CIB UNIGAS 1030, R1025, R1040 Manual Of Instllation - Use - Maintenance

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M03996CH Rel. 7.0 06/2010

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Gas burners

R1025 R1030 R1040

MANUAL OF INSTLLATION - USE - MAINTENANCE

TABLE OF CONTENTS

WARNINGS ........................................................................................................................................................ ....... 3

PART I: INSTALLATION ........................................................................................................................................... 5

GENERAL FEATURES ................................................................................................................................................................... 5

How to interpret the burner’s “Performance curve” ......................................................................................................................... 6

Burner model identification ............................................................................................................................................................. 7

Country and usefulness gas categories .......................................................................................................................................... 7

Overall dimensions ......................................................................................................................................................................... 8

Performance curves ........................................................................................................................................................................ 9

Pressure in the network / gas rate curves ..................................................................................................................................... 10

MOUNTING AND CONNECTING THE BURNER ........................................................................................................................ 11

Packing ......................................................................................................................................................................................... 11

Handling the burner ...................................................................................................................................................................... 11

Fitting the burner to the boiler ....................................................................................................................................................... 12

Matching the burner to the boiler .................................................................................................................................................. 12

GAS TRAIN CONNECTIONS ....................................................................................................................................................... 13

Assembling the gas grain .............................................................................................................................................................. 16

Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) ......................................................................... 17

Pressure adjusting range .............................................................................................................................................................. 18

Electrical connections ................................................................................................................................................................... 20

Rotation of fan motor .................................................................................................................................................................... 20

Combustion head gas pressure curves depending on the flow rate ............................................................................................. 21

Measuring the gas pressure in the combustion head ................................................................................................................... 21

Pressure - rate in combustion head curves ................................................................................................................................. 22

ADJUSTING AIR AND GAS FLOW RATES ................................................................................................................................. 23

Gas Filter ..................................................................................................................................................................................... 23

Adjusting the pilot gas flow rate (Brahama EG12xR gas valve and gas pressure governor) ....................................................... 23

Adjusting air and gas flow rates .................................................................................................................................................... 24

Adjustments - brief description ...................................................................................................................................................... 24

Adjusting procedure ...................................................................................................................................................................... 24

Calibration of air pressure switch .................................................................................................................................................. 28

Calibration of low gas pressure switch .......................................................................................................................................... 28

Adjusting the high gas pressure switch (when provided) .............................................................................................................. 28

PGCP Gas leakage pressure switch (witn Siemens LDU burner control/Siemens LMV Burner Management System) ............. 28

PART II: OPERATION ............................................................................................................................................. 29

OPERATION ................................................................................................................................................................................. 30

PART III: MAINTENANCE ....................................................................................................................................... 31

ROUTINE MAINTENANCE ........................................................................................................................................................... 31

Gas filter maintenance .................................................................................................................................................................. 31

Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group) ............................................ 31

Replacing the spring in the gas valve group ................................................................................................................................. 32

Removing the combustion head ................................................................................................................................................... 32

Adjusting the ignition electrode ..................................................................................................................................................... 33

Replacing the ignition electrode .................................................................................................................................................... 34

Cleaning and replacing the detection photocell ............................................................................................................................ 35

Checking the detection current ..................................................................................................................................................... 35

Seasonal stop ............................................................................................................................................................................... 35

Burner disposal ............................................................................................................................................................................. 35

TROUBLESHOOTING .................................................................................................................................................................. 36

SPARE PARTS ............................................................................................................................................................................. 37

BURNERS EXPLODED VIEW ...................................................................................................................................................... 38

ELECTRICAL WIRING DIAGRAMS ............................................................................................................................................. 41

APPENDIX

WARNINGS

THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER.

INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.

THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.

CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.

1) 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 inte-

grity. 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 cut-

out 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 har-

mless. 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, there-

fore, 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 combu-

stion efficiency level at least equal to the lower level required by the regulations in force;

c check the unit operation for proper combustion, to avoid any harmful

or polluting unburnt gases in excess of the limits permitted by the

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 instruc-

tions 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 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 per-

mitted 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.) 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 com-

pliance 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 ins-

pect 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 desi-

gned 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 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;

-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

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;

- 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 50165 Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods

Gas - Light oil burners

European directives:

- Directive 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

-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 :

-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

;

C.I.B. UNIGAS - M03996CH

PART I: INSTALLATION

GENERAL FEATURES

This series represents monobloc burners made in die-cast aluminium housing with relative flange to work on heating generators. The output range is from 2550kW to 13000kW (according to the burner type).

They can be provided in progressive or fully-modulating version.

Fig. 1

1 Mimic panel with startup switch 2 Gas filter 3 Gas proving system 4 Gas valves group 5 Electrical panel 6 Cover 7 Blast tube + Combustion head (inside) 8 Flange 9 Adjusting cam 10 Actuator 11 Silencer 12 Air damper index 13 Air pressure switch 14 Combustion head adjusting ring nut

The gas coming from the supply line, passes through the valves group provided with filter and stabiliser. This one forces the pressure in the utilisation limits. The electric actuator, that moves proportionally the air damper and the gas butterfly valve, uses an adjusting cam with variable shape. This one allows the optimisation of the flue gas values, as to get an efficient combustion. The combustion head positioning determines the burner’s output. 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’s front side, shows each operating stage.

C.I.B. UNIGAS - M03996CH

-1

100 200 300 400 500 600 700 800 900

Pote nza kW

Contropressione in camera di

combustione mbar

M ...50 (Multibloc DUNGS MB DLE 420 B01) M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)

100 200 300 400 500 600 700 800 900

Potenza / Output (kW)

Minima pressione gas in

rete / Minimum inlet gas

pressure (mbar)

Rp 2" (50)

DN65

How to interpret the burner’s “Performance curve”

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’s ID plate or in the user’s manual).

Example: Furnace input: 600kW Backpressure: 4mbar In the “Performance curve” diagram (Fig. 2), 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.

Fig. 2

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

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 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 p

gas value, calculated before.

Fig. 3

C.I.B. UNIGAS - M03996CH

Burner model identification

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

Type R1025 Model M-. PR. S. *. A. 1. 80

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

(1) BURNER TYPE R1025 - R1030 - R1040

(2) FUEL M - Natural gas

(3) OPERATION (Available versions) PR - Progressive MD - Fully modulating

(4) BLAST TUBE S - Standard L - Extended

(5) DESTINATION COUNTRY

* - see data plate

(6) BURNER VERSION A - Standard

(7) EQUIPMENT 1 = 2 valves + gas proving system

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

(8) GAS CONNECTION 50 = Rp2

65 = DN65 80 = DN80 100 = DN100 125 = DN125

Technical specifications

BRUCIATORE TIPO R1025 M-.....1.50 R1025 M-.....1.xx R1030 M-....1.65 R1030 M-....1.xx R1040 M-.....1.xx

Output min - max kW

Fuel

Gas category (see next paragraph)

Gas rate

Power supply

Total power consumption

Electric motor kW

Protection

Operation

Pressure (see Note 2)

Gas train 50 ØValves Connection 2” - Rp2 - - - -

Gas train 65 ØValves Connection - 2”

Gas train 80 ØValves Connection 3” / DN80 3” / DN80 3” / DN80 3” / DN80 3” / DN80

Gas train 100 ØValves Connection 4” / DN100 4” / DN100 4” / DN100 4” / DN100 4” / DN100

Gas train 125 ØValves Connection - - - - 5” / DN125

Operating temperature °C

Storage Temperature °C

Working service*

min.-max. (Stm

/h)

kW 19 19 22.5 22.5 30.5

2550 - 6700 2550 - 8700 2550 - 9500 2550 - 10600 2550 - 13000

Natural gas

270 - 790 270 - 920 270 - 1000 270 - 1122 270 - 1376

400V 3N~ 50 400V 3N~ 50 400V 3N~ 50 400V 3N~ 50 400V 3N~ 50

18.5 18.5 22 22 30

IP40

Progressive - Fully modulating

1/2 / DN65 2”1/2 / DN65 2”1/2 / DN65 -

-10 ÷ +50

-20 ÷ +60

Internittent

Note1:

Note2:

*NOTE ON THE BURNER WORKING SERVICE: for safety reasons, one controlled shutdown must be performed every 24

all gas flow rates are referred to Stm rific value H

Maximum gas pressure = 500mbar (with Siemens VGD gas valves).

Minimum gas pressure = see gas curves.

= 34.02 MJ/Stm3).

/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (net calo-

hours of continuous operation.

Country and usefulness gas categories

GAS

CATEGORY

2E( R ) B

2ELL

2Er

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

LUPL-----------------------

BE------------------------

NL------------------------

DE------------------------

FR------------------------

COUNTRY

Overall dimensions (mm)

C.I.B. UNIGAS - M03996CH

Burner flange and boiler recommended drilling template

R1025 50 1888 377 25 809 100 544 641 1291 680 2142 1320 822 400 450 709 660 816 M16 651 460 460 1036 200 265 836 80 1092 216 1146 379 330 R1025 65 1888 377 25 827 118 544 641 1291 680 2121 1299 822 400 450 709 660 816 M16 651 460 460 914 200 265 714 80 1092 292 1146 379 330 R1025 80 1888 377 25 841 132 544 641 1291 680 2123 1301 822 400 450 709 660 816 M16 651 460 460 936 200 265 736 80 1092 322 1146 379 330 R1025 100 1888 377 25 854 145 544 641 1291 680 2139 1317 822 400 450 709 660 816 M16 651 460 460 842 200 265 642 80 1092 382 1146 379 330 R1030 65 1888 377 25 827 118 544 657 1291 680 2121 1299 822 454 504 709 660 816 M16 651 460 460 914 200 265 714 80 1092 292 1146 372 330 R1030 80 1888 377 25 841 132 544 657 1291 680 2123 1301 822 454 504 709 660 816 M16 651 460 460 936 200 265 736 80 1092 322 1146 372 330 R1030 100 1888 377 25 854 145 544 657 1291 680 2139 1317 822 454 504 709 660 816 M16 651 460 460 842 200 265 642 80 1092 382 1146 372 330 R1040 80 1888 377 25 841 132 544 657 1291 680 2123 1301 822 514 564 709 660 816 M16 651 460 460 936 200 265 736 80 1192 322 1146 408 330 R1040 100 1888 377 25 854 145 544 657 1291 680 2139 1317 822 514 564 709 660 816 M16 651 460 460 842 200 265 642 80 1192 382 1146 408 330 R1040 125 1888 377 25 884 175 544 657 1291 680 2254 1432 822 514 564 709 660 816 M16 651 460 460 954 200 265 754 80 1192 480 1146 408 330

DN* A AA AD AN AP B BB C CC D E F G H J K L M N O P Q R RR S SS U V W Y Z

*DN = gas valves size NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves.

Performance curves

2000 3000 4000 5000 6000 7000

2000 3000 4000 5000 6000 7000 8000 9000

2000 3000 4000 5000 6000 7000 8000 9000 10000

2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

C.I.B. UNIGAS - M03996CH

R1025 M-.....50

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

R1030 M-.....65

BACK PRESSURE IN

R1025 M-....1.xx

R1030 M-....1.xx

COMBUSTION CHAMBER mbar

R1040 M-.

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

To get the input in kcal/h, multiply value in kW by 860. Data are referred to standard conditions: 1013mbar, 15°C.

NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine. On this diagram the maximum output point is usually reached by adjsuting the combustion head to its “MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is reached setting the combustion head to its “MIN” position. During the first ignition, the combustion head is set in order to find a compromise between the burner output and the generator specifications, that is why the minimum output may be different from the Performance curve minimum.

Pressure in the network / gas rate curves

100

200

300

400

500

150 250 350 450 550 650 750

100

200

300

400

150 250 350 450 550 650 750 850 95 0

DN80

100

200

300

400

200 400 600 800 1000

100

150

200

250

200 400 600 800 1000 1200

DN80

DN100

100

150

200

250

300

350

400

200 400 600 800 1000 1200 1400

DN125

DN100

DN80

C.I.B. UNIGAS - M03996CH

R1025 M-.....50

GAS PRESSURE IN

THE NETWORK mbar

R1030 M-.....65

GAS PRESSURE IN

THE NETWORK mbar

Gas rate Stm3/h

R1025 M-....1.xx

R1030 M-....1.xx

DN6

DN10

Gas rate Stm

Gas rate Stm3/h

R1040 M-.

GAS PRESSURE IN

THE NETWORK mbar

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.

C.I.B. UNIGAS - M03996CH

Eye-bolts

MOUNTING AND CONNECTING THE BURNER

Packing

The burners are despatched in wooden crates whose dimensions are:

2280 x 1730 x 1360 (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 gas train detached; z ceramic fibre plait to be inserted between the burner and the boiler; z envelope containing this manual.

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

Handling the burner

ATTENTION! Handling operations must be performed by trained personnel specialised on handling loads. If these operations are not carried out correctly, the residual risk for the machine to overturn and fall down remains.

To handle the machine, use means suitable to handle requested loads (see par. “Technical specifications”).”

The burner is provided with eye-bolts for lifting.

C.I.B. UNIGAS - M03996CH

Keys

1 Burner 2 Fixing nut 3 Washer 4 Ceramic fibre plait 5 Stud bolt 7 Blast tube

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).

;

Matching the burner to the boiler

To correctly match the burner to the boiler verify the necessary input and the pressure in combustion chamber are included in the burner performance curve; otherwise the choice of the burner must be revised consulting the burner manufacturer.

To choose the blast tube lenght follow the instructions of the boiler manufacturer. In absence of these consider the following:

z Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than 100 mm into

the combustion chamber.

z Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in

respect to the tube bundle plate. The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably-sized

spacer to move the burner backwards.

C.I.B. UNIGAS - M03996CH

678

15 15

MANUFACTURER

INSTALLER

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MANUFACTURER

INSTALLER

15 15

MANUFACTURER

INSTALLER

GAS TRAIN CONNECTIONS

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

ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED.

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

Gas train - 2 (Rp2): Gas train with valves group MBC 1200SE(2 valves + gas filter + pressure governor + pressure switch) + VPS504 gas proving system and pilot gas train

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 and pilot gas train

Key

1 Burner 2 Butterfly valve 3 Gas proving system (option) 4 Maximum gas pressure switch (option*) 5 Minimum gas pressure switch 6Gas filter 7 Bellows unit

8 Manual cutoff valve 10 VGD Valves group 14 Pressure governor with filter 15 Pilot gas valve 18 MBC Valves group (2” with filter provided) 19 MBC Valves group (DN65/80/100) *Note: the high gas pressure switch can be mounted either

upstream or downstream the gas valve but upstream the butterfly gas valve (see item no.4 in the scheme above).

C.I.B. UNIGAS - M03996CH

15 15

MANUFACTURER

INSTALLER

MANUFACTURER

INSTALLER

Gas train 4(DN100/125): Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor +

pressure switch) + PGCP gas leakage pressure switch and pilot gas train

Gas train 4(DN100/125): Gas train with valves group VGD40 (2 valves + gas filter + pressure governor + pressure switch) + PGCP gas leakage pressure switch and pilot gas train

15 15

Key

1 Burner 2 Butterfly valve 4 Maximum gas pressure switch (option*) 5 Minimum gas pressure switch 6Gas filter 7 Bellows unit

8 Manual cutoff valve 10 VGD Valves group 14 Pressure governor with filter 15 Pilot gas valve 16 Gas leakage pressure switch (PGCP) 19 MBC Valves group (DN80/100)

* Note: the high gas pressure switch can be mounted either upstream or downstream the gas valve but upstream the butterfly gas valve (see item no.4 in the scheme above).

C.I.B. UNIGAS - M03996CH

connection to the gas supply network

connection from the pilot gas train to the gas valves

group of the main train























SIEMENS VGD40..

DUNGS MBC3100-5000SE

The pilot gas train is already installed to the burner, the following connections must be executed:

z connection from the filter with stabiliser to the gas supply network z connection from the valve to the main gas train, by means of the pipe provided with the burner.

Fig. 4 - pipe port (3) for connecting the pilot gas train to the valves group of the main gas train

Assembling the gas grain

21D

Keys

1A..1E Gasket 2 Gas filter 3 Gas valves group 4 Bellows unit 5 Manual valve

”direction” arrows for installation

gas supply network

To assemble the main gas train, proceed as follows:

C.I.B. UNIGAS - M03996CH

Fig. 5 - Example of gas train

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. 5) between the elements

NOTE: the bellows unit, the manual valve and the gaskets are not part of the standard supply.

ATTENTION: once the gas train is mounted according to the diagram on Fig. 5, the gas proving test mus be performed,

according to the procedure set by the laws in force.

The procedures of installation fo the gas valves are shown in the next paragraphs, according to the gas train used:

z threaded gas trains with Multibloc Dungs MBC..SE 1200 or Siemens VGD20.. (threaded valves group) z flanged gas trains with Multibloc Dungs MBC..SE 1900-3100-5000 or Siemens VGD40.. (flanged valves group)

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).

C.I.B. UNIGAS - M03996CH

SKP1. SKP2.

7631z05/0101

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); z to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts; z install the valve; z the direction of gas flow must be in accordance with the direction of the arrow on the valve body; z ensure that the bolts on the flanges are properly tightened; z ensure that the connections with all components are tight; 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. 8).

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

SIEMENS VGD..MOUNTING POSITIONS

Fig. 6

Fig. 9

Fig. 7 Fig. 8

Fig. 10

C.I.B. UNIGAS - M03996CH

MOUNTING

POSITIONS

OPTION



 











 















  

PLQ['1











) (

Fig. 11

Mounting positions OPTION

10 = pulse lines

njo/!6!y!EO

# #



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

Mounting

1. Mount flange onto tube lines. Use appropriate sealing agent (see Fig. 11)

2. Insert MBC...SE. Note position of O rings (see Fig. 12).

3. Tighten screws A – H

4. After installation, perform leakage and functional test.

5. Disassembly in reverse order

Fig. 12

MULTIBLOCDUNGS 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.

Fig. 13

Pressure adjusting range

The pressure adjusting range, downstream the gas valves group, changes according to the spring provided with the valve group.

DUNGS MBC..SE Siemens SKP actuator

C.I.B. UNIGAS - M03996CH

Keys

1 spring 2 cap

DUNGS MBC valves:

Performance range (mbar) 4 - 20 20 - 40 40 - 80 80 - 150

Spring colour - red black green

Siemens VGD valves with SKP actuator :

Performance range (mbar) 0 - 22 15 - 120 100 - 250

Spring colour neutral yellow red

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

C.I.B. UNIGAS - M03996CH

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.

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.

As for a complete decription of electrical diagrams, see pag. 41.

PROGRESSIVE BURNERSI

ИFULLY MODULATING BURNERS

PROBE CONNECTION

(**) Probes connection - see Fig. 14

Fig. 14

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.

CAUTION: adjust the thermal cut-out according to the motor rated current value.

C.I.B. UNIGAS - M03996CH

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 limits). During this stage, the combustion head, the gas butterfly valve and the actuator are at the maximum opening. Refer to Fig. 15, 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.

in the flues as shown in the “Recommended combustion values” table and CO in the standard

Fig. 15

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. 15-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig. 15-3). 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 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.

/h (quoted on the x axis) from the pressure

Pressure - rate in combustion head curves

200 400 600 800 1000

100

200 300 400 500 600 700 800 900 1000 1100 1200

200 400 600 800 1000 1200 1400

R1025

Gas pressure in

combustion head

R1030

C.I.B. UNIGAS - M03996CH

Gas rate Stm3/h

R1040

Gas pressure in

combustion head

Gas rate Stm

Gas rate Stm3/h

C.I.B. UNIGAS - M03996CH

LC LB

Brahma gas valve EGx12R

Pressure governor

ADJUSTING AIR AND GAS FLOW RATES

Gas Filter

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.

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 TAB 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 into the pressure supply point PA.

If the test cycle is satisfactory, after a few seconds the consent light LC (yellow) comes on. Otherwise, the lockout light LB (red) comes on.

To restart, it is necessary to reset the appliance by pressing the pushbutton LB.

Adjusting the pilot gas flow rate (Brahama EG12xR gas valve and gas pressure governor)

To change the pilot gas valve flow rate, proceed as follows: 1 remove the protection on the bottom of the valve, moving it counterclockwise (see next picture); 2 rotate clockwise the nut 1 as shown in to close the valve or counterclockwise to open. To perform a finest adjustment, act directly on the pressure governor as follows (see next picture): 3 remove the cap T: to increase the gas pressure at the outlet use a screwdriver on the screw TR as shown on the picture below.

Screw to increase the pressure, unscrew to decrease; once the regulation is performed, replace cap T.

Adjusting air and gas flow rates

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Pressure governor

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: EVER 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:

C.I.B. UNIGAS - M03996CH

Recommended combustion parameters

Fuel

Recommended (%) CO

Recommended (%) O2

Natural gas 9 ÷ 10 3 ÷ 4.8

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 Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a dif-

ferential pressure gauge, as described on par. “Measuring the gas pressure in the combustion head” on page 21.

z 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.

z 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.

Adjusting procedure

To change the burner setting during the testing in the plant, follow the next procedure. On the DUNGS MBC..SE gas valves group, set the pressure regulator to 1/3 of its stroke, using a 2.5 allen key.

C.I.B. UNIGAS - M03996CH

closed holes

open holes

closed holes

open holes

MAN

AUTO

IIIIII

mensions

Dimensions in

SQM4...

III

VIVI

III

MAN-AUTO

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.

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

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.

R1025 - R1030 R1040

1 Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner ope-

2 cam IV (stroke limitation cam) must be set a little higher than the cam III to limit the output in the first seconds the flame appears;

3 Turn the burner on by means of its main switch : if the burner locks press the RESET button on the control panel - see chapter

rates at the lowest output) to safely achieve the high flame stage.

Siemens SQM10

NOTE: cam IV must shift according to cam III.

“OPERATION”.

Siemens SQM40

Actuator cams

I High flame II Stand-by and Ignition III Low flame IV Stroke limitation

C.I.B. UNIGAS - M03996CH

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Siemens VGD..

Dungs MBC..SE

VRA

4 Start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and the burner starts up; 5 drive the burner to high flame stage, by means fo the thermostat TAB (for fully-modulating burners set CMF=1 - see paragraph

“Fully-modulating burners”).

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 governor and the air by means of the related adjusting cam (see next steps).

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 governor 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.

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.

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. 10 Only if necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move

progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when the adjustment is accomplished.

C.I.B. UNIGAS - M03996CH

VRT

“MAX”head position

“MIN” head position

Gas butterfly valve closed Gas butterfly valve open

Attention! Change the combustion head position only if necessary. If so, repeat the air and gas adjustments described above. 11 the air and gas rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV adjusting

cam as to reach the minimum output point. 12 as for the point-to-point regulation, move the gas low flame microswitch (cam III) a little lower than the maximum position (90°); 13 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position;. 14 move cam III to the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw that refers

to the lower position: screw V to increase the rate, unscrew to decrease. 15 Move again cam III towards the minimum to meet the next screw on the adjusting cam and repeat the previous step; go on this way

as to reach the desired low flame point. 16 Now adjust the pressure switches (see next par.).

C.I.B. UNIGAS - M03996CH

Calibration of air pressure switch

To calibrate the air pressure switch, proceed as follows:

z Remove the transparent plastic cap. z Once air and gas 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 until the burner lockout, then read the value on the pressure switch

scale and set it to a value reduced by 15%.

z Repeat the ignition cycle of the burner and check it runs properly. z Refit the transparent plastic cover on the pressure switch.

Calibration of low gas pressure switch

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

z Be sure that the filter is clean. z Remove the transparent plastic cap. z While the burner is operating at the maximum output, test the gas pressure on the pressure port of the minimum gas pressure

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.

Adjusting the high gas pressure switch (when provided)

To calibrate the high pressure switch, proceed as follows according to its mounting position: 1 remove the pressure switch plastic cover; 2 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%. 3 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%; 4 replace the plastic cover.

PGCP Gas leakage pressure switch (witn Siemens LDU burner control/Siemens LMV Burner Management System)

z remove the pressure switch plastic cover; z adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch; z replace the plastic cover.

C.I.B. UNIGAS - M03996CH

PART II: OPERATION

LIMITATIONS OF USE

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.

THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER.

A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER.

THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER).

NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.

OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON.

IN 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.

OPERATION

VPS504

1 Turn on the A switch, on the burner control panel.

C.I.B. UNIGAS - M03996CH

Keys

A Main switch B Lock-out LED C Reset pushbutton for burner control box D Reset pushbutton for gas proving system (only for bur-

E “Gas in the network” signalling LED F “Lock-out” LED for gas proving system G “Hi-flame operation” LED H “Lo-flame operation” LED I “Ignition transformer operation” LED L “EV2 opening” LED M “EV1 opening” LED N “Fan motor overload tripped” LED O “Burner in stand-by” LED P Modulator (only on fully modulating burners) Q “Gas in the network” signalling LED (pilot) R “Solenoid valve EVP operation” LED

S Operation manual selector “CMF”

ners equipped with LDU)

2 Check that the control box is not in lockout position (LED B on), otherwise press reset button C. 3 Check that the pressure switches and thermostats make the burner operate 4 Check that the gas pressure is sufficient (LED E on) 5 The gas proving system checking cycle starts: the proving system LC LED lights up when the cycle ends.

6 When the gas valves checking ends, the burner starting up cycle takes place: if there is a leakage in a gas valve, the gas proving

system locks and the LB and F LEDs light up. To unlock, press LB if the VPS504 gas proving system is provided (see figure), or D

if LDU system is provided.

starts.

7 Tha fan motor starts, the actuator drives the air damper ot the maximum opening position (LED G on); the pre-purge time counting

8 At the end of the pre-purge time, the air damper moves to the ignition position, the ignition transformer is energised (LED I on), the

solenoid gas valves EVP1 and EVP2 are energised as well and consequently EV1 and EV2 (LEDs R, L and M on). 9 Few seconds after the gas valves opening, the transformer is de-energised and LED I turns off; the pilot gas valves are discon-

nected (LED R) later. 10 After some seconds the double-stage, progressive or modulating operation starts (according to the burner model): the burner is dri-

ven automatically into high or low flame ( progressive burners) or driven by the modulator (see the related user’s guide) in modula-

ting burners, according to the requirements of the plant.

C.I.B. UNIGAS - M03996CH

PART III: MAINTENANCE

At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6 months.

WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED!

ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL..

ROUTINE MAINTENANCE

z Clean and examine the gas filter cartridge and replace it if necesssary (see next paragraphs); z Remove and clean the combustion head (see page 32); z Examine and clean the ignition electrode, adjust and replace it if necessary (see page 33) z Examine and clean the detection photoelement, replace it if necessary (see page 35), in case of doubt, check the detection circuit,

after the burner start-up (see Fig. 19-Fig. 20);

z Cleaning and greasing of 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.

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).

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 grea-

ther 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.

6. Pay attention that dirt does not fall inside the valve. Space requirements for fitting filter, A: from 150 to 230 mm.

Fig. 16

C.I.B. UNIGAS - M03996CH



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.

DUNGS MBC..SE SKP Siemens actuator

Removing the combustion head

z Remove the cover C. z remove the electrodes cables; z unscrew the 3 screws V which hold in position the gas manifold G and pull out the complete group as shown in figure.

Note: to replace the combustion head reverse the procedure described above having care to place correctly the O ring (OR) between burner and gas manifold.

Key

VRT Head adjusting screw

AR Threaded rod

V Fixing screw

G Gas manifold

OR “O” ring

CCover

Adjusting the ignition electrode

5mm

= =

ATTENTION: avoid the ignition electrode to contact metallic parts (blast tube, head, etc.), otherwise the burner operation would be compromised. Check the electrode position after any intervention on the combustion head.

Fig. 17 - Detailed view of the diffuser with pilot (P) and ignition elecctrode (E)

C.I.B. UNIGAS - M03996CH

Fig. 18 - Detailed view of the combustion head with pilot (P) and ignition elecctrode (E)

Observe the values shown on next picture. .

Fig. 19

C.I.B. UNIGAS - M03996CH

ECE

Replacing the ignition electrode

ATTENTION: avoid the ignition electrode to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrode position after any intervention on the combustion head.

To replace the ignition electrode, proceed as follows: 1 remove the burner cover 2 disconnect the electrode (E) cable (CE); 3 remove the combustion head (see par. “Removing the combustion head”); 4 loose screw (B) that fasten the ignition electrode (E) to the burner pilot (P); 5 remove the electrode and replace it, referring to the values quoted on Fig. 19.

C.I.B. UNIGAS - M03996CH

TERMINAL BOARD

Control box Minimum detection signal

Siemens LFL1.3..

70µA with UV detector)

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 gas supply 3 remove the photocell from its slot (see next picture); 4 clean the bulbe if dirty, taking care not to touch it with bare hands; 5 if necessary, replace the bulb; 6 replace the photocell into its slot.

Checking the detection current

To check the detection signal follow the scheme in Fig. 20. If the signal is lower than the value quoted, check the posi-

tion of the UV detector (photocell), the electrical contacts and, if necessary, replace the UV detector.

Fig. 20: Detection by photocell QRA..

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

Burner disposal

In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”.

C.I.B. UNIGAS - M03996CH

TROUBLESHOOTING

CAUSE / TROUBLE

STARTS AND

REPEATS THE

CYCLE

TO HI FLAME

DOESN’T SWITCH

OPERATION

LOCKOUT DURING

THE BURNER

DOESN’T START

MAIN SWITCH OPEN z

LACK OF GAS z

HIGH GAS PRESSURE SWITCH DEFECTIVE z

DEFECTIVE THERMOSTAT z

OVERLOAD TRIPPED LOCK OUT z

CONTROLS FUSES INTERRUPTED z

DEFECTIVE AIR PRESSURE SWITCH zz z

PRE-PRGEe

CONTINUES WITH

AND LOCK-OUT

DOESN’T START

THE CYCLE

AND REPEATS

DOESN’T START

DURING

TURNS OFF AND

REPEATS CYCLE

OPERATION

DEFECTIVE CONTROL BOX zzz z

DEFECTIVE ACTUATOR z

AIR PRESSURE SWITCH FAULT OR BAD SETTING z

GAS PRESSURE SWITCH BAD SETTING zzz z

IGNITION TRANSFORMER FAULT z

BUTTERFLY VALVE BAD SETTING z

DEFECTIVE GAS GOVERNOR zzz z

DEFECTIVE HI-LO FLAME THERMOSTAT z

WRONG SETTING FOR ACTUATOR CAM z

PHOTODETECTOR FAULT OR WRONG SETTING z

C.I.B. UNIGAS - M03996CH

SPARE PARTS

Desription Code

R1025 R1030 R1040

CONTROL BOX 2020448 2020448 2020448 GAS PROVING SYSTEM - LDU11 2020413 2020413 2020413 PILOT ELECTRODE 2080258 2080258 2080258 GAS FILTER - DN65 2090117 2090117 GAS FILTER - DN80 2090112 2090112 2090112 GAS FILTER - DN100 2090113 2090113 2090113 GAS FILTER - DN125 - - 2090128 FAN WHEEL 2150063 2150058 2150058 GAS PRESSURE SWITCH - DUNGS GW150 A5 2160077 2160077 GAS PRESSURE SWITCH - DUNGS GW150 A6 2160086 2160086 2160086 GAS PRESSURE SWITCH - DUNGS GW500 A5 2160089 2160089 2160089 AIR PRESSURE SWITCH 2160097 2160097 2160097 IGNITION TRANSFORMER 2170301 2170301 2170301 MOTOR 21802A2 2180294 2180292 GAS VALVE GROUP SIEMENS VGD.. DN65 2190172 2190172 GAS VALVE GROUP SIEMENS VGD.. DN80 2190169 2190169 2190169 GAS VALVE GROUP SIEMENS VGD.. DN100 2190174 2190174 2190174 GAS VALVE GROUP SIEMENS VGD.. DN125 - - 2190184 GAS VALVE ACTUATOR - SIEMENS SKP15 2190181 2190181 2190181 GAS VALVE ACTUATOR - SIEMENS SKP25 2190183 2190183 2190183 GAS VALVE GROUP - DUNGS MBC1900SE DN65 21903M6 21903M6 GAS VALVE GROUP - DUNGS MBC3100SE DN80 21903M7 21903M7 21903M7 GAS VALVE GROUP - DUNGS MBC5000SE DN100 21903M8 21903M8 21903M8 PILOT GAS ELECTROVALVE 2190502 2190502 2190502 GAS PROVING SYSTEM VPS 2191604 2191604 2191604 GAS FLEXIBLE HOSES 234FX07 234FX07 234FX07 ADJUSTING CAM FOIL 2440014 2440014 2440014 ACTUATOR - SIEMENS SQM10 2480004 2480004 2480004 ACTUATOR - SIEMENS SQM40 24800A5 24800A5 24800A5 DETECTION PROBE 2510001 2510001 2510001 BURNER MODULATOR 2570112 2570112 2570112 PRESSURE GOVERNOR WITH FILTER 2800085 2800085 2800085 COMBUSTION HEAD 3060270 3060277 3060292 BLAST TUBE 30910H1 30910H2 30910Q8 IGNITION CABLE 6050143 6050143 6050143

BURNERS EXPLODED VIEW

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

1 AIR INLET CONE 8.8 INDEX LABEL 13.2.1 FRONT CONTROL PANEL

2 SPACER 8.9 AIR DAMPER INDEX 13.2.2 LIGHT

3 BUTTERFLY VALVE ASS.Y 9.1 GAS PRESSURE 13.2.3 LIGHT

4 PHOTOCELL 9.2 GAS SOLENOID VALVE 13.2.4 LOCK-OUT RESET BUTTON

5 PLATE 9.3 GAS GOVERNOR WITH FILTER 13.2.5 PROTECTION

6.1 LEVERAGE 10.1 GAS FILTER 13.2.6 OUTPUT CONTROLLER

6.2.1 ADJUSTING CAM 10.2.1 "SKP" ACTUATOR 13.2.7 SWITCH

6.2.2 ADJUSTING CAM FOIL 10.2.2 "SKP" ACTUATOR 13.2.8 SWITCH

6.3 ADJUSTING CAM SHAFT 10.2.3 GAS PROVING SYSTEM 13.3 COVER

6.4 LEVERAGE 10.2.4 GAS VALVE HOUSING 13.4.1 CONTROL BOX SOCKET

6.5 LEVERAGE 10.2.5 GAS PRESSURE 13.4.2 TIME COUNTER

6.6 ACTUATOR 10.3 FLANGED REVERSIBLE CURVE 13.4.3 BIMETAL RELAY

6.7 LEVER 10.4 REVERSIBLE PIPE 13.4.4 CONTROL BOX

6.8 INDEX LABEL 10.5 FLANGED PIPE 13.4.5 IGNITION TRANSFORMER

6.9 CONNECTOR 10.6 GASKET

6.10 ADJUSTING CAM 11.1 MOTOR

6.11 BRACKET 11.2 FAN WHEEL

6.12 BRACKET 12.1 RING NUT

6.13 PLATE 12.2 IGNITOR

7 STANDARD BLAST TUBE 12.3 COMBUSTION HEAD

8.1 BURNER HOUSING 12.4 GAS MANIFOLD

8.2 INSPECTION GLASS 12.5.1 ADJUSTING BUSH

8.3 CERAMIC FIBRE PLAIT 12.5.2 FALSE LANCE

8.4 AIR PRESSURE SWITCH 12.5.3 OIL GUN HOLDER

8.5 AIR INTAKE ASS.Y 12.6 IGNITION ELECTRODE

8.6.1 SILENCER 12.7 BUSH

8.6.2 SILENCER 12.8 IGNITION CABLE

8.7 BRACKET 13.1 BOARD

C.I.B. UNIGAS - M03996CH

ELECTRICAL WIRING DIAGRAMS

Wiring diagram: Code SE12-059 - Fully-modulating burners Wiring diagram: Code SE12-063 - Progressive burners

COMPLETE KEY

BL Fan motor remote contactor coil (line) BS Fan motor remote contactor coil (star) BT Fan motor remote contactor coil (delta) CAS Auxiliary fan motor contactor (star) CAT Auxiliary fan motor contactor (triangle) CL Fan motor contactor (line) CMF Manual switch: 0)off - 1)high flame - 2)low flame - 3)automatic (from TAB) CR1 Relay contacts CR1-CR2 Relay contacts CS Fan motor contactor (star) CT Fan motor contactor (triangle) CTV Fan motor overload contacts EV1 Gas electro-valve upstream (or valves group) EV2 Gas electro-valve downstream (or valves group) EVP1-2 Pilot gas electro-valve F÷F1 Fuses FC UV flame detector IG Main switch IL Auxiliary line switch L Phase LAF Burner in high flame indicator light LB Burner lockout indicator light LBF Burner in low flame indicator light LEV1 Indicator light for opening of electro-valve EV1 LEV2 Indicator light for opening of electro-valve EV2 LEVP Indicator light for opening of electro-valve EVP... LFL1.xx SIEMENS control box LPG MIN Indicator light for presence of gas in the network LPGP Indicator light for presence of gas in the pilot network LS Burner in stand-by indicator light LSPG Indicator light for leakage of valves LT Indicator light for fan overload tripped LTA Ignition transformer lindicator light MA1 Supply terminal block, plate 1 MA2 Supply terminal block, plate 2 MC1 Terminal block for connection of burner components, plate 1 MC2 Terminal block for connection of burner components, plate 2 MV Fan motor N Neutral PA Combustion air pressure switch PGMAX High gas pressure switch (where supplied, remove the bridge between terminal 156 and 158 in terminal block MC ) PGMIN Low gas pressure switch PGP Pilot gas pressure switch PS Lockout reset button Pt100 Temperature probe 3 terminals Pt100 R1 Auxiliary relay RT Delayed relay for start-up fan motor RWF40.000 ** SIEMENS modulator SD-0/4÷20mA Probe with signal 0÷20mA or 4÷20mA SD-0÷10V Probe with signal 0÷20V SD-PRESS. Pressure probe with 3 terminals (SIEMENS QBE620p..) SD-TEMP. Temperature probe 2 terminals (Pt1000 - SIEMENS QAE2.., QAC2..) SQM10/SQM40 SIEMENS servo control for air damper ST Series of thermostats or pressure switches TA Ignition transformer TAB High/low thermostat (where supplied, remove the bridge between terminals 6 and 7 in terminal block MA) TC Connection for termocouple TM (°) Fan motor thermal VPS504 DUNGS valve leakage monitor device

** The modulator includes a limit switch (terminals Q13 and Q14), it stops the burner if the work parameter overcomes set differential. (°) Set the TM overload tripped to an equal value to: Absorption of data plate (Ampere) to triangle / 1.73

WARNING

1 - Electrical supply 400V 50Hz 3N a.c. 2 - Do not reverse phase with neutral

3 - Ensure burner is properly earthed I

SIEMENS LFL 1.3.. CONTROL BOX

APPENDIX

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.

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.

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.

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 dam-

per, 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 con-

tacts 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 pres-

sostat 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 ter-

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 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

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 main interruptor switch L 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 thermostat or pressostat Sfuse SA damper servo-motor SM synchronous programmer motor V flame signal amplifier V 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

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 interval for creating current between terminals 19 and 20 t6 post-ventilation time t7 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 moni-

toring burners with intermittent pilot lighter.

(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

Note: Specifications and and data subject to change. Errors and omissions excepted.

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: cibunigas@cibunigas.it

CIB UNIGAS 1030, R1025, R1040 Manual Of Instllation - Use - Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual