Page 44 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. Errors and omissions exceptd.

This manual is also suitable for:

Rn515Rn520Rn525

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