CIB UNIGAS KP60 Operating manual

M039193CE Rev. 4.911/2021
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
Progressive
and fully-modulating
gas - heavy oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
KP60
KP72 - KP73

2
DANGERS, WARNINGS AND NOTES OF CAUTION
THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE
USER.
INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING
PRODUCT INSTALLATION AND MAINTENANCE.
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) GENERAL INTRODUCTION
The equipment must be installed in compliance with the regulations in
force, following the manufacturer’s 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 chil-
dren, 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 and accessories.
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 qualified personnel at regular
intervals, following the manufacturer’s instructions.
When a decision is made to discontinue the use of the equipment,
those parts likely to constitute sources of danger shall be made harm-
less.
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.
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.The occurrence of any
of the following circustances may cause explosions, polluting unburnt
gases (example: carbon monoxide CO), burns, serious harm to people,
animals and things:
- Failure to comply with one of the WARNINGS in this chapter
- Incorrect handling, installation, adjustment or maintenance of the burner
- Incorrect use of the burner or incorrect use of its parts or optional supply
2) SPECIAL INSTRUCTIONS FOR BURNERS
The burner should be installed in a suitable room, with ventilation ope-
nings 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 fire-
box.
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 combu-
stion 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 regula-
tions 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 a burner shut-down, reser the control box by means of the
RESET pushbutton. If a second shut-down takes place, call the Tech-
nical Service, without trying to RESET further.
The unit shall be operated and serviced by qualified personnel only, in
compliance with the regulations in force.
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 per-
mitted 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 quali-
fied 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.

3
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
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 desig-
ned 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.
DIRECTIVES AND STANDARDS
Gas burners
European directives
-Regulation 2016/426/UE (appliances burning gaseous fuels)
-2014/35/UE (Low Tension Directive)
-2014/30/UE (Electromagnetic compatibility Directive)
-2006/42/EC (Machinery Directive)
Harmonized standards
-UNI EN 676 (Automatic forced draught burners for gaseous fuels)
-EN 55014-1 (Electromagnetic compatibility- Requirements for house
hold appliances, electric tools and similar apparatus)
-EN 60204-1:2006 (Safety of machinery – Electrical equipment of
machines.)
-CEI EN 60335-1 (Specification for safety of household and similar
electrical appliances);
-CEI EN 60335-2-102 (Household and similar electrical appliances.
Safety. Particular requirements for gas, oil and solid-fuel burning
appliances having electrical connections).
-UNI EN ISO 12100:2010 (Safety of machinery - General principles for
design - Risk assessment and risk reduction);
Light oil burners
European directives
-2014/35/UE (Low Tension Directive)
-2014/30/UE (Electromagnetic compatibility Directive)
-2006/42/EC (Machinery Directive)
Harmonized standards
-UNI EN 267-2011(Automatic forced draught burners for liquid fuels)
-EN 55014-1 (Electromagnetic compatibility- Requirements for house
hold appliances, electric tools and similar apparatus)
-EN 60204-1:2006 (Safety of machinery – Electrical equipment of
machines.)
-CEI EN 60335-1 (Specification for safety of household and similar
electrical appliances);
-CEI EN 60335-2-102 (Household and similar electrical appliances.
Safety. Particular requirements for gas, oil and solid-fuel burning
appliances having electrical connections).
-UNI EN ISO 12100:2010 (Safety of machinery - General principles for
design - Risk assessment and risk reduction);
Heavy oil burners
European Directives
-2014/35/UE (Low Tension Directive)
-2014/30/UE (Electromagnetic compatibility Directive)
-2006/42/EC (Machinery Directive)
Harmonized standards
-UNI EN 267(Automatic forced draught burners for liquid fuels)
-EN 55014-1 (Electromagnetic compatibility- Requirements for house
hold appliances, electric tools and similar apparatus)
-EN 60204-1:2006 (Safety of machinery – Electrical equipment of
machines.)
-CEI EN 60335-1 (Specification for safety of household and similar
electrical appliances);
-CEI EN 60335-2-102 (Household and similar electrical appliances.
Safety. Particular requirements for gas, oil and solid-fuel burning
appliances having electrical connections).
-UNI EN ISO 12100:2010 (Safety of machinery - General principles for
design - Risk assessment and risk reduction);

4
Gas - Light oil burners
European Directives
-Regulation 2016/426/UE (appliances burning gaseous fuels)
-2014/35/UE (Low Tension Directive)
-2014/30/UE (Electromagnetic compatibility Directive)
-2006/42/EC (Machinery Directive)
Harmonized standards
-UNI EN 676 (Automatic forced draught burners for gaseous fuels)
-UNI EN 267(Automatic forced draught burners for liquid fuels)
-EN 55014-1 (Electromagnetic compatibility- Requirements for house
hold appliances, electric tools and similar apparatus)
-EN 60204-1:2006 (Safety of machinery – Electrical equipment of
machines.)
-CEI EN 60335-1 (Specification for safety of household and similar
electrical appliances);
-CEI EN 60335-2-102 (Household and similar electrical appliances.
Safety. Particular requirements for gas, oil and solid-fuel burning
appliances having electrical connections).
-UNI EN ISO 12100:2010 (Safety of machinery - General principles for
design - Risk assessment and risk reduction);
Gas - Heavy oil burners
European directives:
-Regulation 2016/426/UE (appliances burning gaseous fuels)
-2014/35/UE (Low Tension Directive)
-2014/30/UE (Electromagnetic compatibility Directive)
-2006/42/EC (Machinery Directive)
Harmonized standards
-UNI EN 676 (Automatic forced draught burners for gaseous fuels)
-EN 55014-1 (Electromagnetic compatibility- Requirements for house
hold appliances, electric tools and similar apparatus)
-EN 60204-1:2006 (Safety of machinery – Electrical equipment of machi-
nes.)
-CEI EN 60335-1 (Specification for safety of household and similar electri-
cal appliances);
-CEI EN 60335-2-102 (Household and similar electrical appliances.
Safety. Particular requirements for gas, oil and solid-fuel burning
appliances having electrical connections).
-UNI EN ISO 12100:2010 (Safety of machinery - General principles for
design - Risk assessment and risk reduction);
Industrial burners
European directives
-Regulation 2016/426/UE (appliances burning gaseous fuels)
-2014/35/UE (Low Tension Directive)
-2014/30/UE (Electromagnetic compatibility Directive)
-2006/42/EC (Machinery Directive)
Harmonized standards
-EN 55014-1 (Electromagnetic compatibility- Requirements for house
hold appliances, electric tools and similar apparatus)
-EN 746-2 (Industrial thermoprocessing equipment - Part 2: Safety requi-
rements for combustion and fuel handling systems)
-UNI EN ISO 12100:2010 (Safety of machinery - General principles for
design - Risk assessment and risk reduction);
-EN 60204-1:2006 (Safety of machinery – Electrical equipment of machi-
nes.)
-EN 60335-2 (Electrical equipment of non-electric appliances for house-
hold and similar purposes. Safety requirements)
Burner data plate
For the following information, please refer to
the data plate:
burner type and burner model: must be
reported in any communication with the
supplier
burner ID (serial number): must be repor-
ted in any communication with the supplier
date of production (year and month)
information about fuel type and network
pressure
SYMBOLS USED
Figures, illustrations and images used in this manual may differ in appearance from
the actual product.
WARNING!
Failure to observe the warning may result
in irreparable damage to the unit or
damage to the environment
DANGER!
Failure to observe the warning may result
in serious injuries or death.
WARNING!
Failure to observe the warning may result
in electric shock with lethal consequen-
ces
Type --
Model --
Year --
S.Number --
Output --
Oil Flow --
Fuel --
Category --
Gas Pressure --
Viscosity --
El.Supply --
El.Consump. --
Fan Motor --
Protection --
Drwaing n° --
P.I.N. --
BURNER SAFETY
The burners - and the configurations described below - comply with the
regulations in force regarding health, safety and the environment. For
more in-depth information, refer to the declarations of conformity that are
an integral part of this Manual.
Residual risks deriving from misuse and prohibitions
The burner has been built in order to make its operation safe; there are,
however, residual risks.
DANGER! Incorrect motor rotation can seriously
damage property and injure people.
Do not touch any mechanical moving parts with your hands
or any other part of your body. Injury hazard
Do not touch any parts containing fuel (i.e. tank and pipes).
Scalding hazard
Do not use the burner in situations other than the ones pro-
vided for in the data plate.
Do not use fuels other than the ones stated.
Do not use the burner in potentially explosive environ-
ments.
Do not remove or by-pass any machine safety devices.
Do not remove any protection devices or open the burner
or any other component while the burner is running.
Do not disconnect any part of the burner or its components
while the burner is running.
Untrained staff must not modify any linkages.
After any maintenance, it is important to restore the protec-
tion devices before restarting the machine.
All safety devices must be kept in perfect working order.
Personnel authorized to maintain the machine must always
be provided with suitable protections.
ATTENTION: while running, the parts of the burner near
the generator (coupling flange) are subject to overheating.
Where necessary, avoid any contact risks by wearing sui-
table PPE.

C.I.B. UNIGAS - M039193CE
5
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type KP60 Model MP. MD. S. . A. 1. 65
(1) (2) (3) (4) (5) (6) (7) (8)
(1) BURNER TYPE KP60 - KP72 - KP73
(2) FUEL M - Natural gas
N - Heavy oil, viscosity <= 50cSt (7° E) @ 50° C
D - Heavy oil, viscosity <= 400cSt (50° E) @ 50° C
P - Petroleum, viscosity 89cSt (12° E) @ 50° C
(3) OPERATION PR - Progressive
MD - Fully modulating
(4) BLAST TUBE S - Standard
(5) DESTINATION COUNTRY * - see data plate
(6) BURNER VERSION A - Standard
(7) EQUIPMENT 0 = 2 Gas valves
1 = 2 Gas valves + gas proving system
7 = 2 Gas valves+high gas pressure switch
8 = 2 Gas valves + gas proving system+high gas pressure switchl
(8) GAS CONNECTION 32 = Rp1”1/4 40 = Rp1”1/2 50 = Rp2” 65 = DN65 80 = DN80
PART I: INSTALLATION MANUAL
7
4
6
5
1
2
13
3
10
14
9
12 11
8
Note: the figure is indicative only
Keys
1 Mimic panel with startup switch
2 Gas train
3 Electrical panel
4 Cover
5 Blast tube - Combustion head
6 Flange
7 Pump
8 Preheater Tank
9 Motor Pump
10 Air intake
11 Adjusting cams
12 Actuator
13 Oil manifold
14 Head adjusting ring nut

C.I.B. UNIGAS - M039193CE
6
Specifications
* NOTE ON THE WORKING SERVICE: the control box automatically stops after 24h of continuous working. The control box
immediately starts up, automatically.
BURNERS KP60
Output min. kW - max. kW 160 - 880
Fuel Natural gas - Heavy oil
Gas category (see next paragraph)
Heavy oil viscosity See “Burner model identification” table
Oil train inlet pressure bar 2 max
Gas rate min. - max. (Stm3/h) 17 - 93
Gas pressure min. - max. mbar (Note2)
Heavy oil rate min. - max. kg/h 14 - 77
Power supply 400V 3N ~ 50Hz
Total power consumption (Heavy oil) kW 6.65
Total power consumption (Petroleum) kW 3.65
Fan motor kW 1.1
Pump motor kW 0.55
Pre-heater resistors (heavy oil) kW 4.5
Pre-heater resistors (Petroleum) kW 1.5
Protection IP40
Operation Progressive - Fully modulating
Gas Train 32 Valves size/Gas connection 32 / Rp1”1/4
Gas Train 40 Valves size/Gas connection 40 / Rp1”1/2
Gas Train 50 Valves size/Gas connection 50 / Rp 2”
Gas Train 65 Valves size/Gas connection 65 / DN65
Operating temperature °C -10 ÷ +50
Storage temperature °C -20 ÷ +60
Working service * Intermitent
Note1: All gas flow rates are referred to Stm3/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (net
calorific value Hi= 34.02 MJ/Stm3).
Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC valves)
= 500mbar (with Dungs MBC or Siemens VGD gas valves).
Minimum gas pressure = see gas curves.

C.I.B. UNIGAS - M039193CE
7
* NOTE ON THE WORKING SERVICE: the control box automatically stops after 24h of continuous working. The control box
immediately starts up, automatically.
Country and usefulness gas categories
BURNERS KP72 ..0.xx KP72 ..1.xx KP73
Output min. kW - max. kW 330 - 1200 330 - 1550 320 - 2050
Fuel Natural gas - Heavy oil
Gas category (see next paragraph)
Heavy oil viscosity See “Burner model identification” table
Oil train inlet pressure bar 2 max
Gas rate min. - max. (Stm3/h) 35 - 127 35 - 164 34 - 217
Gas pressure min. - max. mbar (Note2)
Heavy oil rate min. - max. kg/h 29 - 107 29 - 138 28 - 179
Power supply 400V 3N ~ 50Hz
Total power consumption (Heavy oil) kW 11.25 11.25 16.6
Total power consumption (Petroleum) kW 5.91 5.91 8.6
Fan motor kW 2.2 2.2 3
Pump motor kW 0.55 0.55 1.1
Pre-heater resistors (heavy oil) kW 8812
Pre-heater resistors (Petroleum) kW 2.66 2.66 4
Protection IP40
Operation Progressive - Fully modulating
Gas Train 40 Valves size / Gas
connection 40 / Rp1”1/2 40 / Rp1”1/2 -
Gas Train 50 Valves size / Gas
connection 50 / Rp 2
Gas Train 65 Valves size / Gas
connection 65 / DN65
Gas Train 80 Valves size / Gas
connection 80 / DN80
Operating temperature °C -10 ÷ +50
Storage temperature °C -20 ÷ +60
Working service Intermitent
Note1: All gas flow rates are referred to Stm3/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (net
calorific value Hi= 34.02 MJ/Stm3).
Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC valves)
= 500mbar (with Dungs MBC or Siemens VGD gas valves).
Minimum gas pressure = see gas curves.
GAS
CATEGORY COUNTRY
I2H AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH
I2E LUPL-----------------------
I2E( R ) B BE------------------------
I2L NL------------------------
I2ELL DE------------------------
I2Er FR------------------------

C.I.B. UNIGAS - M039329CA
8
Overall dimensions - (mm)
A COUNTERFLANGE IS MANDATORY:a gasket must be placed between the generator and the counterflange
*DNAACAEANBBBCCCDDDE F G J K L M O Q R S U W Y Z
KP60
32 1213 89 313 256 374 314 839 493 1251 160 755 496 250 202 240 335 M12 190 368 112 256 580 619 156 120
40 1213 89 313 256 374 314 839 493 1251 160 755 496 250 202 240 335 M12 190 439 112 327 580 619 156 120
50 1213 89 313 256 374 314 839 493 1251 160 755 496 250 202 240 335 M12 190 447 112 335 580 619 156 120
65 1213 89 313 256 374 314 839 493 1436 160 774 496 250 202 240 335 M12 190 515 112 403 560 619 156 120
K
K
O
O
D A
W
G
Y
CC
DD
BB
E F B C
R
Q
LZ
AE
U
AC
S
J
AN
M
n
400
190
n
182
n
270
n
350
n
350
Burner flange
Boiler recommended drilling template Reccomended counterflange

C.I.B. UNIGAS - M039329CA
9
*DN = gas valves size
A COUNTERFLANGE IS MANDATORY:a gasket must be placed between the generator and the counterflange
NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves.
*DNAAABBBCCCDDDEEE F G H J K L MOminOmaxQ R S T U V W Y Z
KP72 xx-...0. 50 1299 - 505 - 794 - 1100 - 580 - 520 300 340 230 300 - M12 216 250 -------211-
KP72 xx-...0. 65 1299 - 505 - 794 - 1230 - 710 - 520 300 340 265 300 - M12 216 250 -------211-
KP72 xx-...0. 80 1299 - 505 - 794 - 1245 - 725 - 520 300 340 265 300 - M12 216 250 -------211-
KP72 xx-...1. 50 1299 - 505 - 794 - 1225 - 705 - 520 300 340 230 300 - M12 216 250 -------211-
KP72 xx-...1. 65 1299 - 505 - 794 - 1340 - 810 - 520 300 340 265 300 - M12 216 250 -------211-
KP72 xx-...1. 80 1299 - 505 - 794 - 1345 - 825 - 520 300 340 265 300 - M12 216 250 -------211-
EF
EE
D
CC
Y
G
J
AA
Z
WL
T
RS
QV
C
B
A
DD
BB
U
x
280
10
440
400
233
233
30°
60°
30°
14

11
Ø340
M12
30°
60°
Ø400
O max
K
K
O min
O max
O min
Boiler recommended drilling template
Burner flange
Reccomended counterflange

C.I.B. UNIGAS - M039329CA
10
*DN = gas valves size
NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves.
ATTENTION: the counterflange is an optional supplied only on request. A gasket must be placed between the generator and the counterflange
DNAAABBBCCCDDDEEE F G J K L MOminOmaxQ R S T U V W Y Z
KP73 50 1320 140 469 373 800 495 1378 475 838 400 540 320 226 300 375 M10 216 250 400 130 270 10 610 216 635 198 150
KP73 65 1320 140 469 373 800 495 1302 475 762 400 540 320 275 300 375 M10 216 250 400 130 270 10 565 313 635 198 150
KP73 80 1320 140 469 373 800 495 1308 475 764 400 540 320 275 300 375 M10 216 250 400 130 270 10 565 344 635 198 150
EF
EE
D
CC
Y
G
J
AA
Z
WL
T
RS
QV
C
B
A
DD
BB
U
O max
K
K
O min
O max
O min
233
233
10
M
8

400

440
10

280
400 3360
12
Reccomended counterflangeBoiler recommended drilling template

C.I.B. UNIGAS - M039329CA
11
KP73
Fig. 1 3I2MD11 v1 Hydraulic diagram
NOTE: POS 25, POS 31, POS 32, POS 33 are optional supply
The following items are included only on certain types of burner: 10, 11, 12
POS OIL TRAIN COMBUSTION AIR TRAIN
1 Filter 18 Air damper with actuator
2 Pump and pressure governor 19 Pressure switch - PA
3 Electrical motor 20 Draught fan with electromotor
33 Pressure gauge with manual valve MAIN GAS TRAIN
4 Electrical preheater tank 21 Filter
Pb4 Temperature probe 22 Pressure switch - PGMIN
Pb1 Temperature probe 23 Safety valve with built in gas governor
Pb3 Temperature probe 24 Proving system
9 3-way solenoid valve 25 Pressure switch - PGMAX
10 Flexible hose 26 Butterfly valve
11 Flexible hose 31 Bellows unit
Pb2 Temperature probe 32 Manual valve
13 Oil distributor
14 Low thermostat - TCI
15 Pressure governor
16 Flexible hose
17 Burner
combustion air inlet
gas inlet
BY OTHERS
BY BURNER CONSTRUCTOR
oil inlet
oil outlet
ATTENTION: connect the oil return line to the degassing bottle (standard UNI 9248), as shown in
the chapter "Recommendations to design heavy oil feeding plants"

C.I.B. UNIGAS - M039329CA
12
KP60, KP72
Fig. 2 - 3I2MD21 v1 Hydraulic diagram
M
P
S
M
M
TC
P
S
PSL
PSL
PSH
PSH
P
S
PSH
PSH
PSL
combustion air inlet
SUPPLIED LOOSE ITEMSON BOARD ITEMS
gas inlet
BY OTHERS
BY BURNER CONSTRUCTOR
.According to the gas train size and the burner type MB-DLE safety
valves are supplied. See the drawing on the left.
oil inlet
oil outlet
LEGEND
POS OIL TRAIN
1Filter
2 Pump and pressure governor
3 Electrical motor
4 Electrical preheater tank
Pb4 Temperature probe
Pb1 Temperature probe
Pb3 Temperature probe
10 Solenoid valve
11 Nozzle shut off needle
Pb2 Temperature probe
12 One way valve
13 Pressure governor
14 Flexible hose
COMBUSTION AIR TRAIN
41 Air damper with actuator
43 Pressure switch - PA
42 Draught fan with electromotor
MAIN GAS TRAIN
21 Filter
22 Pressure switch - PGMIN
23 Safety valve with built in gas governor
24 Proving system pressure switch - PGCP
25 Pressure switch - PGMAX
26 Butterfly valve
26 Pressure switch - PGMIN
27 Safety valve with built in gas governor
28 Pressure switch - PGMIN
29 Proving system pressure switch - PGCP
30 Pressure switch - PGMAX
NOTE POS 25,30 are optional supply
ATTENTION: connect the oil return line to the degassing bottle (standard UNI 9248), as shown in
the chapter "Recommendations to design heavy oil feeding plants"

C.I.B. UNIGAS - M039193CE
13
Performance curves
To get the output in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C.
NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory
tests, but does not represent the regulation range of the machine. On this diagram the maximum output point is usually reached by adj-
suting the combustion head to its “MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is rea-
ched setting the combustion head to its “MIN” position. During the first ignition, the combustion 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.
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
KP60
kW
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
KP72 ...0.xx
kW
KP72 ...1.xx
kW
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
KP73
kW

C.I.B. UNIGAS - M039193CE
14
Pressure in the Network / gas flow rate curves
zGas burners
GAS PRESSURE IN
THE NETWORK mbar
KP60
Stm3/hGas rate Stm3/h
GAS PRESSURE IN
THE NETWORK mbar
KP72 ...0.xx
Stm3/hGas rate Stm3/h
KP72 ...1.xx
Stm3/hGas rate Stm3/h
GAS PRESSURE IN
THE NETWORK mbar
KP73
Stm3/hGas rate Stm3/h
Caution: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis (pres-
sure value in the combustion chamber is not included). To know the minimum pressure at the gas train inlet,
necessary to get the requested gas rate, add the pressure value in the combustion chamber to the value read on
the y-axis.

C.I.B. UNIGAS - M039193CE
15
Combustion head gas pressure curves depending on the flow rate
Curves are referred to pressure = 0mbar in the combustion head!
The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner properly
adjusted (percentage of residual O2 in the flues as shown in the “Recommended combustion values” table and CO in the standard
limits). During this stage, the combustion head, the gas butterfly valve and the actuator are at the maximum opening. Refer to Fig. 3,
showing the correct way to measure the gas pressure, considering the values of pressure in combustion chamber, surveyed by means
of the pressure gauge or taken from the boiler’s Technical specifications.
Fig. 3
Key
1 Generator
2 Pressure outlet on the combustion chamber
3 Gas pressure outlet on the butterfly valve
4 Differential pressure gauge
Measuring the gas pressure in the combustion head
In order to measure the pressure in the combustion head, insert the pressure gauge probes: one into the combustion chamber’s pres-
sure outlet to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner. On
the basis of the measured differential pressure, it is possible to get the maximum flow rate: in the pressure - rate curves (showed on the
next paragraph), it is easy to find out the burner’s output in Stm3/h (quoted on the x axis) from the pressure measured in the combu-
stion head (quoted on the y axis). The data obtained must be considered when adjusting the gas flow rate.
NOTE: THE PRESSURE-RATE CURVES ARE GIVEN AS INFORMATION ONLY; FOR A PROPER SETTING OF THE GAS RATE,
PLEASE REFER TO THE GAS METER READING.
1
2
4
3

C.I.B. UNIGAS - M039193CE
16
Pressure in combustion head - gas rate curves
Gas pressure in
combustion head
KP60 ...
Gas rate Stm3/h
Gas pressure in
combustion head
KP65
Gas rate Stm3/h
KP72
Gas rate Stm3/h
Gas pressure in
combustion head
KP73
Gas rate Stm3/h

C.I.B. UNIGAS - M039193CE
17
MOUNTINGS AND CONNECTIONS
Packing
The burners are despatched in cardboard boxes or wooden cages whose dimensions are:
1730mmx 1280mm x 1020mm (L x P x H)
Packing cases of this kind are affected by humidity and are not suitable for stacking. The fol-
lowing are placed in each packing case:
zburner with gas train detached;
zgasket to be inserted between the burner and the boiler;
zflexible oil pipes;
zoil filter;
zenvelope containing this manual
To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of
materials.
Handling the burner
The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck: the forks must be inserted into the A
anb B ways. Remove the stirrup only once the burner is installed to the boiler.
Fitting the burner to the boiler
To install the burner into the boiler, proceed as follows:
1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)
2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;
3 place the stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;
4 fasten the 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 burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate
insulating material (ceramic fibre cord or refractory cement).
The burner is designed to work positioned according to the picture below. Set the upper side of the burner flange in a horizontal posi-
tion, in order to find the correct inclination of the pre-heating tank. For different installations, please contact the Technical Department.
ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these opera-
tions are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.
To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).
The unpacked burner must be lifted and moved only by means of a fork lift truck.
H
PL
AB
Keys
1 Burner
2 Fixing nut
3 Washer
4 Sealing gasket
5 Stud bolt
7Blasttube

C.I.B. UNIGAS - M039193CE
18
Key
1 Burner flange (upper side indicated)
2 Bracket
3 Pre-heating tank on the burner
SIDE UP
SIDE
DOWN
1
2
3

C.I.B. UNIGAS - M039193CE
19
GAS TRAIN CONNECTIONS
The diagrams show the components of the gas trai included in the delivery and which must be fitted by the installer.The diagrams are in
compliance with the current laws.
Key
WARNING: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE
MANUAL CUTOFF VALVES ARE CLOSED.
Gas train with valves group MB-DLE (2 valves + gas filter + pressure governor) + VPS504 gas proving system
Gas train with valves group VGD with built-in gas pressure governor + gas proving system VPS504
1 Filter (*optional) 6 Butterfly valve
2 Pressure switch - PGMIN 8 Main burner
3 Safety valve with built in gas governor 9 Manual valve(*optional)
4 Proving system (*if provided) 10 Bellows unit(*optional)
5 Pressure switch - PGMAX (*optional)
GAS INLET
BY BURNER CONSTRUCTOR
BY OTHERS
GAS INLET
SUPPLIED BY BURNER
CONSTRUCTOR
BY OTHERS

C.I.B. UNIGAS - M039193CE
20
Assembling the gas grain
Fig. 4 - Example of gas train
To mount the gas train, proceed as follows:
1-a) in case of threaded joints: use proper seals according to the gas used;
1-b) in case of flanged joints: place a gasket (no. 1A..1E - Fig. 4) between the elements
NOTE: the bellows unit, the manual valve and the gaskets are not part of the standard supply.
The procedures of installation fo the gas valves are showed in the next paragraphs, according to the gas train used:
zthreaded gas trains with Multibloc Dungs MB-DLE or Siemens VGD20..
zflanged gas trains with Multibloc Dungs MB-DLE or Siemens VGD40..
ATTENTION: once the gas train is mounted according to the diagram on Fig. 4, the gas proving test mus be performed,
according to the procedure set by the laws in force.
ATTENTION: it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the
valves, during maintenance and cleaning operation of the filters (both the filters outside the valves group and
the ones built-in the gas valves).
1A
5
1B
4
1C
21D
1E
3
Keys
1A..1E Gasket
2 Gas filter
3 Gas valves group
4 Bellows unit
5 Manual valve
”direction” arrows for installation
gas supply network