Unigas KP1025 KP1030 KP1040

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
21.3.1.1 OIL SOLENOID VALVE
5.1
OIL SOLENOID VALVE
8.6.1
GAS PRESSURE
21.3.1.2 OIL MANIFOLD
5.2
ONE-WAY VALVE
8.6.2
GAS VALVE HOUSING
21.3.1.3 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: [email protected]
Note: specifications and data subject to change without notice. Errors and omissions excepted.