Unigas IDEA Series Manual Download Page 3

WARNINGS

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
PRODUCT INSTALLATION AND MAINTENANCE.

THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SEC-
TION OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.

CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.

1)

GENERAL INTRODUCTION

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The equipment must be installed in compliance with the
regulations in force, following the manufacturer’s instruc-
tions, by qualified personnel.

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Qualified personnel means those having technical knowle-
dge in the field of components for civil or industrial heating
systems, sanitary hot water generation and particularly ser-
vice centres authorised by the manufacturer.

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Improper installation may cause injury to people and ani-
mals, or damage to property, for which the manufacturer
cannot be held liable.

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Remove all packaging material and inspect the equipment
for integrity.

In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devi-
ces, plastic bags, foamed polystyrene, etc), should not be left
within the reach of children, as they may prove harmful.

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Before any cleaning or servicing operation, disconnect the
unit from the mains by turning the master switch OFF, and/
or through the cut-out devices that are provided.

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Make sure that inlet or exhaust grilles are unobstructed.

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In case of breakdown and/or defective unit operation,
disconnect the unit. Make no attempt to repair the unit or
take any direct action.

Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly
authorised by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair
the unit’s safety.
To ensure equipment efficiency and proper operation, it is
essential that maintenance operations are performed by quali-
fied personnel at regular intervals, following the manufactu-
rer’s instructions.

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When a decision is made to discontinue the use of the
equipment, those parts likely to constitute sources of dan-
ger shall be made harmless.

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In case the equipment is to be sold or transferred to
another user, or in case the original user should move and
leave the unit behind, make sure that these instructions
accompany the equipment at all times so that they can be
consulted by the new owner and/or the installer.

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For all the units that have been modified or have options fit-
ted then original accessory equipment only shall be used.

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This unit shall be employed exclusively for the use for
which it is meant. Any other use shall be considered as
improper and, therefore, dangerous.

The manufacturer shall not be held liable, by agreement or
otherwise, for damages resulting from improper installation,
use and failure to comply with the instructions supplied by the
manufacturer.

2)

SPECIAL INSTRUCTIONS FOR BURNERS

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The burner should be installed in a suitable room, with ven-
tilation openings complying with the requirements of the
regulations in force, and sufficient for good combustion.

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Only burners designed according to the regulations in force
should be used.

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This burner should be employed exclusively for the use for
which it was designed.

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Before connecting the burner, make sure that the unit
rating is the same as delivery mains (electricity, gas oil, or
other fuel).

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Observe caution with hot burner components. These are,
usually, near to the flame and the fuel pre-heating system,
they become hot during the unit operation and will remain
hot for some time after the burner has stopped.

When the decision is made to discontinue the use of the bur-
ner, the user shall have qualified personnel carry out the fol-
lowing operations:
a) Remove the power supply by disconnecting the power cord

from the mains.

b) Disconnect the fuel supply by means of the hand-operated

shut-off valve and remove the control handwheels from
their spindles.

Special warnings

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Make sure that the burner has, on installation, been firmly
secured to the appliance, so that the flame is generated
inside the appliance firebox.

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Before the burner is started and, thereafter, at least once a
year, have qualified personnel perform the following opera-
tions:

a) set the burner fuel flow rate depending on the heat input of

the appliance;

b) set the flow rate of the combustion-supporting air to obtain

a combustion efficiency level at least equal to the lower
level required by the regulations in force;

c) check the unit operation for proper combustion, to avoid

any harmful or polluting unburnt gases in excess of the
limits permitted by the regulations in force;

d) make sure that control and safety devices are operating

properly;

e) make sure that exhaust ducts intended to discharge the

products of combustion are operating properly;

f) on completion of setting and adjustment operations, make

sure that all mechanical locking devices of controls have
been duly tightened;

g) make sure that a copy of the burner use and maintenance

instructions is available in the boiler room.

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In case of repeated burner shut-downs, do not continue re-
setting the unit manually. Contact qualified personnel to
take care of such defects.

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The unit shall be operated and serviced by qualified per-
sonnel only, in compliance with the regulations in force.

Summary of Contents for IDEA Series

Page 1: ...IDEA RANGE LIGHT OIL BURNERS LO280 LO400 Documentazione Tecnica CIB UNIGAS spa Campodarsego Padova Italy M039134CB Rev 1 12 06 Compying with EMC 79 336 CEE LV 73 23 CEE...

Page 2: ...setting 17 MOD LO400 SETTINGS 18 Priming the pump 18 Fuel rate adjustment 18 Choosing the light oil nozzles 18 First start and air rate setting MOD LO400 20 SERVOCONTROL CAMS SETTING Adjustment of cam...

Page 3: ...ssory equipment only shall be used z This unit shall be employed exclusively for the use for which it is meant Any other use shall be considered as improper and therefore dangerous The manufacturer sh...

Page 4: ...nimals or damage to property for which the manufacturer cannot be held liable z Before installation it is recommended that all the fuel sup ply system pipes be carefully cleaned inside to remove forei...

Page 5: ...oil rate min max kg h 16 35 10 35 Fuel Light oil Light oil Power supply 230V 50Hz Electric motor kW 0 37 0 37 Total power consumption W 0 67 0 67 Weight Kg 42 42 Operation Single stage Double stage Op...

Page 6: ...age 8 Fig 4 Fig 5 Boiler s drilling plate and burner s flange AS AL BS BL C F G H K1 K2 L M N Omin Omax P X Y LO280 732 5 877 5 162 5 307 5 570 396 108 128 215 223 348 M10 219 131 179 155 492 108 LO40...

Page 7: ...High Low flame kW Fig 6 Fig 7 BACK PRESSURE IN CCOMBUSTION CHAMBER mbar LO400 Single stage kW LO400 High Low flame kW Fig 8 Fig 9 0 1 2 3 4 5 6 100 150 200 250 300 350 0 1 2 3 4 5 6 50 100 150 200 250...

Page 8: ...4 socket head screws VTF Fig 10 3 Remove the 4 screws which hold the blast tube to the flanged piece Fig 2 4 Extract the blast tube from the flanged piece and assemble it in the other way round as sho...

Page 9: ...ghts the rod A Fig 18 and shift backward the flange as shown 4 Tight the screw in the backward hole on the rod see picture Fig 19 5 Fix the two extensions supplied along with the burner inside the acc...

Page 10: ...wn by current laws on disposal of materials ATTENZIONE LEGGERE SCRUPOLOSAMENTE LE AVVERTENZE RIPORTATE ALL INIZIO DEL MANUALE Fitting the burner to the boiler To perform the installation proceed as fo...

Page 11: ...rminals T6 and T8 on CN2 TAB connector external side link male connector remove this bridge before thermostat connection Fig 25 Single stage burners Fig 26 High Low flame burners Key C1 C2 Time counte...

Page 12: ...lter fitted 4 Automatic interceptor 5 One way valve 6 Gate valve 7 Quick closing gate valve not in vicinity of tank or boiler Only for installations with gravity siphon or for ced circulation feed sys...

Page 13: ...n port on the pump s body must be sealed by steel plug and washer Double pipe system as for the single pipe system a pipe that connects the tank to the pump s inlet is used besides another pipe that c...

Page 14: ...le sg component The num ber of junctions should be kept to a minimum as they are a possible source of leakage z Do not use PTFE tape on the suction and return line pipes to avoid the possibility that...

Page 15: ...her than the rate referred to the minimum burner output Key EVG Light oil solenoid valve M Manometer P Pump see chapter LIGHT OIL PUMPS Fig 34 NOZZLE PUMP PRESSURE bar 6 7 8 9 10 11 12 13 14 G P H kg...

Page 16: ...2 3 93 4 03 4 13 4 23 4 32 4 41 4 50 0 85 2 89 3 06 3 23 3 39 3 54 3 68 3 82 3 95 4 08 4 21 4 33 4 45 4 57 4 68 4 79 4 90 5 00 5 11 1 00 3 40 3 60 3 80 3 98 4 16 4 33 4 49 4 65 4 80 4 95 5 10 5 24 5 3...

Page 17: ...and II Then passing from the low to high flame stage or viceversa change the setting according to the flame composi tion if cam III is too near to the low flame position cam II flue gas can take plac...

Page 18: ...es refer to Tab 3b and Tab 1b for pump pressure regulation see on pag 23 For further information on fuel pump see also the appendix Choosing the light oil nozzles Tab 3a Single stage LO400 Note all pu...

Page 19: ...PRESSURE kg kcal h kW 10bar 12bar 14bar 30 306 300 356 3 50 4 50 3 00 4 00 3 00 3 50 35 357 350 416 4 00 5 00 3 50 5 00 3 50 4 00 40 408 400 475 4 50 6 00 4 00 5 50 4 00 5 00 45 459 450 534 5 00 6 50...

Page 20: ...burner When the flame appears press the P1 button Fig 40 for a few seconds to fill the second nozzle pipe z The cycle continues and if the TAB thermostat is con nected the flame control apparatus brin...

Page 21: ...ng the first setting set the cam III inbetweens the cam I and II Then passing from the low to high flame stage or viceversa change the setting according to the flame composi tion if cam III is too nea...

Page 22: ...mm2 s Oil temperature 60 C max Inlet pressure 2 bar max 0 35 barto avoid the separation between air and oil Return pressure 2 bar max Rated speed 3600 rpm Keys for Suntec AS47 A pump 1 Pressure gover...

Page 23: ...ponding to the maximum power combu stion head all forward To operate the burner at a lowest strenght progressively shift back the combustion head toward the MIN position rotating the VRT screw clockwi...

Page 24: ...S CORRECT AND SAFE FUNCTIO NING OF THE BURNER THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLA TION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERI...

Page 25: ...Make sure that the set of thermostats or pressure switches triggers burner operation z The burner starting cycle begins and the apparatus starts the burner fan while the ignition transformer switches...

Page 26: ...ust be performed using solvent not metal tools At the end of maintenance operations after first reassembling the burner light the flame and check its shape replacing the noz zle whenever a questionabl...

Page 27: ...PART III MAINTENANCE MANUAL 27 Fig 51 Fig 52 Fig 53 Fig 54 Fig 55 TA CA1 CA2 V1 V2 V3 V4 CE FR...

Page 28: ...e rod T Fig 57 z Reassemble the combustion head and tighten the 4 screws V1 V4 Fig 53 z Remove the combustion head see Removing the combustion head a pagina 26 z Remove the 7 screws V5 V11 which faste...

Page 29: ...make a note in the panel below Fig 61 z Unscrew the V screw that fastens the combustion head and remove the head from the nozzle holder Fig 62 Fig 63 In order to remove the nozzle it is important to...

Page 30: ...e nozzles LO400 z Unscrew the Allen screw VT and remove the combustion head TC z Unscrew the nozzles using two wrenches 16 and 24 mm as shown in Fig 66 Fig 66 Fig 62 Fig 63 Double stage burners Fig 64...

Page 31: ...rners mod LO400 A 8 10 mm B 4 5 6 mm C 8 mm D 5 mm Fig 68 See the diagram in Fig 69 to measure the detection current If the signal doesn t suit the suggested value verify the electric terminal the cle...

Page 32: ...ERATION MAINS SWITCH OPEN FUSES INTERVENTION MAXIMUM PRESSURE SWITCH FAULT INTERVENTION OF THE FAN MOTOR THERMAL CUTOUT AUXILIARIES RELAY FUSES INTERVEN TION FLAME CONTROL DEVICE FAULT SERVOCONTROL FA...

Page 33: ...PART III MAINTENANCE MANUAL 33 WIRING DIAGRAMS Wiring diagram 04 743 LO280 Single stage burners...

Page 34: ...PART III MAINTENANCE MANUAL 34...

Page 35: ...PART III MAINTENANCE MANUAL 35 Wiring diagram 18 116 LO280 Double stage burners...

Page 36: ...PART III MAINTENANCE MANUAL 36...

Page 37: ...DICATOR LIGHT LEVG1 INDICATOR LIGHT FOR OPENING OF ELECTRO VALVE EVG1 LTA IGNITION TRANSFORMER INDICATOR LIGHT MV FAN MOTOR PS LOCK OUT RESET BUTTON WITH LOA44 AND LMO ONLY SATRONIC DKO976 DKW976FLAME...

Page 38: ...PART III MAINTENANCE MANUAL 38 Wiring diagram 18 049 LO400 Single stage burners...

Page 39: ...PART III MAINTENANCE MANUAL 39 Single stage burners 18 049 LO400 Double stage burners...

Page 40: ...PART III MAINTENANCE MANUAL 40 Connectors layout on printed board...

Page 41: ...C5 30601C5 30601A1 30601A0 FUEL FILTER 2090027 2090027 2090025 2090025 SERVOCONTROL 2480057 2480057 FAN 2150071 2150071 2150060 2150060 BLAST TUBE Standard 30900L3 Long 30900L4 Standard 30900L3 Long 3...

Page 42: ...PART III MAINTENANCE MANUAL 42...

Page 43: ...or mounting To dismantle it only requires gentle pressure with a screw driver in the slot of the mounting guide The base dimensions of the socket are exaclty the same as for types LAB LAI and there is...

Page 44: ...here is a flame signal eg from premature ignition due to a faulty sole noid external light short circuit in the photoresisto or wiring malfunc tion in the flame signal amplifier etc at the end of pre...

Page 45: ...n Repetition of start up pro gramme Power cut during start up programme or operation Automatic repetition of programme when power restored Lack of sufficient power 160V Solenoid BV1 de energised sole...

Page 46: ...ss weight controller socket 140g 80g AGK accessories 12g Key to internal diagram AL Remote optical lockout indicator AR Main relay with contacts ar BV Fuel solenoid BR Lockout relay with contacts br E...

Page 47: ...APPENDIX COMPONENTS SPECIFICATIONS 47...

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