KP1025 KP1030 KP1040 Progressive and fully-modulating gas - heavy oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039123CC Rev. 2 10/2008 WARNINGS 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) 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. GENERAL INTRODUCTION z The equipment must be installed in compliance with the regulations in force, following the manufacturer’s instructions, by qualified personnel. z 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. z Improper installation may cause injury to people and animals, or damage to property, for which the manufacturer cannot be held liable. z 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. z Before any cleaning or servicing operation, disconnect the unit from the mains by turning the master switch OFF, and/or through the cutout devices that are provided. z Make sure that inlet or exhaust grilles are unobstructed. z 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 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. z When a decision is made to discontinue the use of the equipment, those parts likely to constitute sources of danger shall be made harmless. z 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. z For all the units that have been modified or have options fitted then original accessory equipment only shall be used. z 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 warnings z Make sure that the burner has, on installation, been firmly secured to the appliance, so that the flame is generated inside the appliance firebox. z 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. z 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 Technical Service, without trying to RESET further. z The unit shall be operated and serviced by qualified personnel only, in compliance with the regulations in force. 3) z z z z z 2) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED 3a) SPECIAL INSTRUCTIONS FOR BURNERS z z 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. z Only burners designed according to the regulations in force should be used. z This burner should be employed exclusively for the use for which it was designed. z Before connecting the burner, make sure that the unit rating is the same as delivery mains (electricity, gas oil, or other fuel). z Observe caution with hot burner components. These are, usually, near to the flame and the fuel pre-heating system, they become hot during the unit operation and will remain hot for some time after the burner has stopped. When the decision is made to discontinue the use of the burner, the user 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; z 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. 2 DIRECTIVES AND STANDARDS Gas burners European directives: - Directive 90/396/CEE - Gas Appliances; - Directive 2006/95/EC on low voltage; - Directive 2004/108/CEE on electromagnetic compatibility Harmonised standards : -UNI EN 676 (Gas Burners; -CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements; - EN 50165 (Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements. 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS GENERAL z 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. z 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. z 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. z When the burner is to remain idle for some time, the fuel supply tap or taps should be closed. Light oil burners European directives: - Directive 2006/95/EC on low voltage; - Directive 2004/108/CEE on electromagnetic compatibility Harmonised standards : -CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements; - EN 50165 (Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements. National standards : -UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods 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. z Do not use gas pipes to earth electrical equipment. z Never leave the burner connected when not in use. Always shut the gas valve off. z 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. z 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. Heavy oil burners European directives: - Directive 2006/95/EC on low voltage; - Directive 2004/108/CEE on electromagnetic compatibility Harmonised standards : -CEI EN 60335-1 Household and similar electrical appliances - SafetyPart 1: General requirements; - EN 50165 Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements. National standards : -UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods Gas - Light oil burners European directives: - Directive 90/396/CEE Gas Appliances; - Directive 2006/95/EC on low voltage; - Directive 2004/108/CEE on electromagnetic compatibility Harmonised standards : -UNI EN 676 Gas Burners -CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements; - EN 50165 Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements. National standards : -UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods Gas - Heavy oil burners European directives: - Directive 90/396/CEE - Gas Appliances; - Directive 2006/95/EC on low voltage; - Directive 2004/108/CEE on electromagnetic compatibility Harmonised standards : -UNI EN 676 (Gas Burners; -CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements; - EN 50165 Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements. National standards : -UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods 3 CIB UNIGAS - M039123CC PART I: INSTALLATION MANUAL Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type KP1025 (1) (1) BURNER TYPE (2) FUEL Model MN. PR. (2) (3) S. *. A. 1. 80 (4) (5) (6) (7) (8) KP1025 - KP1030 - KP1040 MN - Dual fuel gas-heavy oil Heavy oil, standard viscosity <= 7° E @ 50° C MD - Dual fuel gas-heavy oil <= 50° E @ 50° C ME - Dual fuel gas - Ecological heavy oil viscosity lbetween 7°E and 15°E @ 50° C PR - Progressive MD - Fully modulating S - Standard * - see data plate A - Standard 1 = 2 Gas valves + gas proving systeml 8 = 2 Gas valves + gas proving system + maximum gas pressure switchl 65 = DN65 80 = DN80 100 = DN100 125 = DN125 (3) OPERATIONAvailable versions (4) BLAST TUBE (5) DESTINATION COUNTRY (6) BURNER VERSION (7) EQUIPMENT (8) GAS CONNECTION BURNERS KP1025 Output Fuel Category Viscosity Gas rate Gas pressure Heavy oil rate Power supply Total power consumption Fan motor Pump motor Pre-heating resistors Protection Operation Gas Train DN65 Gas Train DN80 Gas Train DN100 Gas Train DN125 Operating temperature Storage temperature Working service* Note1: KP1030 2550 - 8700 min. - max. kW 227 - 775 kW kW kW kW 71 18.5 4 24+24 270 - 921 Valves size / Gas connection Valves size / Gas connection Valves size / Gas connection Valves size / Gas connection °C °C KP1040 2550 - 13000 (see next paragraph) 50 270 - 1005 270 - 1122 (Note2) 227 - 874 227 - 945 400V 3N ~ 50Hz 76 76 22 22 5.5 5.5 24+24 24+24 IP40 Progressive - Fully modulating °E, 50 °C (Stm3/h) min. - max. mbar min. - max. kg/h KP1030 2550 - 9500 2550 - 10600 Natural gas - Heavy oil 65 / DN65 80 / DN80 100 / DN100 - - 270 - 1376 227 - 1160 84 30 5.5 24+24 80 / DN80 100 / DN100 -10 ÷ +50 -20 ÷ +60 Intermittent 80 / DN80 100 / DN100 125 / DN125 All gas flow rates are referred to Stm3/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (nett calorific value Hi = 34.02 MJ/Stm3). Note2: Maximum gas pressure = 500mbar (with Siemens VGD.. gas valves / Dungs MBC.. gas valves) Minimum gas pressure = see gas curves. * NOTE ON THE BURNER WORKING SERVICE: for safety reasons, one controlled shutdown must be performed every 24 hours of continuous operation. Country and usefulness gas categories 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 I2E LU PL - - - - - - - - - I2E( R ) B BE - - - - - - - - - I2L NL - - - - - - - - I2ELL DE - - - - - - - I2Er FR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 RO TR CH OVERALL DIMENSIONS (mm) Burner flange CIB UNIGAS - M039123CC 5 Recommended boiler drilling DN AS AA BS BB C CC D E F G H J K L M N O P Q R S U V W Y Z 65 2084 377 544 641 1408 680 1931 1299 632 400 450 710 660 828 M16 651 460 460 914 200 714 1092 313 1158 328 330 KP1025 80 2084 377 544 641 1408 680 1933 1301 632 400 450 710 660 842 M16 651 460 460 939 200 739 1092 319 1172 328 330 KP1025 100 2084 377 544 641 1408 680 1949 1317 632 400 450 710 660 855 M16 651 460 460 842 200 642 1092 382 1185 328 330 KP1030 65 2084 377 544 657 1408 680 1931 1299 632 454 504 710 660 828 M16 651 460 460 914 200 714 1092 293 1158 372 330 KP1030 80 2084 377 544 657 1408 680 1933 1301 632 454 504 710 660 842 M16 651 460 460 939 200 739 1092 319 1172 372 330 KP1030 100 2084 377 544 657 1408 680 1949 1317 632 454 504 710 660 855 M16 651 460 460 842 200 642 1092 382 1185 372 330 KP1040 80 2084 377 544 657 1408 680 1933 1301 632 514 564 710 660 842 M16 651 460 460 939 200 739 1092 319 1172 372 330 KP1040 100 2084 377 544 657 1408 680 1949 1317 632 514 564 710 660 855 M16 651 460 460 842 200 642 1092 382 1185 372 330 KP1025 *DN = gas valves size NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves. CIB UNIGAS - M039123CC Performance curves BACK PRESSURE IN COMBUSTION CHAMBER mbar KP1025 DN65 - DN80 - DN100 35 30 25 20 15 10 5 0 2000 3000 4000 5000 6000 7000 8000 9000 kW BACK PRESSURE IN COMBUSTION CHAMBER mbar KP1030 DN65 KP1030 DN80 - DN100 35 35 30 30 25 25 20 20 15 15 10 10 5 5 0 2000 3000 4000 5000 6000 7000 8000 9000 10000 0 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 kW BACK PRESSURE IN COMBUSTION CHAMBER mbar KP1040 kW 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. 6 kW CIB UNIGAS - M039123CC Pressure in the network - gas rate curves KP1025 M-....1.xx 400 GAS PRESSURE mbar DN65 300 200 DN80 100 DN100 0 150 250 350 450 550 650 750 850 950 Stm3/h KP1030 M-....1.xx KP1030 M-.....65 600 250 GAS PRESSURE mbar DN80 200 400 150 DN100 100 200 50 0 200 0 400 600 800 200 1000 Stm3/h GAS PRESSURE mbar KP1040 M-....1.xx Stm3/h 7 400 600 800 1000 1200 Stm3/h CIB UNIGAS - M039123CC MOUNTINGS AND CONNECTIONS Packing The burners are despatched wooden cages whose dimensions: Burner: 2280mmx 1730mm x 1360mm (L x P x H) Pumping unit: 1170mm x 770mm x 1610mm (L x P x H) Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing case: 1 1 2 1 1 burner with gas train detached; ceramic fibre plait to be inserted between the burner and the boiler; flexible oil pipes; oil filter; envelope containing this manual H L P To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials. Handling the burner Eyebolts ATTENTION! the lfting and moving operations must be carried out by specialised and trained personnel. If these operations are not carried out perfectly, there is the residual risk of the burner to overturn and fall down. As for moving the burner, use means suited for the weight to sustain (see paragraph “Technical specifications”). The burner is provided with eyebolts, for handling operations. Fitting the burner to the boiler To perform the installation, proceed as follows: 1 drill the furnace plateas decribed in paragraph (“Overall dimensions”); 2 place the burner towards the furnace plate: lift and move the burner by means of its eyebolts placed on the top side (see”Lifting and moving the burner”); 3 screw the stud bolts (5) in the plate holes, according to the burner’s drilling plate described on paragraph “Overall dimensions”; 4 place the gasket on the burner’s flange; 5 install the burner into the boiler; 6 fix the burner to the stud bolts, by means of the fixing nuts, according to Fig. 1. 7 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). Keys 4 1 2 3 4 5 7 Burner Fixing nut Washer Ceramic fibre plait Stud bolt Blast tube Fig. 1 Set the upper side of the burner flange in a horizontal position, in order to obtain the correct inclination of the pre-heating tank. Key 1 Burner flange (upper side indicated) 1 2 Bracket 3 Pre-heating tank on the burner 2 3 8 CIB UNIGAS - M039123CC 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 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: z Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than 100 mm into the combustion chamber. z Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in respect to the tube bundle plate. 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). Gas train connections The diagrams show the components of the gas train included in the delivery and which must be fitted by the installer.The diagrams are in compliance with the current laws. ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED. READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL. Gas train - 1: Gas train with valves group VGD 20/40 with built-in gas pressure governor + VPS504 gas proving system MANUFACTURER 4 INSTALLER 5 1 2 6 7 8 7 8 11 3 15 15 4 14 Gas train 3(DN65/80/100): Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor + pressure switch) + VPS504 gas proving system MANUFACTURER 19 4 INSTALLER 5 1 6 2 4 7 8 7 8 14 3 15 15 9 CIB UNIGAS - M039123CC Gas train 3(DN125): Gas train with valves group VGD40 (2 valves + gas filter + pressure governor + pressure switch)+gas leakage pressure switch (PGCP)+Siemens LDU11/LMV + ignitor gas train 4 16 5 MANUFACTURER INSTALLER 1 7 6 2 8 11 4 15 14 15 7 1 2 3 4 5 6 7 8 10 14 15 18 19 Burner Butterfly valve Gas proving system Maximum gas pressure switch (option) Minimum gas pressure switch Gas filter Bellow joint 8 Manual cutoff valve VGD Valves group Pressure stabiliser with filter Pilot gas valve MBC Valves group (2” with filter provided) MBC Valves group (DN65/80/100) The pilot gas train is already installed to the burner, the following connections must be executed: z connection from the filter with stabiliser to the gas supply network z connection from the valve to the main gas train, by means of the pipe provided with the burner. connection from the pilot gas train to the gas valves group of the main train connection to the gas supply network 3 SIEMENS VGD40.. DUNGS MBC3100-5000SE Fig. 2-pipe port (3) for connecting the pilot gas train to the valves group of the main gas train 10 CIB UNIGAS - M039123CC Assembling the main gas grain gas supply network ”direction” arrows for installation 1A 5 Keys 1B 3 1A..1E 2 3 4 5 1E 1C 1D 4 2 Gasket Gas filter Gas valves group Bellow joint Manual cock Fig. 3 - 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. 3) between the elements NOTE: the bellow joint, the manual cock and the gaskets are not part of the standard supply. ATTENTION: once the gas train is mounted according to the diagram on Fig. 3, the gas proving test mus be performed, according to the procedure set by the laws in force. The procedures of installation fo the gas valves are shown in the next paragraphs, according to the gas train used: threaded gas trains with Multibloc Dungs MBC..SE 1200 or Siemens VGD20.. z flanged gas trains with Multibloc Dungs MBC..SE 1900-3100-5000 or Siemens VGD40.. z MULTIBLOC DUNGS MBC1900-3100-5000SE (Flanged valves group) Mounting 1. Insert setscrews A 2. Insert seals 3. Insert setscrews B 4. Tighten setscrews A + B. Ensure correct seating of the seal! 6. After installation, perform leakage and functional test. 7. Disassembly in reverse order. # # # # Mounting positions OPTION " " " njo/!6!y!EO " 21 EO 2 Fig. 4 22 10 = pulse lines Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure stabiliser) Mounting z When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded); z to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts; z install the valve; z the direction of gas flow must be in accordance with the direction of the arrow on the valve body; z ensure that the bolts on the flanges are properly tightened; z ensure that the connections with all components are tight; 11 CIB UNIGAS - M039123CC z make certain that the O-rings and gaskets between the flanges and the double gas valve are fitted. z Connect the reference gas pipe (TP in figure), to the gas pressure nipples placed on the gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size . Leave the blowhole free (SA in figure). Should the spring fitted not permit satisfactory regulation, ask one of our service centres for a suitable replacement. WARNING: removing the four screws BS causes the device to be unserviceable! SIEMENS VGD..MOUNTING POSIBS TP TIONS SA BS BS BS SKP1. SKP2. 7631z05/0101 Fig. 7 Fig. 6 Fig. 5 Pressure adjusting range The pressure adjusting range, downstream the gas valves group, changes according to the spring provided with the valve group. 1 1 2 2 DUNGS MBC..SE Siemens SKP actuator Keys 1 spring 2 cap DUNGS MBC valves: Performance range (mbar) 4 - 20 20 - 40 40 - 80 80 - 150 - ed black green Performance range (mbar) 0 - 22 15 - 120 100 - 250 Spring colour neutral yellow red Spring colour Siemens VGD valves with SKP actuator: Once the train is installed, connect electrically all its elements: gas valves group, pressure switches, gas proving system. ATTENTION: once the gas train is mounted according to the diagram on Fig. 3, the gas proving test mus be performed, according to the procedure set by the laws in force. 12 CIB UNIGAS - M039123CC Hydraulic system The pumps that are used can be installed both into single-pipe and double-pipe systems. 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, 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-bleeding. 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-stage 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-rotation- referring to the pump shaft). Caution: Changing the direction of rotation, all connections on top and side are reversed. Suntec T G Bleed Bleeding in two-pipe operation is automatic : it is assured by a bleed flat on the piston. In one-pipe operation, the plug of a pressure gauge port must be loosened until the air is evacuated from the system. About the use of fuel pumps z z z z z z z z Make sure that the by-pass plug is not used in a single pipe installation, because the fuel unit will not function properly and damage to the pump and burner motor could result. 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 junctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of junctions 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 deposit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) junctions if possible. An external filter should always be installed in the suction line upstream of the fuel unit. Oil pumps Suntec T pump Viscosity 4 - 800 cSt Oil temperature 0 - 140 °C Minimum suction pressure - 0,45bar to prevent gasing Maximum suction pressure 5 bar Rated speed 3600 rpm max. Key 1 To pressure adjusting valve G3/4 2 Pressure/vacuum gauge port to measure the inlet pressure/vacuum G1/4 3 Pressure gauge port G1/4 4 Inlet G3/4 13 CIB UNIGAS - M039123CC Suntec TV Pressure governor 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 Fig. 8 Assembling the light oil flexible hoses To connect the flexible light 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 inlet and return lines: see the arrows marked on the pump that show the inlet and the return (see previous paragraph). Suntec T R A 14 CIB UNIGAS - M039123CC Connections to the oil gun 1 Inlet (C) Gun with the oil nozzle inside 5 4 2 Return (B) 3 Lance opening (A) 4 Heating wire (only for high density oil burners) 5 Cartdrige-type heater (only for Ecoden or heavy oil burners) 3 2 1 Distribution block 5 1 2 3 15 CIB UNIGAS - M039123CC Guidelines for the appropriate use of heavy oil For a correct operation of heavy oil or dual fuel burners (gas - heavy oil), the supply plant must be correctly build and it must ensure two fundamental conditions: z CONSTANT PRESSURE z CONSTANT TEMPERATURE Here below we explain why it is essential to heat the oil and keep it under pressure. Consider, as an example, a fuel oil with the following properties: z Fuel oil BTZ (low sulphur rate) z Viscosity from 3 to 5 °E at 50 °C Such a fuel (see curve n. 3 in Fig. 9), at a temperature of 20° C, changes its viscosity from 3 - 5 °E to 15-20 °E and, at 10° C the viscosity exceeds 40° E. In such conditions, obviously, the fuel couldn’t be carried from the tank to the burner. Once the oil has been heated, it can’t be sucked by the burner pump, unless you keep it in pressure. In fact, as showed on drawing in Fig. 11, the pump manufacturer states that the minimum feeding pressure must be 1 bar at 40 °C temperature. Should you try to suck the heated oil directly from the tank, you could get cavitation. The burner pump would constantly loose pressure as long as you heat the fuel. In this way you bring the nozzle pressure to values different from the one stated by the nozzle manufacturer. In such way the atomization would result incorrect. From the diagram in Fig. 10, you will find the pre-heating temperature of the oil according to viscosity and, from diagram in Fig. 11, you get the pump feeding pressure according to temperature. Therefore, it is necessary in order to set up a suitable oil circuit, look at the diagrams in Fig. 13 and Fig. 14, taken from UNI 9248 “FEEDING LINES FOR LIQUID FUELS TRANSPORT FROM TANK TO BURNER”. In any case, whatever is the choosen solution to realise the oil circuit, you must act according to what is mentioned here above (constant pressure and constant temperature). After setting up the feeding circuit, you have to decide the temperature and pressure values to be set up in the components of the feeding pipeline and of the burner. Please find here below, a set up table regarding several types of fuels. FUEL VISCOSITY AT 50 °C PIPELINE PRESSURE PIPELINE TEMPERATURE* °E bar °C PUMP SUPPLY TEMPERATURE (DIAGRAM IN Fig. 12) °C Fluid BTZ (ecoflu) 3 7 1-2 20 30 High viscosity BTZ (Ecoden) 7 15 1-2 50 50 High viscosity 15 50 1-2 65 80 Tab. 1 - Supply pipeline FUEL VISCOSITY AT 50 °C NOZZLE PRESSURE MEASURED IN THE GUN °E bar TEMPERATURE ON TEMPERATURE TEMPERATURE TEMPERATURE THE PRE-HEATING OF THE ON THE OIL ON THE PLANT RESISTORS RESISTORS ENABLING ENABLING THERMOSTAT SAFETY THERMOSTAT THERMOSTAT TR* THERMOSTAT TCN TCI TRS min. max. min. max. bar °C °C °C °C RETURN NOZZLE PRESSURE Fluid BTZ (ecoflu) 3 7 25 7 20 100 115 190 80 - High viscosity BTZ (Ecoden) 7 15 25 7 20 125 140 190 100 60 - 80 High viscosity 15 50 25 7 20 145 160 190 110 70 - 90 Tab. 2 - Burner * The temperature in the pre-heater must be set to get a viscosity in the nozzle from 1.4 to 1.6 °E. 16 CIB UNIGAS - M039123CC VISCOSITY UNITS CONVERSION TABLE Cinematics Engler (Degrees) °E Cinematics (Centistokes) cSt Cinematics (Centipoises) cps Saybolt Universal (Seconds) S.S.U. 2.95 20.60 20.60 100 88.4 3.21 23.00 23.00 110 97.1 3.49 25.3 25.3 120 105.9 3.77 27.5 27.5 130 114.8 4.04 29.8 29.8 140 123.6 4.32 32.1 32.1 150 132.4 4.59 34.3 34.3 160 141.1 4.88 36.5 36.5 170 150.0 5.15 38.7 38.7 180 158.8 5.44 41.0 41.0 190 167.5 5.72 43.2 43.2 200 23 176.4 6.28 47.5 47.5 220 25.3 194.0 6.85 51.9 51.9 240 27.0 212 7.38 56.2 56.2 260 28.7 229 7.95 60.6 60.6 280 30.5 247 8.51 64.9 64.9 300 32.5 265 9.24 70.4 70.4 325 35.0 287 9.95 75.8 75.8 350 37.2 309 10.7 81.2 81.2 375 39.5 331 11.4 86.6 86.6 400 42.0 353 12.1 92.0 92.0 425 44.2 375 12.8 97.4 97.4 450 47.0 397 13.5 102.8 102.8 475 49 419 14.2 108.2 108.2 500 51 441 15.6 119.2 119.2 550 56 485 17.0 120.9 120.9 600 61 529 18.5 140.7 140.7 650 66 573 19.9 151.3 151.3 700 71 617 21.3 162.3 162.3 750 76 661 22.7 173.2 173.2 800 81 705 24.2 184.0 184.0 850 86 749 25.6 194.8 194.8 900 91 793 27.0 206 206 950 96 837 28.4 216 216 1000 100 882 34.1 260 260 1200 212 1058 104 39.8 303 303 1400 141 1234 122 45.5 346 346 1600 160 1411 138 51 390 390 1800 180 1587 153 57 433 433 2000 200 1703 170 71 541 541 2500 250 2204 215 85 650 650 3000 300 2646 255 99 758 758 3500 350 3087 300 Tab. 3 17 Saybolt Furol (Seconds) S.S.F. Redwood n. 1 (Seconds) R.S.I Redwood n. 2 (Seconds) R.S.II CIB UNIGAS - M039123CC VISCOSITY vs TEMPERATURE DIAGRAM FOR COMBUSTIBLE OILS 1000 PUMPING LIMIT VISCOSITY (°E) 100 10 1 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 TEMPERATURE (°C) LIGHT OIL 1,3°E AT 20°C HEAVY OIL 2,4°E AT 50°C HEAVY OIL 4°E AT 50°C HEAVY OIL 7,5°E AT 50°C HEAVY OIL 10°E AT 50°C HEAVY OIL 13°E AT 50°C HEAVY OIL 22°E AT 50°C HEAVY OIL 50°C HEAVY OIL 47°E AT 50°C HEAVY OIL 70°E AT 50°C HEAVY OIL 200°E AT 50°C Fig. 9 The burners must be feeded with fuel with a minimum temperature at the pump inlet, as a function of the oil viscosity, as indicated in Fig. 9, Fig. 10 and Fig. 12. 18 CIB UNIGAS - M039123CC Minimum feeding temperature vs. oil viscosity OIL TEMPERATURE FOR PUMP FEEDING VISCOSITY (°E a 50°C) 100 10 1 0 10 20 30 40 50 60 70 80 90 TEMPERATURE (°C) Fig. 10 Pumps operating range PUMP FEEDING PRESSURE 6 Max. for T and TA pumps PRESSURE (bar) 5 Max. for E ..1069 pimps 4 3 2 1 0 40 60 80 100 120 140 160 TEMPERATURE (°C) Fig. 11 The use of heavy oil forces to feed the burner to a pressure strictly related to the oil temperature. This avoids damage to the pump caused by gassification. VISCOSITY vs. TEMPERATURE DIAGRAM 2 VISCOSITY (°E) 1.9 1.8 1.7 1.6 BEST VISCOSITY RANGE FOR A PROPER ATOMIZATION 1.5 1.4 1.3 1.2 50 60 70 3°E AT 50°C 5°E AT 50°C 7°E AT 50°C 12°E AT 50°C 15°E AT 50°C 20°E AT 50°C 50°E AT 50°C 80 90 100 110 120 130 140 150 160 170 180 TEMPERATURE (°C) Fig. 12 19 CIB UNIGAS - M039123CC HYDRAULIC DIAGRAMS Fig. 13 - Hydraulic diagram 3ID0023 - Single burner configuration 20 CIB UNIGAS - M039123CC Fig. 14 - Hydraulic diagram 3ID0014 - Two or more burners configuration 21 CIB UNIGAS - M039123CC Hydraulic Diagram 3ID0014 Hydraulic Diagram 3ID0023 1 Main tank 1 Main tank 2 Bottom valve 2 Bottom valve 3 Main tank pre-heating pipe 3 Main tank pre-heating pipe 4 Oil filter (filtration, 1mm) 4 Oil filter 5 Circuit pressure regulator 5 Circuit pressure regulator 6 Manometer 6 Manometer 7 Pressure regulation by-pass valve 7 Pressure regulation by-pass valve 8 Manual valve 8 Manual valve 9 Oil pump 9 Oil pump 10 Pump pressure regulator 10 Pump pressure regulator 11 Unidirectional valve 11 Unidirectional valve 12 Service tank pre-heating resistor 12 Service tank pre-heating resistor 13 Service tank pre-heating thermostat 13 Service tank pre-heating thermostat 14 Burner consent thermostat 14 Burner consent thermostat 15 Thermometer 15 Thermometer 16 Consent pressure switch for service tank resistor 16 Consent pressure switch for service tank resistor 17 Service tank heating pipe 17 Service tank heating pipe 18 Service tank air drain valve 18 Service tank air drain valve 19 Service tank 19 Service tank 20 Oil filter 20 Oil filter 21 Fuel solenoid valve 21 Fuel solenoid valve 22 Fuel valve 22 Fuel valve 23 Burner pump flexible hoses 23 Burner pump flexible hoses 24 Burner oil pump 24 Burner oil pump 25 Pre-heating tank resistor 25 Pre-heating tank resistor 26 Pre heating tank 26 Pre heating tank 27 Oil consent thermostat 27 Oil consent thermostat 28 Heather safety thermostat 28 Pre-heating tank resistors safety thermostat 29 Thermostat for oil temperature setting 29 Thermostat for oil temperature setting 30 Tank filter 30 Pre-heating tank filter 31 Thermometer 31 Thermometer 32 Check valve 32 Check valve 34 Burner safety solenoid valve 33 Return pressure regulator 35 Oil needle drive piston 34 Burner safety solenoid valve 36 Oil rate regulator 35 Oil needle drive piston 37 Burner consent thermostat 36 Three way valve for piston drive 42 Burner start consent thermostat 37 Burner consent thermostat 43 Burner 42 Air separation bottle 45 Thermostat for pipes pre-heating pumps 43 Burner 46 Water pump for service tank pre-heating (1) 45 Thermostat for pipes pre-heating pumps 47 Water pump for main tank pre-heating (19) 46 Water pump for service tank pre-heating (1) 48 Water pre-heating balance setting valve 47 Water pump for main tank pre-heating (19) 50 Oil circulation pump 48 Valves for setting of pre-heating water balance 52 Oil ring max. pressure switch 52 Oil ring max. pressure switch 22 CIB UNIGAS - M039123CC Electrical connections 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. ATTENTION: 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. z z Remove the cover of the electrical board mounted on the burner. Execute the electrical connections to the power supply terminal board as shown here following, check the direction of rotation of the fan motor and pump motor (see next paragraph) and refit the electrical board cover. WARNING: The burner is provided with a jumper between terminals 6 and 7; in the event of connecting the high/low flame thermostat remove this jumper before connecting the thermostat. IMPORTANT: while connecting electric supply wires to burner’s teminal block be sure that ground wire should be longer than phase and neutral ones. Probes connection Morsettiera alimentazione piastra 1 Morsettiera alimentazione piastra 2 (**) Probes connection (Fig. 15) Connecting the oil heating resistors ELECTRIC MOTOR CONNECTION 18 - 24 kW 400 V 400 V 230V 230V W2 U2 V2 U1 V1 W1 W2 U2 V2 L1 L1 R1 R6 R1 R2 R5 R3 L2 R2 R6 L2 U1 R3 R5 V1 W1 R4 L3 R4 L3 L1 L2 L1 L3 L2 L3 Fig. 15 As for a complete decription of electrical diagrams, see “Electrical wiring diagrams”. Rotation of fan motor and pump motor Once the electrical connection of the burner is executed, remember to check the rotation of the motor. The motor should rotate according to the indication on the body. In the event of wrong rotation, reverse the three-phase supply and check again the rotation of the motor. 23 CIB UNIGAS - M039123CC ADJUSTMENTS Oil thermostat adjustment To find the thermostats, remove the cover of the burner switchboard. Adjust them using a screwdriver on the VR screw as shown in the next picture. NOTE: thermostat TCI is provided on burners fired with fuel oil having a 50° E at 50° C viscosity only. TCN - Oil enabling thermostat (Fig. 16) Adjust this thermostat to a value 10% lower than that showed in the viscosity-temperature diagram (Fig. 9). TRS - Resistor safety thermostat (Fig. 16) The thermostat is set during factory testing at about 190° C. This thermostat trips when the operating temperature exceeds the set limit. Ascertain the cause of the malfunction and reset the thermostat by means of the PR button. PR VR VR TR - Resistor thermostat (Fig. 16) Adjust this thermostat to the correct value according to the viscosity-temperature diagram (Fig. 9) and check the temperature by using a thermometer with a scale of up to 200° C mounted on the pre-heating tank. VR Fig. 16 TCI - Plant enabling thermostat (Fig. 16) This thermostat is fitted on burners fired with oil at a viscosity of 50° E at 50° C only. Set the thermostat according to the data showed on page 16. Adjusting air and gas flow rates ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed. .ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide); if this should happen, make the gas decrease slowly until the normal combustion values are achieved. WARNING: NEVER LOOSE THE SEALED SCREWS! OTHERWISE, THE DEVICE WARRANTY WILL BE IMMEDIATELY INVALIDATE! IMPORTANT! the combustion air excess must be adjusted according to the in the following chart. Recommended combustion parameters Fuel Recommended (%) CO2 Recommended (%) O2 Natural gas 9 ÷ 10 3 ÷ 4.8 Heavy oil <=7°E a 50 °C 11 ÷ 12 4.2 ÷ 6.2 Heavy oil >=7°E a 50 °C 11 ÷ 12.5 4.7 ÷ 6.7 24 CIB UNIGAS - M039123CC 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 servocontrol are at the maximum opening. Refer to Fig. 17, 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. 1 2 4 3 Fig. 17 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 pressure outlet (Fig. 17-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig. 17-3). 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 combustion 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. 25 CIB UNIGAS - M039123CC Pressure in combustion head - gas rate curves KP1030 GAS PRESSURE mbar KP1025 100 90 80 70 60 50 40 30 20 10 0 100 90 80 70 60 50 40 30 20 10 0 150 350 550 750 950 1150 400 600 800 1000 1200 Stm3/h Stm3/h GAS PRESSURE mbar KP1040 Stm3/h Gas Filter The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burners, counters and regulators) from becoming rapidly blocked. The filter is normally installed upstream from all the control and on-off devices. VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off valves. This check is carried out as soon as the boiler thermostat gives a start signal to the burner, creating, by means of the diaphragm pump inside it, a pressure in the test space of 20 mbar higher than the supply pressure. When wishing to monitor the test, install a pressure gauge ranged to that of the pressure supply point PA. If the test cycle is satisfactory, after a few seconds the consent light LC (yellow) comes on. In the opposite case the lockout light LB (red) comes on. To restart it is necessary to reset the appliance by pressing the illuminated pushbutton LB. LC LB PA Fig. 18 26 CIB UNIGAS - M039123CC Adjusting the pilot gas flow rate: gas pressure adjusting pilot valve Brahma EG12*R and pressure governor To change the pilot gas valve flow rate, proceed as follows: 1 remove the protection on the bottom of the valve, moving it counterclockwise (see next picture); 2 rotate clockwise the nut 1 as shown in to close the valve or counterclockwise to open. To perform a finest adjustment, act directly on the pressure stabiliser as follows (see next picture): 3 remove the cap T: to increase the gas pressure at the outlet use a screwdriver on the screw TR as shown below. Screw to increase the pressure, unscrew to decrease; once the regulation is performed, replace cap T. TR T 1 Pressure stabiliser Brahma gas valve EGR*12 Adjustments - brief description Adjust the air and gas flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respectively. z Check that the combustion parameters are in the suggested limits. z z z Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a differential pressure gauge, as described on par. “Measuring the gas pressure in the combustion head” on page 25. Then, adjust the combustion values corresponding to the points between maximum and minimum: set the shape of the adjusting cam foil. The adjusting cam sets the air/gas ratio in those points, regulating the opening-closing of the throttle gas valve. Set, now, the low flame output, acting on the low flame microswitch of the actuator in order to avoid the low flame output increasing too much or that the flues temperature gets too low to cause condensation in the chimney. Adjustment procedure To change the burner setting during the testing in the plant, follow the next procedure. On the DUNGS MBC..SE gas valves group, set the pressure regulator to 1/3 of its stroke, using a 2.5 allen key. 1#S *OOFOTFDITLBOUTDIMàTTFM/P "MMFOLFZOP $MÏEFTJYQBOTNÉMFOP $IJBWFFTBHPOBMFDBWBOS Pressure setting 27 CIB UNIGAS - M039123CC I II III IV V MAN Actuator cams I II III IV V AUTO 1 2 3 4 5 6 7 8 High flame Stand-by and Ignition Low flame (gas) Low flame (oil) Stroke limitation turn the burner on by selecting GAS fuel by means of the burner CM switch (it is placed on the burner control panel - see page 35) check the fan motor rotation (see page 23). Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner operates at the lowest output) to safely achieve the high flame stage. Start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and that the burner starts up; drive the burner to high flame stage, by means fo the thermostat TAB. Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion values and eventually adjusting the gas by means of the valves group stabiliser. go on adjusting air and gas flow rates: check, continuosly, the flue gas analisys, as to avoid combustion with little air; dose the air according to the gas flow rate change following the steps quoted below; acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler/utilisation: - Siemens VGD valves group: remove cap T and act on the VR adjusting screw to increase or decrease the pressure and consequently the gas rate; screwind VR the rate increases, unscrewing it decreases (see next figure). - Dungs MBC..SE valves group: act on its pressure governor to increase or decrease the pressure and consequently the gas rate. T VR 1#S : 9 *OOFOTFDITLBOUTDIMàTTFM/P "MMFOLFZOP $MÏEFTJYQBOTNÉMFOP $IJBWFFTBHPOBMFDBWBOS Dungs MBC..SE Siemens VGD.. To adjust the air flow rate in the high flame stage, loose the RA nut and screw VRA as to get the desired air flow rate: moving the rod TR towards the air damper shaft, the air damper opens and consequently the air flow rate increases, moving it far from the shaft the air damper closes and the air flow rate decreases. Note: once the procedure is perfomed, be sure that the blocking nut RA is fasten. Do not change the position of the air damper rods. TR VRA RA 10 Only if necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when 28 CIB UNIGAS - M039123CC the adjustment is accomplished. “MAX” head position VB VRT ”MIN” head position Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above. 11 the air and gas rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV1 (gas side) adjusting cam as to reach the minimum output point. SV1 V1 V1 SV1 SC Gas throttle valve open ID1 Gas throttle valve closed 12 as for the point-to-point regulation, move the gas low flame microswitch (cam III) a little lower than the maximum position (90°); 13 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position; 14 move cam III to the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw that refers to the lower position: screw V1 to increase the rate, unscrew to decrease. 15 Move again cam III towards the minimum to meet the next screw on the adjusting cam and repeat the previous step; go on this way as to reach the desired low flame point. 16 Now adjust the pressure switches (see next paragraph). Adjsting the air and gas pressure switches The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of the control box unlock pushbutton, placed on the burner control panel. The gas pressure switches check the pressure to avoid the burner operate when the pressure value VR is not in the requested pressure range. Calibration of air pressure switch To calibrate the air pressure switch, proceed as follows: z Remove the transparent plastic cap. z Once air and fuel setting have been accomplished, startup the burner. z During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction (to increase the adjusting pressure) until the burner lockout, then read the value on the pressure switch scale and set it to a value reduced by 15%. z Repeat the ignition cycle of the burner and check it runs properly. z Refit the transparent plastic cover on the pressure switch. Calibration of low gas pressure switch As for the gas pressure switch calibration, proceed as follows: z Be sure that the filter is clean. z Remove the transparent plastic cap. z While the burner is operating at the maximum output, test the gas pressure on the pressure port of the minimum gas pressure 29 CIB UNIGAS - M039123CC z z z z z switch. Slowly close the manual cutoff valve (placed upstream the pressure switch, see gas train installation diagram), until the detected pressure is reduced by 50%. Pay attention that the CO value in the flue gas does not increase: if the CO values are higher than the limits laid down by law, slowly open the cutoff valve as to get values lower than these limits. Check that the burner is operating correctly. Clockwise turn the pressure switch adjusting ring nut (as to increase the pressure value) until the burner stops. Slowly fully open the manual cutoff valve. Refit the transparent plastic cover on the pressure switch. Adjusting the high gas pressure switch (when provided) To calibrate the high pressure switch, proceed as follows: 1 remove the plastic cover; 2 measure the gas pressure in the network, when flame is off; 3 by means of the adjusting ring nut VR, set the value read on step 2, increased by the 30%; 4 replace the plastic cover. PGCP Gas leakage pressure switch (witn SiemensLDU/Siemens LMV burner control) z z z remove the pressure switch plastic cover; adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch; replace the plastic cover.; Fully modulating burners To adjust the fully-modulating burners, use the CMF switch on the burner control panel (see next picture), instead of the TAB thermostat as described on the previous paragraphs about the progressive burners. Go on adjusting the burner as described before, paying attention to use the CMF switch intead of TAB. The CMF position sets the oprating stages: to drive the burner to the high-flame stage, set CMF=1; to drive it to the low-flame stage, set CMF=2. To move the adjusting cam set CMF=1 or 2 and then CMF=0. CMF = 0 CMF = 1 CMF = 2 CMF = 3 CMF 30 stop at the current position high flame operation low flame operation automatic operation CIB UNIGAS - M039123CC Adjusting heavy oil flow rate The oil flow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the chart below and the diagram on Fig. 19 (as far as reading the pressure values, see next paragraphs). NOZZLE DELIVERY PRESSURE bar RETURN PRESSURE MAX. bar RETURN PRESSURE MIN. bar FLUIDICS WR2/BERGONZO B 25 20 7 (recommended) BERGONZO C 25 20 7 (recommended) Tab. 4 Fig. 19 FLOW RATE kg/h DIMENSIONS Min Max 40 13 40 50 16 50 60 20 60 70 23 70 80 26 80 90 30 90 100 33 100 115 38 115 130 43 130 145 48 145 160 53 160 180 59 180 200 66 200 225 74 225 250 82 250 275 91 275 300 99 300 330 109 330 360 119 360 400 132 400 450 148 450 500 165 500 550 181 550 600 198 600 650 214 650 700 231 700 750 250 750 800 267 800 Pressure at nozzle 25bar Pressure at nozzle 357psi Atomisation angle Pressure on return Pressure on return Up to 100kg/h Over 100kg/h % Flow rate ---------------Atomisation angle according to the return pressure _________ % Flow rate Example: as for over 100kg/h nozzles, the 80% of the nozzle flow rate can be obtained with a return pressure at about 18bar (see Fig. 19). 31 CIB UNIGAS - M039123CC Pump flow rate Nozzle flow rate Fig. 20 - Bergonzo nozzle - example with 850kg/h nozzle 1 2 Once the air and gas flow rates are adjusted, turn the burner off, turn the burner on again by means of the CM selector to switch to the heavy oil operation (OIL, on the burner control panel - see page 35). with the electrical panel open, prime the oil pump acting directly on the related CP contactor (see next picture): check the pump motor rotation and keep pressing for some seconds until the oil circuit is charged; 32 CIB UNIGAS - M039123CC 3 bleed the air from the M pressure gauge port (Fig. 21) by loosing the cap without removing it, then release the contactor. Suntec T.. M CP VR 4 5 6 7 8 Fig. 21 Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner operates at the lowest output) to achieve safely the high flame stage . record the high flame value set during the gas operation adjustments (see previous paragraphs); start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and that the bruner starts up; drive the burner to high flame stage, by means fo the thermostat TAB. Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion values and eventually adjusting the oil pressure (see next step). I II III IV V Servocontrol cams MAN I II III IV V AUTO 9 High flame Stand-by and Ignition Low flame (gas) Low flame (oil) Stroke limitation the nozzle suplly pressureis already factory-set and must not be changed. Only if necessary, adjust the supply pressure as follows (see related paragraph);insert a pressure gauge into the port shown on Fig. 22 and act on on the pump adjusting screw VR (see Fig. 21 and page 13) as to get the nozzle pressure at 25bar (according to the nozzle model provided- see page 31). Pressure gauge port PG RP V2 SV2 Fig. 22 Fig. 23 10 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge) without changing the air flow rate set during the gas operation adjustments (see previous paragraph): checking always the combustion parameters, the adjustment is to be performed by means of the SV2 adjusting cam screw (see picture above) when the cam has reached the high flame position. 11 as for the point-to-point regulation in order to set the cam foil shape, move the oil low flame microswitch (cam IV) a little lower than the maximum position (90°); 12 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position; 13 move cam IV (oil low flame) towards the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw that refers to a lower position: screw V2 to increase the rate, unscrew to decrease, in order to get the pressure as 33 CIB UNIGAS - M039123CC 14 15 16 17 shown on chart/diagram on “Adjusting heavy oil flow rate” on page 31, according to the requested rate. Move again cam V towards the minimum to meet the next screw on the adjusting cam and repeat the previous step; go on this way as to reach the desired low flame point. The low flame position must never match the ignition position that is why cam IV must be set 20°- 30° more than the ignition position. Set cam V (“stroke limitation cam”) 5° higher than the lowest “low flame cam” (cam III or cam IV). Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps. 18 Replace the actuator and control panel covers. As far as fully-modulating burners, see paragraph “Fully modulating burners” on page 30. Heavy oil gun Fig. 24 - Nozzle pre-purge Fig. 25 -Ignition Fig. 26 -High flame 34 CIB UNIGAS - M039123CC PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS. THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER. A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER. THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER). NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE. OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON. IN THE EVENT OF REPEATED LOCKOUTS, DO NOT PERSIST WITH THE RESET BUTTON AND CONTACT QUALIFIED PERSONNEL WHO WILL PROCEED TO ELIMINATE THE MALFUNCTION. WARNING: DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR (COUPLING FLANGE) CAN BECOME VERY HOT, AVOID TOUCHING THEM SO AS NOT TO GET BURNT. OPERATION ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Read carefully the “WARNINGS” chapter in this manual. Select the fuel by turning the switch CM on the burner control panel . N.B. if the heavy oil is used, be sure the cutoff valves on the delivery and return pipes are OPEN. z Check that the burner is not locked (LED C lights up); if so, reset it by pressing the reset button D. z Check that the series of thermostats (or pressure switches) enable the burner to start up. Gas Operation z z z z z Check that the gas pressure in the circuit is high enough (LED E and Q on). The valve proving test begins. At the beginning of the start-up cycle the the air damper moves to the maximum opening, the fan motor starts and the pre-purge phase begins. During the pre-purge phase the complete opening of the air damper is signalled by the LED G on the front panel. At the end of the pre-purge stage, the air damper moves to the ignition position, the ignition transformer is energised (signalled by LED I on the panel) and, after few sec.onds the two gas valves EV1 and EV2 are energised (indicator lights L and M on). Few seconds after the opening of the gas valves, the ignition transformer is de-energised and LED I is off. To move from the low flame position, the actuator opening time (<10 s) is controlled by the control box. When this time elapses, the burner operates according the plant needs. Heavy oil Operation z At the beginning of the start-up cycle the air damper moves to the maximum opening, the fan motor starts and the pre-purge phase begins. During the pre-purge phase the complete opening of the air damper is signalled by LED G on the front panel. z At the end of the pre-purge the air damper is brought to the ignition position and the ignition transformer is energised (signalled by LED I on the panel). Few seconds later, the oil valve opens and the ignition transformer is de-energized (LED I off). The burner is now operating and after some seconds the burner is automatically driven into high flame (LED G on), or remains in low flame (LED H on) according to the plant needs. As far as fully-modulating burners, refer to the burner modulator manual. 35 CIB UNIGAS - M039123CC Burner front panel B O H G I N Q F L P M E C D A Fig. 27 - Burner control panel Key A B C D ON-OFF mains switch Lockout signalling lamp Reset button for burner control device Reset button for burner gas proving system (only for burners fitted with Siemens LDU) E F G H I L M N Gas pressure switch enabling signalling lamp Gas proving system lock signalling lamp Hig flame operation signalling lamp Low flame operation signalling lamp Ignition transformer operation signalling light Valve EV2 operation signalling light Valve EV1 operation signalling light Fan motor thermal cutout intervention signalling lamp O P Q R 36 Burner in stand-by signalling lamp Modulator (only fully modulating burners) Pilot pressure switch enabling signalling lamp Valve EVP operation signalling lamp CIB UNIGAS - M039123CC PART III: MAINTENANCE At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6 months. WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED! ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL. ROUTINE MAINTENANCE Clean and examine the gas filter cartridge and replace it if necesssary (see next paragraph). z Check and clean the oil filter cartridge; replace it if necessary (see next paragraphs). z Examine the condition of the oil flexible hoses and check for possible leaks. z Check and clean if necessary the oil heaters and the tank, according to the fuel type and its use; remove the heaters flange fixing nuts and remove the heaters from the tank: clean by using steam or solvents and not metallic things. CAUTION: avoid the contact of steam, solvent and other liquids with the electric terminals of the resistor. On flanged heaters, replace the seal gasket before refitting it. Routine inspections must be carried out to determine the frequency of cleaning. z Clean and examine the filter inside the oil pump. Filter must be thoroughly cleaned at least once in a season to ensure correct working of the fuel unit. To remove the filter, unscrew the four screws on the cover. When reassemble, make sure that the filter is mounted with the feet toward the pump body. If the gasket between cover and pump housing should be damaged, it must be replaced. An external filter should always be installed in the suction line upstream of the fuel unit. z Remove and clean the combustion head (page 38). z Examine and clean the ignition electrodes, adjust and replace if necessary (see page 38). z Examine and clean the detection probe, adjust and replace if necessary (see page 40). z Examine the detection current (see page 40). z Remove and clean (page 39) the heavy oil nozzle (Important: use solvents for cleaning, not metal utensils) and at the end of the maintenance procedures, after replacing the burner, turn it on and check the shape of the flame; if in doubt replace the nozzle. Where the burner is used intensively it is recommended to replace the nozzle as a preventive measure, at the begin of the operating season. z Clean and grease joints and rotating parts. IMPORTANT:Remove the combustion head before checking the ignition electrodes. ATTENTION: when servicing, if it was necessary to disassemble the gas train parts, remember to execute the gas proving test, once the gas train is reassembled, according to the procedure imposed by the law in force. CAUTION: avoid the contact of steam, solvent and other liquids with the electric terminals of the resistor. On flanged heaters, replace the seal gasket before refitting it. Periodic inspections must be carried out to determine the frequency of cleaning. Gas filter maintenance ATTENTION: Before opening the filter, close the manual cutoff valve downstream the filter and bleed the gas; check that inside the filter there is no pressurised gas. To clean or remove the filter, proceed as follows: 1 remove the cap unscrewing the fixing screws (A); 2 remove the filtering cartridge (B), clean it using water and soap, blow it with compressed air(or replace it, if necessary) 3 replace the cartridge in its proper position taking care to place it inbetween the guides as not to hamper the cap replacement; 4 be sure to replace the Or ring into its place (C) and replace the cover fastening by the proper screws (A). A B 37 C CIB UNIGAS - M039123CC Self-cleaning filter Fitted only on high viscosity oil burners. Periodically turn the knob to clean the filter. Removing the combustion head 1 Remove the cover H. 2 Slide the photoresistance out of its housing. 3 Unscrew the V screws that block the gas collector G, loosen the three joints E and remove the ass.y as shown on the following picture. 4 Clean the combustion head by means fo a vacuum cleaner; scrape off the scale by means fo a metallic brush. Note: to remount the burner, follow the same procedure in the reversed order. Key 1 Inlet H L 2 Return 3 Gun opening E Oil piping connections H Cover E L Oil gun 3 2 1 Adjusting the ignition electrode Important Note: check the ignition electrode after each removing of the combustion head. ATTENTION: avoid the ignition electrode to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrode position after any intervention on the combustion head. E P Fig. 28 - Detailed view of the diffuser with pilot (P) and ignition elecctrode (E) Observe the values quoted on Fig. 30. E P P = = E 5 mm Fig. 29 - Detailed view of the combustion head with pilot (P) and ignition elecctrode (E) 38 Fig. 30 CIB UNIGAS - M039123CC Replacing the ignition electrode ATTENTION: avoid the ignition electrode to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrode position after any intervention on the combustion head. To replace the ignition electrode, proceed as follows: 1 remove the burner cover 2 disconnect the electrode (E) cable (CE); 3 remove the combustion head (see par. “Removing the combustion head”); 4 loose screw (B) that fasten the ignition electrode (E) to the burner pilot (P); 5 remove the electrode and replace it, referring to the values quoted on Fig. 30. CE P E B Fig. 31 Removing the oil gun, replacing the nozzle and the electrodes ATTENTION: avoid the electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrodes position after any intervention on the combustion head. To remove the oil gun, proceed as follows: 1 remove the combustion head as described on the prevoius paragraph; 2 loosen the VL screw and remove the oil gun and the electrodes: check the oil gun, replace it if necessary; 3 after removing the oil gun, unscrew the nozzle and replace it if necessary; Caution: adjust the nozzle position according to the air pipe, by means of the VU screw, ance the VL screw is fastened. VU VL Fig. 32 39 CIB UNIGAS - M039123CC Cleaning and replacing the detection photocell The photocell working life is about 10000 working hours (about 1 year), at max 50°C after which it must be replaced. To clean/replace the detection photocell, proceed as follows: 1 Disconnect the system from the electrical power supply. 2 Shut off the fuel supply 3 remove the photocell from its slot (see next picture); 4 clean the bulbe if dirty, taking care not to touch it with bare hands; 5 if necessary, replace the bulb; 6 replace the photocell into its slot. Checking the detection current To check the detection current follow the diagram on Fig. 33. If the signal is less than the value indicated, check the position of the detection electrode or detector, the electrical contacts and, if necessary, replace the electrode or the detector. Control box TERMINAL BOARD MC Minimum detection signal Siemens LFL1.3.. 70µA ( with UV detector) Fig. 33 - Detection with detector QRA... Seasonal stop To stop the burner in the seasonal stop, proceed as follows: 1 turn the burner’s main switch to 0 (Off position) 2 disconnect the power mains 3 close the fuel valve in the supply line. Burner disposal In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”. 40 CIB UNIGAS - M039123CC MAIN SWITCH OPEN LINE FUSES BROKEN LACK OF GAS FAULTY GAS PRESSURE SWITCH FAULTY HIGH PRESSURE SWITCH FAN THERMAL CUTOUT INTERVENTION AUXILIARIES FUSE INTERVENTION FAULTY AIR PRESSURE SWITCH FAULTY CONTROL BOX FAULTY ACTUATOR z z z z z z z z z z z z z IGNITION TRANSFORMER DEFECTIVE ELECTRODES BAD POSITION GAS BUTTERFLY UNCALIBRATED z z z z z z z z z z z z HI-LO FLAME THERMOSTAT DEFECTIVE ACTUATOR CAM UNCALIBRATED z PHOTOCELL DIRTY OR BAD POSITION FAULT ON LIGHT OIL SOLENOID VALVES NOISY FUEL PUMP z GAS GOVERNOR DEFECTIVE FUEL LOW PRESSURE SHUTS OFF AND REPEATS CYCLE DURING OPERATION z z AIR PRESSURE SWITCH UNCALIBRATED OR FAULTY GAS PRESSURE SWITCH UNCALIBRATED LOCKOUT DURING OPERATION DOESN’T SWITCH TO HIGH FLAME STARTS AND REPEATS CYCLE DOESN’T START AND REPEATS CYCLE DOESN’T START AND GOES TO LOCKOUT CONTINUES PREPURGE PHASE CAUSE / TROUBLE BURNER DOESN’T START TROUBLESHOOTING z z z FUEL FILTERS DIRTY 41 CIB UNIGAS - M039123CC 42 CIB UNIGAS - M039123CC 43 CIB UNIGAS - M039123CC 44 CIB UNIGAS - M039123CC 45 CIB UNIGAS - M039123CC 46 CIB UNIGAS - M039123CC 47 CIB UNIGAS - M039123CC 48 CIB UNIGAS - M039123CC 49 CIB UNIGAS - M039123CC 50 CIB UNIGAS - M039123CC SPARE PARTS Desription KP1025 2020448 2080258 2090238 2090117 2090112 2090113 2110312 2150063 2160097 2160077 2160086 2160087 2160089 2170301 2180283 21802A2 2190172 2190169 2190174 2190181 2190183 21903M6 21903M7 21903M8 2190502 2190437 2191604 2340059 2340088 2340089 234FX07 234FX24 2440013 2440014 2480004 2510001 2540133 2560026 2560028 25700A7 2570036 2570112 2590124 2610203 2800085 3060270 30910H1 6050143 6060008 x 2 60600010 VALVE PROVING SYSTEM (SIEMENS LDU) CONTROL BOX (SIEMENS LFL) IGNITION ELECTRODE OIL FILTER GAS FILTER - DN65 GAS FILTER - DN80 GAS FILTER - DN100 CERAMIC FIBRE PLAIT FAN WHEEL AIR PRESSURE SWITCH LOW GAS PRESSURE SWITCH- DUNGS GW150 A5 LOW GAS PRESSURE SWITCH- DUNGS GW150 A6 LOW GAS PRESSURE SWITCH- DUNGS GW500 A6 LOW GAS PRESSURE SWITCH- DUNGS GW500 A5 IGNITION TRANSFORMER PUMP MOTOR FAN MOTOR GAS VALVE GROUP - DN65 - Siemens VGD40.. GAS VALVE GROUP - DN80 - Siemens VGD40.. GAS VALVE GROUP - DN100 - Siemens VGD40.. GAS VALVE GROUP - DN125 - Siemens VGD40.. GAS VALVE ACTUATOR SKP15 GAS VALVE ACTUATOR SKP25 GAS VALVE GROUP - DN65 - Dungs MBC1900SE GAS VALVE GROUP - DN80 - Dungs MBC3100SE GAS VALVE GROUP - DN100 - Dungs MBC5000SE PILOT SOLENOID VALVE OIL SOLENOID VALVE GAS PROVING SYSTEM FLEXIBLE HOSE L=600 1/2” FLEXIBLE HOSE L=385 3/8” FLEXIBLE HOSE L=435 3/8” FLEXIBLE HOSE L=800 1/2” FLEXIBLE HOSE L=347 1/2” SMALL ADJUSTING CAM FOIL BIG ADJUSTING CAM FOIL ACTUATOR SIEMENS SQM10 UV PROBE MOTOR-PUMP COUPLING ADJUSTMENT THERMOMETER (50°-200°) SAFETY THERMOMETER OIL GOVERNOR OIL GOVERNOR SUNTEC TV BURNER MODULATOR (only on fully-modulating burners) PUMP: SUNTEC T NOZZLE - FLUIDICS NOZZLE - BERGONZO B NOZZLE - BERGONZO C PRESSURE GOVERNOR WITH FILTER COMBUSTION HEAD BLAST TUBE IGNITION CABLE OIL HEATER RESISTOR 24 kW CARTRIDGE AUXILIARY RESISTOR 51 Code KP1030 2020448 2080258 2090238 2090117 2090112 2090113 2110312 2150058 2160097 2160086 2160087 2160089 2170301 2180257 2180294 2190172 2190169 2190174 2190181 2190183 21903M6 21903M7 21903M8 2190502 2190437 2191604 2340059 2340088 2340089 234FX07 234FX24 2440013 2440014 2480004 2510001 2540133 2560026 2560028 2570008 2570036 2570112 2590148 2610203 2610210 2800085 3060277 30910H2 6050143 6060008 x 2 60600010 KP1040 2020413 2020448 2080258 2090238 2090117 2090112 2090113 2110312 2150058 2160097 2160086 2160087 2160089 2170301 2180257 2180292 2190172 2190169 2190174 2190184 2190181 2190183 21903M6 21903M7 21903M8 2190502 2190437 2191604 2340059 2340088 2340089 234FX07 234FX24 2440013 2440014 2480004 2510001 2540133 2560026 2560028 2570008 2570036 2570112 2590148 2610203 2610210 2610213 2800085 3060292 30910Q8 6050143 6060008 x 2 60600010 BURNER EXPLODED VIEW DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION 1 STANDARD BLAST TUBE 7.1.7 ACTUATOR 9.9 GAS GOVERNOR WITH FILTER 2.1 BOARD 7.1.8 ROD 10 AIR INLET CONE 2.2.1 POWER CONTROLLER 7.1.9 ROD 11 BURNER HOUSING 2.2.2 FRONT CONTROL PANEL 7.1.10 CAM 11.1 COVER 2.2.3 LIGHT 7.1.11 LEVERAGE 12 CERAMIC FIBRE PLAIT 2.2.4 LIGHT 7.1.12 JOINT 13 NAME PLATE 2.2.5 LOCK-OUT RESET BUTTON 7.1.13 JOINT 14 RING NUT 2.2.6 PROTECTION 7.1.14 ACTUATOR SHAFT 15 INLET 2.2.7 SWITCH 7.2 NET 16 INSPECTION GLASS 2.2.8 SWITCH 7.3 NET 17.1 THROTTLE 2.3 COVER 7.4 AIR INTAKE DAMPER 17.2 PRESSURE PLUG 3.1 SPACER 7.5 AIR INTAKE 17.3 THROTTLE SHAFT 3.2 FAN WHEEL 7.6 LOUVER SHAFT 17.4 BUTTERFLY GAS VALVE 3.3 MOTOR 7.7 LOUVER SHAFT 18 PHOTOCELL 3.4 CLAMPING PLATE 7.8 LOUVER SHAFT 19 BRACKET 4.1 MOTOR 8.1 GAS FILTER 20 BRACKET 4.2 COUPLING 8.2 FLANGE 21.1 O RING 4.3 PRESSURE GOVERNOR 8.3 PIPE 21.2 OIL GUN HOLDER 4.4 PUMP 8.4 FLANGED REVERSIBLE CURVE 21.3 STANDARD COMPLETE OIL GUN 4.5 BRACKET 8.5 REVERSIBLE PIPE 184.108.40.206 OIL SOLENOID VALVE 5.1 OIL SOLENOID VALVE 8.6.1 GAS PRESSURE 220.127.116.11 OIL MANIFOLD 5.2 ONE-WAY VALVE 8.6.2 GAS VALVE HOUSING 18.104.22.168 CONNECTOR 5.3 OIL MANIFOLD 8.6.3 "SKP" ACTUATOR 21.3.2 NOZZLE 5.4 CONNECTOR 8.6.4 "SKP" ACTUATOR 21.3.3 ADJUSTING BUSH 6.1 PRESSURE GAUGE 8.6.5 GAS PROVING SYSTEM 21.3.4 NOZZLE HOLDER 6.2 PRESSURE GOVERNOR 9.1 THREADED GAS PIPE 21.4 GAS MANIFOLD 6.3 BRACKET 9.2 PIPE UNION 21.5 STANDARD COMBUSTION HEAD 7.1.1 BRACKET 9.3 NIPPLE 21.5.1 IGNITION ELECTRODE 7.1.2 THROTTLE SHAFT 9.4 LOCK NUT 21.5.2 IGNITOR 7.1.3 ADJUSTING CAM SHAFT 9.5 GAS PRESSURE 21.6 BRACKET 7.1.4 LEVERAGE 9.6 GAS SOLENOID VALVE 21.7 IGNITION CABLE 7.1.5 ADJUSTING CAM 9.7 UNION ELBOW 22 AIR PRESSURE SWITCH 7.1.6 ADJUSTING CAM 9.8 BRACKET 23 CONNECTOR CIB UNIGAS - M039123CC 52 ITEM CIB UNIGAS - M039123CC 53 APPENDIX SIEMENS LFL 1.3.. CONTROL BOX Automatic programme in the event of interruption and indication of position when interrupted By default, in the event of any kind of interruption, the flow of fuel is immediately interrupted. At the same time the programmer stops and this indicates the position at the time of the interruption. A symbol on the indicator disc shows each time the type of stoppage: No start-up (for example fault in the CLOSED signal for the limit contact "Z" at terminal 8 or some other contact between the terminals 12 and 4 or 4 and 5 is not closed). Start-up suspended because of a fault in the OPEN signal for the limit contact "A" at terminal 8. P Block due to absence of air pressure signal. From this moment onwards any absence of air pressure will cause a block. Block due to malfunction of the flame detector circuit. Start-up interrupted because there is a fault in the MINMUM signal for the auxiliary contact of the damper servo motor at terminal 8. 1 Block due to absence of flame signal at the end of the 1st safety period. From this moment onwards any absence of a flame signal will cause a block. 2 Blockdue to absence of flame signal at the end of the 2nd safety period (flame signal of main burner). Blockdue to absence of flame signal or air pressure during operation. Where a block stoppage occurs at any moment between switch on and pre-ignition without registering any symbol, the cause is normally an unscheduled flame signal. a-b Start-up programme b-b' For time variants:move the programmer on to the automatic stop after the burner starts up (b' = position of the programmer during normal burner operation). b(b')-aPost-ventilation programme after a regulation stop.At the start-up position "a" the programmer stops automatically. . Safety time duration for mono-tube burners .. Safety time duration for twin-tube burners The apparatus can be reset immediately after a block. After resetting (and after the elimination of any problem causing the stoppage or after a power failure) the programmer returns to its start-up position. In this event only the terminals 7, 9, 10 and 11 are live in accordance with the monitoring programme. Only after this the device programs a new startup. Operation The wiring system and also the control system of the programmer "P" have already been given in this manual. The response signals required for the active parts and the flame monitor circuit are shown by a hatching. In the absence of these response signals the mechanism interrupts the start-up programme; the exact time of the interruption can be identified from the visual indicator and will cause a block if the safety code requires it. A consent to start-up by means of the thermostat or pressostat "R" A-B start-up program B-C normal burner operation C regulation stop caused by "R" C-D programmer returns to start-up position A. During the regulation stop only terminals 11 and 12 are live and the damper, through the limit contact "Z" of its servo-motor is in the CLOSED position.The flame detector circuit F is activated (terminals 22 and 23 or 23/4) for the detector test and the paracitic light test. Where the burners do not have dampers (or have an independent 00 damper control mechanism) there must be a bridge between terminals 6 and 8, otherwise the mechanism will not start up the burner. For a burner to start up the following conditions must be met: z Mechanism not blocked/reset. z Damper closed.Limit contact switchZ must be in the CLOSED position and allow current to flow between terminals 11 and 8. z Any contacts checking that the fuel valve (bv...) is closed, or other contacts with similar functions, must be closed between terminal 12 and the air pressostat LP. z The contact for the air pressostat LP must be in the off position (LP test) so as to feed terminal 4. z The gas pressostat contacts GP and the safety thermostat and pressostat contacts W must also be closed. Start-up program A Start-up (R closes the start-up control ring between terminals 4 and 5) The programmer starts up.At the same time the ventilator motor is fed through terminal 6 ( only for pre-ventilation) and, after t7, the ventilator motor or the combustion gas exhaust fan is fed through terminal 7 (preventilation and post-ventilation). At the end of t16, the command opening the damper passes through terminal 9; during the damper opening time the programmer does not move since terminal 8, through which the programmer is fed, is dead. Only once the damper is fully open and the limit contact switch A has switched on, feeding terminal 8, does the programme proceed. t1 Pre-ventilation time with damper fully open (nominal air flow). Shortly after the beginning of the pre-ventilation time, the air pressostat should switch off the current between terminals 4 and 13;otherwisethe apparatus would block (air pressure monitor). At the same time the terminal 14 should be live since current feeding the ignition transformer and the fuel valves passes through this circuit. During pre-ventilation time the flame detector circuit is checked and in the event of an operational defect the monitor brings about a block. At the end of the pre-ventilation time the monitor automatically moves the damper servo-motor, through terminal 10, to the flame ignition position which is governed by the auxiliary contact "M". During this period the programmer stops until terminal 8, is again activatedthrough contact "M". After a few seconds the little programmer motor is directly fed by the active part of the apparatus. After this point terminal 8 plays no further part in the burner ignition process. Mono-tube burner t3 Pre-ignition time waiting the response from the fuel valve at terminal 18. t2 Safety time (start up flame strenght); at the end of the safety time a flame signal should appear at terminal 22 of the amplifier and it should stay on until a regulation stop; if this does not happen the mechanism will block. t4 Interval; at the end of t4, terminal 19 is live. t5 Interval At the end of t5 terminal 20 is live.At the same time the monitor outlets from 9 and 11 and terminal 8 into the active part of the apparatus are kept galvanically separatedso as to protect the monitor itself from recovery voltage through the capacity regulator circuit. Twin-tube burners (**) t3 Preignition time until the all clear to the pilot burner valve at terminal 17. t2 First safety time (pilot flame strenght); at the end of the safety time a flame signal should appear at terminal 22 of the amplifier and it should stay on, until a regulation stop; if it does not, the apparatus will block. t4 Interval until the consent to the fuel valve at terminal 19, for the first flame of the main burner. t9 2nd safety time; at the end of the second safety time the main burner should be lit by means of the pilot. At the end of this period, terminal 17 is dead and therefore the pilot burner will be out. t5 Interval; at the end of t5 terminal 20 is live. At the same time the monitor outlets from 9 to 11 and the terminal 8at the input of the active part of the apparatus are galvanically separated so as to protect the apparatus itself from recovery voltage through the strenght regulator circuit. When the strenght regulator LR at terminal 20 gives the consent, the start-up programme for the apparatus comes to an end. Depending on time variants, the programmer stops either immediately or at the end of a set time, without effecting the position of the contacts. B Operational position of the burner B-C Burner operation (production of heat) While the burner is working the strnght regulator controls the damper, according to the demand for heat, by means of the positioning at nominal load of the auxiliary contact "V" of the damper servocontrol. C Regulation stop for operation of "R" When there is a regulation stop the fuel valves immediately close. At the same time the programmer starts to programme: t6 Post-ventilation time (post-ventilation with the ventilator "G" at terminal 7).Shortly after beginning of the post-ventilation time terminal 10 becomes live and moves the damper to the "MIN" position. The full closure of the damper only happens towards the end of the post-ventilation time and is prompted by an automatic signal from terminal 11 t13 Admissible post-ignition time During this time the flame monitor circuit may still receive a flame signal without the apparatus blocking. D-A End of automatic programme At the end of t6, at the point where the programmer and the automatic contacts have reverted to the starter position, the detection probe test restarts. During an operational stop even an unscheduled flame signal lasting a few seconds can cause a block because during this period an NTC in the circuit acts as retarder.This means that brief unscheduled influences cannot cause a block. (**) Times t3, t2 and t4 only apply only to safety devices in the series 01. Specifications Mains voltage 220V -15%...240V +10% Frequency 50Hz -6%...60Hz +6% Absorbed capacity 3.5 VA Built-in fuse T6.3/250E slow action DIN41571 No. 451915070 External fuse max. 16A Interference N-VDE0875 Flow permitted at terminal 1 5A (DIN 0660 AC3) Flow permitted at control terminals 4A (DIN 0660 AC3) Flow at monitor contacts: input at terminals 4 & 5 1A, 250V input at terminals 4 & 11 1A, 250V input at terminals 4 & 14 function of the load at terminals 16 and 19, min.1A, 250V Emplacement Any Protection IP40 Permitted ambient temp -20...+60° C Min.temperature (trans/storage) -50° C Weight: apparatus approx. 1,000g. base approx. 165g. Ionisation monitor voltage in detector electrode normal working 330V ±10% test 380V ±10% short circuit current max. 0,5 mA Ionisation current, min.request 6 µA max. permitted length for connecting cables normal cable (laid separately**) 80m armoured cable(high frequency) protection at terminal 22 140m UV monitor Voltage in UV detector normal working 330V ±10% test 380V ±10% Detector current, min. request* 70µA Max. detector current normal working 630 µA test 1300 µA Max.length of connecting cable normal cable (laid separately**) 100m armoured cable (high frequency) protected at terminal 22 200m Weight QRA2 60 g QRA10 450 g. *Connect up in parallel to the measuring device a condenser 100µF, 10...25V. ** The wire connecting up the detector electrode should not be in the same sleeve as the other conductor wires. Ignition spark monitor with QRE1 series 02 detector Minimum detector current 30µA Operating times t7 initial delay for ventilator G2 2 t16 initial delay of air damper OPEN consent 4 t11 opening time for damper any t10 initial delay for air pressure monitor8 t1 pre-ventilation time with damper open36 t12 travel time for air damper to MIN positionany t3 t3' pre-ignition time t3 4 t3 't2 t2' safety time (1st safety time for burners with intermittent pilot lighter t2 2 t2 't4 t4' interval between start of t2 and response to valve at terminal 19 t4 10 t4 't9 2nd safety time for burners with intermittent pilot lighter 2 t5 interval between end of t4 and response at terminal 20 10 t20 interval before programmer cuts out after start-upduration of start-up 60 t6 post-ventilation time (G2 only) 12 t13 permitted post-ignition time 12 t16 initial delay from opening consent of the air damper t20 interval until the automatic shut-off of the programming mechanism after the burner start Programmer diagram Key A AI AR AS BR BV EK FE FR G GP H L LK LP LR M QRA QRE R S SA SM V V limit contact switch for damper OPEN position block remote signal main relay (working network) with contacts "ar" Monitor fuse block relay with "br" contacts fuel valve reset button detector electrode of ionisation circuit flame relay with "fr" contacts ventilator motor or burner motor gas pressure switch main interruptor switch block stoppage LED air damper air pressostat safety regulator auxiliary contact switch for damper "MIN" position UV detector ignition spark detector thermostat or pressostat fuse damper servo-motor synchronous programmer motor flame signal amplifier in case of servo-motor: auxiliary contact for response to fuel valve with regard of damper position W safety pressostat or thermostat Z ignition transformer Z in case of servomotor: end of limit contact switch for damper CLOSED position ZBV pilot burner fuel valve ° for mono-tube burners °° for twin-tube burners (1) (2) (3) input for raising QRA detector voltage to test level input for excitation of flame relay during flame detector test circuit (contact XIV) and during safety time (contact IV) Do not press EK for more than 10 seconds t1 t2 *t2 t3 *t3 t4 *t4 t5 t6 t7 pre-ventilation time safety time '1st safety time pre-ignition time 'pre-ignition time interval for creating current between terminals 18 and 19 'interval for creating current between terminals 17 and 19 interval for creating current between terminals 19 and 20 post-ventilation time interval between startup consent and current created at terminal 7 t8 duration of start-up *t9 2nd safety time t10 interval before air pressure monitoring begins t11 damper opening travel time t12 damper closure travel time t13 permissible post-combustion time t16 initial delay of damper OPEN response t20 interval before programmer automatically stops * These times are valid with the use of a series 01 safety device for monitoring burners with intermittent pilot lighter. VALVE PROVING SYSTEM SIEMENS LDU11 The LDU11... gas valve proving system is designed for use in gas-fired plant equipped with two safety shutoff valves. During each startup cycle, the control unit automatically programs the valve proving test and, in the event of a leak, prevents burner startup. The LDU11… control unit is designed to provide automatic gas valve proving (leakage test) based on the pressure proving principle. It is for use in gas-fired plant with or without vent pipe to the atmosphere. For plants without vent pipe, where DIN/DVGW regulations apply, refer to the hints given on "Connection examples with vent pipe to the atmosphere". Gas valve proving is initiated automatically with every burner startup using one or two standard pressure monitors, either z prior to burner startup, z during the pre-purge time, if it lasts at least 60 s, z immediately after the controlled shutdown, or z on completion of the burner control's control program, e.g. on completion of the post-purge time The valve proving test is based on the two-stage pressure proving principle: first, the valve on the mains side is tested by evacuating the test space and by monitoring the atmospheric pressure in it. Then, the valve on the burner side is checked by pressurizing the test space and by monitoring the gas pressure. If the pressure increases excessively during the first test phase (Test 1), or decreases excessively during the second test phase (Test 2), the control unit inhibits burner startup and goes to lockout. In that case, the lockout reset button lights up to indicate the fault. Remote indication of the fault is also possible. A program indicator, which stops whenever a fault occurs, indicates which of the two valves is leaking. Mode of operation To carry out the first phase of the valve proving test, called "Test 1", there must be atmospheric pressure in the length of pipe between the two valves to be tested. In plants with a vent to the atmosphere, this pressure is available if the valve proving test isconducted prior to or during the prepurge time. In plants without a vent pipe, atmospheric pressure is made available as the control unit opens the valve on the burner side during the time "t4". If the valve proving test is performed after the operation of the burner, the valve on the burner side after the controlled shutdown can be kept open until "t4" has elapsed, thus reducing the pressure in the test space and making certain its gas content is burnt off in the combustion chamber during the post-purge time. A prerequisite for this procedure is an appropriate control program of the burner control as provided by Landis & Staefa burner controls type LFE..., LFL..., LGK.... or LEC.... The test space is closed off after it has been evacuated. During the first test phase (Test 1) which follows immediately, the control unit checks if the atmospheric pressure in the test space is maintained using the pressure monitor. If the valve on the mains side is leaking, causing the pressure to rise above the switching point of the pressure monitor, the control unit initiates an alarm and goes to lockout. The program indicator then stops and indicates "Test 1". If the pressure does not increase because the valve closes correctly, the control unit immediately programs the second test phase (Test 2). To do this, the valve on the mains side is pressurized ("filling" of test space). During the second test phase, the pressure may not fall below the switching point of the pressure monitor due to a leak of the valve on the burner side. If it does, the control unit goes to lockout again, thus inhibiting burner startup. On the successful completion of the second test phase, the control unit closes the internal control loop between terminals 3 and 6 (circuit path: terminal 3 - contact "ar 2" -terminals 4 and 5 - contact III - terminal 6). This control loop is usually included in the start control loop of the burner control. After the control loop has been closed, the programming mechanism of the control unit returns to its start position where it switches itself off. During these "idle steps", the position of the control contacts of the programming mechanism remains unchanged. Program and lockout indicator When the unit goes to lockout, the programming mechanism stops and also the position indicator fitted to the spindle of the mechanism. The symbol that stops above the reading mark not only indicates during which test phase lockout occurred, but also after how many programming steps within the test phase (1 step = 2.5 seconds). Specifications Mains voltage AC 220 V -15 %...240 V +10 % AC 100 V -15 %...110 V +10 % Mains frequency 50 Hz -6 %...60 Hz +6 % Power consumption - during the test 3.5 VA - during burner operation 2.5 VA Prefuse (externally) T16/500 V Unit fuse T6,3H250 V to IEC 127 Radio interference protection N to VDE 0875 Perm. input current at terminal 15 A continuous to VDE 0660 AC3 Environmental conditions: Temperature -50...+60 °C Humidity < 95 % r.h. Mechanical conditions class 2M2 Climatic conditions class 3K5 Temperature -20...+60 °C Humidity < 95 % r.h. Condensation, formation of ice and influence of water are not permitted Perm. current rating of control terminals4 A to VDE 0660 AC3 Required switching capacity of pressure switch "DW"1 A min., AC 250 V Mounting position optional Degree of protection IP40 Weight control unit approx. 1000 g base approx. 165 g CE conformity According to the directives of the European Community Electromagnetic compatibility EMC 89/336 EWG include. 92/31 EEC, Gas appliance directive 90/396 EEC Emissions EN 50081-1 Immunity EN 50082-2 Start position = operating position In plants without a vent valve: evacuation of test space through opening of the valve on the burner side Test 1 "Test 1" with atmospheric pressure (valve proving test on the mains side) Filling the test space through opening of the valve on the mains side Test 2 "Test 2" with gas pressure (valve proving test on the burner side) Idle steps until programming mechanism switches itself off Operating position = start position for the next valve proving test In the event of lockout, all terminals receiving voltage from the control unit are de-energized, except terminal 13, which is used for lockout indication. After the unit has been reset, the programming mechanism automatically returns to its start position and immediately reprograms a new valve proving test. Note: do not press the reset button for more than 10 seconds. Control program after a power failure A power failure prior to evacuating the test space does not cause the program sequence to change. If a power failure occurs after the evacuation, the valve proving test will not be continued when power is restored, but the programming mechanism first returns to its start position to reprogram the complete proving test. KEY AL AR AS BR DW Alarm signal "Leaking valve" Main relay with contacts "ar..." Built-in fuse Lockout relay with contacts "br..." Pressure monitor for valve proving test (does not replace the gas pressure monitor used to signal lack of gas) EK... Lockout reset button GP Gas pressure monitor (for lack of gas) HR Auxiliary relay with contacts "hr..." L1 Built-in lockout warning lamp SM Synchronous motor of programming mechanism SK Mains switch Warning notes z The electrical wiring must comply with local and country-specific standards and regulations! z The LDU11... must be completely isolated from the mains before per- forming any work on it! z The LDU11... is a safety device. It is therefore not permitted to open, interfere with or modify the unit! z Check wiring carefully before putting the unit into operation! z Check all safety functions when putting the unit into operation or after replacing a fuse! z Ensure protection against electric shock hazard on the unit and at all electrical connections through appropriate mounting! z Electromagnetic emissions must be checked from an application point of view! z The regulations and standards covering the specific application must be observed! z All installation and commissioning work must be carried out by qualified personnel! z In the geographical areas where DIN standards are in use, the installation must be in compliance with VDE requirement, particularly with the standards DIN/VDE 0100 and 0722! z Condensation and ingress of humidity must be avoided! z Ignition cable must always be laid separately, observing the greatest possible distance to other cables! C.I.B. UNIGAS S.p.A. Via L.Galvani, 9 - 35011 Campodarsego (PD) - ITALY Tel. +39 049 9200944 - Fax +39 049 9200945/9201269 web site: www.cibunigas.it - e-mail: firstname.lastname@example.org Note: specifications and data subject to change without notice. Errors and omissions excepted.