CIB UNIGAS HR1030 Manual

HR1025
HR1030
HR1040
Progressive
and fully-modulating
gas - light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039115CF Rel. 5.0 12/2014
DANGERS, WARNINGS AND NOTES OF CAUTION
THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE
USER.
INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.
THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION
OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
1)
GENERAL INTRODUCTION
was designed.
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.
z
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.The occurrence of any
of the following circustances may cause explosions, polluting unburnt
gases (example: carbon monoxide CO), burns, serious harm to people,
animals and things:
- Failure to comply with one of the WARNINGS in this chapter
- Incorrect handling, installation, adjustment or maintenance of the burner
- Incorrect use of the burner or incorrect use of its parts or optional supply
2)
z
z
z
Special warnings
z Make sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.
z Before the burner is started and, thereafter, at least once a year,
have qualified personnel perform the following operations:
a
set the burner fuel flow rate depending on the heat input of the
appliance;
b
set the flow rate of the combustion-supporting air to obtain a combustion efficiency level at least equal to the lower level required by the
regulations in force;
c
check the unit operation for proper combustion, to avoid any harmful
or polluting unburnt gases in excess of the limits permitted by the
regulations in force;
d
make sure that control and safety devices are operating properly;
e
make sure that exhaust ducts intended to discharge the products of
combustion are operating properly;
f
on completion of setting and adjustment operations, make sure that
all mechanical locking devices of controls have been duly tightened;
g
make sure that a copy of the burner use and maintenance instructions is available in the boiler room.
z In case of a burner shut-down, reser the control box by means of the
RESET pushbutton. If a second shut-down takes place, call the
Technical Service, without trying to RESET further.
z The unit shall be operated and serviced by qualified personnel only,
in compliance with the regulations in force.
3)
GENERAL INSTRUCTIONS DEPENDING ON FUEL USED
3a)
ELECTRICAL CONNECTION
z
z
z
z
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.
Only burners designed according to the regulations in force should
be used.
This burner should be employed exclusively for the use for which it
z
2
For safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.
It is vital that all saftey requirements are met. In case of any doubt,
ask for an accurate inspection of electrics by qualified personnel,
since the manufacturer cannot be held liable for damages that may
be caused by failure to correctly earth the equipment.
Qualified personnel must inspect the system to make sure that it is
adequate to take the maximum power used by the equipment shown
on the equipment rating plate. In particular, make sure that the
system cable cross section is adequate for the power absorbed by
the unit.
No adaptors, multiple outlet sockets and/or extension cables are permitted to connect the unit to the electric mains.
An omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.
The use of any power-operated component implies observance of a
few basic rules, for example:
- do not touch the unit with wet or damp parts of the body and/or with
bare feet;
- do not pull electric cables;
DIRECTIVES AND STANDARDS
Gas burners
European directives:
- Directive 2009/142/EC - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/EC on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;-EN 55014-1Electromagnetic compatibility Requirements for household appliances, electric tools and similar apparatus.
-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.
-EN 60335-2-102 (Household and similar electrical appliances. Safety.
Particular requirements for gas, oil and solid-fuel burning appliances
having electrical connections)
- do not leave the equipment exposed to weather (rain, sun, etc.)
unless expressly required to do so;
- do not allow children or inexperienced persons to use equipment;
z The unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact qualified
personnel to replace.
When the unit is out of use for some time the electric switch supplying all
the power-driven components in the system (i.e. pumps, burner, etc.)
should be switched off.
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
GENERAL
z The burner shall be installed by qualified personnel and in compliance with regulations and provisions in force; wrong installation
can cause injuries to people and animals, or damage to property, for
which the manufacturer cannot be held liable.
z Before installation, it is recommended that all the fuel supply system
pipes be carefully cleaned inside, to remove foreign matter that might
impair the burner operation.
z Before the burner is commissioned, qualified personnel should
inspect the following:
a
the fuel supply system, for proper sealing;
b
the fuel flow rate, to make sure that it has been set based on the
firing rate required of the burner;
c
the burner firing system, to make sure that it is supplied for the designed fuel type;
d
the fuel supply pressure, to make sure that it is included in the range
shown on the rating plate;
e
the fuel supply system, to make sure that the system dimensions are
adequate to the burner firing rate, and that the system is equipped
with all the safety and control devices required by the regulations in
force.
z When the burner is to remain idle for some time, the fuel supply tap
or taps should be closed.
Light oil burners
European directives:
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/EC on electromagnetic compatibility
Harmonised standards :
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
-UNI 267 Automatic forced draught burners for liquid fuels
-EN 55014-1Electromagnetic compatibility - Requirements for household
appliances, electric tools and similar apparatus.
-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
European directives:
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/EC on electromagnetic compatibility
Harmonised standards :
-CEI EN 60335-1 Household and similar electrical appliances - SafetyPart
1: General requirements;
-EN 55014-1Electromagnetic compatibility - Requirements for household
appliances, electric tools and similar apparatus.
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
SPECIAL INSTRUCTIONS FOR USING GAS
Have qualified personnel inspect the installation to ensure that:
a
the gas delivery line and train are in compliance with the regulations
and provisions in force;
b
all gas connections are tight;
c
the boiler room ventilation openings are such that they ensure the air
supply flow required by the current regulations, and in any case are
sufficient for proper combustion.
z Do not use gas pipes to earth electrical equipment.
z Never leave the burner connected when not in use. Always shut the
gas valve off.
z In case of prolonged absence of the user, the main gas delivery
valve to the burner should be shut off.
Precautions if you can smell gas
a
do not operate electric switches, the telephone, or any other item
likely to generate sparks;
b
immediately open doors and windows to create an air flow to purge
the room;
c
close the gas valves;
d
contact qualified personnel.
z Do not obstruct the ventilation openings of the room where gas
appliances are installed, to avoid dangerous conditions such as the
development of toxic or explosive mixtures.
Gas - Light oil burners
European directives:
- Directive 2009/142/EC - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/EC on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 Gas Burners
-EN 55014-1Electromagnetic compatibility - Requirements for household
appliances, electric tools and similar apparatus.
-UNI 267 Automatic forced draught burners for liquid fuels
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Gas - Heavy oil burners
European directives:
- Directive 2009/142/EC - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/EC on electromagnetic compatibility
Harmonised standards :
3
-EN 55014-1Electromagnetic compatibility - Requirements for household
appliances, electric tools and similar apparatus.
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Industrial burners
European directives:
- Directive 2009/142/EC - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/EC on electromagnetic compatibility
Harmonised standards :
-EN 55014-1Electromagnetic compatibility - Requirements for household
appliances, electric tools and similar apparatus.
-EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
-UNI EN 746-2: Industrial thermoprocessing equipment
Burner data plate
For the following information, please refer to
the data plate:
z burner type and burner model: must be
reported in any communication with the
supplier
z burner ID (serial number): must be reported in any communication with the supplier
z date of production (year and month)
z information about fuel type and network
pressure
Type
Model
Year
S.Number
Output
Oil Flow
Fuel
Category
Gas Pressure
Viscosity
El.Supply
El.Consump.
Fan Motor
Protection
Drwaing n°
P.I.N.
-----------------
SYMBOLS USED
WARNING!
DANGER!
WARNING!
Failure to observe the warning may
result in irreparable damage to the
unit or damage to the environment
Failure to observe the warning may
result in serious injuries or death.
Failure to observe the warning may
result in electric shock with lethal consequences
ö
4
PART I: SPECIFICATIONS
PART I: SPECIFICATIONS
1.0 GENERAL FEATURES
This series represents monobloc gas burners made in die-cast aluminium housing, that can burn either gas or light oil, thanks to the
adjustable combustion head which allows a good performance with both fuels.They can be provided in progressive or fully-modulating
version.
5
1
7
4
14
15
3
13
2
6
12
11
10
8
9
16
Fig. 1
Note: the figure is indicative only.
1
2
3
4
5
6
7
8
Mimic panel with startup switch
Gas filter
Gas proving system
Gas valve group
Cover
Flange
Blast tube-Combustion head group
Oil pressure governor
9
10
11
12
13
14
15
16
Actuator
Adjusting cams
Air intake
Air pressure switch
Oil manifold
Head adjusting ring nut
Oil solenoid valve
Oil gun
Gas operation: the gas coming from the supply line, passes through the valves group provided with filter and governor. This one forces the pressure in the utilisation limits. The actuators move proportionally the air damper and the gas butterfly valve, in order to
achieve the optimisation of the gas flue values, as to get an efficient combustion.
Light oil operation:the fuel coming from the supply line, is pushed by the pump to the nozzle and then into the combustion chamber,
where the mixture between fuel and air takes place and consequently the flame.
In the burners, the mixture bertween fuel and air, to perform clean and efficient combustion, is activated by atomisation of oil into very
small particles. This process is achieved making pressurised oil passing through the nozzle.
The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pressure,
pumps are provided with a pressure regulator (except for some models for which a separate regulating valve is provided). Other pumps
are provided with two pressure regulators: one for the high and one for low pressure (in double-stage systems with one nozzle).
The adjustable combustion head can improve the burner performance. The combustion head determines the energetic quality and the
geometry of the flame. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion chamber). The control panel, placed on the burner front side, shows each operating stage.
5
PART I: SPECIFICATIONS
1.1 Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type
HR1025
(1)
Model
1
2
BURNER TYPE
FUEL
3
OPERATION (Available versions)
4
5
BLAST TUBE
DESTINATION COUNTRY
6
BURNER VERSION
7
EQUIPMENT
8
GAS CONNECTION
MG.
(2)
MD. S.
(3) (4)
*.
(5)
A.
(6)
1.
(7)
80.
(8)
HR1025 - HR1030 - HR1040
G - Light oil
M - Natural gas
B - Biogas
L - LPG
C - Town gas
PR - Progressive
MD - Fully modulating
S - Standard
* - see data plate
A - Standard
Y - Special
1 = 2 gas valves + gas proving system
8 = 2 gas valves + gas proving system + maximum gas pressure switch
65 = DN65
80 = DN80
50 = Rp2
1000 = DN100
125 = DN125
6
PART I: SPECIFICATIONS
1.2 Technical Specifications
min. - max. kW
HR1025
MG......50
2550 - 6700
min.- max. (Stm3/h)
274 - 709
BRUCIATORE TIPO
Output
HR1025
HR1030
HR1030
MG......xx
MG.....65
MG.....xx
2550 - 8700
2550 - 9500
2550 - 10600
Natural gas - Light oil
Fuel
Category
HR1040
MG.....xx
2550 - 13000
(see next paragraph)
Gas rate min.-max.
Pressure
274 - 935
270 - 1005
Light oil rate
mbar
min.-max. kg/h
Oil viscosity
cSt @ 40 °C
215 - 800
2 - 7.4
kg/m3
bar
2 max
Oil density
Oil train inlet pressure
270 - 1122
270 - 1376
215 - 893
215 - 1095
(see Note 2)
215 - 564
215 - 730
840
400V 3N ~ 50Hz
Power supply
Total power consumption
kW
23
23
26.5
26.5
36
Electric motor
kW
18.5
18.5
22
22
30
Pump motor
kW
4
4
4
4
5.5
Protection
IP40
Progressive - Fully modulating
Operation
Gas train 50
ØValves / Connection
50 / Rp 2
-
-
-
-
Gas train 65
ØValves / Connection
-
2”1/2 / DN65
2”1/2 / DN65
2”1/2 / DN65
-
Gas train 80
ØValves / Connection
-
3” / DN80
-
3” / DN80
3” / DN80
Gas train 100
ØValves / Connection
-
4” / DN100
-
4” / DN100
4” / DN100
Gas train 125
ØValves / Connection
-
-
-10 ÷ +50
-
5” / DN125
Operating temperature
°C
Storage Temperature
°C
-20 ÷ +60
Intermittent
Working service*
Note1:
All gas flow rates are referred to Stm3/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas
(net calorific value Hi = 34.02 MJ/Stm3);
Note2:
Maximum gas pressure = 360mbar (with Dungs MBDLE)
Maximum gas pressure = 500mbar (with Siemens VGD)
Minimum gas pressure = see gas curves.
* NOTE ON THE WORKING SERVICE: the control box automatically stops after 24h of continuous working. The control box
immediately starts up, automatically.
1.3 Country and usefulness gas categories
GAS
CATEGORY
COUNTRY
I2H
AT
ES GR SE
FI
IE
HU
IS
NO CZ
DK GB
IT
PT
CY
EE
LV
SI
MT
SK
BG
LT
I2E
LU
PL
-
-
-
-
-
-
-
-
-
I2E( R ) B
BE
-
-
-
-
-
-
-
-
-
I2L
NL
-
-
-
-
-
-
-
-
I2ELL
DE
-
-
-
-
-
-
-
I2Er
FR
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
7
RO TR
CH
K
O
1.4 Overall dimensions (mm)
O
K
Burner flange
HR1025
HR1025
HR1025
HR1025
HR1030
HR1030
HR1030
HR1040
HR1040
HR1040
DN* A
50 2088
65 2088
80 2088
100 2088
65 2088
80 2088
100 2088
80 2106
100 2106
125 2106
AA
377
377
377
377
377
377
377
377
377
377
*DN = gas valves size
AB
1452
1452
1452
1452
1452
1452
1452
1452
1452
1452
AC
651
651
651
651
651
651
651
651
651
651
AD
25
25
25
25
25
25
25
25
25
25
AE
585
585
585
585
585
585
585
585
585
585
AN
809
827
841
854
827
841
854
841
854
884
AP
100
118
132
145
118
132
145
132
145
175
B
544
544
544
544
544
544
544
544
544
544
BB
641
641
641
641
657
657
657
657
657
657
C
1544
1544
1544
1544
1544
1544
1544
1562
1562
1562
CC
680
680
680
680
680
680
680
680
680
680
D
E
21421320
21211299
21231301
21391317
21211299
21231301
21391317
21231301
21391317
22541432
F
822
822
822
822
822
822
822
822
822
822
G
400
400
400
400
454
454
454
514
514
514
H
450
450
450
450
504
504
504
564
564
564
J
709
709
709
709
709
709
709
709
709
709
K
660
660
660
660
660
660
660
660
660
660
L
816
816
816
816
816
816
816
816
816
816
M
M16
M16
M16
M16
M16
M16
M16
M16
M16
M16
N
651
651
651
651
651
651
651
651
651
651
O
460
460
460
460
460
460
460
460
460
460
P
460
460
460
460
460
460
460
460
460
460
Q
1036
914
936
842
914
936
842
936
842
954
R
200
200
200
200
200
200
200
200
200
200
RR
265
265
265
265
265
265
265
265
265
265
S
836
714
736
642
714
736
642
736
642
754
SS
80
80
80
80
80
80
80
80
80
80
U
1092
1092
1092
1092
1092
1092
1092
1192
1192
1192
UU
142
142
142
142
142
142
142
142
142
142
V
216
292
322
382
292
322
382
322
382
480
W
1146
1146
1146
1146
1146
1146
1146
1146
1146
1146
Y
379
379
379
379
372
372
372
408
408
408
Z
330
330
330
330
330
330
330
330
330
330
PART I: SPECIFICATIONS
8
Boiler recommended drilling template
Fig. 2 - 3I2MG-17 v1 Hydraulic diagram - nozzle M3
PI
ON BOARD ITEMS SUPPLIED LOOSE ITEMS
M
oil inlet
oil outlet
PS
PI
PSH
PS
PSL
PART I: SPECIFICATIONS
gas inlet
PS
9
M
combustion air
M
BY OTHERS
PSL
LPG inlet
PI
LPG gas - out of Cib Unigas scope of
supply
BY CIB UNIGAS
3I2MG17
POS
OIL TRAIN
Filter
Flexible hose
Pump and pressure governor
Electrical motor
Solenoid valve
Flexible hose
Oil distributor
Pressure gauge with manual valve
One-way valve
Flexible hose
Pressure gauge with manual valve
Pressure governor
Pressure switch
One-way valve
Flexible hose
3-way solenoid valve
Flexible hose
20
21
22
23
24
25
26
27
40
41
42
Manual valve
Bellows unit
Filter
Safety valve with built in gas governor
Pressure switch - PGMIN
Proving system pressure switch - PGCP
Pressure switch - PGMAX
Butterfly valve
COMBUSTION AIR TRAIN
Air damper
Actuator
Pressure switch - PA
Draught fan with electromotor
Burner
PILOT GAS TRAIN
Pressure governor with filter
Pressure switch - PGP
Solenoid valve
The following POS are optional
20 - 21 - 26 - 77 - 78 - 79
43
44
76
77
78
79
Flexible hose
Pilot burner
Pressure governor x LPG tank
Manual valve
Pressure gauge
LPG Tank
10
NOTE
MAIN GAS TRAIN
30
31
32
33
34
PART I: SPECIFICATIONS
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
18
LEGEND
Fig. 3 - 3I2MG-18 v1 Hydraulic diagram - nozzle type G
ON BOARD ITEMS SUPPLIED LOOSE ITEMS
PI
M
oil inlet
oil outlet
PS
PI
PSH
PS
PSL
PART I: SPECIFICATIONS
gas inlet
11
PS
M
combustion air
M
BY OTHERS
PSL
LPG inlet
PI
LPG gas - out of Cib Unigas scope of supply
BY CIB UNIGAS
3I2MG18
POS
OIL TRAIN
Filter
Flexible hose
Pump and pressure governor
Electrical motor
Solenoid valve
Flexible hose
Oil distributor
Pressure gauge with manual valve
One-way valve
Flexible hose
Pressure gauge with manual valve
Pressure governor
Pressure switch
One-way valve
Flexible hose
3-way solenoid valve
Flexible hose
20
21
22
23
24
25
26
27
40
41
42
Manual valve
Bellows unit
Filter
Safety valve with built in gas governor
Pressure switch - PGMIN
Proving system pressure switch - PGCP
Pressure switch - PGMAX
Butterfly valve
COMBUSTION AIR TRAIN
Air damper
Actuator
Pressure switch - PA
Draught fan with electromotor
Burner
PILOT GAS TRAIN
Pressure governor with filter
Pressure switch - PGP
Solenoid valve
The following POS are optional
20 - 21 - 26 - 77 - 78 - 79
43
44
76
77
78
79
Flexible hose
Pilot burner
Pressure governor x LPG tank
Manual valve
Pressure gauge
LPG Tank
12
NOTE
MAIN GAS TRAIN
30
31
32
33
34
PART I: SPECIFICATIONS
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
18
LEGEND
PART I: SPECIFICATIONS
1.5 How to read the burner “Performance curve”
Campo di lavoro bruciatori
Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65
backpressure
in di
Contropressione
in camera
combustion
chamber
combustione
mbar (mbar)
To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed:
z furnace input, in kW or kcal/h (kW = kcal/h / 860);
z backpressure (data are available on the boiler ID plate or in the
user’s manual).
Example:
Furnace input: 600kW
Backpressure: 4mbar
In the “Performance curve” diagram, draw a vertical line matching the
furnace input value and an horizontal line matching the backpressure
value. The burner is suitable if the intersection point A is inside the performance curve.
Data are referred to standard conditions: atmospheric pressure at
1013mbar, ambient temperature at 15°C.
8
7
6
5
A
4
3
2
1
0
-1
100
200
300
400
500
600
700
800
900
Power kW
kW
Potenza
1.6 Checking the proper gas train size
25
pressure (mbar)
minimum
pressure
Minimagas
pressione
gas inin
rete network
/ Minimummbar
inlet gas
the
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 pgas. 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 pgas value, calculated before.
Rp 2" (50)
20
DN65
15
10
5
0
100
200
300
400
500
600
Power
kW(kW)
Potenza
/ Output
13
700
800
900
PART I: SPECIFICATIONS
1.7 Performance Curves
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
HR1025 2”
HR1025 DN65 - DN80 - DN100
35
35
30
30
25
25
20
20
15
15
10
10
5
5
0
2000
3000
4000
5000
6000
0
2000
7000
3000
4000
5000
7000
8000
9000
kW
kW
HR1030 DN80 - DN100
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
HR1030 DN65
6000
kW
kW
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
HR1040
25
20
15
10
5
0
2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000
kW
To get the input in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C
NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory
tests, but does not represent the regulation range of the machine. On this diagram the maximum output point is usually reached by adjsuting the combustion head to its “MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is reached setting the combustion head to its “MIN” position. During the first ignition, the combustion head is set in order to find a
compromise between the burner output and the generator specifications, that is why the minimum output may be different from the Performance curve minimum.
14
PART I: SPECIFICATIONS
Pressure in the Network / gas flow rate curves(natural gas)
GAS PRESSURE IN
THE NETWORK mbar
HR1025 M-....1.xx
GAS PRESSURE IN
THE NETWORK mbar
HR1030 M-.....65
Gas rate Stm3/h
HR1030 M-....1.xx
Gas rate Stm3/h
Gas rate Stm3/h
GAS PRESSURE IN
THE NETWORK mbar
HR1040 M-.
Gas rate Stm3/h
Caution: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis
(pressure value in the combustion chamber is not included). To know the minimum pressure at the gas train
inlet, necessary to get the requested gas rate, add the pressure value in the combustion chamber to the value
read on the y-axis.
15
PART I: SPECIFICATIONS
1.8 Combustion head gas pressure curves depending on the flow rate
The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner properly
adjusted (percentage of residual O2 in the flues as shown in the “Recommended combustion values” table and CO in the standard
limits). During this stage, the combustion head, the gas butterfly valve and the actuator are at the maximum opening. Refer to , 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. 5
Note: the figure is indicative only.
Key
1 Generator
2 Pressure outlet on the combustion chamber
3 Gas pressure outlet on the butterfly valve
4 Differential pressure gauge
1.9 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 to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner.
On the basis of the measured differential pressure, it is possible to get the maximum flow rate: in the pressure - rate curves (showed on
the next paragraph), it is easy to find out the burner’s output in Stm3/h (quoted on the x axis) from the pressure measured in the
combustion head (quoted on the y axis). The data obtained must be considered when adjusting the gas flow rate.
ATTENTION: THE BURNED GAS RATE MUST BE READ AT THE GAS FLOW METER. WHEN IT IS NOT POSSIBLE,
THE USER CAN REFERS TO THE PRESSURE-RATE CURVES AS GENERAL INFORMATION ONLY.
16
PART I: SPECIFICATIONS
1.10 Pressure - rate in combustion head curves (natural gas)
Curves are referred to pressure = 0mbar in the combustion chamber!
Gas pressure in
combustion head
HR1025
Gas pressure in
combustion head
HR1030
Gas rate Stm3/h
HR1040
Gas rate Stm3/h
Gas rate Stm3/h
17
PART II: INSTALLATION
PART II: INSTALLATION
2.0 MOUNTING AND CONNECTING THE BURNER
2.1 Packing
The burners are despatched in wooden crates whose dimensions are:
2270mm x 1720mm x 1320mm (L x P x H)
Packing cases of this type are affected by humidity and are not suitable for stacking.
The following are placed in each packing case:
z burner with detached gas train;
z gasket or ceramic fibre plait (according to burner type) to be inserted between the burner
and the boiler;
z envelope containing this manual and other documents.
z oil flexible hoses;
H
P
L
To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal
of materials.
2.2 Handling the burner
ATTENTION! The handling operations must be carried out by specialised and trained personnel. If these operations are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.
To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).
The unpacked burner must be lifted and moved only by means of a fork lift truck.
The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck: the forks must be inserted into the A
anb B ways. Remove the stirrup only once the burner is installed to the boiler.
Eyebolts
B
A
The burner is provided with eyebolts, for handling operations.
18
Eyebolts
PART II: INSTALLATION
2.3 Fitting the burner to the boiler
To perform the installation, proceed as follows:
1 drill the furnace plateas decribed in paragraph (“Overall dimensions”);
2 place the burner towards the furnace plate: lift and move the burner by means of its eyebolts placed on the top side (see”Lifting and
moving the burner”);
3 screw the stud bolts (5) in the plate holes, according to the burner’s drilling plate described on paragraph “Overall dimensions”;
4 place the ceramic fibre plait on the burner flange;
5 install the burner into the boiler;
6 fix the burner to the stud bolts, by means of the fixing nuts, according to the picture below.
7 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate
insulating material (ceramic fibre cord or refractory cement).
;
Keys
4
1
2
3
4
5
7
Burner
Fixing nut
Washer
Ceramic fibre plait
Stud bolt
Blast tube
The burner is designed to work positioned according to the picture below. For different installations, please contact the Technical
Department.
SIDE UP
SIDE DOWN
Note: the figure is indicative only.
19
PART II: INSTALLATION
2.4 Matching the burner to the boiler
The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose
dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in diameter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with
respect of the application involved. To correctly match the burner to the boiler verify the type of the blast tube (type 1 or type 2). Verify
the necessary input and the pressure in combustion chamber are included in the burner performance curve; otherwise the choice of the
burner must be revised consulting the burner manufacturer. To choose the blast tube lenght follow the instructions of the boiler manufacturer. In absence of these consider the following:
z Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than Dist = 100
mm into the combustion chamber. (please see the picture below)
z Pressurised boilers with flame reversal: in this case the blast tube must penetrate Dm 50 ÷ 100 mm into combustion chamber in
respect to the tube bundle plate.(please see the picture below)
Dist
Dm
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/m3
d) Combustion chamber diameter (m)
Fig. 6 - Firing intensity, diameter and lenght of the test flame tube as a function of the
heat input in kW.
Fig. 6
20
PART II: INSTALLATION
3.0 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 with valves group VGD with built-in gas pressure governor + gas leakage pressure switch (PGCP)
BY OTHERS
PSH
S
PS
SUPPLIED BY BURNER
CONSTRUCTOR
PSL
GAS INLET
ON BOARD ITEMS SUPPLIED LOOSE ITEMS
Key
1
2
3
4
5
Filter
Pressure switch - PGMIN
Safety valve with built in gas governor
Proving system pressure switch (if present) - PGCP
Pressure switch - PGMAX(*optional)
6
8
9
10
Butterfly valve
Main burner
Bellows unit(*optional)
Manual valve(*optional)
Gas train with valves group VGD with built-in gas pressure governor + gas proving system VPS504
BY OTHERS
SUPPLIED BY BURNER
CONSTRUCTOR
GAS INLET
ON BOARD ITEMS SUPPLIED LOOSE ITEMS
Key
1
2
3
4
5
Filter (*optional)
Pressure switch - PGMIN
Safety valve with built in gas governor
Proving system
Pressure switch - PGMAX (*optional)
6
7
8
9
21
Butterfly valve
Main burner
Manual valve(*optional)
Bellows unit(*optional)
PART II: INSTALLATION
3.1 Assembling the gas grain
gas supply network
”direction” arrows for installation
1A
5
1B
Keys
3
1A..1E
2
3
4
5
1E
1C
1D
4
2
Gasket
Gas filter
Gas valves group
Bellows unit
Manual valve
Fig. 7 - 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 - ) between the elements
2)
fasten all the items by means of screws, according to the diagrams showed, observing the mounting direction for each item;
NOTE: the bellows unit, the manual cutoff valve and the gaskets are not part of the standard supply.
ATTENTION: once the gas train is mounted according to the diagram on Fig. 1, the gas proving test mus be performed, according to the procedure set by the laws in force.
ATTENTION: it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the
valves, during maintenance and cleaning operation of the filters (both the filters outside the valves group and
the ones built-in the gas valves).
The pilot gas train is already installed to the burner, the following connections must be executed:
z
connection from the filter with stabiliser to the gas supply network
22
PART II: INSTALLATION
to the burner
connection to the gas supply
network
3
gas proving system connection (optional)
3
SIEMENS VGD40..
Fig. 8 - pipe port (3) for connecting the pilot gas train to the valves group of the main gas train
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 Siemens VGD20..
flanged gas trains with Siemens VGD40..
3.2 Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor)
Mounting
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;
z install the valve;
z the direction of gas flow must be in accordance with the direction of the arrow on the valve body;
z ensure that the bolts on the flanges are properly tightened;
z ensure that the connections with all components are tight;
z make certain that the O-rings and gaskets between the flanges and the double gas valve are fitted.
z Connect the reference gas pipe (TP in figure; 8mm-external size pipe supplied loose), 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.
Caution: the SKP2 diaphragm D must be vertical (see Fig. 7).
WARNING: removing the four screws BS causes the device to be unserviceable!
23
PART II: INSTALLATION
SA
BS
BS
SA
BS
D
TP
BS
SKP1.
SKP2.
7631z05/0101
SIEMENS VGD..MOUNTING
POSITIONS
Fig. 10
Fig. 9
Fig. 11
1
(spring)
2
(cap)
Fig. 12
Siemens VGD valves with SKP actuator :
The pressure adjusting range, upstream the gas valves group, changes according to the spring provided with the valve group.
Performance range (mbar)
0 - 22
15 - 120
100 - 250
Spring colour
neutral
yellow
red
Once the gas train in installed, execute the electrical connections for all its items (gas valves group, gas proving system, pressure
switches).
3.3 Gas Filter (if provided)
The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burner valves, counters and
regulators) from becoming rapidly blocked. The filter is normally installed upstream from all the control and on-off devices.
ATTENTION: it is reccomended to install the filter with gas flow parallel to the floor in order to prevent dust fall
on the safety valve during maintenance operation.
24
PART II: INSTALLATION
3.4 Integrated proving system (burners equipped with LME7x, LMV, LDU)
This paragraph describes the integrated proving system operation sequence:
z At the beginning both the valves (EV1 and EV2) must be closed.
z Test space evacuating: EV1 valve (burner side) opens and keep this position for a preset time (td4), in order the bring the test
space to ambient pressure.Test atmospheric pressure: EV1 closes and keep this position for a preset time (test time td1). The
pressure switch PGCP has not to detect a rise of pressure.
z Test space filling: EV2 opens and keep this position for a preset time (td3), in order to fill the test space.
z Test gas pressure: EV2 closes and keep this position for a preset time (td2). The pressure switch PGCP has not to detect a pressure drop down.
If all of the test phases are passed the proving system test is successful, if not a burner lockout happens.
On LMV5x and LMV2x/3x and LME73 (except LME73.831BC), the valve proving can be parameterized to take place on startup, shutdown, or both.
On LME73.831BC the valve proving is parameterized to take place on startup only.
PS
EV2
EV1
PGCP
/
3.5 Gas Proving System VPS504 (Option)
The VPS504 check the operation of the seal of the gas shut off valves. This check, carried out
as soon as the boiler thermostat gives a start signal to the burner, creates, by means of the
diaphragm pump inside it, a pressure in the test space of 20 mbar higher than the supply pressure.
When wishing to monitor the test, install a pressure gauge ranged to that of the pressure supply point PA. If the test cycle is satisfactory, after a few seconds the consent light LC (yellow)
comes on. In the opposite case the lockout light LB (red) comes on. To restart it is necessary
to reset the appliance by pressing the illuminated pushbutton LB.
LC
LB
PA
25
PART II: INSTALLATION
4.0 OIL TRAIN CONNECTIONS
4.1 Hydraulic diagrams for light oil supplying circuits
Fig. 13 - Gravity circuit
Fig. 14 - Ring circuit
Fig. 15 - 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
26
PART II: INSTALLATION
4.2 Installation diagram of light oil pipes
PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL.
From tank
To tank
Fig. 16 - Double-pipe system
The burner is supplied with filter and flexible hoses, all the parts upstream the filter and downstream the return flexible hose, must be
installed by the customer. As far as the hoses connection, see the related paragraph.
Key
1 Burner
2 Flexible hoses (fitted)
3 Light oil filter (fitted)
4 Automatic interceptor (*)
5 One-way valve (*)
6 Gate valve
7 Quick-closing gate-valve (outside the tank or boiler rooms)
(*) Only for installations with gravity, siphon or forced
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.
Depending on the installed pump, it is possible to design the plant for single or double pipe feeding line
Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is driven to
the nozzle: a part comes out from the nozzle while the othe part goes back to the pump. In this system, the by-pass plug, if provided,
must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer.
Double-pipe system: as for the single pipe system, a pipe that connects the tank to the pump’s inlet is used besides another pipe that
connects the pump’s return port to the tank, as well. The excess of oil goes back to the tank: this installation can be considered self-bleeding. If provided, the inside by-pass plug must be installed to avoid air and fuel passing through the pump.
Burners come out from the factory provided for double-pipe systems. They can be suited for single-pipe system (recommended in the
case of gravity feed) as decribed before.To change from a 1-pipe system to a 2-pipe-system, insert the by-pass plug G (as for ccw-rotation- referring to the pump shaft).
Caution: Changing the direction of rotation, all connections on top and side are reversed.
Suntec T
G
27
PART II: INSTALLATION
4.3 About the use of fuel pumps
z
z
z
z
z
z
z
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 the fuel unit.
Suntec T..
Viscosity
3 - 75 cSt
Oil temperature
0 - 150 °C
Minimum suction pressure
- 0.45 bar to prevent gasing
Maximum suction pressure
5 bar
Rated speed
3600 rpm max.
Key
1
Inlet G3/4
2
Pressure gauge port G1/4
3
Vacuum gauge port to measure the inlet vacuum G1/4
4
To pressure adjusting valve G3/4
"Note: pump with “C” rotation.
4.4 Connecting the oil flexible hoses to the pump
To connect the flexible oil hoses to the pump, proceed as follows, according to the pump provided:
1 remove the closing nuts A (on the pump inlet) and R (from pump to the burner);
2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the lines: see the arrows marked
on the pump.
For further information, refer to the technical documentation of the pump.
Suntec T+TV
R
A
28
PART II: INSTALLATION
5.0 ELECTRICAL CONNECTIONS
WARNING! Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse
the phase and neutral connections. fit a differential thermal magnet switch adequate for connection to the
mains.
WARNING! before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be
sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the
“Electrical connections” section.
ATTENTION: Connecting electrical supply wires to the burner teminal block MA, be sure that the ground wire is
longer than phase and neutral ones.
To execute the electrical connections, proceed as follows:
1 remove the cover from the electrical board, unscrewing the fixing screws;
2 execute the electrical connections to the supply terminal board as shown in the attached wiring diagrams;
3 check the direction of the fan motor (see next paragraph);
4 refit the panel cover.
WARNING: (only for double stage and progressive burners) The burner is provided with an electrical bridge
between terminals 6 and 7; when connecting the high/low flame thermostat, remove this bridge before connecting the thermostat.
5.1 Rotation of electric motor
Once the electrical connection of the burner is executed, remember to check the rotation of the electric motor. The motor should rotate
according to the “arrow” symbol on the body. In the event of wrong rotation, reverse the three-phase supply and check again the rotation of the motor.
CAUTION: check the motor thermal cut-out adjustment
NOTE: the burners are supplied for three-phase 380 V or 400 V supply, and in the case of three-phase 220 V or 230 V supply it
is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped
relay.
5.2 Note on elecrtical supply
If the power supply to the burner is 230V three-phase or 230V phase-phase (without a neutral), with the Siemens control box, between
the terminal 2 (terminal X3-04-4 in case of LMV2x, LMV3x, LMV5x, LME7x) on the board and the earth terminal, an RC Siemens
RC466890660 filter must be inserted.
Key
C - Capacitor (22nF/250V)
LME / LMV - Siemens control box
R - Resistor (1Mohm)
M - Terminal 2 (LGB,LMC,LME), terminal X3-04-4 ( LMV2x,
LMV3x, LMV5, LME7x)
RC466890660 - RC Siemens filter
M
- LMV2/3.. - LMV5..
For LMV5 control box, please refer to the clabeling recommendations avaible on the Siemens CD attached to the burner
29
PART III: OPERATION
PART III: OPERATION
WARNING: 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.
DANGER: 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!
LIMITATIONS OF USE
THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.
THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO
QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER.
A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND
SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF
THE BURNER.
THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION
OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN
PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER).
NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE EXCEPT FOR ITS MAINTENANCE.
TO SECURE THE MACHINE, ACT ON THE ISOLATOR SWITCH. IN CASE OF ANOMALIES THAT REQUIRED A SHUT DOWN OF
THE BURNER, IT’S POSSIBLE TO ACT ON THE AUXILIARY LINE SWITCH, LOCATED ON THE BURNER FRONT PANEL.
IN CASE OF A BURNER SHUT-DOWN, RESET THE CONTROL BOX BY MEANS OF THE RESET PUSHBUTTON. IF A SECOND
SHUT-DOWN TAKES PLACE, CALL THE TECHNICAL SERVICE, WITHOUT TRYING TO RESET FURTHER.
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.
30
PART III: OPERATION
Fig. 17 - Burner control panel
B1
B6
B2 B3
P2
B4
B5
G1
P1
G2
G3
A1
G4
S2
S1
S3
Keys
S1
S2
S3
B1
B2
B3
B4
B5
B6
G1
G2
G3
G4
A1
P1
P2
Main switch
Reset pushbutton for control box
CMF switch (0=stop, 1=low flame, 2=high flame, 3=automatic) - fully modulating burners only
Lock-out LED
Hi-flame operation LED
Lo-flame operation LED
“Ignition transformer operation” LED
“Fan motor overload tripped” LED
Stand-by signalling lamp
Gas valves EV2 operation signalling lamp
Gas valves EV1 operation signalling lamp
Gas pressure switch signal lamp
Gas proving system lockout signalling lamp
Burner Modulator (only on fully modulating burners)
“Gas in the network” signalling LED (pilot)
“Solenoid valve EVP operation” LED
31
PART III: OPERATION
5.3 Gas operation
Check the gas feeding pressure is sufficient (signalling lamp G3 on).
z
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 B1 turns on.
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 B4 is on); the gas valves open.
z Few seconds after the valves opening, the transformer is de-energised and lamp B4 turns off.
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 B2 on the frontal panel.
z
5.4 Light oil operation
z
z
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.
At the end of the pre-purge time, the actuator is in the light oil ignition position: the ignition transformer is energised (lamp B4 on);
the ignitor gas valves and the light oil valves open. Few seconds after the valves opening, the transformer is de-energised and
lamp B4 turns off.
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 B2 on the burner control panel.
32
PART III: OPERATION
5.5 AIR FLOW AND FUEL ADJUSTMENT
WARNING! 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 fuel decrease slowly until the normal
combustion values are achieved.
WARNING! the combustion air excess must be adjusted according to the values in the following chart.
Recommended combustion parameters
Fuel
Recommended (%) CO2
Recommended (%) O2
Natural gas
9 ÷ 10
3 ÷ 4.8
5.6 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.
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.
5.7 Air and Gas Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator
1
2
3
4
5
6
check the fan motor rotation.
Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner operates at the lowest output) to safely achieve the high flame stage.
Start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and that the burner starts
up;
drive the burner to high flame stage, by means fo the thermostat TAB.
Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion
values and eventually adjusting the gas by means of the valves group stabiliser.
go on adjusting air and gas flow rates: check, continuosly, the flue gas analisys, as to avoid combustion with little air; dose the air
according to the gas flow rate change following the steps quoted below;
Siemens SQM40
mensions
Dimensions in
VI
SQM4...
Actuator cams (SQM40)
V
MAN-AUTO
I
II
III
VI
IV
III
II
High flame
Stand-by
Low flame - gas
Ignition - gas
I
7
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).
33
PART III: OPERATION
T
VR
Siemens VGD..
8
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.
RA
TR
VRA
9
If necessary, adjust the combustion head position (see the dedicated paragraph)..
Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above.
10 The air and gas rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV1 (gas
side) adjusting cam as to reach the minimum output point.
11 as for the point-to-point regulation, move the gas low flame microswitch 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 the gas low flame microswitch to the minimum to move the actuator towards the low flame until the two bearings find the
adjusting screw that refers to the lower position: screw V1 to increase the rate, unscrew to decrease.
V1
Gas throttle valve open
SV1
Gas throttle valve closed
SV2
14 Move again the gas low flame microswitch 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 Now adjust the pressure switches.
34
PART III: OPERATION
5.8 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.
CMF = 0 stop at the current position
CMF
CMF = 1 high flame operation
CMF = 2 low flame operation
CMF = 3 automatic operation
5.9 Gas valves Siemens VGD - Version with SKP2. (provided with pressure stabilizer).
To increase or decrease gas pressure, and therefore gas flow rate, remove the cap T
and use a screwdriver to adjust the regulating screw VR. Turn clockwise to increase
the flow rate, counterclockwise to reduce it.
T
VR
5.10 Setting 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 VR
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.
5.11 Calibration of low gas pressure switch
As for the gas pressure switch calibration, proceed as follows:
z Be sure that the filter is clean.
z Remove the transparent plastic cap.
z While the burner is operating at the maximum output, test the gas pressure on the pressure port of the minimum gas pressure
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.
z Check that the burner is operating correctly.
z Clockwise turn the pressure switch adjusting ring nut (as to increase the pressure value) until the burner stops.
z Slowly fully open the manual cutoff valve.
z Refit the transparent plastic cover on the pressure switch.
5.12 Adjusting the maximum gas pressure switch (when provided)
To calibrate the maximum pressure switch, proceed as follows according to its mounting position:
1 remove the pressure switch plastic cover;
35
PART III: OPERATION
2
3
4
if the maximum pressure switch is mounted upstreaam the gas valves: measure the gas pressure in the network, when flame is off;
by means of the adjusting ring nut VR, set the value read, increased by the 30%.
if the maximum pressure switch is mounted downstream the “gas governor-gas valves” group and upstream the butterfly valve:
light the burner, adjust it according to the procedure in the previous paragrph. Then, measure the gas pressure at the operating
flow rate, downstream the “gas governor-gas valves” group and upstream the butterfly valve; by means of the adjusting ring nut
VR, set the value read on step 2, increased by the 30%;
replace the plastic cover.
5.13 Calibration of air pressure switch
To calibrate the air pressure switch, proceed as follows:
z Remove the transparent plastic cap.
z Once air and fuel setting have been accomplished, startup the burner.
z During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction (to increase the adjusting pressure) until the burner lockout, then read the value on the pressure switch scale and set it to a value reduced by 15%.
z Repeat the ignition cycle of the burner and check it runs properly.
z Refit the transparent plastic cover on the pressure switch.
5.14 PGCP Gas leakage pressure switch (witn Siemens LDU/LME7x burner control/Siemens LMV Burner Management System)
z
z
z
remove the pressure switch plastic cover;
adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch;
replace the plastic cover.
5.15 Adjusting the combustion head
Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above.
Only if necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when the
adjustment is accomplished.
“MAX” head position
VB
VRT
”MIN” head position
WARNING: please read carefully the paragraph “Fuel” at the beginning of this manual.
36
PART III: OPERATION
6.0 Adjustment procedure for light oil operation
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 table below and the diagram on Fig. 20 (as far as reading the pressure
values, see next paragraphs).
NOZZLE
NOZZLE
SUPPLY PRESSURE
bar
HIGH FLAME
RETURN PRESSURE
bar
LOW FLAME
RETURN PRESSURE
bar
FLUIDICS WR2/UNIGAS M3
25
19-20
7 (recommended
BERGONZO B
25
18 - 21
7 (recommended)
MONARCH NOZZLE
Pressure
FLOW RATE kg/
h
DIMENSIONS
Min
Max
40
13
40
50
16
50
60
20
60
70
23
70
80
26
80
90
30
90
100
33
100
115
38
115
130
43
130
145
48
145
160
53
160
180
59
180
200
66
200
225
74
225
250
82
250
275
91
275
300
99
300
330
109
330
360
119
360
400
132
400
450
148
450
500
165
500
550
181
550
600
198
600
650
214
650
700
231
700
750
250
750
800
267
Tab. 7
800
at
nozzle
Pressure
at
nozzle
Atomisation
Pressure on return
Pressure on return
Up to 100kg/h
Over 100kg/h
% Flow rate
Fig. 18
---------------Atomisation angle according to the return pressure
_________ % Flow rate
N.B. Specific gravity of the light oil: 0.840kg/dm3
Example: as far as over 100kg/h nozzles, the 80% of the nozzle flow rate can be obtained with a return pressure at about 18bar
37
PART III: OPERATION
Pump flow rate
Nozzle flow rate
Fig. 19 - Bergonzo B nozzle - example with 850kg/h nozzle
38
PART III: OPERATION
7.1 Oil Flow Rate Settings
1
2
Once the air and gas flow rates are adjusted, turn the burner off, switch to the oil operation (OIL, on the burner control panel).
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 by loosing the cap without removing it, then release the contactor.
Suntec T..
M
VR
4
5
6
7
Fig. 20
Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner operates at the lowest output) to safely achieve the high flame stage .
Start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and that the bruner starts
up;
drive the burner to high flame stage, by means fo the thermostat TAB (as far as fully-modulating burners, see the related paragraph).
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).
Siemens SQM40
mensions
Dimensions in
VI
Actuator cams (SQM40)
SQM4...
I
II
III
IV
V
VI
V
MAN-AUTO
IV
III
II
High flame
Stand-by
Low flame - gas
Low flame - oil
Ignition - oil
Ignition - gas
I
8
Only if necessary, adjust the supply pressure as follows;insert a pressure gauge into the port shown on figure and act on on the
pump adjusting screw VR. Pressure values are indicated at the beginning of this paragraph.
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 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.
10 once the oil rate is adjusted at the maximum output (the air rate was adjusted in the gas regulation), go on with the point to point
adjustment on the SV2 (light oil side) adjusting cam as to reach the minimum output point, as described on the next steps.
11 as for the point-to-point regulation, move the gas low flame microswitch 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 (as far as
fully-modulating burners, see the related paragraph);
13 move the low flame cam 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 V2 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 The low flame position must never match the ignition position that is why the cam must be set 20°- 30° more than the ignition posi39
PART III: OPERATION
tion.
Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps.
PG
SC
PG
V1
Pressure gauge port
RP
V2
RP
SV2
SV2
SV1
Fig. 22
Fig. 21
Fig. 23
7.2 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.
CMF = 0 stop at the current position
CMF = 1 high flame operation
CMF
CMF = 2 low flame operation
CMF = 3 automatic operation
7.3 Maximum oil pressure switch
The oil pressure switch on the return line, checks that the pressure does not exceed a default
value. This value must not be higher than the maximum acceptable pressure on the return line
(this value is reported on the specification table). A pressure change on the return line could
affect the combustion parameters: for this reason, the pressure switch must be set, say, at 20%
over the pressure recorded during the combustion adjustment.
It is recommended to verify that the combustion parameters are within the range of acceptable
values even against a pressure variation that gets close to the limit of the pressure switch
This check should be carried out along the whole range of the burner output.
In case of inacceptable values, reduce from 20% to 15% the overpressure; later on, repeat the
adjustments described above.
40
PART IV: MAINTENANCE
PART IV: 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..
8.0 ROUTINE MAINTENANCE
z
z
z
z
z
Clean and examine the gas filter cartridge and replace it if necesssary;
Remove and clean the combustion head;
Examine and clean the ignition electrodes, adjust and replace them if necessary;
Examine and clean the detection electrode/photoelement (according to the burner models), replace it if necessary, in case of
doubt, check the detection circuit, after the burner start-up;
Clean and grease leverages 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.
8.1 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 “O” ring into its place (C) and replace the cover fastening by the proper screws (A).
A
B
41
C
PART IV: MAINTENANCE
8.2 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 Oring in it.
6 Stick the adhesive label for spring identification on the type plate.
3
1
SKP Siemens actuator
8.3 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.
Note: to replace the combustion head, reverse the operations described above.
4 Clean the combustion head by means of a vacuum cleaner; scrape off the scale by means of a metallic brush.
Key
1 Inlet
H
L
2 Return
3 Gun opening
V
E Oil piping connections
G
H Cover
E
L Oil gun
3 2 1
42
PART IV: MAINTENANCE
8.4 Adjusting the ignition electrode
ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler
operation would be compromised. Check the electrode position after any intervention on the combustion head.
E
P
Fig. 24 - Detailed view of the diffuser with pilot (P) and ignition elecctrode (E)
E
P
Fig. 25 - Detailed view of the combustion head with pilot (P) and ignition elecctrode (E)
Observe the values shown on next picture.
.
P
= =
E
5mm
Fig. 26
43
PART IV: MAINTENANCE
8.5 Replacing the ignition electrode
ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler
operation would be compromised. Check the electrode position after any intervention on the combustion head.
To replace the ignition electrode, proceed as follows:
1 remove the burner cover
2 disconnect the electrode (E) cable (CE);
3 remove the combustion head (see par. “Removing the combustion head”);
4 loose screw (B) that fasten the ignition electrode (E) to the burner pilot (P);
5 remove the electrode and replace it, referring to the values quoted on figure.
CE
P
E
B
8.6 Checking the detection current
.To check the detection signal follow the scheme in the picture below. If the signal is less than the value indicated, check the position of
the detection electrode or detector, the electrical contacts and, if necessary, replace the electrode or the detector.
Control box
Minimum detection signal
Siemens LME7...
70µA with UV detector)
Siemens LFL1.3..
70µA with UV detector)
TERMINAL BOARD
MC
Fig. 27: Detection by photocell QRA..
Fig. 28: Detection by photocell QRA..
8.7 Cleaning and replacing the detection photocell
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.
44
PART IV: MAINTENANCE
8.8 Seasonal stop
To stop the burner in the seasonal stop, proceed as follows:
1 turn the burner main switch to 0 (Off position)
2 disconnect the power mains
3 close the fuel valve of the supply line
8.9 Burner disposal
In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”.
45
PART IV: MAINTENANCE
9.0 TROUBLESHOOTING
MAIN SWITCH OPEN
LINE FUSE INTERVENTION
MAX. PRESSURE SWITCH FAULT
FAN THERMAL CUTOUT INTERVENTION
AUXILIARY RELAIS FUSES INTERVENTION
CONTROL BOX FAULT
z
z
z
z
z
z
THE BURNER STOPS
AND REPEATS THE
CYCLE DURING OPERATION
THE BURNER
STOPS DURING
OPERATION
THE BURNER
DOESN’T SWITCH
TO HIGH FLAME
THE BURNER
STARTS AND
STOPS
THE BURNER
DOESN’T START
AND STOPS
NOISY FUEL PUMP
THE BURNER
REPEATS PREPURGE
THE BURNER
DOESN’T START
9.1 Heavy oil operation
z
z
z
z
z
z
SERVOCONTROL FAULT
SMOKEY FLAME
IGNITION TRANSFORMER FAULT
z
IGNITION ELECTRODE DIRTY OR WRONG
POSITIONED
z
z
z
z
z
z
z
z
z
DIRTY NOZZLE
FUEL SOLENOID VALVE DEFECTIVE
PHOTORESISTOR DIRTY OR DEFECTIVE
HI-LO FLAME THERMOSTAT DEFECTIVE
z
WRONG POSITION OF SERVOCONTROL
CAMS
z
FUEL PRESSURE TOO LOW
z
DIRTY FUEL FILTERS
46
z
z
z
9.2 Gas operation
MAIN SWITCH OPEN
LACK OF GAS
MAXIMUM GAS PRESSURE SWITCH DEFECTIVE
THERMOSTATS/PRESSURE SWITCHES DEFECTIVES
OVERLOAD TRIPPED INTERVENTION
AUXILIARIES FUSE INTERRUPTED
DEFECTIVE ACTUATOR
AIR PRESSURE SWITCH FAULT OR BAD SETTING
47
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
TURNS OFF AND REPEATS
CYCLE DURING OPERATION
LOCK-OUT DURING
OPERATION
DOESEN’T RETURN IN LOW
FLAME
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
ACTUATOR CAM WRONG SETTING
z
z
z
BAD CONNECTION OR DEFECTIVE HIGH/LOW FLAME
THERMOSTAT OR PRESSURE SWITCH
UV PROBE DIRTY OR DEFECTIVE
DOESEN’T SWITCH TO HIGH
FLAME
THE FLAME MONITOR
DEVICE DOESN’T
GIVECONSENT TO START
STARTS AND LOCK-OUT
STARTS AND REPEATS THE
CYCLE
DOESN’T START AND
REPEATS THE CYCLE
DOESN’T START AND LOCKOUT
z
z
z
z
z
z
z
z
PART IV: MAINTENANCE
DEFECTIVE CONTROL BOX
z
z
z
z
z
z
z
z
z
CONTINUE WITH PREPURGE
CAUSE
THE BURNER
DOESN’TSTART
TROUBLE
10.0 WIRING DIAGRAMS
Refer to the attached wiring diagrams.
WARNING
1 - Electrical supply 230V 50Hz 1 a.c./400V 50Hz 3N a.c.
2 - Do not reverse phase with neutral
3 - Ensure burner is properly earthed
PART IV: MAINTENANCE
48
11.0
BURNER EXPLODED VIEW
DESCRIPTION
ITEM
DESCRIPTION
ITEM
DESCRIPTION
1
2
3
4
5
6
7
8.1
8.2
8.2.1
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.11.1
8.12.1
8.12.2
8.12.3
8.12.4
9
10.1
10.2
10.3
10.4
AIR INLET CONE
SPACER
FLEXIBLE HOSE
FLEXIBLE HOSE
FLEXIBLE HOSE
BUTTERFLY GAS VALVE
PHOTOCELL
LEVERAGE
ADJUSTING CAM
ADJUSTING CAM FOIL
ADJUSTING CAM SHAFT
BUSH
ACTUATOR
INDEX LABEL
ACTUATOR SHAFT
BRACKET
BRACKET
BUSH
ADJUSTING CAM
ADJUSTING CAM FOIL
PRESSURE GAUGE
PRESSURE GOVERNOR
OIL GOVERNOR CYLINDER
MANUAL VALVE
STANDARD BLAST TUBE
RING NUT
IGNITOR
COMBUSTION HEAD
GAS MANIFOLD
10.5.1
10.5.2
10.5.2.1.1
10.6
10.7
10.8
10.9
11.1
11.1.1
11.2
11.3
11.4
11.5.1
11.5.2
11.6
11.7
11.8
12.1
12.2
12.3
13.1
13.2.1
13.2.2
13.2.3
13.2.4
13.2.5
13.3
13.4
13.5
ADJUSTING BUSH
STANDARD COMPLETE OIL GUN
SOLENOID VALVE
IGNITION CABLE
GAS FLEXIBLE HOSE
IGNITION ELECTRODE
BUSH
BURNER HOUSING
COVER
CERAMIC FIBRE PLAIT
AIR PRESSURE SWITCH
AIR DAMPER
SILENCER
AIR DAMPER SILENCER
NAME PLATE
INDEX LABEL
AIR DAMPER INDEX
GAS PRESSURE
GAS SOLENOID VALVE
GAS GOVERNOR WITH FILTER
GAS FILTER
"SKP" ACTUATOR
"SKP" ACTUATOR
GAS PROVING SYSTEM
GAS VALVE HOUSING
GAS PRESSURE
FLANGED REVERSIBLE CURVE
REVERSIBLE PIPE
FLANGED PIPE
14.1
14.2
14.3
14.4
14.5
14.6
15.1
15.2
15.3
15.4
16.1
16.2
17.1
17.2
17.3.1
17.3.2
17.3.3
17.3.4
17.3.5
17.3.6
17.3.7
17.3.8
18.1
18.2
18.3
BRACKET
PUMP
COUPLING
PRESSURE GOVERNOR
PLATE
MOTOR
OIL MANIFOLD
SOLENOID VALVE
ONE-WAY VALVE
OIL MANIFOLD
MOTOR
FAN WHEEL
BOARD
COVER
FRONT CONTROL PANEL
LIGHT
LIGHT
LOCK-OUT RESET BUTTON
PROTECTION
SWITCH
SWITCH
OUTPUT CONTROLLER
CONTROL BOX
IGNITION TRANSFORMER
CONTROL BOX SOCKET
PART IV: MAINTENANCE
49
ITEM
PART IV: MAINTENANCE
50
10.5.2.1.1
APPENDIX
SIEMENS LFL 1.3.. CONTROL BOX
Automatic programme in the event of interruption and indication of position when interrupted
By default, in the event of any kind of interruption, the flow of fuel is immediately interrupted. At the same time the programmer stops and this indicates the position at the time of the interruption.
A symbol on the indicator disc shows each time the type of stoppage:
No start-up (for example fault in the CLOSED signal for the
limit contact "Z" at terminal 8 or some other contact between
the terminals 12 and 4 or 4 and 5 is not closed).
Start-up suspended because of a fault in the OPEN signal
for the limit contact "A" at terminal 8.
P
Block due to absence of air pressure signal. From this
moment onwards any absence of air pressure will cause a
block.
Block due to malfunction of the flame detector circuit.
Start-up interrupted because there is a fault in the MINMUM
signal for the auxiliary contact of the damper servo motor at
terminal 8.
1
Block due to absence of flame signal at the end of the 1st
safety period.
From this moment onwards any absence of a flame signal will cause a
block.
2
Blockdue to absence of flame signal at the end of the 2nd
safety period (flame signal of main burner).
Blockdue to absence of flame signal or air pressure during
operation.
Where a block stoppage occurs at any moment between switch on and
pre-ignition without registering any symbol, the cause is normally an
unscheduled flame signal.
a-b Start-up programme
b-b' For time variants:move the programmer on to the automatic stop
after the burner starts up (b' = position of the programmer during normal
burner operation).
b(b')-aPost-ventilation programme after a regulation stop.At the start-up
position "a" the programmer stops automatically.
.
Safety time duration for mono-tube burners
..
Safety time duration for twin-tube burners
The apparatus can be reset immediately after a block. After resetting (and
after the elimination of any problem causing the stoppage or after a power
failure) the programmer returns to its start-up position. In this event only
the terminals 7, 9, 10 and 11 are live in accordance with the monitoring
programme. Only after this the device programs a new startup.
Operation
The wiring system and also the control system of the programmer "P"
have already been given in this manual. The response signals required
for the active parts and the flame monitor circuit are shown by a hatching.
In the absence of these response signals the mechanism interrupts the
start-up programme; the exact time of the interruption can be identified
from the visual indicator and will cause a block if the safety code requires
it.
A
consent to start-up by means of the thermostat or pressostat "R"
A-B start-up program
B-C normal burner operation
C
regulation stop caused by "R"
C-D programmer returns to start-up position A.
During the regulation stop only terminals 11 and 12 are live and the damper, through the limit contact "Z" of its servo-motor is in the CLOSED position.The flame detector circuit F is activated (terminals 22 and 23 or 23/4)
for the detector test and the paracitic light test.
Where the burners do not have dampers (or have an independent 00
damper control mechanism) there must be a bridge between terminals 6
and 8, otherwise the mechanism will not start up the burner.
For a burner to start up the following conditions must be met:
z Mechanism not blocked/reset.
z Damper closed.Limit contact switchZ must be in the CLOSED position
and allow current to flow between terminals 11 and 8.
z Any contacts checking that the fuel valve (bv...) is closed, or other contacts with similar functions, must be closed between terminal 12 and
the air pressostat LP.
z The contact for the air pressostat LP must be in the off position (LP
test) so as to feed terminal 4.
z The gas pressostat contacts GP and the safety thermostat and pressostat contacts W must also be closed.
Start-up program
A Start-up
(R closes the start-up control ring between terminals 4 and 5)
The programmer starts up.At the same time the ventilator motor is fed
through terminal 6 ( only for pre-ventilation) and, after t7, the ventilator
motor or the combustion gas exhaust fan is fed through terminal 7 (preventilation and post-ventilation).
At the end of t16, the command opening the damper passes through terminal 9; during the damper opening time the programmer does not move
since terminal 8, through which the programmer is fed, is dead.
Only once the damper is fully open and the limit contact switch A has
switched on, feeding terminal 8, does the programme proceed.
t1
Pre-ventilation time with damper fully open (nominal air flow).
Shortly after the beginning of the pre-ventilation time, the air pressostat
should switch off the current between terminals 4 and 13;otherwisethe
apparatus would block (air pressure monitor).
At the same time the terminal 14 should be live since current feeding the
ignition transformer and the fuel valves passes through this circuit.
During pre-ventilation time the flame detector circuit is checked and in the
event of an operational defect the monitor brings about a block.
At the end of the pre-ventilation time the monitor automatically moves the
damper servo-motor, through terminal 10, to the flame ignition position
which is governed by the auxiliary contact "M".
During this period the programmer stops until terminal 8, is again activatedthrough contact "M".
After a few seconds the little programmer motor is directly fed by the
active part of the apparatus.
After this point terminal 8 plays no further part in the burner ignition process.
Mono-tube burner
t3
Pre-ignition time waiting the response from the fuel valve at terminal 18.
t2
Safety time (start up flame strenght); at the end of the safety time a
flame signal should appear at terminal 22 of the amplifier and it should
stay on until a regulation stop; if this does not happen the mechanism will
block.
t4
Interval; at the end of t4, terminal 19 is live.
t5
Interval At the end of t5 terminal 20 is live.At the same time the
monitor outlets from 9 and 11 and terminal 8 into the active part of the
apparatus are kept galvanically separatedso as to protect the monitor
itself from recovery voltage through the capacity regulator circuit.
Twin-tube burners (**)
t3
Preignition time until the all clear to the pilot burner valve at
terminal 17.
t2
First safety time (pilot flame strenght); at the end of the safety time
a flame signal should appear at terminal 22 of the amplifier and it should
stay on, until a regulation stop; if it does not, the apparatus will block.
t4
Interval until the consent to the fuel valve at terminal 19, for the first
flame of the main burner.
t9
2nd safety time; at the end of the second safety time the main burner should be lit by means of the pilot. At the end of this period, terminal
17 is dead and therefore the pilot burner will be out.
t5
Interval; at the end of t5 terminal 20 is live. At the same time the
monitor outlets from 9 to 11 and the terminal 8at the input of the active
part of the apparatus are galvanically separated so as to protect the apparatus itself from recovery voltage through the strenght regulator circuit.
When the strenght regulator LR at terminal 20 gives the consent,
the start-up programme for the apparatus comes to an end. Depending on
time variants, the programmer stops either immediately or at the end of a
set time, without effecting the position of the contacts.
B
Operational position of the burner
B-C Burner operation (production of heat)
While the burner is working the strnght regulator controls the damper,
according to the demand for heat, by means of the positioning at nominal
load of the auxiliary contact "V" of the damper servocontrol.
C
Regulation stop for operation of "R"
When there is a regulation stop the fuel valves immediately close. At the
same time the programmer starts to programme:
t6
Post-ventilation time (post-ventilation with the ventilator "G" at terminal 7).Shortly after beginning of the post-ventilation time terminal 10
becomes live and moves the damper to the "MIN" position. The full closure of the damper only happens towards the end of the post-ventilation
time and is prompted by an automatic signal from terminal 11
t13 Admissible post-ignition time
During this time the flame monitor circuit may still receive a flame signal
without the apparatus blocking.
D-A End of automatic programme
At the end of t6, at the point where the programmer and the automatic
contacts have reverted to the starter position, the detection probe test
restarts.
During an operational stop even an unscheduled flame signal lasting a
few seconds can cause a block because during this period an NTC in the
circuit acts as retarder.This means that brief unscheduled influences cannot cause a block.
(**) Times t3, t2 and t4 only apply only to safety devices in the series 01.
Specifications
Mains voltage
220V -15%...240V +10%
Frequency
50Hz -6%...60Hz +6%
Absorbed capacity
3.5 VA
Built-in fuse
T6.3/250E slow action DIN41571 No.
451915070
External fuse
max. 16A
Interference
N-VDE0875
Flow permitted at terminal 1
5A (DIN 0660 AC3)
Flow permitted at control terminals
4A (DIN 0660 AC3)
Flow at monitor contacts:
input at terminals 4 & 5
1A, 250V
input at terminals 4 & 11
1A, 250V
input at terminals 4 & 14
function of the load at terminals 16 and
19, min.1A, 250V
Emplacement
Any
Protection
IP40
Permitted ambient temp
-20...+60° C
Min.temperature (trans/storage) -50° C
Weight:
apparatus
approx. 1,000g.
base
approx. 165g.
Ionisation monitor
voltage in detector electrode
normal working
330V ±10%
test
380V ±10%
short circuit current
max. 0,5 mA
Ionisation current, min.request 6 µA
max. permitted length for connecting cables
normal cable (laid separately**) 80m
armoured cable(high frequency) protection at terminal 22
140m
UV monitor
Voltage in UV detector
normal working
330V ±10%
test
380V ±10%
Detector current, min. request* 70µA
Max. detector current
normal working
630 µA
test
1300 µA
Max.length of connecting cable
normal cable (laid separately**) 100m
armoured cable (high frequency) protected at terminal 22
200m
Weight
QRA2
60 g
QRA10
450 g.
*Connect up in parallel to the measuring device a condenser 100µF,
10...25V.
** The wire connecting up the detector electrode should not be in the
same sleeve as the other conductor wires.
Ignition spark monitor with QRE1 series 02 detector
Minimum detector current
30µA
Operating times
t7 initial delay for ventilator G2 2
t16 initial delay of air damper OPEN consent
4
t11 opening time for damper
any
t10 initial delay for air pressure monitor8
t1 pre-ventilation time with damper open36
t12 travel time for air damper to MIN positionany
t3 t3' pre-ignition time
t3
4
t3
't2 t2' safety time (1st safety time for burners with intermittent pilot
lighter
t2
2
t2
't4 t4' interval between start of t2 and response to valve at terminal 19
t4
10
t4
't9 2nd safety time for burners with intermittent pilot lighter 2
t5 interval between end of t4 and response at terminal 20 10
t20 interval before programmer cuts out after start-upduration of start-up
60
t6 post-ventilation time (G2 only)
12
t13 permitted post-ignition time
12
t16 initial delay from opening consent of the air damper
t20 interval until the automatic shut-off of the programming mechanism
after the burner start
Programmer diagram
Key
A
AI
AR
AS
BR
BV
EK
FE
FR
G
GP
H
L
LK
LP
LR
M
QRA
QRE
R
S
SA
SM
V
V
limit contact switch for damper OPEN position
block remote signal
main relay (working network) with contacts "ar"
Monitor fuse
block relay with "br" contacts
fuel valve
reset button
detector electrode of ionisation circuit
flame relay with "fr" contacts
ventilator motor or burner motor
gas pressure switch
main interruptor switch
block stoppage LED
air damper
air pressostat
safety regulator
auxiliary contact switch for damper "MIN" position
UV detector
ignition spark detector
thermostat or pressostat
fuse
damper servo-motor
synchronous programmer motor
flame signal amplifier
in case of servo-motor: auxiliary contact for response to fuel
valve with regard of damper position
W
safety pressostat or thermostat
Z
ignition transformer
Z
in case of servomotor: end of limit contact switch for damper
CLOSED position
ZBV pilot burner fuel valve
°
for mono-tube burners
°°
for twin-tube burners
(1)
(2)
(3)
input for raising QRA detector voltage to test level
input for excitation of flame relay during flame detector test
circuit (contact XIV) and during safety time (contact IV)
Do not press EK for more than 10 seconds
t1
t2
*t2
t3
*t3
t4
*t4
t5
t6
t7
pre-ventilation time
safety time
'1st safety time
pre-ignition time
'pre-ignition time
interval for creating current between terminals 18 and 19
'interval for creating current between terminals 17 and 19
interval for creating current between terminals 19 and 20
post-ventilation time
interval between startup consent and current created at
terminal 7
t8
duration of start-up
*t9
2nd safety time
t10 interval before air pressure monitoring begins
t11 damper opening travel time
t12 damper closure travel time
t13 permissible post-combustion time
t16 initial delay of damper OPEN response
t20 interval before programmer automatically stops
* These times are valid with the use of a series 01 safety device for monitoring burners with intermittent pilot lighter.
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.