Unigas PG60 Manual Of Installation - Use - Maintenance Download

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MANUAL OF INSTALLATION - USE - MAINTENANCE

PG60
PG70
PG81

M039191CA Rel: 0.1 09/2011

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Progressive / Fully-modulating

Light oil burners

Summary of Contents for PG60

Page 1: ...MANUAL OF INSTALLATION USE MAINTENANCE PG60 PG70 PG81 M039191CA Rel 0 1 09 2011 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive Fully modulating Light oil burners ...

Page 2: ...motor rotation 16 ADJUSTMENTS 17 Adjustments brief description 17 Adjustment procedure 17 Adjustment by the Berger STM30 actuator 18 Adjustment by the Siemens SQL33 servocontrol 21 Fully modulating burners 25 Calibration of air pressure switch when provided 25 PART II OPERATION 26 OPERATION 26 Burner control panel 27 PART III MAINTENANCE 28 ROUTINE MAINTENANCE 28 Light oil filter maintenance 28 Re...

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: ...n of the combustion head determines the burner output The air comburent and fuel light oil are for ced into the combustion chamber as to let the flame light up How to interpret the burner s Performance curve To check if the burner is suitable for the boiler to which it must be installled the following parameters are needed z furnace input in kW or kcal h kW kcal h 860 z backpressure data are avail...

Page 6: ...bient temperature at 15 C BURNERS PG60 PG70 PG81 Output min max kW 151 791 291 1047 264 1900 Light oil rate min max kg h 13 67 25 88 22 160 Fuel Light oil Viscosity 1 3 E 20 C Power supply 400V 3N 50Hz Electric motor kW 1 1 2 2 3 Total power consumption kW 1 6 2 7 3 5 Approx weight kg 55 85 85 Operation Progressive Fully modulating Operating temperature C 10 50 Storage temperature C 20 60 Working ...

Page 7: ...B BL C CL D E F G K H P M N PG60 760 244 442 1004 1202 270 300 570 153 240 182 190 M10 269 PG70 725 310 460 1035 1185 355 420 775 198 300 228 233 M10 330 PG81 825 340 490 1165 1315 355 420 775 234 300 264 233 M10 330 boiler drilling plate P P H N M ...

Page 8: ...according to the procedure described on paragraph Handling the burner 3 place the 4 stud bolts 5 on the hole of the boiler s door according to the burner s drilling plate 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...

Page 9: ... in plants where gravity or ring feed systems are provided install an automatic interception device see n 4 Fig 2 Gravity circuit Fig 3 Ring circuit Fig 4 Suction circuit Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve ...

Page 10: ...and fuel passing through the pump Burners are factory set for double pipe systems They can be suited for single pipe system recommended in the case of gravity feed as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rota tion referring to the pump shaft Caution Changing the direction of rotation all connections on top and side are reversed Fig ...

Page 11: ... for a considerable length of time for example when there is a long suction line to bleed To avoid damages inject some lubrication oil into the vacuum inlet z Care must 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 the...

Page 12: ...PumpSuntec AJ6 Viscosity 2 8 75 cSt Oil temperature 60 C max Inlet maximum pressure 2 bar Inlet minimum pressure 0 45 bar to avoid gasing Rated speed 3600 rpm max Suntec J6 J7 Oil viscosity 2 8 200 cSt Oil temperature 0 90 C Min suction pressure 0 45 barto avoid gasing Max suction pressure 1 5 bar Max return pressure 1 5 bar Rotation speed 3600 rpm max Oil viscosity 2 5 200 cSt Oil temperature 10 ...

Page 13: ...lexible 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 Suntec TA Oil viscosity 4 450 cSt Oil temperature 0 140 C Min suction pressure 0 45 barto avoid gasing Max suction pressure 5 bar Max return pressure 5 bar Rotation speed 3600 rpm max Danfoss KSM Oil viscosity 2 5 450 cSt...

Page 14: ...chamber The part of fuel that is not burnt goes back to the tank through the return circuit The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see pag 22 Fig 6 Stand by Fig 7 Prepurge Fig 8 Low flame Fig 9 High flame Key 1 Light oil pump 2 Light oil solenoid valve 3 Nozzle 4 Servocontrol 5 Adjusting cam 6 pressure gauge 7 Pressure regulator 8 O...

Page 15: ...ow rate BERGONZO nozzle is provided set the return pressure at 11bar supply at 20bar on the delivery to get a 220kg h flow rate If the return pressure needed is 5bar instead act on the V adjusting screw on the pressure gover nor see chapter on page 18 The flow rate will then be about 95kg h see the example showed on the Bergonzo diagram Fig 10 NOZZLE NOZZLE SUPPLY PRESSURE bar HIGH FLAME RETURN PR...

Page 16: ...ase 230 V supply it is necessary to modify the electrical connections inside the terminal box of the electric motor and replace the thermal cutout relay 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 ADE QUATE FOR CONNECTION TO THE MAINS STRICTLY OBSERVE THE DATA PLATE WARNI...

Page 17: ...the chimney Adjustment procedure To change the burner setting during the testing in the plant follow the next procedure according to the actuator model provided mod Berger STM30 or mod Siemens SQL z PG60 Berger STA12 z PG70 PG81 Berger STM30 Siemens SQL33 ATTENTION before starting the burner up be sure that the manual cutoff valves are open Be sure that the mains switch is closed Before starting u...

Page 18: ...safely the high flame stage 4 Turn the burner on by means of its main switch A if the burner locks LED B on in the control panel press the RESET button C on the control panel see next picture see chapter OPERATION on page 26 5 be sure that the actuator cam for the Startup enabling signal when used is 5 more than the ignition cam 6 start the burner up by means of the thermostat series and wait unti...

Page 19: ...Fig 15 Fig 16 and act on on the pu mp adjusting screw VR see Fig 14 as to get the nozzle pressure at 20bar Bergonzo nozzles see diagram on Fig 10 Fig 15 Light oil manifold PG60 Fig 16 Combustion head with light oil gun PG70 PG81 STA12 Actuator cams ST2 High flame ST0 Stand by and Ignition ST1 Low flame MV Startup signal STM30 Actuator cams I High flame II Stand by and Ignition III Low flame V Star...

Page 20: ...change the position of the air damper rods 12 The burner is factory set with the head in its MAX position maximum output PG60 To let the burner operate at a lower output turn clockwise the VRT screw and move progressively the combustion head back towards the MIN position PG70 PG81 To let the burner operate at a lower output loose the VB screw and move progressively the combustion head back towards...

Page 21: ...at the previous step go on this way as to reach the desired low flame point 18 The low flame position must never match the ignition position that is why cam III must be set 20 30 more than the ignition posi tion Turn the burner off then start it up again If the adjustment is not correct repeat the previous steps Adjustment by the Siemens SQL33 servocontrol 1 Open the electrical panel to check the ...

Page 22: ...rminal no 6 or by setting MAN on the RWF40 modulator or by setting 0 by means of the CMF switch only for fully modulating burners 8 set the actuator on the manual mode MAN by means of the MAN AUTO switch see next pictures 9 manually drive the adjusting cam SV to the high flame position and set the actuator to the AUTO mode by the related switch see picture to lock the adjusting cam 10 the nozzle s...

Page 23: ...21 when the cam has reached the high flame position 12 To adjust the air flow rate in the high flame stage loose the RA nut and screw VRA as to get the desired air flow rate moving the rod TR towards the air damper shaft the air damper opens and consequently the air flow rate increases moving it far from the shaft the air damper closes and the air flow rate decreases Note once the procedure is per...

Page 24: ... turn the adjusting cam SV and set again the actuator to the AUTO mode to lock the adjusting cam 16 act on the V screw that mathces the bearings referring to the adjusting cam position 17 to adjust the next screw set again the actuator mode to MAN turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw adjust it and go on this way to adjust all the scre...

Page 25: ...ow 1 Keep pushed for 5 seconds the EXIT button on the modulator for further details see the burner modulator manual when the LED with the hand symbol lights up press the arrow button driving the actuator to the maximum opening position progressively 2 stop its stroke when it meets each screw V adjust the air rate by adjusting the V screw that matches each bearing 3 Push the EXIT button to quit the...

Page 26: ... THE RESET PUSHBUTTON IF A SECOND SHUT 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 1 Set to the ON position the switch A on the control panel of the burner 2 Check the control box is not in the lock...

Page 27: ...lling lamp for light oil solenoid valve opening E Thermal cutout intervention signalling lamp F High flame operation signalling lamp G Low flame operation signalling lamp H Ignition transformer operation signalling lamp P Siemens modulator Q Manual operation mode switch PG60 Fig 22 PG70 PG81 Fig 23 B C A D E H G F P B P C Q A D E H G F P ...

Page 28: ...their ceramic insulators clean adjust and replace if necessary z remove and clean the oil nozzles IMPORTANT do not clean the nozzles using metallic or sharp utensils use only solvents or steam at the end of maintenance operations refit the burner turn it on and check the combustion If in doubt replace the defec tive nozzle s In case of intensive use of the burner the nozzles must be replaced at th...

Page 29: ...s of a vacuum cleaner to scrape off the scale use a metallic brush Note to replace the combustion head reverse the procedure described above Removing the oil gun PG70 PG81 Once the combustion head is removed as described before remove the oil gun as foloows 1 unscrew the connectors from the 2 oil pipes E in figure using 2 spanners to avoid loosening the connections attached to the distri butor blo...

Page 30: ...24 Cleaning and replacing the detection photoresistor To clean replace the photoresistor proceed as follows 1 disconnect the system from the electrical power supply 2 shut off the fuel supply 3 remove the photoresistor from its slot 4 clean it using a clean cloth do not use any cleansing spray 5 if necessary replace it 6 insert the photoresistor into its slot ATTENTION avoid the ignition electrode...

Page 31: ...rrent intensity with flame 45µA Maximum current intensity without flame 5 5µA Maximum possible current intensit with flamey 45µA 100µA 100µA THE BURNER DOESN T START THE BURNER REPEATS PRE PURGE NOISY FUEL PUMP THE BURNER DOESN T START AND STOPS THE BURNER STARTS AND STOPS THE BURNER DOESN T SWITCH TO HIGH FLAME THE BURNER STOPS DURING OPERATION THE BURNER STOPS AND REPEATS THE CYCLE DURING OPE RA...

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Page 50: ... 2340003 2 FLEXIBLE HOSES L 275 2340091 2340091 1 FLEXIBLE HOSES L 335 3 8 2340087 2340087 1 ADJUSTING CAM FOIL 2440013 2440013 2440013 2 SERVOCONTROL mod SIEMENS 2480009 2480022 2480022 1 SERVOCONTROL mod BERGER 2480053 2480090 2480090 1 PHOTORESISTOR mod SIEMENS QRB 2510003 2510003 2510003 1 PRESSURE GOVERNOR 2570054 2570054 2570054 1 PUMP mod SUNTEC 2590103 2590109 2590118 1 PUMP mod DANFOSS 25...

Page 51: ...g operation the burner will initiate lo ck out T he rep etition count is re started each time controlled switching on by R W SB takes place Operation Lock out reset button EK is the key operatin g element for resetting the burner control and for activating deactivating t he diagnostic functions The multicolour LED is the key indicating element for bo th visual diagnosis and interface diagnosis Red...

Page 52: ...h Z Ignition transformer t4 Interval from flame signal to release BV2 TSA Ignition safety time tw Waiting time for oil pre heating B Time of flame establishment C Operating position D Controlled shut down by R µC1 Microcontroller 1 µC2 Microcontroller 2 General unit data Mains voltage AC 230 V 10 15 AC 110 V 10 15 Mains frequency 50 60 Hz 6 External primary fuse Si 5 A slow Power consumption 12 VA...

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