Related Manuals for Unigas PN1025
Summary of Contents for Unigas PN1025
- Page 1 PN1025 PN1030 PN1040 Progressive, Fully-modulating Heavy oil Burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039117CC Rel. 3.0 07/2022...
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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 PRODUCT INSTALLATION AND MAINTENANCE. -
Page 3: Directives And Standards
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS DIRECTIVES AND STANDARDS Gas burners GENERAL European directives The burner shall be installed by qualified personnel and in compliance -Regulation 2016/426/UE (appliances burning gaseous fuels) with regulations and provisions in force; wrong installation can cause -2014/35/UE (Low Tension Directive) injuries to people and animals, or damage to property, for which the -2014/30/UE (Electromagnetic compatibility Directive) -
Page 4: Symbols Used
Burner data plate Type For the following information, please refer to Model Gas - Light oil burners Year the data plate: European Directives S.Number -Regulation 2016/426/UE (appliances burning gaseous fuels) burner type and burner model: must be Output Oil Flow -2014/35/UE (Low Tension Directive) reported in any communication with the Fuel... -
Page 5: Burner Model Identification
Burners are identified by burner type and model. Burner model identification is described as follows.. Type PN1025 Model (1) BURNER TYPE PN1025 - PN1030 - PN1040 N - Heavy oil, viscosity <= 50cSt (7° E) @ 50° C E - Heavy oil, viscosity <= 110cSt (15°E) @ 50° C (2) FUEL D - Heavy oil, viscosity <= 400cSt (50°... -
Page 6: Performance Curves
C.I.B. UNIGAS - M039117CC Performance Curves PN1025 PN1030 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 2500 3500 4500 5500 6500 7500 8500 PN1040 2000 3000 4000 5000 6000 7000 8000 9000 1 0000 1 1 000 1 2000 1 3000 To get the input in kcal/h, multiply value in kW by 860. - Page 7 Overall dimensions (mm) Recommended boiler drilling jig Burner flange PN1025 1960 2154 1560 1574 1145 PN1030 1938 2132 1538 1574 1145 PN1040 1970 2164 1570 1574 1145 *AS/BS = measure referred to standard blast tube *AL/BL = measure referred to extended blast tube...
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Page 8: Installing The Burner
C.I.B. UNIGAS - M039117CC INSTALLING THE BURNER Packing Burners are despatched in wooden crates whose dimensions are:730mm x 1280mm x 1020mm (L x P x 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 C.I.B. UNIGAS - M039117CC The burner is designed to work positioned according to the picture below. Set the upper side of the burner flange in a horizontal posi- tion, in order to find the correct inclination of the pre-heating tank. For different installations, please contact the Technical Department.
- Page 10 C.I.B. UNIGAS - M039117CC Double-pipe and single-pipe system The pumps that are used 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 pump’s 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.
- Page 11 C.I.B. UNIGAS - M039117CC 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 12 C.I.B. UNIGAS - M039117CC Connections to the oil gun Gun with the oil nozzle inside 1 Inlet 2 Return 3 Gun opening 4 Heating wire (only for high density oil burners) 5 Cartdrige-type heater (only for oil with viscosuty > 110 cSt)
- Page 13 C.I.B. UNIGAS - M039117CC PIPELINE PIPELINE HEAVY OIL VISCOSITY AT 50 °C PRESSURE TEMPERATURE cSt (°E) °C < 50 (7) 1- 2 > 50 (7) < 110 (15) 1- 2 > 110 (15) < 400 (50) 1- 2 Tab. 1...
- Page 14 C.I.B. UNIGAS - M039117CC 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 15 C.I.B. UNIGAS - M039117CC 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 16 C.I.B. UNIGAS - M039117CC 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 17: Hydraulic Diagrams
C.I.B. UNIGAS - M039117CC HYDRAULIC DIAGRAMS Fig. 8 - Hydraulic diagram 3ID0023 - Single burner configuration... - Page 18 C.I.B. UNIGAS - M039117CC Fig. 9 - Hydraulic diagram 3ID0014 - Two or more burners configuration...
- Page 19 C.I.B. UNIGAS - M039117CC 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 20: Adjusting The Burner
C.I.B. UNIGAS - M039117CC ADJUSTING THE BURNER Adjusting the pilot gas flow rate: gas valve Brahma EG12xR and pressure govrnor To change the pilot gas valve flow rate, proceed as follows: remove the protection on the bottom of the valve, moving it counterclockwise (see next picture);... - Page 21 C.I.B. UNIGAS - M039117CC 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 below (as far as reading the pressure values, see next paragraphs).
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- Page 26 C.I.B. UNIGAS - M039117CC 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. .ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide);...
- Page 27 C.I.B. UNIGAS - M039117CC SQM40.265 Actuator cams Version with flame control LMO 24.255 / 44.255 Version with flame control LAL 2.25 (RD) I High flame (RD) I High flame (BU) II Stand-by (BU) II Stand-by (OG) III Low flame (OG) III...
- Page 28 C.I.B. UNIGAS - M039117CC Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above. 14 as for the point-to-point regulation in order to set the cam foil shape, move the low flame microswitch (cam III) a little lower than the maximum position (90°);...
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Page 29: Oil Circuit
C.I.B. UNIGAS - M039117CC 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: Limitations Of Use
C.I.B. UNIGAS - M039117CC 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 - M039117CC Control panel Keys 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 Burner lockout Burner in stand-by... -
Page 32: Routine Maintenance
C.I.B. UNIGAS - M039117CC 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 C.I.B. UNIGAS - M039117CC Removing the combustion head Remove the cover H. Slide the UV photoelectric cell out of its housing. Unscrew the oil connections E (Fig. 24) connecting the flexible pipes to the gun L and remove the whole assembly as shown in Fig.
- Page 34 C.I.B. UNIGAS - M039117CC Nozzle and electrode correct positions To guarantee a good ignition the measures below must be respected; see also Fig. 27. Place the nozzle according to the combustion head; unscrew VB and move the combustion head. Check the ignition electrode at the end of the procedure.
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Page 35: Troubleshooting
C.I.B. UNIGAS - M039117CC 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 AIR INLET CONE 16.8.7 22.2.1 IGNITION ELECTRODE BURNER HOUSING 16.8.8 LEVERAGE 22.2.7 DETECTION ELECTRODE COVER 16.8.9 22.2.8 NOZZLE CERAMIC FIBRE PLAIT 16.8.10 JOINT 22.3 STANDARD COMPLETE OIL GUN NAME PLATE 16.8.11 JOINT 22.3.1 NOZZLE RING NUT... -
Page 38: Spare Parts
SPARE PARTS DESCRIPTION PN1025 PN1030 PN1040 2020114 2020114 2020114 CONTROL BOX KROM-SCHROEDER IFW 2020420 2020420 2020420 CONTROL BOX SIEMENS LAL 2080115 2080115 2080115 PILOT FLAME DETECTION ELECTRODE 2080258 2080258 2080258 PILOT IGNITION ELECTRODE 2090238 2090238 2090238 FILTER FOR ECO/DENSE OIL... -
Page 39: Electrical Wiring Diagrams
ELECTRICAL WIRING DIAGRAMS SE12-154: Progressive burners wiring diagramÏ SE12-155: Fully-modulating burners wiring diagram WARNING: 1 - Power supply 400V 50Hz 3N AC 2 - Don’t reverse phase with neutral 3 - Ensure the burner is properly earthed... - Page 55 APPENDIX Postignition time: - «Z» must be connected to terminal 15 SIEMENS LAL.. CONTROL BOX - With short preignition, «Z» remains on until «TSA» has elapsed connec- tion to terminal 16. Control and supervision of oil atomization burners Interval «BV1 – BV2» or «BV1 - LR»: On completion of «t4», vol- For burners of medium to high capacity tage is present at terminal 19.
- Page 56 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 ... b r1 Startup sequence b-b’...
- Page 57 Postpurge time (with «M2») In the case of UV control, one IFW 15 flame detector must be used per burner. A diode of type EM 513 must be fitted as shown on the wiring dia- Interval between start command and voltage at terminal 7 (start gram (Fig.
- Page 60 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.
- Page 61 RWF55.5X & RWF55.6X User manual M12926CA Rel.0.1 10/2015...
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Page 62: Device Installation
DEVICE INSTALLATION Fixing system Drilling dimensions:... -
Page 63: Front Panel
FRONT PANEL Burner release Controlling element CLOSED/stage 1 Controlling element OPEN/stage 2 Operating mode 2-stage Actual value display (red) and parameter value USB led Comunication via interface Operating mode 2-stage Thermal shock protection Alarm function Decrease value Increase value ESC button Enter button... -
Page 64: Navigation Menu
NAVIGATION MENU User Level - Opr Parameter level SP1 or SP2 (editable) dSP readable and editable through bin1 = 2 InP1 or y (only display) Basic display Parameter level - PArA Pb1, dt, rt, db, tt Heating controllerHYS1 , HYS2 , HYS3 Cooling controller HYS4 , HYS5 , HYS6... - Page 65 PID parameters set and modifications (PArA): Push Enter button, on the green display Opr appears; using the down arrow, scroll until group PArA is reached and push Enter. On the green display Pb1 e appears and on the red one the set parameter. Push is sequence the down or up arrow the menu is scrolled. Push Enter to select and the arrows to choose the desired value.
- Page 66 Setting the kind of sensor to be connected to the device: Push the Enter button: on the lower display (green) Opr appears. Using the up and down arrows find ConF. Push Enter to confirm. Now on the green display the group InP appears. Push Enter and InP1 is displaied. Enter to confirm.You are inside InP1; the green display shows Sen1 (sensor type), while the red display shows the chosen sensor code Push Enter to enter the Sen1 parameter, then choose the desired sensor using the arrows.
- Page 67 ConF > InP >InP2 Input 2 : this input can be used to specify an external setpoint or carry out setpoint shifting Parameter Value Description no function FnC2 external setpoint (display SPE) setpoint shifting (display dSP) angular positioning feedback SEn2 0 ÷...
- Page 68 ConF > Cntr Here, the type of controller, operating action, setpoint limits and presettings for self-optimization are selected Parameter Value Description CtYP 3-position controller (open-stop-close) ontroller type continuative action controller (0 ÷10V 4 ÷ 20mA) heating controller CACt control action cooling controller minimum set-point scale -1999..0..+9999...
- Page 69 Alarm functionAF The alarm function can be used to monitor the analog inputs. If the limit value is exceeded, multifunctional relay K6 (terminals 6N and 6P) is activated (depending on the switching characteristic) The alarm function can have different switching functions (lk1 to lk8) and can be set to a deviation from the active setpoint or to a fixed limit value Limit value AL relative to setpoint (x) Fixed limit value AL...
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Page 70: Switched-Off
ConF > AF Parameter Value Description FnCt Without function type of control monitored input Ik1 = InP1 monitored input Ik2 = InP1 monitored input Ik3 = InP1 monitored input Ik4 = InP1 monitored input Ik5 = InP1 monitored input Ik6 = InP1 monitored input Ik7 =... - Page 71 ConF > binF This setting decides on the use of the binary inputsD1, D2, DG Parameter Value Description without function bin1 binary imput terminals set-point changeover (SP1 / SP2) – D1) set-point shift (Opr > dSP parameter = value of set-point modify) 2 = l input alarm changeover of operating mode...
- Page 72 ConF > IntF The controller can be integrated into a data network using an optional RS-485 (terminals R+ and R-) interface or an optional Profibus DP interface(only modelRWF55.6x terminalsC1-C2-C3-C4) Parameter Value Description bdrt 0 = 4800 baud baudrate 1 = 9600 baud 2 = 19200 baud 3 = 38400 baud Address in the data network...
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Page 73: Display Of Software Version
Display of software version : The software version is shown by pushing Enter + UP arrow on the upper display Weather-compensated setpoint shifting(climatic regulation): The RWF55 can be configured so that weather-compensated setpoint shifting is activated when an LG-Ni1000 outside sensor or a Pt1000 is connected (see parameter InP3). - Page 74 Modbus interface The tables that follow in this chapter specify the addresses of the readable and writable words that the customer is able to access. The customer may read and/or write the values using SCADA programs, PLCs, or similar. The entries under Access have the following meanings: R/O Read Only, value can only be read R/W Read/Write, value can be read and written The number of characters specified under Data type in the case of character strings includes the final \0.
- Page 75 Configuration level Address Access Data type Signal reference Parameter 0x3426 Float SCL1 Start of display input 1 0x3428 Float SCH1 End of display input 1 0x3432 Float SCL2 Start value input 2 0x3434 Float SCH2 End value input 2 0x3486 Float Start of setpoint limitation 0x3488...
- Page 76 Dati dell’apparecchio Address Access Data type Signal reference Parameter 0x8000 Char12 Software version 0x8006 Char14 VdN number Stato dell’apparecchio Address Access Data type Signal reference Parameter 0x0200 Word Outputs and states Bit 0 Output 1 Bit 1 Output 3 Bit 2 Output 2 Bit 3 Output 4...
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Page 77: Electric Connections
Electric connections : With 7 pins connector version With terminals version Corrispondences bornes entre RWF55.5x y RWF40.0x0Matches terminals betweenRWF55.5x and RWF40.0x0... - Page 78 Parameters summarising for RWF55.xx : ConF ConF Navigation menù Inp1 Cntr diSP PArA Types of probe SEn1 OFF1 Unit dECP Pb. 1 HYS1 (*) HYS3 (*) SP1 (*) ...
- Page 79 APPENDIX: PROBES CONNECTION To assure the utmost comfort, the control system needs reliable information, which can be obtained provided the sensors have been installed correctly. Sensors measure and transmit all variations encountered at their location. Measurement is taken based on design features (time constant) and according to specific operating conditions.With wiring run in raceways, the sheath (or pipe) containing the wires must be plugged at the sensor's terminal board so that currents of air cannot affect the sensor's measurements.
- Page 80 Duct or pipe sensors Installing pressure sensors Installing temperature sensors A - installation on ducts carrying fluids at max. temperature 80°C For measuring outlet air: B - installation on ducts at temperature over 80°C and for refrigerants "after delivery fan or C - installation on ducts at high temperatures : "after coil to be controlled, at a distance of at least 0,5 m ·"increase length of siphon...
- Page 81 Immersion or strap-on sensors Immersion probes installation Sensors must be installed on the stretch of pipe in which fluid circula- tes all the time. The rigid stem (sensing element doing the measuring) must be inser- ted by at least 75mm and must face the direction of flow. Recommended locations: on a bend or on a straight stretch of pipe but tilted by 45°...
- Page 82 Duct pressure switches and sensors Installing differential pressure probes for air Basic principles Measuring static pressure(i.e. pressure exerted by air on pipe walls) A - Control a filter (clogging) Measuring dinamic pressure B - Control a fan (upstream/downstream) Legend Kg/m3, specific weight of air m/s, air speed 9.81 m/s2 gravity acceleration mm C.A., dynamic pressure...
- Page 84 Note: Specifications and data subject to change. Errors and omissions excepted.
- Page 85 MANUALE USER SUPPORT MULTI-THERMOSTAT MCX06C MCX06C is a multi-thermostat with four 100k NTC inputs. It can control up to 4 temperatures showing them (not more than 2 at the same time) on a couple of displays. It is used to check and adjust oil heater temperatures. it works as follows: as soon as the burner control gives the GO to the digital 1 input (terminals DI1-COM), the adjustment program runs (the relevant LED is ON).
- Page 86 Connections from terminal side : 24V AC Probe connection: input AI1 = probe Pb1 = set-point “tr” = oil heater temperature probe; input AI2 = probe Pb2 = set-point “tCI” = plant consent temperature probe (when installed); input AI3 = probe Pb3 = set-point “OIL” = oil heater output temperature probe (PID regulation); input AI4 = probe Pb4 = set-point “tcn”...
- Page 87 (tCI - Pb2 probe only for mechanical atomizing burners) Menu : To enter the menu below, keep pushing ENTER for more than 3 s. Menu code Sub-menu code Function Notes Probes values You can see in sequence the 4 probe values (UP and DOWN keys): the probe code is on display A (Pb1,..., Pb4) and the probe value is on display B (not fitted or out...
- Page 88 submenu CnF - configuration parameters group : Visibility Password Modbus Menu Parameter Description Additional description Default U.M. condition level index CONFIGURATION Analog Input 1 This parameter enables or disables the Probe 1 Presence probe Calibration Probe 1 Don't modify it -20,0 20,0 °C...
- Page 89 Visibility Modbus Menu Parameter Description Additional description Default U.M. condition Level index Autotuning Output temperature hysteresis Don't modify it 50,0 °C Startup number Don't modify it Measurement cycles number Don't modify it Max. differential command Don't modify it exit 0,01 10,00 10,00 Differential reduction exit...
- Page 90 Submenu REG – regulation parameters group : Visibility Modbus Menu Parameter Description Additional description Default U.M. condition Level index REGULATION Probe 1 Set-point Probe 1 Don't modify it (Tank resistor) -50,0 200,0 °C Probe 1 - Low Temperature Alarm Don't modify it Threshold -50,0 200,0...
- Page 91 Visibility Modbus Menu Parameter Description Additional description Default U.M. condition Level index Overshooting for Integral action Don't modify it (Oil tank exit) 1000 Derivative action enabling Don't modify it (Oil tank exit) Filtering factor for derivative action Don't modify it (Oil tank exit) Duty cicle PWM for output DO3 Don't modify it...
- Page 92 Alarms & Warning: When the red triangle on the top left lights, one or more alarms are activated. When the red key on the left lights, the output N05-C5 is active and the relay KTRS switches the resistors OFF. Check the reason, correct the failure and, as soon as the temperature is lower than trS, reset it through ALA/rES . In order to show active alarms and warnings, select the relevant menu through ALA/Act.and, using the UP and DOWN buttons, scroll the lines.