Unigas HTP92A Installation, User's, And Maintenance Manual

HTP90A - HTP91A

HTP92A - HTP93A

HTP512A - HTP515A

HTP520A - HTP525A

Progressive

and fully-modulating gas - light oil burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

M039219CA Rev. 0 0 8 /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 PRO-

DUCT INSTALLATION AND MAINTENANCE.

THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION

OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.

CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE..

1) GENERAL INTRODUCTION 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.

2) SPECIAL INSTRUCTIONS FOR BURNERS 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 shall have qualified personnel carry out the following operations: a Remove the power supply by disconnecting the power cord from the mains.

b) Disconnect the fuel supply by means of the hand-operated shut-off valve and remove the control handwheels from their spindles.

Special warnings 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 repeated burner shut-downs, do not continue re-setting the unit manually. Contact qualified personnel to take care of such defects.

z The unit shall be operated and serviced by qualified personnel only, in compliance with the regulations in force.

3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED

3a) ELECTRICAL CONNECTION z For safety reasons the unit must be efficiently earthed and installed as required by current safety regulations.

z

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.

z 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.

z

No adaptors, multiple outlet sockets and/or extension cables are permitted to connect the unit to the electric mains.

z An omnipolar switch shall be provided for connection to mains, as required by the current safety regulations.

z

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.)

2

should be switched off.

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.

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.

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.

Light oil burners


Directive 2006/95/EC on low voltage ;





- 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

Heavy oil burners


Directive 2006/95/EC on low voltage ;



-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.



Gas - Light oil burners


- Directive 90/396/CEE Gas Appliances;




-UNI EN 676 Gas Burners






Gas - Heavy oil burners


- Directive 90/396/CEE - Gas Appliances;




-UNI EN 676 (Gas Burners;






3

C.I.B. UNIGAS - M039219CA

PART I: INSTALLATION MANUAL

GENERAL FEATURES

This series of industrial burners is designed for all those applications that require big-sized air fans or air-flue heat exchangers to be installed in sound-proof areas to reduce noise. They can be provided with built-in or separate-mounted control panel (console or wallmounted).

Burner

Gas train

Pumping unit

Fan

Electric panel

Note: the picture shows one of the possible installations. Fan, electrical panel and pumping unit can be placed according to the customer needs.

How to choose the burner

To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed: z fuel z z z z z z z z z z z z z furnace input, in kW or kcal/h (kW = kcal/h / 860); boiler type; combustione head type (reverse flame or three phase)’ temperature or pressure of the thermal carrier fluid

Comburent air temperature

Air duct positioning

Pressure in the combustion chamber

Elevation (altitude) of burner installation

Gas train (only for gas burners)

Pumping unit (only for light-oil or heavy-oil burners)

Air fan

Bilt-in or separated control panel backpressure (data are available on the boiler’s ID plate or in the user’s manual).

Burners provided with built-in control panel are designed for IP40 index of protection. For other values of IP, please contact the CIB

UNIGAS Technical Dpt.

4


Power output diagram at 15àC air temperature

TP525A

TP1030

0

TP520A

TP515A

TP512A

TP93A

TP92A

TP91A

TP90A

2000 4000 6000

TP1050

8000

Burner performance range

10000 12000 14000 16000

Example: z z z z z

Data requested: z furnace input; air temperature altitude furnace input: 9600kW air temperature: 15°C altitude: 0m

Fig. 1

See the diagram in Fig. 2, as to find the burners that better suite the power range requested in the exmple (9600kW). Once the models are founded out, the choice regards technical and economical features. Technical features can be summarised in a higher modulation ratio (fewer start-ups, less consumption, fewer swigings in the generator temperature and pressure values.

Checking the proper gas train size

To check the proper gas train size, it is necessary to the available gas pressure value upstream the burner’s gas valve. Then subtract the backpressure. The result is called p gas.

Draw a vertical line matching the furnace input value (600kW, in the example), quoted on the x-axis, as far as intercepitng the network pressure curve, according to the installed gas train (DN65, in the example). From the interception point, draw an horizontal line as far as matching, on the y-axis, the value of pressure necessary to get the requested furnace input. This value must be lower or equal to the p gas value, calculated before.

25

20

15

10

5

0

100

Tipo / Type P60

M-...50 (Multibloc DUNGS MB-DLE 420 B01)

M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)

200 300

Rp 2" (50)

400 500 600

Potenza / Output (kW)

700

DN65

800 900

Fig. 2

5


BURNER SPECIFICATIONS

Burner model identification

Burners are identified by burner type and model. Burner model identification is described as follows.

Type HTP91A Model MG. PR. S. *. A. 1. 80

(1) (2) (3) (4) (5) (6) (7) (8)

(1) BURNER TYPE

(2) FUEL

HTP91A

M - Natural gas G - Light oil

(3) OPERATION

(4) BLAST TUBE

(5) DESTINATION COUNTRY

(6) BURNER VERSION

(7) EQUIPMENT

(8) GAS CONNECTION

PR - Progressive MD - Fully modulating

S - Standard

* - see data plate

A - Standard Y - Special

1 = 2 valves + gas proving system

8 = 2 valves + gas proving system + maximum pressure switch

50 = Rp2 65 = DN65

80 = DN80 100 = DN100

Technical specifications

Note: the Output values are referred to comburent air temperature lower than 50°C.

BURNER TYPE

Output

Fuel

Gas category

Gas rate

Gas pressure

Oil viscosity

Oil density

Light oil rate

Power supply

Total power consumption


Protection

Operation

Gas train 50

Gas train 65

Gas train 80

Gas train 100

Operating temperature

Storage Temperature

Working service*

Ø min - max kW min.-max. (Stm cSt @ 40°C min.-max. kg/h

Valves kg/m kW kW

/Connection

ØValves / Connection



°C

°C

3

3

/h)

HTP90A

320-2300

34 - 243

27 - 194

0.55

1.05

HTP91A

480 - 2670

HTP92A

480 - 3050

Natural gas - Light oil

(see next paragraph)

51 - 283 51 - 323

(see Note 2)

2 - 7.4

0.84

40 - 225 40 - 257

230V 3~ / 400V 3N~ 50Hz

1.1

1.6

1.1

1.6

IP40

Progressive - Fully modulating

2” / Rp 2

2”

1/2

/ DN65

3” / DN80

4” / DN100

-10 ÷ +50

-20 ÷ +60

Intermittent

HTP93A

550 - 4100

58 - 434

46 - 345

1.1

1.6

6

BURNER TYPE

Output

Fuel

Gas category

Gas rate

Gas pressure

Oil viscosity

Oil density

Oil rate

Power supply

Pump motor


Protection

Operation

Gas train 50

Gas train 65

Gas train 80

Gas train 100

Operating temperature

Storage Temperature

Working service*

C.I.B. UNIGAS - M039219CA min - max kW min.-max. (Stm cSt @ 40°C kg/m kW kW




ØValves /Connection

°C

°C

3

3

/h) min.-max. (kg/h)

HTP512A

600-4500

HTP515A

770 - 5200

HTP520A

1000 - 6400

Natural gas - Light oil

(see next paragraph)

81 - 550 106 - 677

HTP525A

2000 - 9750

63 - 476 212 - 1032

(see Note 2)

2 - 7.4

0.84

50 - 379 65 - 438

230V 3~ / 400V 3N~ 50Hz

84 - 539

1.1

1.6

1.5

2

1.5

2

IP40

Progressive - Fully modulating

2” / Rp 2

168 - 821

400V 3N~ 50Hz

4

4.5

-

2”

1/2

/ DN65

3” / DN80

4” / DN100

-10 ÷ +50

-20 ÷ +60

Intermittent

Note1:

Note2: all gas flow rates are referred to Stm 3 /h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (net calorific value H i

= 34.02 MJ/Stm

3

).

Maximum gas pressure = 360mbar (with Dungs MBC gas valves).

= 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.

NOTE: Choosing the nozzle for light oil, consider Hi equal to 10200 kcal/kg.

Country and usefulness gas categories

GAS

CATEGORY

I

2H

I

2E

I

2E( R ) B

I

2L

I

2ELL

I

2Er

NL

DE

FR

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

COUNTRY

AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH

LU PL -

BE -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

7

Overall dimensions (mm)

Air inlet flange and burner flange Boiler drilling plate

DN A B C CC D E F G H J JJ K KK L M N O

HTP90A 50 1356 490 866 305 1342 852 490 234 264 329 185 360 510 695 M14 424 300

HTP90A 65 1356 490 866 305 1447 957 490 234 264 288 185 360 510 695 M14 424 300

HTP90A 80 1356 490 866 305 1449 959 490 234 264 307 185 360 510 695 M14 424 300

HTP90A 100 1356 490 866 305 1539 1049 490 234 264 447 185 360 510 695 M14 424 300

HTP91A 50 1356 490 866 305 1342 852 490 265 295 329 185 360 510 695 M14 424 300

HTP91A 65 1356 490 866 305 1447 957 490 265 295 288 185 360 510 695 M14 424 300

HTP91A 80 1356 490 866 305 1449 959 490 265 295 307 185 360 510 695 M14 424 300

HTP91A 100 1356 490 866 305 1539 1049 490 265 295 447 185 360 510 695 M14 424 300

HTP92A 50 1356 490 866 305 1342 852 490 269 299 329 185 360 510 695 M14 424 300

HTP92A 65 1356 490 866 305 1447 957 490 269 299 288 185 360 510 695 M14 424 300

HTP92A 80 1356 490 866 305 1449 959 490 269 299 307 185 360 510 695 M14 424 300

HTP92A 100 1356 490 866 305 1539 1049 490 269 299 447 185 360 510 695 M14 424 300

HTP93A 50 1361 495 866 305 1342 852 490 304 344 329 185 360 510 695 M14 424 300

HTP93A 65 1361 495 866 305 1447 957 490 304 344 288 185 360 510 695 M14 424 300

HTP93A 80 1361 495 866 305 1449 959 490 304 344 307 185 360 510 695 M14 424 300

HTP93A 100 1361 495 866 305 1539 1049 490 304 344 447 185 360 510 695 M14 424 300

DN = gas valves size.

NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves.

610

610

610

610

610

610

610

610

610

OO

610

610

610

610

610

610

610

P Q

300 522

300 551

300 592

300 672

300 522

300 551

300 592

300 672

300 522

300 551

300 592

300 672

300 522

300 551

300 592

300 672

524

374

403

444

524

374

403

444

524

S

374

403

444

524

374

403

444

148

148

148

148

148

148

148

148

148

R

148

148

148

148

148

148

148

824

624

750

750

824

624

750

750

824

U

624

750

750

824

624

750

750

V W Y Z

216 875 198 180

293 875 198 180

322 875 198 180

382 875 198 180

216 875 228 180

293 875 228 180

322 875 228 180

382 875 228 180

216 875 228 180

293 875 228 180

322 875 228 180

382 875 228 180

216 875 228 180

293 875 228 180

322 875 228 180

382 875 228 180

Air inlet flange Burner flange Recommended burner counterflange Recommended boiler drilling plate

DN A B C CC D E F G H J JJ K KK L M N O OO P

HTP512A 50 1475 520 955 314 1570 1071 499 340 380 494 185 460 530 715 M14 552 390 693 390

HTP512A 65 1475 520 955 314 1548 1049 499 340 380 494 185 460 530 715 M14 552 390 693 390

HTP512A 80 1475 520 955 314 1583 1084 499 340 380 494 185 460 530 715 M14 552 390 693 390

HTP512A 100 1475 520 955 314 1666 1167 499 340 380 494 185 460 530 715 M14 552 390 693 390

HTP515A 50 1491 520 971 314 1570 1071 499 380 420 494 185 460 530 715 M14 552 390 693 390

HTP515A 65 1491 520 971 314 1548 1049 499 380 420 494 185 460 530 715 M14 552 390 693 390

HTP515A 80 1491 520 971 314 1583 1084 499 380 420 494 185 460 530 715 M14 552 390 693 390

PP Q QQ R S U V W Y Z x 765 x 160 605 843 216 945 286 230 x 643 x 160 483 843 293 945 286 230 x 695 x 160 535 875 322 945 286 230 x 802 x 160 642 942 382 945 286 230 x 765 x 160 605 843 216 945 312 230 x 643 x 160 483 843 293 945 312 230 x 695 x 160 535 875 322 945 312 230

HTP515A 100 1491 520 971 314 1666 1167 499 380 420 494 185 460 530 715 M14 552 390 693 390

HTP520A 50 1497 520 977 314 1570 1071 499 400 440 494 185 460 530 715 M14 552 390 693 390

HTP520A 65 1497 520 977 314 1548 1049 499 400 440 494 185 460 530 715 M14 552 390 693 390

HTP520A 80 1497 520 977 314 1583 1084 499 400 440 494 185 460 530 715 M14 552 390 693 390 x 802 x 160 642 942 382 945 312 230 x 765 x 160 605 843 216 945 328 230 x 643 x 160 483 843 293 945 328 230 x 695 x 160 535 875 322 945 328 230

HTP520A 100 1497 520 977 314 1666 1167 499 400 440 494 185 460 530 715 M14 552 390 693 390 x 802 x 160 642 942 382 945 328 230

HTP525A 50 1497 520 977 314 1570 1071 499 434 474* 494 185 460 530 715 M14 721* 390 693 510* 510* 765 550* 160 605 843 216 945 328 230

HTP525A 65 1497 520 977 314 1548 1049 499 434 474* 494 185 460 530 715 M14 721* 390 693 510* 510* 643 550* 160 483 843 293 945 328 230

HTP525A 80 1497 520 977 314 1583 1084 499 434 474* 494 185 460 530 715 M14 721* 390 693 510* 510* 695 550* 160 535 875 322 945 328 230

HTP525A 100 1497 520 977 314 1666 1167 499 434 474* 494 185 460 530 715 M14 721* 390 693 510* 510* 802 550* 160 642 942 382 945 328 230

DN = gas valves size.

* It is recommended to fit a counterflange between burner and boiler. As an alternative, make a smaller hole H, but greather than Y and fit the blast tube from the internal side of boiler

NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves.

Performance Curves


Output diagram (air temperature = 15°C)

HTP525A

0

HTP520A

HTP515A

HTP512A

HTP93A

HTP92A

HTP91A

HTP90A

2000 4000 6000 8000 10000 12000 14000 16000

To get the input in kcal/h, multiply value in kW by 860.

Data are referred to standard conditions: 1013mbar, 15°C.

10


Pressure in the Network / gas flow rate curves

HTP90A

70

HTP91A

60

50

40

30

20

10

0

Rp 2" (50)

DN100

DN65

DN80

90

80

70

60

50

40

30

20

10

0

50

30 50 70 90 110 130 150 170 190 210 230 250

HTP92A

Stm

3

/h

HTP93A

120

100

80

60

40

20

0

50 100 150 200 250 300

Rp 2" (50)

DN65

DN80

DN100

350

Stm

3

/h

200

160

120

80

40

0

50

100 150 200

Rp 2" (50)

250

DN65

DN80

DN100

300

Stm

3

/h

Rp 2" (50)

DN65

DN80

DN100

100 150 200 250 300 350 400 450 500

Stm

3

/h

HTP512A

200

150 Rp 2" (50)

100

DN65

50

DN80

DN100

0

50 100 150 200 250 300 350 400 450 500 550

Stm

3

/h

HTP515A

250

200

Rp 2" (50)

150

DN65

100

DN80

50

DN100

0

50 100 150 200 250 300 350 400 450 500 550 600 650

Stm

3

/h

HTP520A

400

350

300

Rp 2" (50)

250

200

150

DN65

100

50

DN80

DN100

0

100 150 200 250 300 350 400 450 500 550 600 650 700 750

Stm

3

/h

HTP525A

5 0 0

4 5 0

4 0 0

3 5 0

3 0 0

2 5 0

2 0 0

1 5 0

1 0 0

5 0

0

2 0 0 3 0 0 4 0 0 5 0 0 6 0 0

D N 6 5

D N 8 0

D N 1 0 0

7 0 0 8 0 0 9 0 0 1 0 0 0 1 1 0 0

Stm

3

/h

11


MOUNTING AND CONNECTING THE BURNER

Packing

The burners are despatched in wooden crates. Their dimensions are:

9xA series: 1740mm x 1270mm x 1010mm (LW x PH x HD)

5xxA series: 1740mm x 1420mm x 110mm (LW x PH x HD)

1 burner with gas train detached;

1 gasket to be inserted between the burner and the boiler; H

1 envelope containing this manual

Packing cases of this type are affected by humidity and are not suitable for stacking.

To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials.

Handling the burner

ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these operations are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.

To move the burner, use means suitable to support its weight (see paragraph

“Technical specifications”).

The burner is provided with eyebolts, for handling operations.

P

Eyebolts

L

Fitting the burner to the boiler

To install the burner into the boiler, proceed as follows:

1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)

2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;

3 place the 4 stud bolts (5) on the hole of the boiler’s door, according to the burner’s drilling plate described on paragraph “Overall dimensions”;

4 fasten the 4 stud bolts;

5 place the gasket on the burner flange;

6 install the burner into the boiler;

7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture.

8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material (ceramic fibre cord or refractory cement).

Keys

1 Burner

2 Fixing nut

3 Washer

4 Sealing gasket

5 Stud bolt

7 Blast tube

Fan installation

Pay attention when designing the air duct: dimensioning must be performed according to the flow rate, the temperature, the distance between the fan and the burner and according to the fan features as well.

ATTENTION!

The bellows unit provided is made of canvas and is provided with blocking spacers to avoid breaking it during installation: first place the bellows unit between flanges, then remove the spacers. Canvas has to be stretched after the installation, but not stressed.

12


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 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.

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).

Key a) Heat output in kW b) Lenght of the flame tube in meters c) Flame tube firing intensity in MW/m 3 d) Combustion chamber diameter (m)

Fig. 3 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat input in kW.

Fig. 3

Gas train connections

The diagrams show the components of the gas trai included in the delivery and which must be fitted by the installer.The diagrams are in compliance with the current laws.

ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE

MANUAL CUTOFF VALVES ARE CLOSED.

Gas train - 1 - Gas train with valves group VGD 20/40 with built-in gas pressure governor + VPS504 gas proving system

MANUFACTURER INSTALLER

10 4 5

1

6 7 8

2

3

Gas train - 2 (Rp2) - Gas train with valves group MBC 1200SE(2 valves + gas filter + pressure governor + pressure switch) +

VPS504 gas proving system


18 4 5

1

7 8

2

3

13


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


19 4 5

1

6 7 8

2

3

Gas train - 4 - Gas train with valves group VGD 20/40.. with built-in gas pressure governor + PGCP gas leakage pressure switch

MANUFACTURER

4 5

INSTALLER

1

2 6 7 8

10

16

Gas train - 5 (Rp2) - Gas train with valves group MBC 1200SE (2 valves + gas filter + pressure governor) + PGCP gas leakage pressure switch


18 5 4

1

2 7 8

16

Gas train - 6 (DN65/80/100) Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor) + PGCP gas leakage pressure switch

19

MANUFACTURER

5 4

INSTALLER

1

2 6 7 8

16

Keys

1 Burner

2 Butterfly valve

3 Gas proving system

4 Maximum gas pressure switch (option)

5 Minimum gas pressure switch

6 Gas filter

7 Bellow joint

8 Manual cutoff valve

10 VGD Valves group

16 PGCP gas leakage pressure switch

18 MBC Valves group (2” with built-in filter)

19 MBC Valves group (DN65/80/100)

14

Assembling the gas grain

To assemble the gas train, proceed as follows:


”direction” arrows for installation gas supply network

1E

3

1C 4

1B

5

1A

Keys

3

4

1A..1E

2

5

Gasket

Gas filter

Gas valves group

Bellow joint

Manual cock

1D 2

Fig. 4 - Example of gas train

To mount the gas train, proceed as follows:

1-a) in case of threaded joints: use proper seals according to the gas used;

1-b) in case of flanged joints: place a gasket (no. 1A..1E - Fig. 4) between the elements

NOTE: the 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. 4, 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 showed in the next paragraphs, according to the gas train used: z z threaded gas trains with Multibloc Dungs MBC..SE 1200 or Siemens VGD20..

flanged gas trains with Multibloc Dungs MBC..SE 1900-3100-5000 or Siemens VGD40..

Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor)

Mounting z z z z z z z z

When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded); to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts; install the valve; the direction of gas flow must be in accordance with the direction of the arrow on the valve body; ensure that the bolts on the flanges are properly tightened; ensure that the connections with all components are tight; make certain that the O-rings and gaskets between the flanges and the double gas valve are fitted.

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.

15


WARNING: removing the four screws BS causes the device to be unserviceable!

SIEMENS VGD..MOUNTING

POSITIONS

BS

BS

SA

TP

BS

BS

SKP1.

SKP2.

Fig. 5

Fig. 6

MULTIBLOC DUNGS MBC300-700-1200SE (Threaded valves group)

Mounting

1. Mount flange onto tube lines. Use appropriate sealing agent (see Fig. 8)

2. Insert MBC...SE. Note position of O rings (see Fig. 9).

3. Tighten screws A – H

4. After installation, perform leakage and functional test.

5. Disassembly in reverse order

MOUNTING

POSITIONS

OPTION

PLQ['1

'1

Ó

£

2 = Pulse lines

S

%U

"

#

$

%

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

"

"

EO

21

2

22

10 = pulse lines

Fig. 10

Fig. 9

7631z05/0101

Fig. 7

#

#

"

"

Fig. 8

'

&

)

(

16


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

Keys

1 spring

2 cap

DUNGS MBC valves:

Performance range (mbar)

Spring colour

4 - 20

-

Siemens VGD valves with SKP actuator:

Performance range (mbar)

Spring colour

0 - 22 neutral

20 - 40 ed

15 - 120 yellow red

Siemens SKP actuator

40 - 80 black

100 - 250

80 - 150 green

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. 4, the gas proving test mus be performed, according to the procedure set by the laws in force.

Hydraulic diagrams for light oil supplying circuits

Fig. 11 - Gravity circuit

17


Fig. 12 - Ring circuit

Fig. 13 - Suction circuit

Key

1 Manual valve

2 Light oil filter

3 Light oil feeding pump

4 One way valve

5 Flexible hoses

6 Relief valve

NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n. 4).

Installation diagram of light oil pipes

PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL.

From tank

To tank

Fig. 14 - Double-pipe system

The burner is supplied with filter and flexible hoses, all the parts upstream the filter must be installed by the customer. As far as the hoses connection, see the related paragraph.

.

Key

1 Burner

2 Flexible hoses (fitted)

3 Light oil filter (fitted)

4 Automatic interceptor (*)

5 One-way valve (*)

6 Gate valve

7 Quick-closing gate-valve (outside the tank or boiler rooms)

(*) Only for installations with gravity, siphon or forced circulation feed systems. If the device installed is a solenoid valve, a timer must be installed to delay the valve closing.

The direct connection of the device without a timer may cause pump breaks.

18


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 pulg, 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 pum’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.

pipeline length in meters.

Danfoss KSM..

Suntec TA

Suntec T

G

G

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.

Light oil pumps

Suntec TA..

Oil viscosity

Oil temperature

Min. suction pressure

Max. suction pressure

Max. return pressure

Rotation speed

4 - 450 cSt

0 - 140°C

- 0.45 barto avoid gasing

5 bar

5 bar

3600 rpm max.

19


Danfoss KSM..

Oil viscosity

Oil temperature

Max. suction pressure

Min. suction pressure

Max. return pressure

Rotation speed

2.5 ÷ 450 cSt

-10 ÷ 160 °C

4 bar

-0.45 bar to avoid gasing

4 bar

3450 rpm max

5

7

2

3

Keys

1 Pressure regulator

Pressure/Vacuum gauge port to measure inlet pressure/vacuum

Pressure gauge port

Suction

To the nozzle

8 Return

Suntec T pump

Viscosity

Oil temperature

Minimum suction pressure

4 - 800 cSt

0 - 140 °C

- 0.45 bar to prevent gasing

Maximum suction pressure 5 bar

2

3

4

Rated speed

Key

1 To pressure adjusting valve G3/4

3600 rpm max.

Pressure/vacuum gauge port to measure the inlet pressure/vacuum G1/4

Pressure gauge port G1/4

Inlet G3/4

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.

4

5

2

3

Key

1 Cap nut

Gasket

Adjusting screw

Lock nut

Gasket

Fig. 15

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 prevoius paragraph).

Suntec TA..

Danfoss KSM..

Suntec T

R

A R

A

20

R

A


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.

NOTE: if the burner is provided with separate control panel, please refer to the wiring diagrams.

To execute the electrical connections, proceed as follows:

1 remove the cover from the electrical board, unscrewing the fixing screws;

2 execute the electrical connections to the supply terminal board as shown in the following diagrams,

3 check the direction of the fan motor (see next pargraph)

4 refit the panel cover.

WARNING: The burner is provided with an electrical bridge between terminals 6 and 7; when connecting the high/ low flame thermostat, remove this bridge before connecting the thermostat.

IMPORTANT: Connecting electrical supply wires to the burner teminal block MA, be sure that the ground wire is longer than phase and neutral ones.

Connect the three-phase supply to terminals L1, L2, L3 and PE (ground); then shunt the phase and neutral wires (Fig. 17) for the auxiliaries on the printed circuit (N-terminal = neutral; L-terminal = phase)

Fig. 16: Power supply terminal board Fig. 17: Electric motor connection

Keys - Fig. 17

IG : main switch

KM1 : fan motor’s contactor

M : fan motor

TV : fan motor thermal cutout

21


Electrical wiring diagram for burners provided with printed circuit (standard configuration).

As far as connections, refer to the terminal block shown on Fig. 18.

Fig. 18: Terminal board for connections on printed circuit

1 Connect the signal conductors from the boiler to the burner, as for the next elements (Fig. 19 - Fig. 21):

ST : thermostat/pressure switch series

TAB : High/low flame thermostat

2 Connect the signal conductors from the burner to the boiler, as for the next elements (Fig. 19 - Fig. 21)

LB : Burner’s lockout signalling LED

LSPG : Gas proving system’ lockout signalling LED

3 In case of modulating burners, the 5, 6 and 7 terminals, on the MA teminal block, are already connected to the regulating modulator (mod. RWF40 ). A 4-pole plug coming out from the electrical panel is provided for the temperature and pressure probes connections (see Fig. 20).

Note: the regulating modulator is provided according to the ordered probe

Fig. 19: Progressive burners

RWF40 >>>

Fig. 21: Fully modulating burners

22

Fig. 20: Probes connection


Electrical wiring diagram for burners with no printed circuit provided

If the burner is ordered without printed circuit, follow the next connections diagrams.

Fig. 22 - Progressive burners

Fig. 24 - Fully modulating burners

Probes connection by means of the 7-pins plug (Fig. 25) see Fig. 23 for connections.

Fig. 23 - Probes connection

Fig. 25

Rotation of fan motor

Once the electrical connection of the burner is executed, remember to check the rotation of the fan 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.

NOTE:

( except for motors with “star-delta” start up

):

burners are supplied for three-phase 400V supply, and in the case of three-phase 230V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay.

23


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 O

2

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.

26, 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. 26

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. 26-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig. 26-3). 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 Stm

3

/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.

24


Pressure in combustion head - gas flow rate curves

HTP90A HTP91A

25

40

20

15

10

5

0

30 50 70 90 110 130 150 170 190 210 230 250

35

30

25

20

15

10

5

0

40 60 80 100 120 140 160 180 200 220 240 260 280 300

HTP92A

Stm3/h

HTP93A

45

40

35

30

25

20

15

10

5

0

40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340

Stm

3

/h

Stm3/h

50

45

40

35

30

25

20

15

10

5

0

50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450

Stm

3

/h

HTP512A

35

30

25

20

15

10

5

0

50 100 150 200 250 300 350 400 450 500

Stm

3

/h

HTP515A

40

35

30

25

20

15

10

5

0

50 100 150 200 250 300 350 400 450 500 550 600

Stm

3

/h

HTP520A HTP525A

140

50

45

40

35

30

25

20

15

10

5

0

50 100 150 200 250 300 350 400 450 500 550 600 650 700

120

100

80

60

40

20

Stm

3

/h

0

200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050

Stm

3

/h

25

ADJUSTING AIR AND GAS FLOW RATES


3

2

Keys

1 Gas filter

2 Gas proving system

3 Gas valves

4 Adjusting cam

5 Actuator

4

5

1

Fig. 27

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.

PA

LC

LB

Fig. 28

Actuators

Two actuator models can be provided: z Berger STM30.. (see page 28) or z Siemens SQL33.. (see page 29).

26


Air and gas flow rate adjustements

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:

Fuel

Natural gas

Light oil

Recommended combustion parameters

Recommended (%) CO

2

9 ÷ 10

11.5 ÷ 13

Recommended (%) O

2

3 ÷ 4.8

2.9 ÷ 4.9

During the factory test, the gas butterfly valve, air damper in low flame and actuator are set to average values.

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 24.

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.

To change the burner setting during the testing in the plant, follows the next procedure, according to the servocontrol model provided

(mod. Berger STM30.. or mod. Siemens SQL..).

Adjusting procedure

If the burner is provided with 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

Pressure setting

*OOFOTFDITLBOUTDIMàTTFM/P

"MMFOLFZOP

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Now, adjust the burner according to the actuator model provided.

The burner is factory-set wih the adjusting plate holes fully open, and the combustion head at its MAX position, so it is fit to work at the maximum output.

To adjust the gas flow, partially close the holes, as follows:

1 loosen the three V screws that fix the adjusting plate D ;

2 insert a screwdriver on the adjusting plate notches and let it move CW/CCW as to open/close the holes;

3 once the adjustmet is performed, fasten the V screws.

CAUTION: perform these adjustments once the burner is turned off and cooled.

27

z HTP91A - HTP92A - HTP93A

V

D

C.I.B. UNIGAS - M039219CA open holes z HTP512A - HTP515A - HTP520A - HTP525A

V

D

open holes close d holes close d holes

Now, adjust the burner according to the actuator model provided.

Settings by means of Berger STM30.. actuator

1 set GAS fuel by means of the burner CM switch (it is placed on the burner control panel)

MAN-AUTO

STM30.. actuator cams

I

II

High flame

Stand-by and Ignition

III Low flame

2 check the fan motor rotation (see “Rotation of fan motor” on page 23).

3 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.

4 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;

5 drive the burner to high flame stage, by means fo the thermostat TAB .

6 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.

7 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;

8 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

Siemens VGD..

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Dungs MBC..SE

9 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.

28


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 the air and gas rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV adjusting cam as to reach the minimum output point.

11 as for the point-to-point regulation, move the gas low flame microswitch (cam III) 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 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 V to increase the rate, unscrew to decrease.

14 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.

15 If it is necessary to change the burner output in the low flame stage, move cam III: the low flame position must never match the ignition position, that is why cam III must be set 20°-30° more than cam II.

16 Now adjust the pressure switches (see next par.).

SV

SC

PA

ID1

VF

SV

V

Keys

GV gas valves group

ID1 air damper index

ID2 index

PA air pressure switch

SC actuator

SV adjusting cam

V adjusting screws

VF butterfly valve

GV ID2

Gas butterfly valve closed Gas butterfly valve open

.Adjustment by the Siemens SQL33.. actuator

1 set GAS fuel by means of the burner CM switch (it is placed on the burner control panel);

2 check the fan motor rotation (see “Rotation of fan motor” on page 23).

3 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;

4 the burner starts up with the actuator on the ignition position, set it to the MAN (manual mode), by the MAN/AUTO selector (ignition position= read on the air damper index ID1 - see picture on previous page);

5 disconnect the TAB thermostat removing the wire from the terminal no. 6 or by setting MAN on the RWF40 modulatore or by setting 0 by means of the CMF switch (only for fully-modulating burners);

6 set the actuator on the manual mode (MAN) by means of the MAN/AUTO switch (see next pictures).

7 manually drive the adjusting cam SV to the high flame position and set the actuator to the AUTO mode (by the related switch - see picture) to lock the adjusting cam.

AUTO

MAN

BF

G

SQL330.. actuator cams

BF = Low flame

B = plastic cam

G = cam locking lever

B

8 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;

9 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).

29


- Dungs MBC..SE valves group: act on its pressure governor to increase or decrease the pressure and consequently the gas rate.:

10 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

11 the air and gas rate are now adjusted at the maximum output, go on with the point to point adjustment on the SV adjusting cam as to reach the minimum output point: gradually move the adjusting cam in order to adjust each of the V screws as to set the cam foil shape as described on the next steps:

12 to change the SV position set the actuator on the manual mode (MAN), turn the adjusting cam SV and set again the actuator to the

AUTO mode to lock the adjusting cam;

SV

SC

PA

ID1

VF

SV

V

Keys

GV gas valves group

ID1 air damper index

ID2 index

PA air pressure switch

SC actuator

SV adjusting cam

V adjusting screws

VF butterfly valve

GV

ID2

13 act on the V screw that mathces the bearings referring to the adjusting cam position;

14 to adjust the next screw, set again the actuator mode to MAN, turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw; adjust it and go on this way to adjust all the screws in order to set the cam foil shape, according to the combustion values read.

15 Once the cam foil shape is defined, reconnect the TAB thermostat reconnecting the wire to the terminal no.6 or setting the RWF40 burner modulator to AUTO or the CMF switch to 3 (only for fully-modulating burner).

16 Turn the burner off, then start it up again.

17 Once the pre-purge time comes to end, drive the burner to the high flame stage by the TAB thermostat and check the combustion values;

18 drive the burner to low flame, if necessary adjust the low flame size (ouput) by inserting a screwdriver on the slot F to move the BF cam.

BF

F

19 The low flame position must never match the ignition position that is why cam BF must be set 20°- 30° more than the ignition position (see ID1 index on previous pictures).

20 Now adjust the pressure switches (see next paragraph).

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 stop at the current position

CMF = 1 high flame operation

CMF = 2 low flame operation

CMF = 3 automatic operation

30

Calibration of 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 is not in the requested pressure range.

VR

Calibration of air pressure switch

z z

To calibrate the air pressure switch, proceed as follows: z z z

Remove the transparent plastic cap.

Once air and gas setting have been accomplished, startup the burner.

During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout, then read the value on the pressure switch scale and set it to a value reduced by 15%.

Repeat the ignition cycle of the burner and check it runs properly.

Refit the transparent plastic cover on the pressure switch.

Calibration of low gas pressure switch

z z z z

As for the gas pressure switch calibration, proceed as follows: z z z

Be sure that the filter is clean.

Remove the transparent plastic cap.

While the burner is operating at the maximum output, test the gas pressure on the pressure port of the minimum gas pressure switch.

z 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.

z z

PGCP Gas leakage pressure switch (witn SiemensLDU/Siemens LMV burner control)

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.

31


Adjusting light oil flow rate

The light 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. 29-Fig. 30 (as far as reading the pressure values, see next paragraphs).

NOZZLE

DELIVERY

PRESSURE bar

BERGONZO A3 20

RETURN

PRESSURE MAX.

bar

11 ÷ 13

RETURN

PRESSURE MIN.

bar

6 (recommended)

FLUIDICS WR2 25 20 7 (recommended)

Fig. 29

Example (Bergonzo): if a 220kg/h flow rate BERGONZO nozzle is provided, set the return pressure at 11bar, supply at 20bar on the delivery to get a 220kg/h flow rate. If the return pressure needed is 5bar, instead, act on the V adjusting screw on the pressure governor (see chapter on page 32). The flow rate will then be about 95kg/h (see the example showed on the Bergonzo diagram-Fig. 29).

32


275

300

330

360

400

450

500

550

600

650

700

750

800

DIMENSIONS

40

50

60

70

80

90

100

115

130

145

160

180

200

225

250

181

198

214

231

250

267

82

91

99

109

119

132

148

165

53

59

66

74

33

38

43

48

FLOW RATE kg/h

Min Max

13

16

40

50

20

23

26

30

60

70

80

90

100

115

130

145

160

180

200

225

550

600

650

700

750

800

250

275

300

330

360

400

450

500

Fig. 30

Example (Fluidics): 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. 30).

Oil Flow Rate Settings by means of Berger STM30.. actuator

1 Once the air and gas flow rates are adjusted, turn the burner off, switch it on again by turning the CM switch to the oil operation

(OIL, on the burner control panel).

2 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;

CP

3 bleed the air from the M pressure gauge port (Fig. 31) by loosing the cap without removing it, then release the contactor.

Suntec TA..

Danfoss KSM..

Suntec T..

M

M

VR

M

VR

VR

Fig. 31

4 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 .

33


5 record the high flame value set during the gas operation adjustments (see previous paragraphs);

6 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;

7 drive the burner to high flame stage, by means fo the thermostat TAB .

8 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).

MAN-AUTO

STM30.. actuator cams

I

II

High flame

Stand-by and Ignition

III Low flame (gas)

V Low flame (oil)

9 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. 32 and act on on the pump adjusting screw VR (see

Fig. 31 and page 20) as to get the nozzle pressure at 20 bar or 25bar (according to the nozzle model provided: Bergonzo or Fluidics nozzles - see page 32-33).

Pressure gauge port PG

RP

V2

SV2

Fig. 32 Fig. 33

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) 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 V) 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 V(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 showed on chart/diagram on “Adjusting light oil flow rate” on page 32, according to the requested rate.

14 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.

15 The low flame position must never match the ignition position that is why cam V must be set 20°- 30° more than the ignition position.

Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps.

Adjustment by the Siemens SQL33.. actuator

1 Once the air and gas flow rates are adjusted, turn the burner off, switch the CM switch to the heavy oil operation (OIL, on the burner control panel (see page 37).

2 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;

CP

3 bleed the air from the M pressure gauge port (Fig. 31) by loosing the cap without removing it, then release the contactor.

4 record the high flame value set during the gas operation adjustments (see prevoius paragraphs);

5 Start the burner up by means of the thermostat series and wait unitl the pre-purge phase comes to end and that burner starts up;

6 the burner starts up with the actuator on the ignition position, set it to the MAN (manual mode), by the MAN/AUTO selector (ignition position= read on the air damper index ID1 );

7 disconnect the TAB thermostat removing the wire from the terminal no. 6 or by setting MAN on the RWF40 modulatore or by setting 0 by means of the CMF switch (only for fully-modulating burners);

34


8 manually drive the adjusting cam SV2 to the high flame position and set the actuator to the AUTO mode (by the related switch - see picture) to lock the adjusting cam.

AB

AUTO

MAN

G

SQL33.. actuator cams

AB = High flame

BF1 = Low flame (gas)

BF2 = Low flame (oil)

B = plastic clamp

G = cam locking lever

B

AB

BF1

BF2

The nozzle supply 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. 34 and act on on the pump adjusting screw VR (see Fig.

31 and page 20) as to get the nozzle pressure at 20 bar or 25bar (according to the nozzle model provided: Bergonzo or Fluidics nozzles - see page 32-33).

Pressure gauge port

RP

PG

V2

SV2

Fig. 34 Fig. 35

9 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 prevoius paragraph): checking always the combustion parameters, the adjustment is to be performed by means of the SV2 adjusting cam screw (see picture) when the cam has reached the high flame position.

10 once the air and oil flow rate have been adjusted at the maximum output, go on with the point to point adjustment on the SV2 adjusting cam as to reach the minimum output point: gradually move the adjusting cam in order to adjust each of the V2 screws as to describe the cam foil shape.

11 to change the SV2 position set the actuator on the manual mode (MAN), turn the adjusting cam SV2 and set again the actuator to the AUTO mode to lock the adjusting cam;

12 act on the V2 screw that mathces the bearings referring to the adjusting cam position;

13 to adjust the next screw, set again the actuator mode to MAN, turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw; adjust it and go on this way to adjust all the screws in order to set the cam foil shape, according to the combustion values read.

14 Once the cam foil shape is defined, reconnect the TAB thermostat reconnecting the wire to the terminal no.6 or setting the RWF40 burner modulator to AUTO or the CMF switch to 3 (only for fully-modulating burner).

15 Turn the burner off then start it up again.

16 Once the pre-purge time comes to end, drive the burner to the high flame stage by the TAB thermostat: check the combustion values;

17 drive the burner to low flame, if necessary adjust the low flame size (output) by inserting a screwdriver on the slot F to move the

BF2 cam.

BF2

F

35


18 The low flame position must never match the ignition position that is why cam BF2 must be set 20°- 30° more than the ignition position.

19 Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps.

As far as fully-modulating burners, see paragraph on page 30.

Light oil circuit

The fuel is pushed into the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor. The solenoid valve 2 set the fuel immission into the combustion chamber. The part of fuel that is not burnt goes back to the tank through the return circuit. The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set (see prevoius paragraph).

Fig. 36 - Stand-by

Fig. 37 - Prepurge

36

Fig. 38 - Low flame

Fig. 39 - High flame

Key

1 Light oil pump

2 Light oil solenoid valve

3 Nozzle

4 Actuator

5 Adjusting cam

6 pressure gauge

7 Pressure regulator

8 One-way valve


PART II: OPERATION

LIMITATIONS OF USE

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CON-

NECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSI-

DERED 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 AUTHORI-

SED 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 PER-

SONNEL 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.

z z z

Choose the typer of fuel by turning the A switch, on the burner control panel.

CAUTION: if the fuel chosen is light oil, be sure the cutoff valves on the feed and return pipes are open.

Check the control box is not locked (signalling light O , on); if so, reset it by means of the pushbutton C .

Check the series of thermostats and pressure switches turn the burner to on.

Gas operation

z z

Check the gas feeding pressure is sufficient (signalling lamp G on).

the gas proving system test begins; when the test is performed the proving system LED turns on. At the end of the test, the burner staring cycle begins: in case of leakage in a valve, the gas proving system stops the burner and the lamp E turns on. Reset it, by means of the reset pushbutton on the device, in burners with VPS504 (pushbutton LB in picture), or by the D pushbutton on the burner panel if this one is fitted with LDU11 proving system.

LC

LB

VPS504

NOTE: if the burner is fitted with Dungs VPS504, the pre-purgue phase starts once the gas proving system is successfully performed.

Since the pre-purgue phase must be carried out with the maximum air rate, the control box drives the actuator opening and when the maximum opening position is achieved, the pre-purge time counting starts.

z At the end of the pre-purge time, the actuator drives the complete closing (ignition with gas position) and, as this is achieved the ignition transformer is energised (LED L is on); the gas valves open.

z Few seconds after the valves opening, the transformer is de-energised and lamp L turns off.

37

C.I.B. UNIGAS - M039219CA z The burner is now operating, meanwhile the actuator goes to the high flame position and, after some seconds, the two-stage operation begins; the burner is driven automatically to high flame or low flame, according to the plant requirements.

Operation in high or low flame is signalled by lamp N on the frontal panel.

Light oil operation

z The fan motor starts and the pre-purge phase as well. Since the pre-purge phase must be carried out at the maximum air rate, the control box drives the actuator opening and when the maximum opening position is reached, the pre-purge time counting starts.

z At the end of the pre-purge time, the actuator is in the light oil ignition position: the ignition transformer is energised (lamp L on); the light oil valves open. Few seconds after the valves opening, the transformer is de-energised and lamp L turns off.

z The burner is now operating, meanwhile the actuator goes to the high flame position; after some seconds, the two-stage operation begins; the burner is driven automatically to high flame or low flame, according to the plant requirements.

Operation in high or low flame is signalled by LED N on the burner control panel.

38


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.

z z z z z z

ROUTINE MAINTENANCE

z Check and clean the gas filter cartridge, if necessary replace it (see next paragraghs);

Check and clean the fuel filter cartdrige, replace if necessary.

Check and clean the filter inside the light 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.

Check the fuel hoses for possible leaks.

Remove, check and clean the combustion head (see page 40);

Check ignition electrodes, clean, adjust and, if necessary, replace them (see page 41);

Check and carefully clean the UV detector, replace it if necessary; if in doubt, check the detection current, once the burner starts up

(see on page 41).

z z

Remove and clean the fuel nozzle (Important: cleaning must be performed using solvent, not metal tools!

).

At the end of maintenance operations after the burner reassembly, light the flame and check its shape, replacing the nozzle whenever a questionable flame shape appears. Whenever the burner is used intensely, we recommend preventively replacing the nozzle at the start of each heating season.

Clean and grease sliding and rotating parts.

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.

Light oil filter maintenance

For correct and proper servicing, proceed as follows:

1 cutoff the required pipe section;

2 unscrew the filter cup;

3 remove the filtering cartridge, wash it with gasoline; if necessary, replace it; check the tightening

O-rings and replace them if necessary;

4 replace the cup and restore the pipe line.

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

C

39


Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group)

Inspect the filter at least once a year.

z Change the filter, if pressure value between pressure connections 1 and 2 is greather than 10 mbar.

z Change the filter, if pressure value between pressure connections 1 and 2 is twice as high compared to the last inspection.

1. Interrupt gas supply: close ball valve

2. Remove screws 1-2

3. Replace the filter insert 3

4. Screw in screws 1-2 without use force to fasten.

5. Perform leakage and funcion test.

Space requirements for fitting filter, A: from 150 to 230 mm.

Fig. 40

Removing the combustion head

1 Remove the top H .

2 Remove the UV detector out of its housing: disconnect electrode cables and the light oil flexible hoses.

3 Loosen the screws V holding the gas manifold G , loosen the two connectors E and remove the assembly as shown.

4 Clean the combustion head by means of a vacuum cleaner; scrape off the scale by means of a metallic brush.

Note: to replace the combustion head, reverse the operations described above.

H

V

G

E

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;

4 in order to replace the electrodes, unscrew the VE fixing screws and remove them: place the new electrodes being careful to observe the measures showed on pag.: reassemlbe following the reversed procedure.

Caution : adjust the nozzle position according to the air pipe, by means of the VU screw, ance the VL screw is fastened.

VU

VE

G

V

VL

40


Adjusting the electrodes position

Adjust the electrodes position, according to the quotes shown on the next picture.

U

E

Keys

E electrodes

TA air pipe

TG ignition gas pipe

U nozzle

TA TG

Fig. 41

Replacing the spring in the gas valve group

To replace the spring in the gas valve group,proceed as follows:

1 Carefully twist the protection cap 1 and the O-ring 2.

2 remove the “set value” spring 3 from housing 4.

3 Replace spring 3.

4 Carefully insert the new “set value” spring. Pay attention to mount properly. First insert the spring part with smaller diameter in the housing.

5 Place O-ring 2 in protective cap 1. Screw in the protective cap with the O-ring in it.

6 Stick the adhesive label for spring identification on the type plate.

3

4

3

1

2

1

4

1

DUNGS MBC..SE

SKP Siemens actuator

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 figure);

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.

41


Checking the detection current

To check the detection signal follow the scheme in Fig. 42 or Fig. 43. 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.

TERMINAL BOARD MC

27

µA DC

TERMINAL BOARD

Control box

Siemens

LFL1.3..

Siemens

LFL1.3..

Minimum detection signal

6µA (with electrode)

70µA (with UV detector)

Fig. 42: Detection by electrode

Fig. 43: Detection by photocell QRA..

Check of the detection current (with printed circuit)

To check the detection signal remove the bridge on “TEST ER” or “TEST UV” and connect a micro ammeter when Fig. 44. If the signal is less than the value indicated, check the position of the detection electrode or detector, the electrical contacts (one ER terminal for the electrode, two FC terminals for the

UV probe - see pictureon the side) and, if necessary, replace the electrode or the UV detector.

ER

Fig. 44

FC

Control box

Minimum detection signal

Siemens LFL1.3..

6µA (with electrode)

Siemens LFL1.3.. 70µA (with UV detector)

+ µA - µA + electrode UV detector

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 cock of 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”.

42

TROUBLESHOOTING

TROUBLE

CAUSE

MAIN SWITCH OPEN

LACK OF GAS

MAXIMUM GAS PRESSURE SWITCH DEFECTIVE

THERMOSTATS/PRESSURE SWITCHES DEFECTIVES

OVERLOAD TRIPPED INTERVENTION

AUXILIARIES FUSE INTERRUPTED

DEFECTIVE CONTROL BOX

DEFECTIVE ACTUATOR

AIR PRESSURE SWITCH FAULT OR BAD SETTING

MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS

FILTER DIRTY

IGNITION TRANSFORMER FAULT

IGNITION ELECTRODES BAD POSITION

BUTTERFLY VALVE BAD SETTING

DEFECTIVE GAS GOVERNOR

GAS VALVE DEFECTIVE

BAD CONNECTION OR DEFECTIVE HIGH/LOW FLAME

THERMOSTAT OR PRESSURE SWITCH

ACTUATOR CAM WRONG SETTING

UV PROBE DIRTY OR DEFECTIVE z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z


SPARE PARTS

Desription

CONTROL BOX

IGNITION ELECTRODE

OIL FILTER

GAS FILTER - Rp 2

GAS FILTER - DN65

GAS FILTER - DN80

GAS FILTER - DN100

GASKET

AIR PRESSURE SWITCH

GAS PRESSURE SWITCH- DUNGS GW50 A5




GAS PRESSURE SWITCH- ANTUNES DMG050



GAS PRESSURE SWITCH- ANTUNES FCG500

IGNITION TRANSFORMER

PUMP MOTOR

GAS VALVE GROUP - Rp2” - Siemens VGD20..

GAS VALVE GROUP - DN65 - Siemens VGD40..



GAS VALVE ACTUATOR SKP15


GAS VALVE GROUP - Rp2” - Dungs MBC1200SE

GAS VALVE GROUP - DN65 - Dungs MBC1900SE



GAS PROVING SYSTEM

GAS PROVING SYSTEM

FLEXIBLE HOSE L=1500

FLEXIBLE HOSE L=335

FLEXIBLE HOSE L=385

SMALL ADJUSTING CAM FOIL

BIG ADJUSTING CAM FOIL

ACTUATOR SIEMENS SQL33.03

ACTUATOR BERGER STM30/24

UV PROBE

MOTOR-PUMP COUPLING

LIGHT OIL GOVERNOR

BURNER MODULATOR (only for fully-modulating burners)

PUMP SUNTEC

PUMP DANFOSS

NOZZLE

OIL GUN

COMBUSTION HEAD

BLAST TUBE

IGNITION CABLE

PRINTED CIRCUIT BOARD

HTP90A

2020448

21903M8

2190403

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540019

2570054

2570112

2590118

2590310

2610202

2700231

30600R2

30900N1

6050108

6100533

21600A3

21600A4

21600A7

2170302

2180201

2190171

2190172

2190169

2190174

2190181

2190183

21903M5

21903M6

21903M7

2080292

2090018

2090019

2090117

2090117

2090112

2110048

2160065

2160076

2160077

2160087

2160089

21600A2

Code

HTP92A

2020448

21903M8

2190403

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540019

2570054

2570112

2590119

2590311

2610202

2700231

30600R3

30900M4

6050108

6100533

21600A3

21600A4

21600A7

2170302

2180202

2190171

2190172

2190169

2190174

2190181

2190183

21903M5

21903M6

21903M7

2080292

2090018

2090119

2090117

2090112

2090113

2110048

2160065

2160076

2160077

2160087

2160089

21600A2

HTP91A

2020448

21903M8

2190403

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540019

2570054

2570112

2590119

2590311

2610202

2700231

30600R3

30900M3

6050108

6100533

21600A3

21600A4

21600A7

2170302

2180202

2190171

2190172

2190169

2190174

2190181

2190183

21903M5

21903M6

21903M7

2080292

2090018

2090019

2090117

2090112

2090113

2110048

2160065

2160076

2160077

2160087

2160089

21600A2

HTP93A

2020448

21903M8

2190403

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540019

2570077

2570112

2590120

2590312

2610203

2700236

30600R3

30910M6

6050108

6100533

21600A3

21600A4

21600A7

2170302

2180202

2190171

2190172

2190169

2190174

2190181

2190183

21903M5

21903M6

21903M7

2080292

2090018

2090119

2090117

2090112

2090113

2110048

2160065

2160076

2160077

2160087

2160089

21600A2

44


Desription

CONTROL BOX

IGNITION ELECTRODE

OIL FILTER

GAS FILTER - Rp 2

GAS FILTER - DN65

GAS FILTER - DN80

GAS FILTER - DN100

GASKET

AIR PRESSURE SWITCH








GAS PRESSURE SWITCH- ANTUNES FCG500


PUMP MOTOR

GAS VALVE GROUP - Rp2” - Siemens VGD20..






GAS VALVE GROUP - Rp2” - Dungs MBC1200SE




OIL SOLENOID VALVE

GAS PROVING SYSTEM

FLEXIBLE HOSE L=1500

FLEXIBLE HOSE L=335

FLEXIBLE HOSE L=385

SMALL ADJUSTING CAM FOIL

BIG ADJUSTING CAM FOIL

ACTUATOR SIEMENS SQL33.03

ACTUATOR BERGER STM30/24

UV PROBE

MOTOR-PUMP COUPLING

LIGHT OIL GOVERNOR

SUNTEC TV LIGHT OIL GOVERNOR

BURNER MODULATOR (only for fully-modulating burners)

PUMP PUMP SUNTEC

PUMP PUMP DANFOSS

NOZZLE

OIL GUN

COMBUSTION HEAD

BLAST TUBE

IGNITION CABLE

PRINTED CIRCUIT BOARD

2190174

2190181

2190183

21903M5

21903M6

21903M7

21903M8

2190403

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540019

2570077

-

2570112

2590120

2590312

2610203

2700232

30600R4

3091075

6050108

6100533

HTP512A

2020448

2080292

2090018

2090119

2090117

2090112

2090113

2110047

2160065

2160076

2160077

2160087

2160089

21600A2

21600A3

21600A4

21600A7

2170302

2180202

2190171

2190172

2190169

2190174

2190181

2190183

21903M5

21903M6

21903M7

21903M8

2190403

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540126

25700B2

-

2570112

2590121

2590313

2610203

2700232

30600R5

3091076

6050108

6100533

2160077

2160087

2160089

21600A2

21600A3

21600A4

21600A7

2170302

2180223

2190171

2190172

2190169

HTP515A

Code

HTP520A

2020448

2080292

2090018

2090119

2090117

2090112

2090113

2110047

2160065

2160076

2020448

2080292

2090018

2090119

2090117

2090112

2090113

2110047

2160065

2160076

2160077

2160087

2160089

21600A2

21600A3

21600A4

21600A7

2170302

2180223

2190171

2190172

2190169

25700B2

-

2570112

2590121

2590313

2610203

2700232

30600R6

30910H4

6050108

6100533

2190174

2190181

2190183

21903M5

21903M6

21903M7

21903M8

2190403

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540126

2190174

2190181

2190183

21903M5

21903M6

21903M7

21903M8

2190750

2191604

2340004

2340087

2340088

2440013

2440014

2480040

2480090

2510001

2540133

25700A7

2570036

2570112

2590124

-

2610203

2700232

30600R6

30910L9

6050108

-

HTP525A

2020448

2080292

2090018

2090119

2090117

2090112

2090113

2110047

2160065

2160076

2160077

2160087

2160089

21600A2

21600A3

21600A4

21600A7

2170302

2180219

2190171

2190172

2190169

45


WIRING DIAGRAMS

Wiring diagram Cod. 05-680 - Progressive burners

Wiring diagram Cod. 05-681 - Fully modulating burners

Wiring diagram HTP525 Cod. 11-336/1 - Progressive burners

Wiring diagram HTP525 Cod. 11-339/1- Fully modulating burners

Wiring diagram 21-002/3 - Burners fitted with printed circuit - Complete key

BERGERSTM30..

CM

CMF

ER

EV1

EV2

EVG1/EVG2

F1/FU1/FU2

AIR DAMPER ACTUAROE (ALTERNATIVE)

FUEL MANUAL SELECTOR: 0) STOP - 1) GAS - 2) LIGHT OIL

MANUAL SWITCH 0)OFF 1)HIGH FLAME 2)LOW FLAME 3)AUTOMATIC

FLAME DETECTION ELECTRODE

GAS ELECTRO-VALVE UPSTREAM (OR VALVES GROUP)

GAS ELECTRO-VALVE DOWNSTREAM (OR VALVES GROUP)

LIGHT OIL SOLENOID VALVE

AUXILIARY FUSE

F2

F3

FU

F4/FU3

FAN MOTOR LINE FUSE

LINE FUSE

FUSE

PUMP LINE FUSE

FC

IG

UV FLAME DETECTOR

MAIN DISCONNECTOR

IL AUXILIARY LINE SWITCH

KA1/KA1.3/KA2/KA3.8 AUXILIARY RELAY

KM1/KM1.1/KM2.5

KM2/KM3.1

KM2.5S

KM2.5T

KT2.6

LAF

LB

LBF

LEV1

LEV2

LEVG

LPGMIN

LS

LSPG

LT

LTA

FAN MOTOR CONTACTOR

PUMP MOTOR CONTACTOR

FAN MOTOR CONTACTOR (STAR)

FAN MOTOR CONTACTOR (DELTA)

STAR/DELTA DELAYED RELAY

BURNER IN HIGH FLAME INDICATOR LIGHT

INDICATOR LIGHT FOR BURNER LOCK-OUT

BURNER IN LOW FLAME INDICATOR LIGHT

INDICATOR LIGHT FOR OPENING OF ELECTRO-VALVE [EV1]

INDICATOR LIGHT FOR OPENING OF ELECTRO-VALVE [EV2]

INDICATOR LIGHT FOR EVG 1/2 OPENING

INDICATOR LIGHT FOR PRESENCE OF GAS IN THE NETWORK

INDICATOR LIGHT FOR BURNER STAND-BY

INDICATOR LIGHT FOR LEAKAGE OF VALVES

INDICATOR LIGHT FOR FAN OVERLOAD TRIPPED

IGNITION TRANSFORMER INDICATOR LIGHT

MV

MP

PA

PGMAX

PGMIN

PS

PT100

SD-0÷10V

FAN MOTOR

LIGHT OIL PUMP MOTOR

COMBUSTION AIR PRESSURE SWITCH

MAXIMUM PRESSURE GAS SWITCH (OPTIONAL)

MINIMUM GAS PRESSURE SWITCH

LOCK-OUT RESET BUTTON

TEMPERATURE PROBE

TENSION SIGNAL

SD-0/4÷20mA

SD-PRESS

CURRENT SIGNAL

PRESSURE PROBE

SD-TEMP.

TEMPERATURE PROBE

SIEMENS LFL 1.3xx

CONTROL BOX

SIEMENS RWF40

SQL33.03

ST

TA

TAB

BURNER MODULATOR

AIR DAMPER ACTUATOR

SERIES OF THERMOSTATS OR PRESSURE SWITCHES


TC

TP

TV

VPS504

HIGH-LOW THERMOSTAT/PRESSURE SWITCHES (IF FITTED REMOVE THE BRIDGE BETWEEN TERMINALS

6 AND 7 ON TERMINAL BOARD MA)

THERMOCOUPLE

PUMP MOTOR THERMAL

FAN MOTOR THERMAL

GAS PROVING SYSTEM

ACTUATOR CAMS

3

6

SQL33- STM30..

Y1 I High Flame

Y2 II Stand-by and ignition

III Gas Low Flame

V Light Oil Low Flame

ATTENTION:

1- Power supply 400V 50 Hz, 3N a.c.

2- Don’t reverse phase with neutral

3- Ensure burner is properly hearted

46

Wiring diagram 21-002/3

WIRING DIAGRAM - Cod. 11-336/2


50


51


52

WIRING DIAGRAM - Cod. 11-339/2


53


54


55


56

APPENDIX

A

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

1 terminal 8.

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.

consent to start-up by means of the thermostat or pressostat "R"

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 nal 18.

Pre-ignition time waiting the response from the fuel valve at termit2 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: minal 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

Frequency

Absorbed capacity

Built-in fuse

220V -15%...240V +10%

50Hz -6%...60Hz +6%

3.5 VA

T6.3/250E slow action DIN41571 No.

External fuse

451915070 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 input at terminals 4 & 11 input at terminals 4 & 14

1A, 250V

1A, 250V 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 base approx. 1,000g.

approx. 165g.

Ionisation monitor voltage in detector electrode normal working test short circuit current

330V ±10%

380V ±10% 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 test

330V ±10%

380V ±10%

Detector current, min. request* 70µA

Max. detector current normal working 630 µA test

Max.length of connecting cable

1300 µA normal cable (laid separately**) 100m armoured cable (high frequency) protected at terminal 22

200m

Weight

QRA2

QRA10

60 g

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 t3

4

'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 t4

10

'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) t13 permitted post-ignition time

12

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

Key

A limit contact switch for damper OPEN position

AI block remote signal

AR main relay (working network) with contacts "ar"

AS Monitor fuse

BR block relay with "br" contacts

BV fuel valve

EK reset button

FE detector electrode of ionisation circuit

FR flame relay with "fr" contacts

G ventilator motor or burner motor

GP gas pressure switch

H

L main interruptor switch block stoppage LED

LK air damper

LP air pressostat

LR safety regulator

M auxiliary contact switch for damper "MIN" position

QRA UV detector

QRE ignition spark detector

R

S thermostat or pressostat fuse

SA damper servo-motor

SM synchronous programmer motor

V

V

W flame signal amplifier in case of servo-motor: auxiliary contact for response to fuel valve with regard of damper position safety pressostat or thermostat

Z

Z ignition transformer 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) input for raising QRA detector voltage to test level

(2) input for excitation of flame relay during flame detector test circuit (contact XIV) and during safety time (contact IV)

(3) Do not press EK for more than 10 seconds

Programmer diagram t1 pre-ventilation time t2 safety time

*t2 '1st safety time t3 pre-ignition time

*t3 'pre-ignition time t4 interval for creating current between terminals 18 and 19

*t4 'interval for creating current between terminals 17 and 19 t5 t6 t7 interval for creating current between terminals 19 and 20 post-ventilation time interval between startup consent and current created at terminal 7 duration of start-up t8

*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.

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. Errors and omissions exceptd.

Unigas HTP92A Installation, User's, And Maintenance Manual

Assistant Bot

Progressive

and fully-modulating gas - light oil burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

GENERAL FEATURES

How to choose the burner

Checking the proper gas train size

BURNER SPECIFICATIONS

Burner model identification

Technical specifications

Country and usefulness gas categories

Overall dimensions (mm)

Performance Curves

Pressure in the Network / gas flow rate curves

MOUNTING AND CONNECTING THE BURNER

Packing

Handling the burner

Fitting the burner to the boiler

Fan installation

Matching the burner to the boiler

Gas train connections

Assembling the gas grain

Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor)

Pressure adjusting range

Hydraulic diagrams for light oil supplying circuits

Installation diagram of light oil pipes

Bleed

About the use of fuel pumps

Light oil pumps

Suntec T pump

Suntec TV Pressure governor

Assembling the light oil flexible hoses

R

A R

A

R

A

Electrical connections

Electrical wiring diagram for burners provided with printed circuit (standard configuration).

Electrical wiring diagram for burners with no printed circuit provided

Rotation of fan motor

Combustion head gas pressure curves depending on the flow rate

Measuring the gas pressure in the combustion head

Pressure in combustion head - gas flow rate curves

ADJUSTING AIR AND GAS FLOW RATES

Gas Filter

VPS504 Gas proving system

Actuators

Air and gas flow rate adjustements

Adjustments - brief description

Adjusting procedure

V

D

V

D

Settings by means of Berger STM30.. actuator

SV

SC

PA

ID1

VF

SV

V

GV ID2

.Adjustment by the Siemens SQL33.. actuator

SV

SC

PA

ID1

VF

SV

V

GV

ID2

BF

F

Fully modulating burners

Calibration of air and gas pressure switches