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Summary of Contents for CIB UNIGAS PBY1025
- Page 1 PBY1025 PBY1030 PBY1040 Progressive, Fully-modulating Heavy oil Burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039126CE Rel. 4.1 04/2010...
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Page 2: Table Of Contents
TABLE OF CONTENTS WARNINGS ................................3 PART I: INSTALLATION ............................5 GENERAL FEATURES ................................... 5 Burner model identification ................................6 Technical Specifications ................................. 6 Performance Curves ..................................7 Overall dimensions ..................................8 INSTALLING THE BURNER ................................9 Packing ......................................9 Handling the burner .................................. -
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 personnel to replace. DIRECTIVES AND STANDARDS When the unit is out of use for some time the electric switch supplying all Gas burners the power-driven components in the system (i.e. pumps, burner, etc.) European directives: should be switched off. - Directive 2009/142/EC - Gas Appliances;...
- Page 5 -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.
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Page 6: Part I: Installation
C.I.B. UNIGAS - M039126CE PART I: INSTALLATION GENERAL FEATURES This particular burner series has been developed to use compressed air or alternatively steam, to atomize heavy oil. In this way we have achieved higher efficiency compared to mechanical atomization. These burners are equipped with a low pressure nozzle which permits to save fuel and, above all, to preserve the whole system. -
Page 7: Burner Model Identification
Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type PBY1025 Model (1) BURNER TYPE PBY1025 - PBY1030 - PBY1040 ≤ (2) FUEL H - heavy oil, viscosity 4000cSt (530°E) @ 50°C... -
Page 8: Performance Curves
C.I.B. UNIGAS - M039126CE Performance Curves PBY1025 PBY1030 2500 3500 4500 5500 6500 7500 8500 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 PBY1040 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 To get the input in kcal/h, multiply value in kW by 860. -
Page 9: Overall Dimensions
(PBY1025) A(*S) A(*L) AA AM B(*S) B(*L) BB PP QQ PBY1025 1784 1980 377 641 1408 680 1312 680 632 472 522 660 815 M16 651 460 460 49 1145 379 330 PBY1030 1761 2006 377 657 1408 680 1312 680 632 633 524 660 815 M16... -
Page 10: Installing The Burner
C.I.B. UNIGAS - M039126CE INSTALLING THE BURNER Packing Burners are despatched in wooden crates whose dimensions are: 2280 mm x 1730 mm x 1360 mm(L x P x H) Packing cases of this kind are affected by humidity and are not suitable for stacking. The fol- lowing are placed in each packing case: burner;... -
Page 11: Electrical Connections
C.I.B. UNIGAS - M039126CE 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 12: Fan Motor And Pump Motor Direction
C.I.B. UNIGAS - M039126CE Fan motor and pump motor direction Once the electrical connection of the burner is performed, remember to check the rotation of the motor. The motor should rotate accor- ding to the arrow shown on the next picture. In the event of incorrect rotation reverse the three-phase supply and check again the rota- tion of the motor. -
Page 13: Pipe Heating System
THERMOSTAT TCI °E °C °C °C < 50 (7) 2 (PBY1025/1030) / 4 (PBY1040) > 50 (7) < 110 (15) 2 (PBY1025/1030) / 4 (PBY1040) > 110 (15) < 400 (50) 2 (PBY1025/1030) / 4 (PBY1040) > 400 (50) <4000 (530) 2 (PBY1025/1030) / 4 (PBY1040) Tab. - Page 14 C.I.B. UNIGAS - M039126CE 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...
- Page 15 C.I.B. UNIGAS - M039126CE 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...
- Page 16 C.I.B. UNIGAS - M039126CE 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.
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Page 17: Hydraulic Diagrams
HYDRAULIC DIAGRAMS Fig. 13 - Hydraulic diagram 3ID0024... - Page 18 3ID0024 KEYS OIL TRAIN Main tank OIL PUMPING UNIT Manual valve Filter Pump coupled to electrical motor Safety valve One-way valve Manual valve Pressure gauge High pressure switch - PO MAX DAILY TANK Daily tank Heating device Electrical resistor Pressure gauge High pressure switch - PO MAX Low pressure switch - PO MIN Low thermostat - TCN...
- Page 19 Fig. 14 - Hydraulic diagram 3I2D-02 (PBY1025)
- Page 20 3I2D-02 KEYS 3I2D-02 KEYS OIL TRAIN PILOT GAS TRAIN Filter Pressure governor with filter Pump coupled to an electrical motor Pressure switch - PGP Flexible hose Solenoid valve Manual valve Flexible hose Pressure gauge Pilot burner Pressure governor Pressure governor for L.P.G. tank Manual valve COMBUSTION AIR TRAIN Thermostat - TR...
- Page 21 Fig. 15 - Hydraulic diagram 3I2-D03 (PBY1030/PBY1040)
- Page 22 3I2D-03 KEYS 3I2D-03 KEYS OIL TRAIN PILOT GAS TRAIN Filter Pressure governor with filter Pump coupled to an electrical motor Pressure switch - PGP Flexible hose Solenoid valve Manual valve Flexible hose Pressure gauge Pilot burner Pressure governor Pressure governor for L.P.G. tank Manual valve COMBUSTION AIR TRAIN Thermostat - TR...
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Page 23: Pilot Gas Train
C.I.B. UNIGAS - M039126CE Pilot gas train The connection to the pilot gas train must be done according to the following scheme BURNER MANUFACTURER INSTALLER L.P.G. Fig. 16 Gas valves Gas pressure switch Gas governor with filter Bellows unit Manual cutoff valve Pressure governor Tank Gas supply: LPG... -
Page 24: Light Oil Pilot
C.I.B. UNIGAS - M039126CE Light oil pilot The burner can be provided with light oil pilot, instead of gas pilot. light oil pilot nozzle light oil pilot pump Fig. 17 EVG Light oil solenoid valve Manometer Pump Heavy oil pumps The pump provided with the burner must be installed according to the hydraulic diagram. -
Page 25: Light Oil Pilot Pump
C.I.B. UNIGAS - M039126CE Light oil pilot pump Suntec AS47-57-67 B Oil viscosity 2 - 12 cSt Oil temperature 0 - 60 °C Max. suction pressure 2 bar max. Max. return pressure 2 bar max. Min. suction pressure - 0.45 barto avoid gasing Rotation speed 3600 rpm max. -
Page 26: Connecting The Oil Flexible Hoses To The Burner
C.I.B. UNIGAS - M039126CE Connecting the oil flexible hoses to the pump To connect the flexible oil hoses to the pump, proceed as follows, according to the pump provided: remove the closing nuts A (on the pump inlet) and B (from pump to the burner); screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the lines: see the arrows marked on the pump. -
Page 27: Adjusting Air And Fuel Rate
C.I.B. UNIGAS - M039126CE Hydraulic connections Compressed Air Nozzle cleaning air Fig. 19 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 28: Pneumatic Noozles
C.I.B. UNIGAS - M039126CE Fluidics noozles The oil flow rate can be adjusted choosing nozzles that suit the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted in the diagram below (as far as reading the pressure values, see next paragraphs). Nozzle 32-Y - A°... -
Page 29: Oil Thermostat Adjustment
C.I.B. UNIGAS - M039126CE Oil thermostat adjustment All thermostats are located inside the control panel. To set the temperature use a small screwdriver. Such temperature must be set during burner operation, checking temperature in the thermometer mounted on the pre-heating tank. We suggest a thermometer with scale up to 200°... -
Page 30: Oil Flow Rate Settings
C.I.B. UNIGAS - M039126CE Oil Flow Rate Settings With the electrical panel open, prime the oil pump acting directly on the related contactor CP (see next picture): check the pump motor rotation (see “Fan motor and pump motor direction” on page 11) and keep pressing for some seconds until the oil circuit is charged;... - Page 31 C.I.B. UNIGAS - M039126CE compressed air pressure gauge oil pressure gauge Fig. 23 Set the atomising air pressure switch PA (Fig. 24) at 0.5 bar Set the pilot gas pressure switch PG (Fig. 25) at 50 mbar. Fig. 26 - Atomising air flow rate adjustment Fig.
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Page 32: Calibration Of Air Pressure Switch
C.I.B. UNIGAS - M039126CE combustion parameters, the adjustment is to be performed by means of the SV adjusting cam screw V (Fig. 31) when the cam has rea- ched the high flame position. 12 The atomising air flow rate and pressure can be adjusted with the VA screw (Fig. 26). Too low a pressure produces poor atomising with smoke in the flue. -
Page 33: Evl Air Valve For Gun Cleaning
C.I.B. UNIGAS - M039126CE CMF = 0 stop at the current position CMF = 1 high flame operation CMF = 2 low flame operation CMF = 3 automatic operation EVL air valve for gun cleaning After the flame is off, an automatic system provides the compressed air to clean the gun. Fig. -
Page 34: Part Ii: Operation
C.I.B. UNIGAS - M039126CE 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 35: Control Panel
C.I.B. UNIGAS - M039126CE Control panel High flame lamp Low flame lamp Ignition transformer lamp Fan motor thermal cutout lamp Burner lockout lamp Burner stand-by lamp Solenoid valve lamp Atomisation air pressure switch lamp Compressed air solenoid valve lamp Heating resistors safety thermostat lamp Plant enabling thermostat lamp MD Siemens modulator (on fully modulating versions only) Oil pump in operation... -
Page 36: Part Iii: Maintenance
C.I.B. UNIGAS - M039126CE 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 37: Maintenance Of The Gas Governor With Filter (Pilot Gas Train)
C.I.B. UNIGAS - M039126CE Maintenance of the gas governor with filter (pilot gas train) Before disassmbling the device, be sure that there is no pressurised gas inside it. To check the filtering part (1) on threaded bodies (see Fig. 34): remove the bottom cover, unscrewing the fixing screws;... -
Page 38: Removing The Oil Gun, Replacing/Adjusting The Nozzle And The Ignition Electrode
C.I.B. UNIGAS - M039126CE Removing the oil gun, replacing/adjusting the nozzle and the ignition electrode ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrode position after any intervention on the combustion head. To remove the oil gun, proceed as follows: remove the combustion head as described on the prevoius paragraph;... -
Page 39: Checking The Detection Current
C.I.B. UNIGAS - M039126CE Checking the detection current To measure the detection signal follow the diagram in Fig. 38. If the signal is not in the advised range, check the electrical contacts, the cleaning of the combustion head, the position of the photore- sistor and if necessary replace it. -
Page 40: Troubleshooting
C.I.B. UNIGAS - M039126CE 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 FAULTY CONTROL BOX AIR ACTUATOR MALFUNCTION CIRCUIT ENABLING THERMOSTAT SMOKY FLAME FAULTY IGNITION TRANSFORMER IGNITION ELECTRODE WRONGLY POSITIONED DIRTY NOZZLE... -
Page 41: Burner Exploded View
BURNER EXPLODED VIEW ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION AIR INLET CONE 20.1 AIR PRESSURE SWITCH 23.4 NOZZLE HOLDER BURNER HOUSING 20.2 COMPRESSED AIR SOLENOID VALVE 23.5 COMBUSTION HEAD COVER 20.3 ONE-WAY VALVE 23.6 IGNITION CABLE CERAMIC FIBRE PLAIT 20.4 COMPRESSED ARI GOVERNOR WITH FILTER 23.7.1 IGNITION ELECTRODE... -
Page 43: Spare Parts
C.I.B. UNIGAS - M039126CE SPARE PARTS DESCRIPTION PBY1025 PBY1030 PBY1040 2020420 2020420 2020420 CONTROL BOX 2080257 2080257 2080257 IGNITION ELECTRODE 2090209 2090209 2090209 OIL FILTER 2090001 2090001 2090001 LIGHT OIL PILOT FILTER 2150063 2150058 2150058 FAN WHEEL 2160097 2160065 2160065... -
Page 44: Appendix
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 45 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 46 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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