Unigas RG91 User manual

M039421CA 0.104/2022
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
Microprocessor controlled
MANUAL OF INSTALLATION - USE - MAINTENANCE
LMV5x
Light oil burners
RG91, RG92, RG93
RG510, RG515,
RG520, RG525

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.

PART I: SPECIFICATIONS
5
BURNERS FEATURES
Fig. 1
1 Control panel
2 Electrical panel
3Pump
4 Burner flange
5 Blast tube-combustion head
6 Burner cover
7 Oil pressure governor
8 Pump motor
9 Actuator
10 Air inlet
11 Fan Motor
12 Gun and head adjusting ring nut
Light oil operation:the fuel coming from the supply line, is pushed by the pump to the nozzle and then into the combustion chamber,
where the mixture between fuel and air takes place and consequently the flame.
In the burners, the mixture bertween fuel and air, to perform clean and efficient combustion, is activated by atomisation of oil into very
small particles. This process is achieved making pressurised oil passing through the nozzle.
The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pressure,
pumps are provided with a pressure regulator (except for some models for which a separate regulating valve is provided). Other pumps
are provided with two pressure regulators: one for the high and one for low pressure (in double-stage systems with one nozzle).
The adjustable combustion head can improve the burner performance. The combustion head determines the energetic quality and the
geometry of the flame. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion cham-
ber).
The control panel, placed on the burner front side, shows each operating stage.
PART I: SPECIFICATIONS
10
5
6
4
3
2
1
9
12
9
7
11
8

PART I: SPECIFICATIONS
6
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Fuel
Type RG520 Model G-. PR. S. . A. ES.
(1) (2) (3) (4) (5) (6) (7)
(1) BURNER TYPE RG91 - RG92 - RG93 - RG510 - RG515 - RG520 - RG525
(2) FUEL G- Light oil
K- Kerosene
(3) OPERATION (Available versions) PR - Progressive MD - Fully modulating
(4) BLAST TUBE S - standard L - extended
(5) DESTINATION COUNTRY * - see data plate*
(6) BURNER VERSION A - Standard
(7) MICRO-PROCESSOR CONTROL ES = with no O2 trim control, with no VSD control
EO = with O2trim control, with no VSD control
EI = with no O2trim control, with VSD control
EK = with O2trim control, with VSD control
DANGER! The burner must be used only with the fuel specified in the burner data
plate.
Type --
Model --
Year --
S.Number --
Output --
Oil Flow --
Fuel --
Category --
Gas Pressure --
Viscosity --
El.Supply --
El.Consump. --

PART I: SPECIFICATIONS
7
Technical specifications
NOTE: Choosing the nozzle for light oil, consider Hi equal to 42.7 MJ/kg.
BURNERS RG91 RG92 RG93
Output min - max kW 698 - 2093 849 - 2558 550 - 4100
Light oil rate min - max kg/h 59 - 176 72 - 215 46 - 345
Fuel Light oil
Viscosity cSt @ 40 °C 2 - 7,4
Density kg/m3840
Oil train pressure inlet bar max 4
Power supply 400V 3N ~ 50Hz
Fan motor kW 4 5,5 7,5
Pump motor kW 1,1 1,1 1,1
Total power consumption kW 5,6 7,19,1
Index of protection IP40
Approx. weight kg 220 220 230
Operation Progressive - Fully modulating
Operating temperature °C -10 ÷ +50
Storage temperature °C -20 ÷ +60
Working service * Continuous
BURNERS RG510 RG515 RG520 RG525
Output min - max kW 1314 - 3953 1628 - 4884 2326 - 6977 2000 - 8000
Fuel Light oil
Light oil rate min - max kg/h 111 - 333 137 - 411 196 - 588 169 - 674
Viscosity cSt @ 40 °C 2 - 7,4
Density kg/m3840
Oil train pressure inlet bar max 4
Power supply 400V 3N ~ 50Hz
Electric motor kW 7,5 11 15 18,5
Pump motor kW 1,1 1,5 1,5 3
Total power consumption kW 9,1 13 17 22
Operation Progressive - Fully modulating
Index of protection IP40
Operating temperature °C -10 ÷ +50
Storage temperature °C -20 ÷ +60
Working service Continuous
WARNING: Burners are suitable only for indoor operation with a maximum relative humidity of 80%

PART I: SPECIFICATIONS
8
Performance curves
To get the input 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 adjsuting the combustion head to its
“MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is reached 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 Performance curve minimum
PRESSURE IN
COMBUSTION CHAMBER mbar
RG91
kW
RG92
kW
PRESSURE IN
COMBUSTION CHAMBER mbar
RG93
kW
PRESSURE IN
COMBUSTION CHAMBER mbar
RG510
kW
RG515
kW
PRESSURE IN
COMBUSTION CHAMBER mbar
RG520
kW
RG525
kW
0
2
4
6
8
10
12
14
16
18
400 800 1200 1600 2000 2400
0
2
4
6
8
10
12
14
16
18
400 800 1200 1600 2000 2400 2800
0
2
4
6
8
10
12
14
16
0 500 1000 1500 2000 2500 3000 3500 4000 4500
0
4
8
12
16
20
24
1000 1800 2600 3400 4200
0
4
8
12
16
20
24
1200 2000 2800 3600 4400 5200
0
4
8
12
16
20
24
2000 2800 3600 4400 5200 6000 6800 7600
0
4
8
12
16
20
24
1500 2500 3500 4500 5500 6500 7500 8500

PART I: SPECIFICATIONS
9
Overall dimensions (mm)
*AS/BS: measure referred to burner with standard blast tube provided
*AL/BL: measure referred to burner with extended blast tube provided
A (AS) A (AL) AA AB AC AD AE B (BS) B (BL) BB C CC E F G H K L M N Omin Omax P W Y Z
RG91 1345 1518 242 820 421 35 380 300 473 419 1045 422 419 434 238 268 360 513 M12 417 280 310 295 698 228 185
RG92 1339 1512 242 820 421 35 380 294 467 419 1045 422 419 434 266 296 360 513 M12 417 280 310 295 698 228 185
RG93 1346 1536 242 820 431 35 380 301 491 460 1045 422 460 434 292 322 360 513 M12 417 280 310 295 698 228 185
boiler recommended dril-
ling template
burner flange

PART I: SPECIFICATIONS
10
*AS/BS: measure referred to burner with standard blast tube providedmeasure referred to burner with standard blast tube provided
*AL/BL: measure referred to burner with extended blast tube providedmeasure referred to burner with extended blast tube provided
A (AS) A (AL) AA AB AC AD B (BS) B (BL) BBCCCD E FG H KLMNOPUUWY Z
RG510 1451 1671 219 217 246 35 310 530 468 1141 571 1313 671 642 329 369 540 496 M14 552 390 390 x 766 328 270
RG515 1451 1671 219 217 246 35 310 530 508 1141 571 1323 681 642 350 390 540 496 M14 552 390 390 x 766 328 270
RG520 1451 1671 219 207 250 35 310 530 508 1141 571 1323 681 642 370 410 540 496 M14 552 390 390 114 880 328 270
RG525 1511 1691 219 197 275 35 350 530 650 1161 571 1341 698 642 434 484 540 496 M14 552 390 390 172 938 434 270
recommended boiler drilling
burner flange

PART II: INSTALLATION
11
MOUNTING AND CONNECTING THE BURNER
Transport and storage
If the product must be stored, avoid humid and corrosive places. Observe the temperatures stated in the burner data table at the begin-
ning of this manual. The packages containing the burners must be locked inside the means of transport in such a way as to guarantee
the absence of dangerous movements and avoid any possible damage.
In case of storage, the burners must be stored inside their packaging, in storerooms protected from the weather. Avoid humid or corro-
sive places and respect the temperatures indicated in the burner data table at the beginning of this manual.
Packing
The burners are dispatched in wooden packages whose dimensions are:
series 9x: 1720 mm x 1270 mm x 1020 mm (L x P x H)
series 5xx: 1800 mm x 1500 mm x 1300 mm (L x P x H)
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are pla-
ced in each packing case.
burner;
light oil flexible hoses;
light oil filter;
gasket to be inserted between the burner and the boiler;
envelope containing this manual.
To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials.
Fitting the burner to the boiler
To install the burner into the boiler, proceed as follows:
make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)
place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;
place the 4 stud bolts (5), according to the burner’s drilling plate described on paragraph “Overall dimensions”;
fasten the 4 stud bolts;
place the ceramic fibre plait on the burner flange;
install the burner into the boiler;
fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture.
After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insu-
lating material (ceramic fibre cord or refractory cement).
The burner is designed to work positioned according to the picture below. For different installations, please contact the Technical
ATTENTION! The equipment must be installed in compliance with the regulations in force, following the manufac-
turer’s instructions, by qualified personnel. All handling operations must be carried out with appropriate
resources and qualified personnel
ATTENTION: Use intact and correctly dimensioned hoisting equipment, conforms to the local regulations and
health and safety regulations. Do not stand under lifted loads.
PART II: INSTALLATION
H
PL
4
1
2
345
6
7
6
Keys
1 Burner
2 Fixing nut
3 Washer
4 Ceramic fibre plait
5 Stud bolt
7Blasttube

PART II: INSTALLATION
12
Department.
Matching the burner to the boiler
The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose
dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in
diameter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with
respect of the application involved. To correctly match the burner to the boiler verify the type of the blast tube . Verify the necessary
input and the pressure in combustion chamber are included in the burner performance curve; otherwise the choice of the burner must
be revised consulting the burner manufacturer. To choose the blast tube lenght follow the instructions of the boiler manufacturer. In
absence of these consider the following:
Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than Dist = 100
mm into the combustion chamber. (please see the picture below)
Pressurised boilers with flame reversal: in this case the blast tube must penetrate Dm 50 ÷ 100 mm into combustion chamber in
respect to the tube bundle plate.(please see the picture below)
The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably- sized
spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).
Handling the burner
The burner is mounted on a support 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.
Note: the figure is indicative only.
WARNING! Carefully seal the free space between blast tube and the refractory lining with ceramic fibre rope or
other suitable means.
WARNING! The handling operations must be carried out by specialised and trained personnel. If these
operations 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 spec-
ifications”).
The unpacked burner must be lifted and moved only by means of a fork lift truck.
SIDE UP
SIDE DOWN
Dist. = 100 mm
DM = 50 ÷ 100 mm
B
A
Dist. DM
A: ceramic fibre
B: refractory wall
AB

PART II: INSTALLATION
13
OIL TRAIN CONNECTIONS
Hydraulic diagrams for light oil supplying circuits
NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n. 4 - Fig. 5).
Installation diagram of light oil pipes
Depending on the installed pump, it is possible to design the plant for single or double pipe feeding line
Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is driven to
the nozzle: a part comes out from the nozzle while the othe part goes back to the pump. In this system, the by-pass plug, if provided,
please read carefully the “warnings” chapter at the beginning of this manual.
1
3
2
Key
1 Manual valve
2 Light oil filter
3 Light oil feeding pump
4 One way valve
5 Flexible hoses
6 Relief valve
NOTE: in plants where gravity or ring feed systems are provided,
install an automatic interception device.
RING CIRCUITGRAVITY CIRCUIT
SUCTION CIRCUIT
From tank
To tank
The burner is supplied with filter and flexible
hoses, all the parts upstream the filter and
downstream the return flexible hose, must be
installed by the customer. As far as the hoses
connection, see the related paragraph.
Key
1 Burner
2 Flexible hoses (fitted)
3 Light oil filter (fitted)
4 Automatic interceptor (*)
5 One-way valve (*)
6 Gate valve
7 Quick-closing gate-valve (outside the tank or boiler rooms)
(*) Only for installations with gravity, siphon or forced cir-
culation feed systems. If the device installed is a solenoid
valve, a timer must be installed to delay the valve closing.
The direct connection of the device without a timer may
cause pump breaks.
Fig. 1 - Double-pipe system

PART II: INSTALLATION
14
must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer.
Double-pipe system: as for the single pipe system, a pipe that connects the tank to the pump’s inlet is used besides another pipe that
connects the pump’s return port to the tank, as well. The excess of oil goes back to the tank: this installation can be considered self-ble-
eding. If provided, the inside by-pass plug must be installed to avoid air and fuel passing through the pump.
Burners come out from the factory provided 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.HP UHE series pumps: a kit (Art.-Nr.:
0841211) is required for the transition from 2-pipe to 1-pipe system
About the use of fuel pumps
Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth,
thus obstructing them.
After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of the
tank, thus avoiding the possibility that they might be sucked into the pump.
On initial commissioning a "dry" operation is foreseen 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.
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.
Pipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal jun-
ctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of jun-
ctions should be kept to a minimum as they are a possible source of leakage.
Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could depo-
sit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) jun-
ctions if possible.
An external filter should always be installed in the suction line upstream the fuel unit.
Diesel filters
ATTENTION: before the burner first start, it is mandatory to fill the adduction pipes with diesel fuel and bleed out residual
air bubbles. Prior to switching on the burner, check direction of rotation of the pump motor by briefly pressing the starter
switch; ensure there are no anomalous sounds during equipment operation, and only then turn on the burner. Neglect to
comply with this requirement will invalidate the burner warranty.
G
G
Suntec TA Pumps Suntec T Pumps
Item Note Connection Max. operating
pressure
Max. operating
temperature
Filtering
degree
Protec-
tion
5 20151PE (*) -3/8” 1 bar -20, 60 °C 100 μ-
6 20201PL (*) -3/8” 1 bar -20, 60 °C 100 μ-
7 GA70501 -1” 4 bar 90 °C 100 μIP65
(*) Supplied per pilot diesel fuel if present

PART II: INSTALLATION
15
Light oil pumps
The pumps provided with these burners are Suntec TA (except mod. RG525).
RG525: Suntec T pump and Suntec TV pressure governor are provided.
1. Inlet G1/2
2. To the nozzle G1/2
3. Return G1/2
4. Pressure gauge port G1/4
5. Vacuum gauge port G1/4
6. Pressure governor
"Note: pump with “C” rotation.
Suntec TV Pressure governor
Suntec TA..
Oil viscosity 3 ÷ 75 cSt
Oil temperature 0 ÷ 150°C
Min. suction pressure - 0.45 bar to avoid gasing
Max. suction pressure 5 bar
Max. return pressure 5 bar
Rotation speed 3600 rpm max.
Suntec T..
Viscosity 3 - 75 cSt
Oil temperature 0 - 150 °C
Minimum suction pressure - 0.45bar to prevent gasing
Maximum suction pressure 5 bar
Rated speed 3600 rpm max.
Key
1 Inlet G3/4
2 Pressure gauge port G1/4
3 Vacuum gauge port to measure the inlet vacuum G1/4
4 To pressure adjusting valve G3/4
Vite di regolazione
della pressione
All'ugello
Entrata
Ritorno
Olio in pressione
Olio by-passato
Pressure adjustment
Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase
pressure, twist adjusting screw 3 clockwise.
To decrease the pressure, twist screw counterclockwise. Tight the lock
nut 4, refit the gasket 2 and the cap nut 1.
Key
1 Cap nut
2 Gasket
3 Adjusting screw
4 Lock nut
5 Gasket

PART II: INSTALLATION
16
Connecting the oil flexible hoses to the pump
To connect the flexible oil hoses to the pump, proceed as follows, according to the pump provided:
1 remove the closing nuts A and R on the inlet and return connections of the pump;
2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the lines: see the arrows marked
on the pump.
For further information, refer to the technical documentation of the pump.
.
Suntec TA. Suntec T..
R
A
R
A

PART II: INSTALLATION
17
BURNERS WITH INVERTER VARIANT (if provided)
The LMV51.300 / LMV52.xxx, HAGC31-CU01 e LMV37.400/LMV26.300 electronic cam burners with fan motor driven by inverter in
addition to the air and fuel adjustment curves also have a fan motor speed adjustment curve.
The LMV5x, HAGC31-CU01 equipment through a sensor controls the fan motor revolutions and with a signal in 4÷20mA controls it
through the inverter.The LMV2x equipment through a sensor controls the fan motor revolutions and with a signal in 0÷10V controls it
through the inverter.
Generally the curve of the inverter goes from 50% to 100% of the engine revolutions. This, in addition to improving the setting of the
burner also allows a saving on the consumption of the fan engine.
Terminal interface with Inverter
KOSTAL Tipo Modello
LMV5
XXXXX M-. MD. xx. xx. x. x. xxx. EI.
XXXXX M-. MD. xx. xx. x. x. xxx. EG.
XXXXX MG. MD. xx. xx. x. x. xxx. EK.
XXXXX MG. MD. xx. xx. x. x. xxx. ER.
LMV2x/3x XXXXX M-. MD. xx. xx. x. x. xxx. EB.
XXXXX MG. MD. xx. xx. x. x. xxx. EC.
A B CD
INVEOR M
INVEOR
Mx-xxxx-xxxx - LP02/LP04-...
LMV5 - HAGC31-CU01 LMV2x/3x
Connection to brake
resistors when provi-
ded
Braking resistances

PART II: INSTALLATION
18
BURNERS WITH INVERTER VARIANT (if provided)
The LMV51.300 / LMV52.xxx e LMV37.400/LMV26.300 electronic cam burners with fan motor driven by inverter in addition to the air
and fuel adjustment curves also have a fan motor speed adjustment curve.
The LMV5x equipment through a sensor controls the fan motor revolutions and with a signal in 4÷20mA controls it through the inverter.
The LMV2x equipment through a sensor controls the fan motor revolutions and with a signal in 0÷10V controls it through the inverter.
Generally the curve of the inverter goes from 50% to 100% of the engine revolutions. This, in addition to improving the setting of the
burner also allows a saving on the consumption of the fan engine..
Terminal interface with Inverter
DANFOSS
Type Model
LMV5
XXXXX M-. MD. xx. xx. x. x. xxx. EI.
XXXXX M-. MD. xx. xx. x. x. xxx. EG.
XXXXX MG. MD. xx. xx. x. x. xxx. EK.
XXXXX MG. MD. xx. xx. x. x. xxx. ER.
LMV2x/3x XXXXX M-. MD. xx. xx. x. x. xxx. EB.
XXXXX MG. MD. xx. xx. x. x. xxx. EC.
Danfoss FC101
Danfoss FC102
Two series of interchangeable Inverters version with
Inverter FC101 and FC102
LMV5 LMV2x/3x
Braking resistances
possibility of use only for FC102

PART II: INSTALLATION
19
ELECTRICAL CONNECTIONS
To execute the electrical connections, proceed as follows:
1 remove the cover from the electrical board, unscrewing the fixing screws;
2 execute the electrical connections to the supply terminal board as shown in the attached wiring diagrams;
3 check the direction of the fan motor (see next paragraph);
1 refit the panel cover.
Rotation of electric motor
Once the electrical connection of the burner is executed, remember to check the rotation of the electric motor. The motor should rotate
according to the “arrow” symbol on the body. In the event of wrong rotation, reverse the three-phase supply and check again the rota-
tion of the motor.
NOTE: the burners are supplied for three-phase 380/400/415/480 V supply, and in the case of three-phase 220/230/240 V sup-
ply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload
tripped relay.
Note on electrical supply
In the case where the power supply of the AUXILIARIES of the phase-phase burner (without a neutral), for the flame detection it is
necessary to connect the RC circuit Siemens between the terminal 2 (terminal X3-04-4 in case of LMV2x, LMV3x, LMV5x, LME7x) of
the base and the earth terminal, RC466890660. For LMV5 control box, please refer to the clabeling recommendations avaible on the
Siemens CD attached to the burner
WARNING! 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 adequate for connection to the mains.
WARNING! before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be
sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the
“Electrical connections” section.
ATTENTION: Connecting electrical supply wires to the burner teminal block MA, be sure that the ground wire is
longer than phase and neutral ones.
WARNING: (only for double stage and progressive burners) The burner is provided with an electrical bridge
between terminals 6 and 7; when connecting the high/low flame thermostat, remove this bridge before connecting
the thermostat.
CAUTION: check the motor thermal cut-out adjustment
LMV2/3... - LMV5...
M
Key
C - Capacitor (22 nF , 250 V)
LME / LMV - Siemens control box
R - Resistor (1 MΩ)
M: Terminal 2 (LGB, LME), Terminal X3-04-4 ( LMV2x, LMV3x,
LMV5, LME7x)
RC466890660 - RC Siemens filter

PART II: INSTALLATION
20
ADJUSTING AIR AND LIGHT OIL FLOW RATE
Light oil nozzles
The oil flow rate can be adjusted choosing a nozzle that suits the boiler/utilisation output and setting the delivery and return pressure
values according to the ones quoted on the following charts.
NOZZLE NOZZLE SUPPLY
PRESSURE (bar)
HIGH FLAME
RETURN PRESSURE (bar)
LOW FLAME
RETURN PRESSURE (bar)
BERGONZO A3 20 11 - 13 5 (recommended))
FLUIDICS WR2/UNIGAS M3 25 See table below 7 (recommended)
FLUIDICS NOZZLE: REFERENCE DIAGRAM (INDICATIVE ONLY)
Tab. 1
NOZZLE SUPPLY PRESSURE = 25 bar
ATTENTION! To achieve the maximum flow rate close completely the return line.
DIMENSIONS
FLOW RATE kg/h
Indicative
pessure on
return (bar)
Min Max
40 13 40 19
50 16 50 22
60 20 60 20
70 23 70 23
80 26 80 23
90 30 90 22
100 33 100 22
115 38 115 21
130 43 130 22
145 48 145 21
160 53 160 21
180 59 180 22
200 66 200 21
225 74 225 22
250 82 250 22
275 91 275 22
300 99 300 23
330 109 330 23
360 119 360 22
400 132 400 22
450 148 450 22
500 165 500 22
550 181 550 22
600 198 600 23
650 214 650 23
700 231 700 23
750 250 750 23
800 267 800 22
850 284 850 22
Pressure on return (psi)
Up to 100kg/h
Over 100kg/h
Flow rate
Atomisation angle
Pressure on return
(bar)
Supply 25 bar
- - - - - Atomisation angle according to the return pressure
      % Flow rate
viscosity at nozzle = 5 cSt