INDUSTRIAL BURNER MODEL

URB 4

M09973CA Rev. 00 12/00

CLIENT:
DESCON ENGINEERING
PROJECT 00P270

Technical Documentation CIB Unigas - Campodarsego (PD - Italy)

NOTICES
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 SECTION OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
1)

2)

GENERAL INTRODUCTION

The equipment must be installed in compliance with the regulations in force, following the manufacturers instructions, by
qualified personnel.
Qualified personnel means those having technical knowledge
in the field of components for civil or industrial heating
systems, sanitary hot water generation and particularly service centres authorised by the manufacturer.
Improper installation may cause injury to people and animals,
or damage to property, for which the manufacturer cannot be
held liable.
* 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 devices, plastic bags, foamed polystyrene, etc), should not be left
within the reach of children, as they may prove harmful.
* 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.
* Make sure that inlet or exhaust grilles are unobstructed.
* 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 units safety.
To ensure equipment efficiency and proper operation, it is
essential that maintenance operations are performed by qualified personnel at regular intervals, following the manufacturers instructions.
* When a decision is made to discontinue the use of the equipment, those parts likely to constitute sources of danger shall
be made harmless.
* 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.
* For all the units that have been modified or have options fitted then original accessory equipment only shall be used.
* 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.

SPECIAL INSTRUCTIONS FOR BURNERS

*The burner should be installed in a suitable room, with ventilation openings complying with the requirements of the regulations in force, and sufficient for good combustion.
* Only burners designed according to the regulations in force
should be used.
* This burner should be employed exclusively for the use for
which it was designed.
* Before connecting the burner, make sure that the unit rating
is the same as delivery mains (electricity, gas oil, or other
fuel).
*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) 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
* Make sure that the burner has, on installation, been firmly
secured to the appliance, so that the flame is generated inside
the appliance firebox.
* Before the burner is started and, thereafter, at least once a
year, have qualified personnel perform the following operations:
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.
* In case of repeated burner shut-downs, do not continue resetting the unit manually. Contact qualified personnel to take
care of such defects.
* The unit shall be operated and serviced by qualified personnel only, in compliance with the regulations in force.

NOTICES

3b) FIRING WITH GAS, GASOIL OR OTHER FUELS

3) GENERAL INSTRUCTIONS DEPENDING ON FUEL

USED
3a) ELECTRICAL CONNECTION
* For safety reasons the unit must be efficiently earthed and
installed as required by current safety regulations.
* It is vital that all saftey requirements are met. In case of any
doubt, ask for an accurate inspection of electrics by qualified
personnel, since the manufacturer cannot be held liable for
damages that may be caused by failure to correctly earth the
equipment.
* Qualified personnel must inspect the system to make sure
that it is adequate to take the maximum power used by the
equipment shown on the equipment rating plate. In particular,
make sure that the system cable cross section is adequate for
the power absorbed by the unit.
* No adaptors, multiple outlet sockets and/or extension cables
are permitted to connect the unit to the electric mains.
An omnipolar switch shall be provided for connection to
mains, as required by the current safety regulations.
The use of any power-operated component implies
observance of a few basic rules, for example:
- do not touch the unit with wet or damp parts of the body and/
or with bare feet;
- do not pull electric cables;
- do not leave the equipment exposed to weather (rain, sun,
etc.) unless expressly required to do so;
- do not allow children or inexperienced persons to use equipment;
* The unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact
qualified personnel to replace.
* When the unit is out of use for some time the electric switch
supplying all the power-driven components in the system (i.e.
pumps, burner, etc.) should be switched off.

GENERAL
* The burner shall be installed by qualified personnel and in
compliance with regulations and provisions in force; wrong
installation can cause injuries to people and animals, or
damage to property, for which the manufacturer cannot be
held liable.
* Before installation, it is recommended that all the fuel supply
system pipes be carefully cleaned inside, to remove foreign
matter that might impair the burner operation.
* Before the burner is commissioned, qualified personnel
should inspect the following:
a) the fuel supply system, for proper sealing;
b) the fuel flow rate, to make sure that it has been set based
on the firing rate required of the burner;
c) the burner firing system, to make sure that it is supplied for
the designed fuel type;
d) the fuel supply pressure, to make sure that it is included in
the range shown on the rating plate;
e) the fuel supply system, to make sure that the system
dimensions are adequate to the burner firing rate, and that the
system is equipped with all the safety and control devices
required by the regulations in force.
* When the burner is to remain idle for some time, the fuel
supply tap or taps should be closed.
SPECIAL INSTRUCTIONS FOR USING GAS
* Have qualified personnel inspect the installation to ensure
that:
a) the gas delivery line and train are in compliance with the
regulations and provisions in force;
b) all gas connections are tight;
c) the boiler room ventilation openings are such that they
ensure the air supply flow required by the current regulations,
and in any case are sufficient for proper combustion.
* Do not use gas pipes to earth electrical equipment.
* Never leave the burner connected when not in use. Always
shut the gas valve off.
* In case of prolonged absence of the user, the main gas delivery valve to the burner should be shut off.
Precautions if you can smell gas
a) do not operate electric switches, the telephone, or any
other item likely to generate sparks;
b) immediately open doors and windows to create an air flow
to purge the room;
c) close the gas valves;
d) contact qualified personnel.
* Do not obstruct the ventilation openings of the room where
gas appliances are installed, to avoid dangerous conditions
such as the development of toxic or explosive mixtures.

NOTICES

CONTENTS
WINDBOX AND REGISTER ASSEMBLY ................................................................................................................. 7
INSTALLATION ......................................................................................................................................................... 7
ADJUSTMENT OF AIR PRESSURE SWITCH .......................................................................................................... 7
ELECTRIC CONTROL BOX INSTALLATION .......................................................................................................... 8
REFRACTORY TILE .................................................................................................................................................. 10
PILOT BURNER ........................................................................................................................................................ 11
ADJUSTMENTS ........................................................................................................................................................ 11
ADJUSTMENT OF GAS PRESSURE GOVERNOR ................................................................................................. 11
ADJUSTMENT OF GAS PRESSURE SWITCH ........................................................................................................ 11
MAIN GAS TRAIN ..................................................................................................................................................... 12
ADJUSTMENTS ........................................................................................................................................................ 12
OIL PUMPING UNIT .................................................................................................................................................. 13
ADJUSTMENTS ........................................................................................................................................................ 13
ADJUSTMENT OF OIL PRESSURE SAFETY VALVE ............................................................................................. 13
MAINTENANCE ......................................................................................................................................................... 13
OIL FILTER CLEANING ............................................................................................................................................ 13
OIL HEATING UNIT ................................................................................................................................................... 14
ADJUSTMENTS ........................................................................................................................................................ 15
ADJUSTMENT OF OIL TEMPERATURE REGULATOR .......................................................................................... 15
ADJUSTMENT OF OIL TEMPERATURE SWITCHES ............................................................................................. 15
MAINTENANCE ......................................................................................................................................................... 15
STEAM FILTER CLEANING ..................................................................................................................................... 15
OIL HANDLING UNIT ................................................................................................................................................ 16
ADJUSTMENTS ........................................................................................................................................................ 17
OIL PRESSURE SETTING ........................................................................................................................................ 17
OIL PRESSURE SWITCH SETTING (PO min.) ........................................................................................................ 17
OIL THERMOSTAT SETTING ................................................................................................................................... 17
STEAM PRESSURE SETTING ................................................................................................................................. 17
MAINTENANCE ......................................................................................................................................................... 17
STEAM FILTER CLEANING ..................................................................................................................................... 17
DIFFUSER POSITION ............................................................................................................................................... 18
NOZZLE POSITION ................................................................................................................................................... 18
BURNER FAMILIARIZATION AND INSPECTION .................................................................................................... 19
PRELIMINARY INSPECTION .................................................................................................................................... 19
SUGGESTED INSTALLATION INSPECTION CHECKLIST GENERAL .................................................................. 19
GAS FIRING .............................................................................................................................................................. 19
OIL FIRING ................................................................................................................................................................ 19
OPERATING SEQUENCE ......................................................................................................................................... 20
GAS MODE ................................................................................................................................................................ 20
OIL MODE .................................................................................................................................................................. 20
FIRING CHANGE FROM LANCE n 1 TO LANCE n 2 ........................................................................................... 20
TROUBLESHOOTING GUIDE .................................................................................................................................. 21
SPARE PART LIST .................................................................................................................................................... 25

1 GENERAL DESCRIPTION OF THE SYSTEM

The forced draft burner combines the advantages of the proven register, windbox and fan to supply 100% of combustion air in
one complete package. Combustion controls, safety controls, fuel trains with all valving prepiped and wired are an integral parts
of the burner package.
Burner mounting and installation time is minimised. Component operation is checked and tested at the factory prior to shipment.
Package systems are available for heat requirements that range from 10.000 kW to 60.000 kW.
Application
The package burner combustion systems engineered for application to package or field erected boilers and heaters. These forced draft burners can be adapted to the firing of air heaters and dryers. The high turndown efficient forced draft package burne r
can replace multiple burners on many boiler or heater conversions, resulting in improved operating efficiencies.
The package burner modular design permits utilisation of existing power plant equipment such as blowers, combustion air preheaters, boiler feedwater controls, draft controls and annunciators. On boilers with extremely wide furnaces, multiple burners
can be incorporated in a single package system. The package burner system can be utilised for both vertical and horizontal
firing.
Fuels
The forced draft package burners can be supplied for single fuels for gas or oil firing, as well as simultaneous firing of multiple
fuels.
Steam atomisation for oil firing is standard. Air atomisation is an available option.
Combustion Safety Controls
The forced draft package burners safety control system provides continuous monitoring of the firing operation. A pre-purge of
adequate air changes occurs followed by safe pilot and mainflame ignition at the minimum fire position.
Components of the safeguard system are factory assembled, wired and tested and enclosed in a suitable enclosure required for
the particular burner environment. The control cabinet assembly is factory mounted on the burners. All burner mounted
components are factory wired to the control cabinet and the complete assembly is factory tested as a unit.
Combustion Fuel-Air Controls
The standard forced draft package burners include an electrical self-contained master steam pressure controller. This controller
is in direct contact with the boiler steam pressure that is to be maintained. A change in steam pressure immediately results in a
corresponding change of fuel-air input to the burner necessary to maintain a constant steam pressure on the boiler. Standard
control mode is automatic. The burner firing rate can also be adjusted manually from a remote manual control station located
in the burner control cabinet, when so desired. The system is a single point positioning system utilising a common jackshaft
which, in turn, is directly connected to characterisable fuel control valves and forced air volume dampers.
Parallel positioning combustion control systems are also available. A common master controls a fuel controller and air controller.
These controllers operate an air volume controller and a fuel volume controller. With this system, the forced draft fan can be
located at a distance from the burner. Manual-automatic stations are provided for manual operation of the system. Program
solenoid valves are included to provide automatic operation.
Which follows is a typical burner assembly.

Fig. 1 - TYPICAL BURNER ASSEMBLY - Key

1
OIL GUN SUPPORT
2
OCTAGONAL FRONTPLATE
3
BUSH
4
REGISTER ASSEMBLY
5
WINDBOX
6
REGISTER RING
7
REFRACTORY TILE
8
PILOT BURNER

9
10
11
12
13
14
15
16

DIFFUSER CONE
GAS PORTS
REFRACTORY TILE RING
BOILER PLATE
GAS RING
SPACER SPOOL ASSEMBLY
REGISTER LOUVER
OIL GUN ASSEMBLY

2
WINDBOX AND REGISTER ASSEMBLY
The forced draft package burner windbox is constructed of heavy gauge welded steel. Burner registers are mounted in the windbox to permit easy access for maintenance.
Balanced air distribution in the windbox assures optimum mixing of fuels with turbulent air.
Insulated windboxes for use with pre-heated combustion air are available. Fuel piping trains and associated hardware are
mounted on self-supporting frames welded to the burner windbox.
The burner and combustion system presents a compact, economical and attractive assembly.
Basically two types of burner registers can be included in the package burner assembly.
2.1 INSTALLATION
The steel structure has to be put in the right position providing to avoid any damaging to the accessories installed on it, for
instance piping, pressure switches, valves, or other projecting items.
The windbox is supplied with a steel flange to be fixed to the boiler according to the delivered drawings different for each size.
The installation has to be done according to all the relevant safety rules. A good installation guarantees a long life to the burner.

2.2 ADJUSTMENT OF AIR PRESSURE SWITCH

Always follow manufacturer instructions for detailed
procedures.
Pressure switches are electric devices opening or
closing safety contacts when air pressure is too high
or too low.
The initial value must be set to 10 mbar.

ADJUSTING WHEEL

Fig. 2

3
ELECTRIC CONTROL BOX INSTALLATION
It has to be installed in order to:
! Provide a good ventilation
! Avoid any heating
! Avoid any vibrations
! Be water and dust proof
Remember to ground the steel structure!

Fig. 3 - ELECTRIC BOX

Fig. 3a - CONTROL PANEL

CONTROL PANEL - Complete Key

CLFan motor contactor - line
CMManual operation switch 1)gas 0)off 2)oil
CFMManual operation switch
CP1-2Auxiliary contacts pump motor
CR1CR9-Auxiliary relay contacts
CSFan motor contactor - star
CTFan motor contactor - triangle
FFuse
IGBMain switch with door-interblock
ILBurner auxiliary switch
IP1IP5- Magneto-thermic switch for electrical protection
IRAAuxiliary trim heater switch (for oil filter and pump)
LBIndicating light for burner lockout
LDU11LANDIS valve leakage monitor device
LFGIndicating light for gas burner mode
LFL1.xx- LANDIS flame monitor device
LFNIndicating light for oil burner mode
LLIndicating light for presence of tension on the electric box
LPN1Indicator light for oil pump1 functioning
LPN2Indicator light for oil pump2 functioning
LPV1Indicator light for fan motor on
LPV2Indicator light for fan motor off
LRAAuxiliary trim heater indicator light
LRPOil trim heater indicator light
LSIndicating light for burner STAND-BY
LSBGIndicating light for gas low pressure
LSPGIndicating light for leakage of gas valves
LTIndicating light for motor thermal lockout
LTAIndicator light for ignition transformer functioning
LTOMAX- Indicating light for high oil temperature (signal from TO max)
LTP1Indicator light for oil pump 1 thermal lockout
LTP2Indicator light for oil pump 2 thermal lockout
PRReset button for RVW20
PS1Lockout reset button LFL..
PS2Lockout reset button LDU11
PV1Fan motor on button
PV2Fan motor off button
R1R9Auxiliary relays
SPNOil pump selector 1)pump1 0)off 2)pump2

4
REFRACTORY TILE
It is necessary that the tile be installed properly. There must be adequate room for expansion and the tile must not bear the weight of the boiler front wall refractory. It is also important that the tile doesnt extend into the furnace area past the inner face of
the boiler front refractory over 50 mm. Installation drawing below provides instructions for installing the tile segments. Important
points to be considered during installation are:
! before the tile is installed, it is necessary to be sure no boiler frontwall refractory weight will be supported by the tile. It is advisable to install a refractory arch of either arch or circle brick or plastic refractory to an inside finished diameter noted on the
installation drawing as Furnace opening I.D.. This provides a good solid background for the tile and removes the boiler frontwall refractory weight from the tile.
! the space between the burner tile and the refractory throat should be filled with a plastic refractory or castable on the bottom
half of the throat to pick up the weight of the tile and should be filled with high temperature insulation on the top half to allow
for tile and frontwall refractory expansion. A good bonding mortar of high temperature and low shrink should be used to bond
the tile together.

Fig. 4

Key
1
Firebrick ring not by CIB Unigas
2
Fill bottom half of space with castable or plastic refractory
3
Fill top half of space with high temperature insulation
Rough dimensions of burner tile in mm

10

Tile Size

12

14

16

18

20

22

24

26

28

30

32

34

36

305

356

406

457

508

559

660

711

762

813

864

914

610

660

711

762

813

864

914

965

1016 1067 1118 1168 1219 1270

711

762

813

864

914

965

1016 1067 1118 1168 1219 1270 1321

5
PILOT BURNER
The burner is equipped with an electrically ignited gas pilot which can be operated with either natural or liquid petroleum gas.
It is composed by a net diffuser, an electrode for ignition, an isolator, one or two electromagnetic valves and a pressure governor.
Pilots utilise also a raw gas tube that induces raw fuel into the pilot flame that greatly increases its size for ease of main f lame
ignition.
The pilot provides sufficient flame to instantly, reliably ignite the main burner fuel, providing that pressure has to be regulated in
order to have a good flame; it means that:
! pressure has not to drop too much for not loosing the flame
! pressure has not to increase too much for avoiding flame breaking.
PILOT GAS TRAIN

Fig. 5

Key
1
2
3
4
5
6
7

Manually operated valve (3/4)

Pilot burner
Pressure gauge with manual cock (600 mbar)
Pressure switch(Dungs GW50)
Gas governor with filter(FRG/2MT with spring 140-320)
Safety gas valve for pilot (EG12L - EG12 SR)
3993706Flexible hose (flex 1/2)

5.1

ADJUSTMENTS

5.2 ADJUSTMENT OF GAS PRESSURE GOVERNOR

Always follow manufacturer instructions for detailed procedures. Each regulator must be fitted with the right spring for
it to function properly. Further, the spring position must be
adjusted to obtain the exact pressure required at the inlet of
gas valves and other controls.

Fig. 6

5.3 ADJUSTMENT OF GAS PRESSURE SWITCH

Always follow manufacturer instructions for detailed
procedures.
Pressure switches are electric devices opening or closing safety contacts when gas pressure is too high or
too low.
The initial value should be set to 80 mbar.

ADJUSTING WHEEL

Fig. 7
11

MAIN GAS TRAIN

Fig. 8
Key
1
Manually operated valve (2)
2
Main Gas Burner
3
Pressure gauge with manual cock (1 mbar)
4
Pressure switch (Dungs GW500)
5
Gas safety valve (MVD520/5 / VGG10504 + SKP20, red spring AGA23)
6
Pressure switch for tightness control (Dungs GW150)
7
Butterfly valve with servomotor (P510+SQM54)
8
Gas governor with filter (FRG/2MC 2 + spring 180-450)
9
Belllows unit (Giuliani Anello 2)
The gas flow is controlled by means of pressure downstream of the regulator and by means of butterfly position. Properly sized
nozzles are installed for getting the right gas flow rate according to furnace and gas train pressure.
6.1 ADJUSTMENTS
Fig. 9 - MINIMUM GAS PRESSURE SWITCH
Always follow manufacturer instructions for detailed procedures.
Pressure switches are electric devices opening or closing safety contacts when gas
pressure is too high or too low. Set the desired pressure by means of the adjusting
wheel W; initial value: 200 mbar.
For tuning of set point, read pressure at the outlet while burner is at maximum flow
rate, then set pressure switch at 50% of the read pressure.
Fig. 9 - MAXIMUM GAS PRESSURE SWITCH
Always follow manufacturer instructions for detailed procedures.
Pressure switches are electric devices opening or closing safety contacts when gas
pressure is too high or too low. Set the desired pressure by means of the adjusting
wheel W; initial value: 300 mbar.
For tuning of set point, read pressure at the outlet while burner is at maximum flow
rate, then set pressure switch at 130% of the read pressure.
PRESSURE SWITCH FOR TIGHTNESS CONTROL
Always follow manufacturer instructions for detailed procedures.
Pressure switches are electric devices opening or closing safety contacts when gas
pressure is too high or too low.
Set the desired pressure by means of the adjusting wheel; set the initial value to 200
mbar.
Fig. 10 - GAS FILTER CLEANING
Be sure that valve upstream of filter is closed and pressure inside filter itself is zero.
Take off filter cover after having unscrewed locking bolts.
Replace or clean filter pad. Clean filter box, too.
Fig. 11 - SAFETY GAS VALVE
To increase or decrease the gas pressure, and therefore gas flow, remove the cap
and use a screwdriver to adjust the regulator screw VR.
Turn clockwise to increase the flow, anti-clockwise to reduce it.
Connect up the gas tubing to the gas pressure nipple TP.
Leave the breather SA free.
Should the spring that is fitted not permit satisfactory regulation, ask one of our service centres for a suitable replacement.

Fig. 9

Fig. 10

SA
TP

Fig. 11

12

VR

7
OIL PUMPING UNIT
The oil pumping unit is sketched below.
The pump is identified by:
! maximum rate
! pressure
! rotation speed
The pump delivers more oil then needed by the nozzle for obtaining the firing rate. For reducing the flow rate to the nozzle, the
pressure regulating valve of the oil handling unit has to be adjusted. The balance returns to the tank.

Oil line is traced with self regulating wire

5
6

From oil ring

Fig. 12
1
Key
1
2
3
4
5
6

Manually operated valve 2

Oil filter GA 51000 2
Oil pump Suntec TA3 C + motor 1.5 kW
Check valve 2
Pressure gauge 0 6 bar
Pressure gauge 0 40 bar

7.1 ADJUSTMENTS
7.2 ADJUSTMENT OF OIL PRESSURE SAFETY VALVE
Always follow manufacturer instructions for detailed procedures.
The safety valve just after the oil outlet (sometimes it is a built-in one) avoids any mechanical breaking to the pump in case of
abnormal pressure increasing along the line. The safety pressure is adjusted by means of the screw 1 in Fig. 13: turning
clockwise the pressure increases.
OIL PUMP SUNTEC TA
Technical Data
Suction
max. 0.5 bar
Max. recommended depression to avoid formation of air bubbles 0.35 bar
Rotation speed 3600 r.p.m.
Operational viscosity 4 to 450 cSt
1
2
3
5
7
8

Pressure regulator
Pressure gauge
Vacuum gauge
Nozzle
Suction
Return

7.3 MAINTENANCE
7.4 OIL FILTER CLEANING
Make sure that the fluids to be filtered be compatible with the
filter material. Follow the arrow direction carefully.
Working maximum pressure and temperature should never
exceeded. Install the filter with the filtering pack flywheel turned
upwards. No special maintenance is required. To prevent filtering pack from getting stuck, turn the filter a few times at least
once a week.
For a complete cleaning of the filter, loosen the screws on the
cover, raise the cover and clean with light oil or kerosene.

Fig. 13

Fig. 14
13

OIL HEATING UNIT

4
Fig. 15
5
9

10

11

Water Discharge

Steam Inlet
P= 8.8 bar
6

Air Supply
P= 4.5 bar
2
1
2
3
4
5
6
7
8
9
10
11
12

14

Electric heater 18 kW
Air governor with filter (Conflow FR10)
Thermoregulator (Conflow 83R15)
Temperature switches TCN+TR+TRS
Heat exchanger (Varisco N.V. 168-1152 + suction breaker valve 1/2 RPVC015)
Manually operated valve DN15
Steam strainer DN15
Steam modulating valve (Conflow 1000 AR DN15)
Temperature probe 50 - 150C
Water discharger (Conflow SSG25 1512 1/2)
Flow indicator (Conflow IF150/2 1/2)
Electric heater

8.1 ADJUSTMENTS
8.2 ADJUSTMENT OF OIL TEMPERATURE REGULATOR
Set manually the index in fig. 14, to fix the temperature. Initial value must be set to 120C.
See also the addendum for details.

Key
1 Setting knob
2
Set temperature
3
Actual temperature
4
Air input pressure
5
Air output pressure
6
Graduated scale

2
3

Fig. 16
Fig. 17
8.3 ADJUSTMENT OF OIL TEMPERATURE SWITCHES
Remove the cover C and set the thermostats as follows:
TR 120 C
TRS 190 C
TCN 80 C

8.4 MAINTENANCE
8.5 STEAM FILTER CLEANING
! Be sure the pipeline is not under pressure; untight
the screws B;
! remove the cap C and slip off the filtering element F
for an accurate cleaning.
Before refitting the cap be sure the gasket is not damaged and replace it if necessary.

Fig. 18
B

F
C
B

15

Key
1
2
2.1
3
4
5
6
7
7.1
8
9
9.1
10

Oil Governor (Carraro UBAN AS1/130 1/2

Pressure gauge 16 bar
Pressure gauge 6 bar
Pressure switch (Danfoss RT1)
Temperature switch
Temperature switch
Thermometer 200 C
Metering valve (Hauck S3-11
SQM54)
Metering valve (Hauck S3-13 hand operated)
Air operated NC valve (Asco E29A384 1/2 + pilot Camozzi 3/2 1/8)
Manually operated valve 1/2
Manually operated valve DN15

10.1
11
12
13
14
15
16
17
8)
18
19
20
21
22

16

Water discharger (Conflow SSG25 1512 1/2)

Flow indicator (Conflow IF150/2 1/2)
Oil flow totaliser (Isoil ARD 15 1/2)
Needle manual valve 1/2
Oil Glycoil separator

Check valve 1/2

Check valve (Conflow RPX DN15)
Flexible hose 1/2 Lenght= 1m
Steam stainer (Conflow FY16 DN15)
Steam differential pressure regulator (Carraro UBAN V/D2/AF2/130)
Main lance (or spare lance altenatively)
Spare lance (or main lance alternatively)
Air operated N.O. valve (ASCO E290 A387 1/2+pilot Camozzi 3/2 1/
9
OIL HANDLING UNIT
The oil handling unit is sketched below.
Fig. 19

9.1

ADJUSTMENTS
S

9.2 OIL PRESSURE SETTING

Adjust the oil pressure by means of the screw S, placed under the
cap C. Turn clockwise to increase the pressure or counterclockwise
to decrease it.

Fig. 20
9.3 OIL PRESSURE SWITCH SETTING (PO min.)
Adjust the pressure range by means of the knob A, reading the
scale B. Set the initial pressure to 1 bar.

A
B

Fig. 21

9.4 OIL THERMOSTAT SETTING

Set the initial value in the oil thermostat TCI, to 90 C

Fig. 22
TCI

9.5 STEAM PRESSURE SETTING

To set the steam pressure regulator:
turn the screw S to adjust the differential pressure, turning clockwise
to increase and anticlockwise to decrease.
Key
S
Adjusting screw
OUT Steam outlet
IN
Steam inlet

10 MAINTENANCE
10.1 STEAM FILTER CLEANING
Please refer to page 15

IN

OUT

Fig. 23
17

11 DIFFUSER POSITION
The position of the diffuser inside the refractory tile can be adjusted while the burner is running. The locking screws have to be
unscrewed and the whole lance moved back or forward.
The initial position is at the beginning of the cone of the refractory tile. If the fuel wets the tile, move the diffuser forward.

LOCKING SCREW

Fig. 24

REFRACTORY CONE BEGINNING

REFRACTORY CONE END

12 NOZZLE POSITION
The position of the oil tip respect to the diffuser can be adjusted while the burner is running unscrewing the bolt highlighted in the
sketch and moving the oil-steam manifold back or forward.
For getting the best position, set the initial value of A equal to zero. It means that tip holes are aligned with the smallestbase of
the diffuser cone.
Then, move the tip ahead looking at the flame colour. The best position is when the flame is the brightest without wetting the diffuser itself. Anyway, look always at the flue gas analysis.

LOCKING BOLT

Fig. 25

18

13 BURNER FAMILIARIZATION AND INSPECTION

13.1 PRELIMINARY INSPECTION
The burner should be visually checked for damage and loose components as these conditions can occur during shipment,
through improper handling, by tempering, or through improper care storage at the job site.
Check for:
! Obvious damage to housing, air inlet, and components mounted thereon
! Tightness of fasteners, tube fittings, plugs, etc
! Tightness of electrical connections and terminals.
! Tightness of adjustment mechanism such as ball-joint swivel connectors and control arms.
! Accumulations of oil, dust, dirt, water, or other foreign matter on, in, or near the burner.
13.2 SUGGESTED INSTALLATION INSPECTION CHECKLIST GENERAL
! Is burner installed in accordance with applicable installation drawings?
! Is the refractory tile completely dry, cured and ready for firing at full boiler input?
! Has the proper electrical voltage been connected to the burner control box as shown on the burner material list?
! Has the burner wiring been checked for completeness and accuracy?
! Have 3-phase motors been properly wired and checked for correct rotation?
! Are the boiler mounted limit controls such as low water cutoffs, high limit controls, operating controls, modulating controls,
etc., properly installed and wired?
! Are the boiler controls the right type and range for the installation?
! Is the boiler water supply, including feed pumps, properly connected and is the boiler filled with water?
! Is sufficient load connected to the boiler so that it can be fired continuously at full rating?
! If boiler load is not connected, can steam be wasted so that boiler can be fired continuously at full rating without endangering
personnel or equipment?
! If the installation is a hot water boiler, have the circulating pumps been completely installed, wired, and tested to assure proper operation so that the burner can be fired continuously at full rating?
! For new boiler installations, has the boiler been boiled out in accordance with the boiler manufacturers instructions?
! Have the boiler breaching connections to the stack been completed and are they open and unobstructed?
! Is draft control equipment required and, if so, installed?
! Have adequate provisions for combustion air been installed?
! Is all specified auxiliary equipment mounted and wired? This may include outdoor temperature controls, oil flow switches,
space thermostats, water flow switches, motorized combustion air louvers, etc
13.3 GAS FIRING
! Are all gas train components installed and have they been properly selected, sized and assembled?
! Have properly sized vent lines been installed on all gas train components which require venting? This includes such items as
pressure regulators, normally open vent valves, diaphragm valves, low and high gas pressure switches, etc
! Have gas train piping and components been tested and proven gas tight?
! Have the gas line been purged?
Is the proper gas pressure available at the inlet to the controls which meets the requirement shown on the burner material list?
13.4 OIL FIRING
! Is the oil tank installed and filled with the proper type and grade of fuel oil as required by the burner material list?
! Is the proper oil pressure, temperature and viscosity available at the inlet to the controls which meets the requirements
shown on the burner material list and/or oil system sheet?
! Have oil supply and return lines been properly sized to meet the maximum pumping capacity of the pump and has the system
been purged and proven leak proof?

19

14 OPERATING SEQUENCE
14.1 GAS MODE
! The draught fan motor start after a call for heating by the operating control and the pre purge cycle starts.
! If the minimum gas pressure switch and the air pressure switch are in the closed position, the cycle continues.
! The air louver is in the closed (low fire) position.
! At the end of the pre-purge, the gas pilot ignition transformer is energised, the pilot gas solenoid valves open.
! Main gas valves open; the burner ignites at low fire rate.
! The flame detector proves the flame.
! The gas pilot solenoid valves are shut off and the burner runs only with the main gas train.
! After this, the modulating motor is driven by the power controller according to the heat release request in order to match the
boiler load.
! Gas butterfly valve and air louver are driven according to the set curves of the controller or according to the mechanical devices linking the two components.
14.2 OIL MODE
! The draught fan motor start after a call for heating by the operating control.
! The oil is circulated by the pump as soon as the oil temperature switch (TCN) is turned on.
! Then the pre purge cycle starts.
! The oil is vented to the return line passing through the metering valve.
! When the oil temperature reaches the set point (TCI), the cycle continues providing the minimum oil pressure switch and the
air pressure switch are in the closed position.
! The air louver is in the closed (low fire) position
! At the end of the pre-purge, the gas pilot ignition transformer is energised, the pilot gas solenoid valves open.
! Main oil and steam (or air) valves open, oil return line is closed and the burner ignites at low fire rate.
! The flame detector proves the flame.
! The gas pilot solenoid valves are shut off and the burner runs with oil only.
! After this, the modulating motor is driven by the power controller according to the heat release request in order to match the
boiler load.
! Oil metering valve and air louver are driven according to the set curves of the controller or according to the mechanical
devces linking the two components
14.3 FIRING CHANGE FROM LANCE n 1 TO LANCE n 2
If, while oil firing, it is requested to change the operating lance from lance n 1 to lance n 2, follow these instructions.
! set the burner output to the minimum firing position operating on the appropriate selector of the remote control panel.
! Check lance n 2. It must be in the same position of the firing lance (n 1) respect to the diffuser cone
! Lance n 2: connect the flexible hoses either of the oil and of the air/steam.
! Lance n 2: open the air/steam valve.
! Lance n 2: open the manual globe oil valve
! Move the knob acting on item #7.1 of the oil handling unit following the arrows. Put the knob at its end position (it means full
opening of lance 2 and closing position for lance 1). When lance n 1 is operating, label "1" is visible, while, when lance n 2
is operating, label "2" is visible.
! Lance 1: close the manual globe oil valve and, later on, close the air/steam valve.
If the oil lance should be removed while the burner is in operation, close the lance seat by means of a steel plate.

20

15 TROUBLESHOOTING GUIDE
GAS BURNERS
THE BURNER DOESN'T LIGHT
No electric power supply
Wait for electric power supply is back
Main switch open
Close the switch
Thermostats open
Check set points and thermostat connections
Bad thermostat set point or broken thermostat
Set or replace the thermostat
No gas pressure
Restore gas pressure
Safety devices (manually operated safety thermostat or pressure Restore safety devices; wait that boiler reaches its temperature
Broken fuses
Replace fuses. Check Ampere absorption
Fan thermal contacts open (only three phases)
Reset contacts and check ampere absorption
Burner control locked out
Reset and check its functionality
Burner control damaged
Replace burner control
GAS LEAKAGE: BURNER LOCKS OUT (NO FLAME)
Gas flow too low
Increase the gas flow
Check gas filter cleanness
Check butterfly valve opening when burner is starting (only Hi-Low
Ignition electrodes discharge to ground because dirty or broken Clean or replace electrodes
Bad electrodes setting
Check electrodes position referring to instruction manual
Electrical ignition cables damaged
Replace cables
Bad position of cables in the ignition transformer or into the
Improve the installation
Ignition transformer damaged
Replace the transformer
BURNER LOCKS OUT WITH FLAME PRESENCE
Bad flame detector set
Flame detector damaged

Replace or adjust flame detector

Bad cables of flame detector
Check cables
Burner control damaged
Replace burner control
Phase and neutral inverted
Adjust connections
Ground missing or damaged
Check ground continuity
Voltage on neutral
Take off tension on neutral (if necessary install the circuit RC466
Too small flame (due to not much gas)
Adjust gas flow
Check gas filter cleanness
Too much combustion air
Adjust air flow rate
BURNER CONTINUES TO PERFORM THE PRE-PURGE
Burner control damaged
Replace burner control
Air servomotor damaged
Replace servomotor
BURNER CONTINUES TO PERFORM ALL ITS FEATURES WITHOUT IGNITING THE BURNER
Air pressure switch damaged or bad links
Check air pressure switch functions and links
Burner control damaged
Replace burner control
BURNER LOCKS OUT WITHOUT ANY GAS FLOW
Check tension on valves; if necessary replace valve or the burner
Gas valves don't open
Check if the gas pressure is so high that the valve cannot open
Gas valves completely closed
Open valves
Pressure governor too closed
Adjust the pressure governor
Butterfly valve too closed
Open the butterfly valve
Maximum pressure switch (if installed ) open.
Check connection and functionality
Air pressure switch doesn't close the NO contact
Check connections
Check pressure switch functionality
BURNER LOCKS OUT AND THE BURNER CONTROL WINDOW SHOWS A P (LANDIS & STAEFA ONLY)
Air pressure switch damaged (it keeps the stand-by position) or Check air pressure switch functionality
Reset air pressure switch
Air pressure switch connections wrong
Check connections
Air fan damaged
Replace motor
No power supply
Reset power supply
Air damper too closed
Adjust air damper position
BURNER LOCKS OUT WHILE NORMAL RUNNING
Flame detector circuit interrupted
Check wiring
Check photocell
Burner control damaged
Replace burner control
Maximum gas pressure switch damaged or badly set
Reset pressure switch or replace it
WHEN STARTING, THE BURNER OPENS FOR A WHILE VALVES AND THEN REPEATS FROM THE BEGINNING THE CYCLE
Gas pressure switch badly set
Reset the pressure switch
Gas filter dirty
Clean gas filter
Gas governor too low or damaged
Reset or replace the governor

21

BURNER STANDS WHILE RUNNING WITHOUT ANY SWITCHING OF THERMOSTATS

Thermal contacts of fan motor open
Reset contacts and check values
Check current absorption
FAN MOTOR DOESN'T START
Internal motor wiring broken
Replace wiring or complete motor
Fan motor starter broken
Replace starter
Fuses broken (three phases only)
Replace fuses and check ampere absorption
BURNERS DOESN'T DO HIGH FLAME
Thermostat hi-low flame badly set or damaged
Reset or replace thermostat
Servomotor cam badly set
Reset servomotor cam
SOMETIMES THE SERVOMOTOR RUNS IN THE WRONG WAY
Servomotor capacitor damaged
Replace capacitor

22

OIL BURNERS
BURNER DOESN'T LIGHT
No electric power supply
Wait for electric power supply is back
Main switch open
Close the switch
Thermostats open
Check set points and thermostat connections
Bad thermostat set point or broken thermostat
Set or replace the thermostat
No gas pressure
Restore gas pressure
Safety devices (manually operated safety thermostat or pressure Restore safety devices; wait that boiler reaches its temperature
switch and so on...) open
then check safety device functionality
Broken fuses
Replace fuses. Check current absorption
Fan thermal contacts open (only three-phases)
Reset contacts and check current absorption
Burner control locked out
Reset and check its functionality
Burner control damaged
Replace burner control
BURNER LOCKS-OUT WITH FLAME PRESENCE
Flame detector dirty or damaged
Clean or replace flame detector
Burner control damaged
Replace burner control
Smoking flame
Reset combustion air flow rate
Check the nozzle an, if necessary, replace it
Check cleaness of combustion head
Check chimney suction
Check boiler cleaness
Combustion head dirty
Clean combustion head
BURNER LOCKS OUT WITHOUT ANY FUEL FLOW RATE
No fuel
Fill the tank
Pump joint broken
Check pump pressure
Pump damaged
Check pump suction
Replace pump
Compressed air (or steam) too high
Released compressed air (or steam) pressure
Oil metering valve not open far enough
Check air pressure
Check servomotor position
Oil valve not energized
Check wiring path or replace valve
Fan motor not efficient
Adjust or replace the motor
Fun or pump motor runs in the wrong way
Change rotation
Obstructed nozzle
Clean or replace the nozzle
check valve in the tank locked or leaking
Clean or replace the valve
Oil filter dirty
Pump filter dirty
Clean filter
Solenoid valve dirty or broken
Clean or replace solenoid valve
BURNER LOCKS-OUT WITH FUEL FLOW RATE (NO FLAME)
Oil pressure too low
Reset oil pressure
Nozzle dirty or damaged
Clean or replace the nozzle
Water in the tank
Take off all the water from the tank
Clean all filters
Suction too high
Check suction before pump. If necessary clean filters.
Ignition electrodes grounded because dirty or damaged
Clean or replace electrodes
Ignition electrodes badly set
Check electrodes position referring to instruction manual
Cables damaged
Replace cables
Bad position of cables in the ignition transformer or into the
Improve the installation
eletrodes
Ignition transformer damaged
Replace the transformer
PUMP TOO NOISY
Suction too high (over 3.5 bar) (dirty filters, check valve in the tank
Clean filters
locked and so on...)
Replace check valve in the tank
Flexible hoses damaged
Replace flexible hoses
Air infiltration in the pipes
Take off all infiltration
Pipe too long or too narrow
Increase line size
BURNER RUMBLES WHEN MODULATING TO HIGH FIRE
Burner is too lean
Adjust air-oil ratio
Drawer assembly not set properly
Check drawer position
Oil may be too hot
Check oil temperature
Flame is blowing off head
Check head position
CARBON BUILD-UP ON THE FIRESIDES OF THE BOILER
Oil flame not retaining the head
Dirty nozzle
Clean the nozzle
Oil too cold
Check the oil temperature
Oil spray impinging on burner head
Check position of the nozzle respect to the head
Spray angle of the nozzle too wide
Reduce spray angle
FLAME IRREGULAR OR SPARKING
23

Oil pressure at nozzle too low

Reset oil pressure
Air flow rate too high
Adjust air flow rate
Oil is too cold
Adjust oil themperature
Dirt in the oil
Check filters
Water in the fuel
Take off the water
Oil impingement on the combustion head
Drawer assembly far too rear
Nozzle is not protruding through centerhole of air diffuser
Oil flame not retaining to the head
Nozzle dirty or damaged
Clean the nozzle or, if necessary, replace it
BURNER LIGHTS BUT FLAME DOESN'T RETAIN TO BURNER HEAD
Drawer assembly not positioned correctly
Move forward or bakward
Nozzle too far forward through centerhole of diffuser
Move nozzle backward respect to diffuser
Oil or air pressure at nozzle is too low
Increase oil or air pressure
Air louver too open
Reduce air louver opening
Too much spread between oil and air (or steam) pressure
Set the spread to a proper value
Oil temperature too high or too low
Set the temperature to a proper value
FLAME IRREGULAR OR SMOKING
Not enough combustion air
Adjust air flow rate
Nozzle dirty or damaged
Clean or, if necessary, replace it
Flame is too big for furnace or nozzle spray angleis wrong
Check burner-furnace coupling
Change nozzle with a suitable one
Nozzle spray angle wrong (flame too long or too wide)
Replace the nozzle
Boiler dirty
Clean the boiler
Not enough suction at chimney
Check chimney cleaness or size
Pressure at nozzle too low
Reset oil pressure
Oil too cold
Reset oil temperature
Combustion air inlet dirty
Clean the air inlet
Flame is too small respect to furnace volume
Replace nozzle or reset pump pressure
FUEL GAS TEMPERATURE TOO HIGH
Boiler dirty
Clean the boiler
Oil flow rate too high
Adjust oil pressure or replace the nozzle

24

16

SPARE PART LIST Project 00P270 - URB4

DESCRIPTION
Burner Control LFL 1.333
Electronic cam RVW 20
Regulator Gefran 1600 V RRR0-I0-1801
Pressure probe QBE 620 - 40 bar
Tightness control LDU11
Flame control QRA10C
Servomotor Landis SQM54.480A2
Potentiometer Landis ASZ 12.803
Electric transformer Cofi 820
Refractory tile (1 piece)
Gas valve Landis VGG 10.504
Gas governor Landis SKP20
Gas valve Dungs MVD 520/5
Gas valve Brahma EG12L
Gas valve Brahma EG12SR
Gas governor Madas FRG/2MT
Gas governor Madas FRG/2MC 2
Gas pressure switch Dungs GW 150
Gas pressure switch Dungs GW 500
Oil pump Suntec TA3C
Oil filter Giuliani Anello 51000/0.5 2"
Oil nozzle tip AB100
Mixing plug AB100
Oil valve Joucomatic N.C. E290A384
Oil valve Joucomatic N.O. E290A387
Oil pressure switch Danfoss RT 1
Oil governor Carraro UBAN AS1/130
Oil metering valve Hauck S3-11
Oil metering valve Hauck S3-13
Oil temperature regulator Conflow 83R15
Camozzi air valve N.C. 1/8"
Steam valve Conflow 1100AR DN15 N.C.
Steam check valve Conflow RPX DN15
Steam strainer Conflow FY16 DN15
Steam manual valve DN 15
Water discharger Conflow SSG25 1512
Flow indicator Conflow IF150/2
Air governor Conflow FR10
Steam modulating valve Conflow 1000 AR DN15
Differential steam valve Carraro UBAN V/D2/AF2/130 DN15

CODE
2020448
2570101
2560162
2020413
2510013
2480051
2560139
2170108
2994116
2190150
2190120
21903F9
2190510
2190502
""2800067
2160026
2160034
2590119
2090209
"2190704
"2190705
2160081
"2570066
2570017
2570018
2570067
2190734
2191310
2191416
2090308
2810032
"2191309
2191307
2800125
2191304
2192405

25