Unigas PBY510 Manual Of Installation - Use - Maintenance Download Page 1

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MANUAL OF INSTALLATION - USE - MAINTENANCE

PBY90 - PBY91 - PBY92

PBY510 - PBY515
PBY520 - PBY525

M03993CH Rel. 7.

/2010

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Progressive, Fully-modulating

Heavy oil Burners

Summary of Contents for PBY510

Page 1: ...AL OF INSTALLATION USE MAINTENANCE PBY90 PBY91 PBY92 PBY510 PBY515 PBY520 PBY525 M03993CH Rel 7 3 06 2010 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive Fully modulating Heavy oil Burners ...

Page 2: ...il flexible hoses to the burner 24 Connecting the compressed air hoses 24 ADJUSTING AIR AND FUEL RATE 25 Oil thermostat adjustment 26 Adjusting the pilot gas flow rate gas valve Brahma EG12xR and pressure governor 26 Adjustments brief description 26 Oil Flow Rate Settings by means of Berger STM30 Siemens SQM40 actuator 27 Adjustment by the Siemens SQL33 actuator 29 Calibration of air pressure swit...

Page 3: ...ains electricity gas oil or other fuel z 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 burner the user shall have qualified personnel carry out the following operations a Rem...

Page 4: ...of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards 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 ...

Page 5: ...t 8 bar must be provided on the site All burners are ignited by means of a pilot flame burning LPG or Natural gas The standard ver sion of the burner uses compressed air to atomize oil fuel If compressed air is not available on site it is possible to use steam to ato mise oil fuel by using a special kit In any case compressed air is essential to ignite the burner when steam is not available to con...

Page 6: ...er model identification table Heavy oil rate min max kg h 60 178 45 223 62 267 Gas pressure max mbar 500 Gas pressure after gas governor mbar 100 Compressed air pressure min max bar 4 10 Power supply 400V 3N a c 50Hz Total power consumption kW 12 25 13 25 18 75 Fan motor kW 3 4 5 5 Pump motor kW 0 75 0 75 0 75 Pre heater resistors kW 8 8 12 Protection IP40 Approx weight kg 165 175 185 Operation Pr...

Page 7: ...tion head is set in order to find a compromise between the burner output and the generator specifications that is why the minimum output may be different from the Per formance curve minimum PRESSURE IN COMBUSTION CHAMBER mbar PBY90 kW PBY91 kW PRESSURE IN COMBUSTION CHAMBER mbar PBY92 kW PBY510 kW PRESSURE IN COMBUSTION CHAMBER mbar PBY515 kW PBY520 kW PRESSURE IN COMBUSTION CHAMBER mbar PBY525 kW...

Page 8: ...64 532 992 532 460 246 276 360 464 M12 417 280 310 295 105 60 43 504 34 693 228 180 PBY91 1262 237 35 250 479 298 419 964 532 992 532 460 262 292 360 464 M12 417 280 310 295 105 60 43 504 34 693 228 180 PBY92 1265 237 35 250 479 301 419 964 532 992 532 460 292 322 360 464 M12 417 280 310 295 105 60 43 504 34 693 228 180 boiler recommended drilling template ...

Page 9: ...2 571 501 345 385 540 498 M14 552 390 390 109 115 44 547 30 827 245 270 PBY515 1364 1544 219 35 265 448 350 530 508 1014 571 1072 571 501 384 424 540 498 M14 552 390 390 109 115 44 547 30 827 276 270 PBY520 1364 1544 219 35 265 448 350 530 508 1014 571 1072 571 501 422 472 540 498 M14 552 390 390 109 115 44 547 x 827 300 270 PBY525 1408 219 35 265 448 350 642 1058 571 1142 642 501 422 472 540 498 ...

Page 10: ...rocedure described on paragraph Handling the burner 3 place the 4 stud bolts 5 on boiler s door according to the burner s drilling template described on paragraph Overall dimensions 4 fasten the 4 stud bolts 5 place the gasket on the burner flange 6 install the burner into the boiler 7 fix the burner to the stud bolts by means of the fixing nuts according to the next picture 8 After fitting the bu...

Page 11: ...C I B UNIGAS M03993CH 11 Key 1 Burner flange upper side indicated 2 Bracket 3 Pre heating tank on the burner SIDE UP SIDE DOWN 1 2 3 ...

Page 12: ...r s main switch is in 0 position OFF too Read carefully the chapter WARNINGS and the Electrical connections section WARNING The burner is provided with an electrical bridge between terminals 6 and 7 when connecting the high low flame thermostat remove this bridge before connecting the thermostat IMPORTANT Connecting electrical supply wires to the burner teminal block MA be sure that the ground wir...

Page 13: ...he oil must be also pressurised The pressurisation is also necessary to feed the burner pump avoiding its cavitation because of the high suction at the inlet The supplying system scope is to pump and heat oil The oil viscosity is referred in various unit measures the most common are E cSt Saybolt and Redwood scales Table 3 shows the various unit convertions e g 132 cSt viscosity corresponds to 17 ...

Page 14: ...and the winding dimensioning and other construcitve details must be provided by the installer Adjusting the supplying oil ring According to the heavy oil viscosity used in the table below indicative temperature and pressure values to be set are shown Note the temperature and pressure range allowed by the supplying ring components must be checked in the specifications table of the components themse...

Page 15: ... 1 4 48 150 19 3 128 14 48 43 2 5 92 200 23 5 170 18 9 54 7 35 250 28 212 23 45 65 8 79 300 32 5 254 28 87 6 11 7 400 41 9 338 37 1 110 14 6 500 51 6 423 46 2 132 17 5 600 61 4 508 55 4 154 20 45 700 71 1 592 64 6 176 23 35 800 81 677 73 8 198 26 3 900 91 762 83 220 29 2 1000 100 7 896 92 1 330 43 8 1500 150 1270 138 2 440 58 4 2000 200 1690 184 2 550 73 2500 250 2120 230 660 87 6 3000 300 2540 27...

Page 16: ...0 30 40 50 60 70 80 90 100 110 120 130 140 150 160 TEMPERATURE C VISCOSITY E 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 HEAVY OIL 70 E AT 50 C HEAVY OIL 200 E AT 50 C ...

Page 17: ...ture at the pump inlet should be 80 C see diagram Indicative diagram showing the oil pressure according to its temperature OIL TEMPERATURE FOR PUMP FEEDING 1 10 100 0 10 20 30 40 50 60 70 80 90 TEMPERATURE C VISCOSITY E a 50 C Fig 11 PUMP FEEDING PRESSURE Max for E 1069 pimps Max for T and TA pumps 0 1 2 3 4 5 6 40 60 80 100 120 140 160 TEMPERATURE C PRESSURE bar Fig 12 ...

Page 18: ...C I B UNIGAS M03993CH 18 HYDRAULIC DIAGRAMS Fig 13 Hydraulic diagram 3ID0024 ...

Page 19: ...ressure gauge 9 High pressure switch PO MAX DAILY TANK 10 Daily tank 11 Heating device 12 Electrical resistor 13 Pressure gauge 14 High pressure switch PO MAX 15 Low pressure switch PO MIN 16 Low thermostat TCN 17 Thermometer 18 High thermostat TRS 19 Thermostat TR 20 Manual valve 21 Manual valve PRESSURE GOVERNOR UNIT 22 Pressure gauge 23 Manual valve 24 Pressure governor 25 Needle valve ...

Page 20: ...C I B UNIGAS M03993CH 20 Fig 14 Hydraulic diagram 3I2D01 ...

Page 21: ... actuator 9 Low thermostat TCI 38 Draught fan with electromotor 10 High thermostat TRS 39 Pressure switch PA 11 Electrical preheater tank STEAM TRAIN OPTIONAL 12 Thermometer 40 Manual valve 13 Pneumatic valve 41 Filter 14 Metering valve 42 Pressure switch 15 Main burner 43 Water separator COMPRESSED AIR TRAIN 44 Water discharger 16 Pressure governor with filter 45 Flow indicator 17 Solenoid valve ...

Page 22: ...n is already installed into the burner the connection from the pressure governor with filter to the gas supply network must be carried out Once the gas train in installed execute the electrical connections for all its items gas valves group pressure switch ATTENTION once the gas train is mounted according to the diagram on Fig 15 the gas proving test must be performed according to the procedure se...

Page 23: ...t be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the joint noise and overloading the gears z Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical seal junc tions preferred Junction threads elbow joints and couplings should be sealed with removable sg component The num...

Page 24: ...p Connecting the oil flexible hoses to the burner To connect the flexible oil hoses to the pump proceed as follows according to the pump provided 1 remove the closing nuts H on the heater and R on the oil pressure governor of the inlet and return connections 2 screw the rotating nut of the two flexible hoses on the burner being careful to avoid exchanging the inlet and return lines see the arrows ...

Page 25: ...de if this should happen make the fuel decrease slowly until the normal combustion values are achieved Before starting up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pump seal to break IMPORTANT the combustion air excess must be adjusted according to the values in the following chart Recommended combustion parameters Fuel Recommended CO2 ...

Page 26: ...d oil flow rates at the maximum output high flame first by means of the air damper and the adjusting cam res pectively z Check that the combustion parameters are in the suggested limits z Then adjust the combustion values corresponding to the points between maximum and minimum set the shape of the adjusting cam foil The adjusting cam sets the air fuel ratio in those points regulating the opening c...

Page 27: ...itch A see next picture if the burner locks LED B on in the control panel press the RESET button C on the control panel See OPERATION on page 34 5 Start the burner up by means of the thermostat series terminals 3 and 4 see wiring diagrams and wait unitl the pre purge phase comes to end and that burner starts up 6 drive the burner to high flame stage by means fo the thermostat TAB high low flame th...

Page 28: ...ep 8 If the required flow rate is not reached increase the feeding pressure by means of the Suntec TV governor see picture below 12 in order to get the maximum oil flow rate adjust the pressure reading its value on the oil pressure gauge Fig 25 checking always the combustion parameters the adjustment is to be performed by means of the SV adjusting cam screw V Fig 26 when the cam has rea ched the h...

Page 29: ...low flame microswitch cam III a little lower than the maximum position 90 17 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position 18 move cam III towards the minimum to make the actuator move towards the low flame until the two bearings find the adjusting screw that refers to a lower position screw V to increase the rate unscrew to dec...

Page 30: ...on set it to the MAN manual mode by the MAN AUTO selector read the ignition position on the air damper index 6 disconnect the TAB thermostat removing the wire from the terminal no 6 or by setting MAN on the RWF40 output controller or by setting 0 by means of the CMF switch only for fully modulating burners 7 set the actuator to the manual mode MAN by means of the MAN AUTO switch see next pictures ...

Page 31: ...ion parameters the adjustment is to be performed by means of the SV adjusting cam screw Fig 33 when the cam has reached the high flame position 14 The atomising air flow rate and pressure can be adjusted with the VA screw Fig 30 Too low a pressure produces poor atomising with smoke in the flue A too high a pressure produces instability and the flame can be cut off A too low pressure produces poor ...

Page 32: ...urner off then start it up again 23 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 24 drive the burner to low flame if necessary adjust the low flame size output by inserting a screwdriver on the slot F to move the BF cam 25 The low flame position must never match the ignition position that is why...

Page 33: ...lve for gun cleaning After the flame is off an automatic system provides the compressed air to clean the gun Fig 34 CMF CMF 0 stop at the current position CMF 1 high flame operation CMF 2 low flame operation CMF 3 automatic operation EVL ...

Page 34: ...DOWN TAKES PLACE CALL THE TECHNICAL SERVICE WITHOUT TRYING TO RESET FURTHER WARNING DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR COUPLING FLANGE CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT OPERATION z Turn the burner on by means of its main switch S1 see next pictures z Check that the burner is not locked LED E lights up if so reset it by pressing the...

Page 35: ...tors safety thermostat lamp M Plant enabling thermostat lamp MD Siemens output controller on fully modulating versions only N Oil pump in operation O Pilot solenoid valve lamp PH Heavy oil operation lamp Q Pilot gas pressure switch R Reset pushbutton for control box S Pre heater in operation lamp S1 Main switch S2 Pump operation selector MAN AUTO S3 Fuel operation selector S4 Auxiliary resistors s...

Page 36: ...Where the burner is used intensively it is recommended to replace the nozzle as a preventive measure at the begin of the opera ting season z Clean and grease joints and rotating parts IMPORTANT Remove the combustion head before checking the ignition electrode z Remove and clean the compressed air regulator A in Fig 35 z Remove and clean the oil regulator B in Fig 35 Fig 35 Maintenance of the gas g...

Page 37: ...combustion head z Remove the cover H z Slide the photoresistor out of its housing z Unscrew the flexible hoses from the gun burner side and remove the whole assembly as shown on Fig 38 Fig 38 Fig 36 threaded body Fig 37 1 2 4 3 filter slots ...

Page 38: ...e being careful to observe the measures in mm shown on next pictures and reassemble following the reversed procedure 5 To adjust the nozzle position unscrew the fixing screw move the nozzle backwards or forwards then fix the screw on the new position In the example from 1 to 2 see picture below Fig 37 C 0 mm factory set to change the nozzle position please contact the Technical Dpt PBY90 B 0 8mm P...

Page 39: ...sposal follow the instructions according to the laws in force in your country about the Disposal of materials TROUBLESHOOTING CAUSES TROUBLES DOES NOT START UP CONTINUES PRE PURGUE IBURNER STARTS UP WITH COLD OIL DOES NOT IGNITE AND GOES TO SHUT DOWN DOES NOT DRIVE TO HIGH FLAME GOES TO SHUT DOWN DURING OPERATION GOES OFF AND REPEATS THE CYCLE DURING OPERATION MAIN SWITCH OFF z LINE FUSES BLOWN z ...

Page 40: ...PRESSURE SWITCH 18 7 RESISTOR 14 1 GASKET 19 1 NOZZLE 14 2 GASKET 19 2 NOZZLE HOLDER 14 3 OIL SOLENOID VALVE 19 3 COMBUSTION HEAD 14 4 COMPRESSED AIR SOLENOID VALVE 19 4 IGNITION CABLE 14 5 PNEUMATIC OIL VALVE 19 5 1 pilot ELECTRODE 14 6 PRESSURE GAUGE 19 5 2 PILOT 14 7 OIL PRESSURE GOVERNOR 20 1 MOTOR MOUNTING FLANGE 14 8 COMPRESSED AIR PRESSURE GOVERNOR 20 2 FAN WHEEL 14 9 OIL MANIFOLD 20 3 MOTO...

Page 41: ...C I B UNIGAS M03993CH 41 ...

Page 42: ...ERNOR WITH FILTER 28 2 FAN WHEEL 13 SCREW 24 1 AIR PRESSURE SWITCH 28 3 MOTOR 14 INSPECTION GLASS 24 2 OIL SOLENOID VALVE 29 1 BOARD 15 PHOTORESISTOR 24 3 ONE WAY VALVE 29 2 COVER 16 PUMP 25 1 FAIRLEAD 29 3 1 LIGHT 17 AIR PRESSURE SWITCH PIPE 25 2 FAIRLEAD 29 3 2 LIGHT 18 STANDARD BLAST TUBE 26 1 NET 29 3 3 LOCK OUT RESET BUTTON 19 AIR PRESSURE SWITCH 26 2 AIR INTAKE DAMPER 29 3 4 PROTECTION 20 1 ...

Page 43: ...C I B UNIGAS M03993CH 43 ...

Page 44: ...14 2440014 2440014 2440014 2440014 2440014 ACTUATOR mod SIEMENS SQL 2480007 2480007 2480007 2480007 2480007 2480007 2480007 ACTUATOR mod BERGER STM30 2480090 2480090 2480090 2480090 2480090 2480090 2480090 ACTUATOR mod SIEMENS SQM40 24800A5 24800A5 24800A5 24800A5 24800A5 24800A5 24800A5 PHOTORESISTOR SIEMENS QRB 2510008 2510008 2510008 2510008 2510008 2510008 2510008 RESISTOR THERMOSTATTR TCN TCI...

Page 45: ...iliary switch v in the actuator t5 Interval On completion of t5 terminal 20 receives power At the same time control outputs 9 to 11 and input 8 are galvanically separated from the LAL s control section LAL is now protected against reverse voltages from the load control circuit With the release of LR at terminal 20 the startup sequence of the LAL ends After a few idle steps steps with no contact po...

Page 46: ...artup sequence Specifications Power supply AC 230 V 15 10 for LAL2 on request AC 100 V 15 AC 110 V 10 Frequency 50 Hz 6 60 Hz 6 Absorption AC 3 5 VA Mounting position optional Protection IP 40 Perm input current at terminal 1 AC 5 A max 20 A peak Perm current rating of control terminals 3 6 7 9 11 15 20 4 A max 20 A peak Internal fuse T6 3H250V according to IEC 127 External fuse max 10 A Weight De...

Page 47: ...t terminal 7 start delay time for M2 t8 Duration of startup sequence excluding t11 and t12 t10 Interval from startup to the beginning of the air pressure check t11 Air damper running time to the OPEN position t12 Air damper running time to the low fire position MIN t13 Permissible afterburn time t16 Interval to the OPEN command for the air damper t20 For self shutdown of the sequence switch A t11 ...

Page 48: ...a subject to change without notice Errors and omissions excepted 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 ...

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