CIB UNIGAS R91A, R520A, R525A, R92A, R93A Manual Of Installation - Use - Maintenance

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M039209CG Rel. 6.0 03/2015

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Gas burners

Progressive / Fully modulating

MANUAL OF INSTALLATION - USE - MAINTENANCE

R91A - R92A - R93A

R512A -R515A

R520A - R525A

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

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.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) 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 ha rmful

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

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 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;-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)

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

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

Harmonised standards :

2004/108/EC on electromagnetic compatibility

-EN 55014-1Electromagnetic compatibility - Requirements for household

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. --

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 repor-

ted in any communication with the supplier

z date of production (year and month) z information about fuel type and network

pressure

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

1.0 GENERAL FEATURES

PART I: SPECIFICATIONS

Note: the figure is indicative only 1 Control panel with startup switch 2Gas train 3 Electrical panel

4 Cover 5 Blast tube + Combustion head 6 Flange 7 Silencer 8 Adjusting cam 9 Actuator 10 Air pressure switch 11 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 adj usti ng cam with variable shape. This one allows the optimisation of the gas flue values, as to get an efficient combustion. The comb ustion 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.

PART I: SPECIFICATIONS

Type -Model -Year -S.Number -Output -Oil Flow -Fuel -Category -Gas Pressure -Viscosity -El.Supply -El.Consump. --

2.0 Burner model identification

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

Type R91A Model M-. MD. S. *. A. 1. 80.

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

1 BURNER TYPE R91A, R92A, R93A, R512A, R515A, R520A, R525A 2 FUEL M - Natural gas

L - LPG

3 OPERATION (Available versions) PR - Progressive

MD - Fully modulating 4 BLAST TUBE S - Standard 5 DESTINATION COUNTRY

6 BURNER VERSION A - Standard

7 EQUIPMENT 1 = 2 gas valves + gas proving system

8 GAS CONNECTION 50 = Rp2 65 = DN65

* - see data plate

Y - SpecialeSpecial

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

80 = DN80 100 = DN100

2.1 Fuel

ATTENTION! The burner must be used only with the fuel sp ecified in the burner data plate .

2.2 Technical Specifications

BURNER TYPE R91A M-... R92A M-... R93A M-...

Output min. - max. kW Fuel Category Gas rateGas pressure mbar Power supply Total power consumption Electric motor Protection Operation Gas train 50 Gas train 65 Gas train 80 Gas train 100 Operating temperature °C Storage Temperature °C Working service (*) Intermitent

Natural gas

min.- max. (Stm3/h)

kW kW

Valves size / Gas connection 50 / Rp 2 Valves size / Gas connection 65 / DN65 Valves size / Gas connection 80 / DN80 Valves size / Gas connection 100 / DN100

480 - 2670 480 - 3050 550 - 4100

Natural gas

M -

see next paragraph)

(

51 - 283 51 - 323 58 - 434

see Note 2)

(

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

4.5 6.0 8.0

45.57.5 IP40

Progressive - Fully modulating

-10 ÷ +50

-20 ÷ +60

PART I: SPECIFICATIONS

BURNER TYPE R91A L-... R92A L-... R93A L-...

Output min. - max. kW Fuel Category Gas rate- LPG Gas pressure mbar Power supply Total power consumption Electric motor Protection Operation Gas train 50 Gas train 65 Gas train 80 Gas train 100 Operating temperature °C Storage Temperature °C Working service (*) Intermitent

Note1:

Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE)

All gas flow rates are referred to Stm

(net calorific value H

= 500mbar (with Siemens VGD)

Minimum gas pressure = see gas curves.

= 34.02 MJ/Stm3); for L.P.G. (net calorific value Hi = 93.5 MJ/Stm3)

min.- max. (Stm3/h)

kW kW

Valves size / Gas connection 50 / Rp 2 Valves size / Gas connection 65 / DN65 Valves size / Gas connection 80 / DN80 Valves size / Gas connection 100 / DN100

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

480 - 2670 480 - 3050 550 - 4100

LPG

L -

17.9 - 100 17.9 - 114 20 - 153

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

4.5 6.0 8.0

45.57.5

3B/P

see Note 2)

(

IP40

Progressive - Fully modulating

-10 ÷ +50

-20 ÷ +60

* NOTE ON THE WORKING SERVICE: the control box automatically stops after 24h of continuous working. The control box immediately starts up, automatically.

PART I: SPECIFICATIONS

BURNER TYPE R512A M-... R515A M-... R520A M-... R525A M-....50 R525A M-....xx

Output min. - max. kW Fuel Category Gas rate-

Natural gas

min.- max. (Stm3/h) PressureGas pressure mbar Power supply Total power consumption Electric motor

kW kW

Protection Operation Gas train 50 Gas train 65 Gas train 80 Gas train 100

Valves size / Gas connection Valves size / Gas connection Valves size / Gas connection

Valves size / Gas connection Operating temperature °C Storage Temperature °C

600 - 4500 770 - 5200 1000 - 6400 2000 - 6700 2000 - 8000

M -

Natural gas

(

see next paragraph)

63 - 476 81 - 550 106 - 677 212 - 709 212 - 847

(

see Note 2)

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

9.7 11.5 16.5 19 19

9.2 11 15 18.5 18.5 IP40

Progressive - Fully modulating

50 / Rp2 65 / DN65 80 / DN80 80 / DN80 80 / DN80 - 80 / DN80

100 / DN100

50 / Rp2 50 / Rp2 50 / Rp2

65 / DN65 65 / DN65

100 / DN100 100 / DN100 - 100 / DN100

-10 ÷ +50

-20 ÷ +60

Working service (*) Intermitent

BURNER TYPE R512A L-... R515A L-... R520A L-... R525A L-....50 R525A L-....xx

Output min. - max. kW Fuel Category

Gas rate- LPG

min.- max. (Stm3/h) PressureGas pressure mbar Power supply Total power consumption Electric motor

kW kW

Protection Operation Gas train 50 Gas train 65 Gas train 80 Gas train 100

Valves size / Gas connection Valves size / Gas connection Valves size / Gas connection

Valves size / Gas connection Operating temperature °C Storage Temperature °C

600 - 4500 770 - 5200 1000 - 6400 2000 - 6700 2000 - 8000

LPG

L -

3B/P

22 - 167 28 - 194 37 - 238 74 - 250 74 - 300

(

see Note 2)

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

9.7 11.5 16.5 19 19

9.2 11 15 18.5 18.5 IP40

Progressive - Fully modulating

50 / Rp2 65 / DN65 80 / DN80 80 / DN80 80 / DN80 - 80 / DN80

100 / DN100

50 / Rp2 50 / Rp2 50 / Rp2

65 / DN65 65 / DN65

100 / DN100 100 / DN100 - 100 / DN100

-10 ÷ +50

-20 ÷ +60

Working service (*) Intermitent

- 65 / DN65

Note1:

All gas flow rates are referred to Stm

(net calorific value H

= 34.02 MJ/Stm3); for L.P.G. (net calorific value Hi = 93.5 MJ/Stm3)

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

Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE)

= 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.

2.3 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

2.4 Overall dimensions (mm)

E F

O max

O min

Boiler recommended drilling tem-

plate

Burner flange

PART I: SPECIFICATIONS

DN* A AAADANAP B BBCCCD E F GH I J K L MNOminOmaxP QR S U VWY Z R91A R91A R91A R91A R92A R92A R92A R92A R93A R93A R93A R93A

*DN = gas valves size

50 1495 242 35 550 100 490 441 1005 421 1160 725 435 265 295 228 450 360 464 M12 424 280 310 300 532 148 384 624 190 649 228 185 65 1495 242 35 564 117 490 441 1005 421 1406 971 435 265 295 228 447 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 80 1495 242 35 579 132 490 441 1005 421 1437 1002 435 265 295 228 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185

100 1495 242 35 592 145 490 441 1005 421 1520 1085 435 265 295 228 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 185

50 1495 242 35 550 100 490 441 1005 421 1160 725 435 269 299 228 450 360 464 M12 424 280 310 300 532 148 384 624 190 649 228 185 65 1495 242 35 564 117 490 441 1005 421 1406 971 435 269 299 228 447 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 80 1495 242 35 579 132 490 441 1005 421 1437 1002 435 269 299 228 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185

100 1495 242 35 592 145 490 441 1005 421 1520 1085 435 269 299 228 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 185

50 1500 242 35 550 100 495 460 1005 421 1160 725 435 304 344 228 450 360 464 M12 424 280 310 300 532 148 384 624 190 649 228 185 65 1500 242 35 564 117 495 460 1005 421 1406 971 435 304 344 228 447 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 80 1500 242 35 579 132 495 460 1005 421 1437 1002 435 304 344 228 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185

100 1500 242 35 592 145 495 460 1005 421 1520 1085 435 304 344 228 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 185

E F

Boiler recommended drilling template

Burner flange

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

50 1683 320 35 595 100 530 517 1153 446 1590 946 644 340 380 494 540 494 M14 552 390 390 763 149 614 845 190 764 311 270

R512A

R515A

R520A

R525A

65 1683 320 35 611 117 530 517 1153 446 1613 969 644 340 380 494 540 494 M14 552 390 390 636 149 487 845 292 764 311 270 80 1683 320 35 626 132 530 517 1153 446 1646 1002 644 340 380 494 540 494 M14 552 390 390 687 149 538 875 310 764 311 270

100 1683 320 35 639 145 530 517 1153 446 1726 1082 644 340 380 494 540 494 M14 552 390 390 791 149 642 942 353 764 311 270

50 1683 320 35 595 100 530 517 1153 446 1590 946 644 380 420 494 540 494 M14 552 390 390 763 149 614 845 190 764 316 270 65 1683 320 35 611 117 530 517 1153 446 1613 969 644 380 420 494 540 494 M14 552 390 390 636 149 487 845 292 764 316 270 80 1683 320 35 626 132 530 517 1153 446 1646 1002 644 380 420 494 540 494 M14 552 390 390 687 149 538 875 310 764 316 270

100 1683 320 35 639 145 530 517 1153 446 1726 1082 644 380 420 494 540 494 M14 552 390 390 791 149 642 942 353 764 316 270

50 1683 320 35 595 100 530 517 1153 446 1590 946 644 400 440 494 540 604 M14 552 390 390 763 149 614 845 190 874 328 270 65 1683 320 35 611 117 530 517 1153 446 1613 969 644 400 440 494 540 604 M14 552 390 390 636 149 487 845 292 874 328 270 80 1683 320 35 626 132 530 517 1153 446 1646 1002 644 400 440 494 540 604 M14 552 390 390 687 149 538 875 310 874 328 270

100 1683 320 35 639 145 530 517 1153 446 1726 1082 644 400 440 494 540 604 M14 552 390 390 791 149 642 942 353 874 328 270

50 1683 205 35 595 100 530 650 1153 570 1590 946 644 434 484 494 540 604 M14 552 390 390 763 149 614 845 190 874 328 270 65 1683 205 35 611 117 530 650 1153 570 1613 969 644 434 484 494 540 604 M14 552 390 390 636 149 487 845 292 874 328 270 80 1683 205 35 626 132 530 650 1153 570 1646 1002 644 434 484 494 540 604 M14 552 390 390 687 149 538 875 310 874 328 270

100 1683 205 35 639 145 530 650 1153 570 1726 1082 644 434 484 494 540 604 M14 552 390 390 791 149 642 942 353 874 328 270

*DN = gas valves size

PART I: SPECIFICATIONS

2.5 How to read the burner “Performance curve”

Campo di lavoro bruciatori

Tipo P60 Mod. M-x x.x.IT.A.0.50 - M-.x x.x.IT.A.0.65

-1

100 200 300 400 500 600 700 800 900

Pote nza kW

Contropressione in camera di

combustione mbar

backpressure in

combustion chamber (mbar)

Power kW

100 200 300 400 500 600 700 800 900

Potenza / Output (k W)

Minima pressione gas in

rete / Minimum inlet gas

pressure (mbar)

Rp 2" (50)

DN65

Power kW

minimum gas pressure in

the network 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 th e 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.

2.6 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 pgas value, calculated before.

PART I: SPECIFICATIONS

400 800 1200 1600 2000 2400 2800

400 800 1200 1600 2000 2400 2800 3200

0 500 1000 1500 2000 2500 3000 3500 4000 4500

500 1500 2500 3500 4500

500 1500 2500 3500 4500 5500

500 1500 2500 3500 4500 5500 6500 7500

1500 2500 3500 4500 5500 6500 7500

1500 2500 3500 4500 5500 6500 7500 8500

2.7 Performance Curves

R91A

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

R93A

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

R515A

R92A

R512A

R520A

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

R525A Rp2

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: atmospheric pressure at 1013mbar, ambient temperature at 15°C NOTE: The performance curve is a diagram that rep resents 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 “A djusting the combustion head”); the minimum output point is r eached 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.

R525A DN65-80-100

2.8 Pressure in the Network / gas flow rate curves (natural gas)

PART I: SPECIFICATIONS

R91A M-..

GAS PRESSURE mbar

R93A M-..

GAS PRESSURE mbar

R515A M-..

Stm

R92A M-..

R512A M-..

R520A M-..

Stm3/h

GAS PRESSURE mbar

Stm

R525A M-.. Rp2

R525A M-.. DN65-80-100

GAS PRESSURE mbar

Stm

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 inclu ded). 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.

Stm3/h

Stm

PART I: SPECIFICATIONS

2.9 Pressure in the Network / gas flow rate curves(LPG)

R91A L-..

GAS PRESSURE mbar

Stm

R93A L-..

GAS PRESSURE mbar

R512A L-..

GAS PRESSURE mbar

R520A L-..

Stm

GAS PRESSURE mbar

Stm

PART I: SPECIFICATIONS

2.10 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 an d 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 Te ch ni cal specifications.

Fig. 4

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

2.11 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 Stm 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.

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

PART I: SPECIFICATIONS

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

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

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

50 100 150 200 250 300 350 400 450 500

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

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

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

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

2.12 Pressure - rate in combustion head curves (natural gas)

Curves are referred to pressure = 0mbar in the combustion chamber!

R92A M-..

Gas pressure in

combustion head

R91A M-..

R93A M-..

Gas pressure in

combustion head

R515A M-..

GAS PRESSURE mbar

Stm

Stm3/h

R512A M-..

R520A M-..

Stm3/h

R525A M-.. Rp2

GAS PRESSURE mbar

R525A M-.. DN65-80-100

Stm3/h

2.13 Pressure - rate in combustion head curves (LPG)

10 20 30 40 50 60 70 80 90 100 110

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

20 40 60 80 100 120 140 160 180

25 5 0 75 100 125 150 175 200 225 250

Curves are referred to pressure = 0mbar in the combustion chamber!

Gas pressure in

combustion head

R91A L-..

R93A L-..

PART I: SPECIFICATIONS

R512A L-..

Gas pressure in

combustion head

R520A L-..

Stm

GAS PRESSURE mbar

Stm

PART II: INSTALLATION

3.0 MOUNTING AND CONNECTING THE BURNER

3.1 Packing

The burners are despatched in wooden crates whose dimensions are:

z 9xA series: 1672mm x 1072mm x 1016mm (L x P x H) z 5xxA series: 1886mm x 1456mm x 1120mm (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.

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

3.2 Handling the burner

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

To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”). The unpacked burner must be lifted and moved only by means of a fork lift truck.

The burner is mounted on a stirrup provided for hand ling the burne r by means of a fork l ift truck: the forks must be inserted into the A anb B ways. Remove the stirrup only once the burner is installed to the boiler.

PART II: INSTALLATION

Keys

1 Burner 2 Fixing nut 3 Washer 4 Sealing gasket 5 Stud bolt 7Blast tube

Dist

3.3 Fitting the burner to the boiler

To install the burner into the boiler, proceed as follows: 1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) 2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; 3 place the 4 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensi ons”; 4 fasten the 4 stud bolts; 5 place the gasket on the burner flange; 6 install the burner into the boiler; 7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture. 8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is seal ed with appropriate

insulating material (ceramic fibre cord or refractory cement).

3.4 Matching the burner to the boiler

The burners described in this manual have been tested with combustion chambers that co mply with EN676 regulation and whose dimensions are described in the diagram . In case the burner mu st be coupled with boilers with a combustion chamber smaller in diameter or shorter than those described in the di agram, 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 choo se the blast tube lenght follo w the instructions of the boi ler 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)

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

PART II: INSTALLATION

spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).

Key

a) Heat output in kW b) Lenght of the flame tube in meters c) Flame tube firing intensity in MW/m

d) Combustion chamber diameter (m)

Fig. 5 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat input in kW.

Fig. 5

PART II: INSTALLATION

GAS INLET

SUPPLIED BY BURNER CONSTRUCTOR

BY OTHERS

GAS INLET

SUPPLIED BY BURNER CONSTRUCTOR

BY OTHERS

4.0 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)

Key

1 Filter 6 Butterfly valve 2 Pressure switch - PGMIN 8 Main burner 3 Safety valve with built in gas governor 9 Bellows unit(*optional) 4 Proving system pressure switch (*if supplied) - PGCP 10 Manual valve(*optional) 5 Pressure switch - PGMAX(*optional)

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

Key

1 Filter (*optional) 6 Butterfly valve 2 Pressure switch - PGMIN 7 Main burner 3 Safety valve with built in gas governor 8 Manual valve(*optional) 4 Proving system (*if provided) 9 Bellows unit(*optional) 5 Pressure switch - PGMAX (*optional)

PART II: INSTALLATION

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

4.1 Assembling the gas grain

Fig. 6 - Example of gas train

To mount the gas train, proceed as follows: 1-a) in case of threade d joints: use proper seals according to the gas used; 1-b) in case of flanged joints: place a gasket (no. 1A..1E - Fig. 6) 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. 6, 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 procedures of installation fo the gas valves are showed in the next paragraphs, according to the gas trai n used:

z threaded gas trains with Siemens VGD20.. z flanged gas trains with Siemens VGD40..

PART II: INSTALLATION

SKP1. SKP2.

BS BS

7631z05/0101

SIEMENS VGD..MOUNTING

POSITIONS

(cap)

(spring)

Fig. 10

4.2 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. 10).

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

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).

4.3 Gas Filter (if provided)

Fig. 7

Fig. 8

Fig. 9

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.

PART II: INSTALLATION

EV1

EV2

PGCP

ATTENTION: it is reccomended to install the filter with gas flow parallel to the floor in or der to prevent dust fall on the safety valve during maintenance operation.

4.4 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 fo r 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 fo r a preset time (td2). The pressu re switch PGCP has not to detect a pres-

sure 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, shut-

down, or both. On LME73.831BC the valve proving is parameterized to take place on startup only.

4.5 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.

5.0 ELECTRICAL CONNECTIONS

- LMV2/3.. - LMV5..

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 p osition (OFF) too. Read carefully th e chapter “WARNINGS”, and the “Electrical connections” section.

ATTENTION: Connecting electrical supply wires to the bu rner teminal bloc k MA, be s ure that th e gro und wire is

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 diag rams; 3 check the direction of the fan motor (see next paragraph); 4 refit the panel cover.

longer than phase and neutral ones.

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, r emove this bridge before co nnecting the thermostat.

PART II: INSTALLATION

5.1 Rotation of electric motor

Once the electrical connection of the burner is executed, remember to check th e rotation of the e lectric 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

For LMV5 control box, please refer to the clabeling recommendations avaible on the Siemens CD attached to the burner

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 th e 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.

Fig. 11 - Burner front panel

6100803

PART III: OPERATION

Keys

B1 Lock-out LED B2 Hi-flame operation LED B3 Lo-flame operation LED B4 “Ignition transformer operation” LED B5 “Fan motor overload tripped” LED G1 “EV2 opening” LED G2 “EV1 opening” LED G3 “Gas pressure switch signal ” LED S1 Main switch S3 (only on fully modulating burners) Operation selector MAN - AUTO (operation in manual or automatic mode):

MIN = operation with minimum output 0 = Stop MAX = operation at the maximum output

A1 Burner Modulator (only on fully modulating burners)

5.3 Gas operation

z 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 maxi mum ai r rate, the control box drives the actuator opening and wh en 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 wi th 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-sta ge ope-

ration 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.

PART III: OPERATION

MAN-AUTO

mensions

Dimensions in

SQM4...

III

VIVI

III

6.0 AIR FLOW AND FUEL ADJUSTMENT

WARNING! During commissioning opera tio ns , do no t l et the bu rner o perate with insufficient air flow (dange r 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 (%) CO

Recommended (%) O2

Natural gas 9 ÷ 10 3 ÷ 4.8

LPG 11 ÷ 12 2.8 ÷ 4.3

6.1 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 mea ns of a

differential pressure gauge.

z Then, adjust the combustion values corresponding to the points between maximum and minimum: set the sha pe 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.

6.2 Air and Gas Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator

1 check the fan motor rotation. 2 Only for burners provided with Multibloc MB-DLE gas valves: before starting the burner up, set the slow opening. To set the slow

opening, remove cover T, reverse it upside down and use it as a tool to rotate screw VR. Clockwise rotation reduces start flow rate,

anticlockwise rotation increases it. Do not use a screwdriver on the screw VR! Note: the screw VSB must be removed only in case of replacemente of the coil. 3 Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner ope-

rates at the lowest output) to safely achieve the high flame stage. 4 Start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end an d that the burner starts

up; 5 drive the burner to high flame stage, by means fo the thermostat TAB. 6 Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion

values and eventually adjusting the gas by means of the valves group stabiliser. 7 go on adjusting air and gas flow rates: check, continuosly, the flue gas analisys, as to avoid combustion with little air; dos e the air

according to the gas flow rate change following the steps quoted below;

Siemens SQM40

Actuator cams (SQM40)

I High flame II Stand-by

8 acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values

III Low flame - gas VI Ignition - gas

PART III: OPERATION

Siemens VGD..

VRA

SV1

ID1

SV1

Gas throttle valve open

Gas throttle valve closed

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 conse-

quently the gas rate; screwind VR the rate increases, unscrewing it decreases (see next figure).

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 o f the air damper

rods.

10 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.

11 The air and gas rate are now adjusted at the maximum power stage, go on with the point to point ad justement on the SV1 (gas

side) adjusting cam as to reach the minimum output point. 12 as for the point-to-point regulation, move the gas low flame microswitch 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 the gas low flame microswitch to the minimum to move the actuator towards the l ow flame until the two bearings find the

adjusting screw that refers to the lower position: screw V1 to increase the rate, unscrew to decrease.

15 Move again the gas low flame microswitch towards the minimum to meet the next screw on the adjustin g cam and repeat th e pre-

vious step; go on this way as to reach the desired low flame point. 16 Now adjust the pressure switches.

Fully-modulating burners

PART III: OPERATION

CMF

.To adjust the fully-modulating burners, use the CMF switch on the burner control panel (se e next picture), in ste ad of the TAB thermostat as described on the previous paragraphs about the progre ssive burners. Go on adjusting the burner as describ ed 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 = 2 low flame operation CMF = 3 automatic operation

6.3 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.

6.4 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 burner control panel.

The gas pressure switches check the pressure to avoid the burner operate when the pres- sure value is not in the requested pressure range.

6.5 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 pre ssure 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.

6.6 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; 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%.

PART III: OPERATION

3 if the maximum pressure switch is mounted downstream the “g as governor-gas valves” group and upstream the butterfly valve:

light the burner, adjust it according to the procedu re in the previous paragrph. Then, measure the gas pressure at the operatin g

flow rate, downstream the “gas governor-gas valves” group and upstream the butterfly va lve; by means of the adjusting ring nut

VR, set the value read on step 2, increased by the 30%; 4 replace the plastic cover.

6.7 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 adju-

sting 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.

6.8 PGCP Gas leakage pressure switch (witn Siemens LDU/LME7x 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.

PART III: OPERATION

VRT

“MAX” head position

”MIN” head position

closed holes

opened holes

6.9 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 p osition, by turning clockwise the VRT ring nut. Fasten VB screw when th e adjustment is accomplished.

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

6.10 Center head holes gas flow regulation (natural gas burners)

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.

The adjusting plate correct position must be regulated in the plant during the commissioning.

The factory setting depends on the type of fuel for which the burner is designed:

z For natural gas burners, plate holes are fully opened

6.11 Center head holes gas flow regulation (LPG burners))

The adjusting plate correct position must be regulated in the plant during the commissioning.

closed holes

opened holes

The factory setting depends on the type of fuel for which the burner is designed:

z For LPG burners, plate holes are opened about 1.5mm (9x series) or 1.3 (5xx series)

PART III: OPERATION

PART IV: MAINTENANCE

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..

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

7.0 ROUTINE MAINTENANCE

z Clean and examine the gas filter cartridge and replace it if necesssary; z Remove and clean the combustion head; z Examine and clean the ignition electrodes, adjust and replace them if necessary; z Examine and clean the detection electrode/pho toelement (according to the burner models), replace it if necessary, in case of

doubt, check the detection circuit, after the burner start-up;

z 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.

7.1 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).

7.2 Replacing the spring in the gas valve group

SKP Siemens actuator

GAR

VRT

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.

PART IV: MAINTENANCE

7.3 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. z Some models are provided with the T baffle. Move the gas manifold ahead and remove the baffle. z Pull out the complete group as shown in the picture below. z Clean the combustion head by a compressed air blow or, in case of scale, scrape it off by a scratchbrush.

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

Key

VRT Head adjusti ng screw AR Threaded rod V Fixing screw G Gas manifold OR ”O” r ing CCover T Baffle

Fig. 12

PART IV: MAINTENANCE

7.4 Electrodes Adjustment

Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion head.

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

Adjust the electrodes position, according to the quotes shown othe next picture

Fig. 13

7.5 Replacing the ignition electrodes

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

To replace the ignition electrodes, proceed as follows: 1 remove the burner cover 2 loose the nuts that fasten the electrodes group to the combustion head (A); 3 disconnect the electrodes cables (B); 4 loose the security dowes of the adjusting ring nut (C); 5 shift the electrodes group back to the outside and remove the combustion head (D), 6 loose the screw of th eignition electrodes support (E); 7 remove the electrodes and replace them paying attention to the measures showed in figure (F-G). 8 reassemble the burner by fllowing the procedure in the reversed order.

DEF

PART IV: MAINTENANCE

Control box Minimum detection signal

Siemens LME7..

2µA (with electrode)

Control box Minimum detection signal

Siemens LME7...

70µA with UV detector)

7.6 Replacing the detection electrode

ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), other wise the boiler operation would be compromised. Check the electrode position after any intervention on the combustion head.

To replace the detection electrode, proceed as follows: 1 remove the combustion head according to the procedure on paragraph “Removing the combustion head”; 2 by means of an allen key, loose the fixing screws of the detection electrode ER and replace it; 3 replace the combustion head.

7.7 Checking the detection current (natural gas)

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.

Fig. 14: Detection by electrode

7.8 Checking the detection current (L.PG.)

Fig. 15: Detection by photocell QRA..

7.9 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

PART IV: MAINTENANCE

7.10 Burner disposal

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

8.0 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

TROUBLESHOOTING

CAUSE

MAIN SWITCH OPEN LACK OF GAS MAXIMUM GAS PRESSURE SWITCH DEFECTIVE THERMOSTATS/PRESSURE SWITCHES DEFECTIVES OVERLOAD TRIPPED INTERVENTION AUXILIARIES FUSE INTERRUPTED DEFECTIVE CONTROL BOX DEFECTIVE ACTUATOR AIR PRESSURE SWITCH FAULT OR BAD SETTING MINIMUM GAS PRESSURE SWIT C H D EFE C TIVE OR GAS

FILTER DIRTY

IGNITION TRANSFORMER FAULT IGNITION ELECTRODES BAD POSITION BUTTERFLY VALVE BAD SETTING DEFECTIVE GAS GOVERNOR GAS VALVE DEFECTIVE BAD CONNECTION OR DEFECTIVE HIGH/LOW FLAME

THERMOSTAT OR PRESSURE SWITCH ACTUATOR CAM WRONG SETTING UV PROBE DIRTY OR DEFECTIVE

TROUBLE

THE BURNER

DOESN’TSTART

CONTINUE WITH PRE-

PURGE

DOESN’T START AND LOCK-

OUT

DOESN’T START AND

REPEATS THE CYCLE

STARTS AND REPEATS THE

CYCLE

STARTS AND LOCK-OUT

THE FLAME MONITOR

DEVICE DOESN’T

GIVECONSENT TO START

DOESEN’T SWITCH TO HIGH

FLAME

DOESEN’T RETURN IN LOW

FLAME

LOCK-OUT DURING

OPERATION

TTURNS OF AND REPEATS

CYCLE DURING OPERATION

z zz zz zz z z z zzz z z zzz

PART IV: MAINTENANCE

zzzz

zzzz z

z z zz zzz z z

zzz

zz z

9.0 BURNER EXPLODED VIEW

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

1 FLANGE 8 STANDARD BLAST TUBE 13.4.2 GAS VALVE HOUSING 2 AIR INLET CONE 9 AIR DAMPER INDEX 13.4.3 "SKP" ACTUATOR 3 INDEX LABEL 10 IGNITION CABLE 13.4.4 "SKP" ACTUATOR 4 PRESSURE PLUG 11 DETECTION CABLE 13.4.5 GAS PROVING SYSTEM 5 BUTTERFLY GAS VALVE 12.1 NET 14.1 FAN WHEEL 6 BRACKET 12.2 BURNER HOUSING 14.2 MOTOR

7.1 INDEX LABEL 12.3 FLANGE 15.1 DETECTION ELECTRODE

7.2 BUSH 12.4 CERAMIC FIBRE PLAIT 15.2 RING NUT

7.3 BUSH 12.5 PRESSURE PLUG 15.3 GAS MANIFOLD

7.4 BUSH 12.6 INLET 15.4 COMBUSTION HEAD

7.5 ADJUSTING CAM SHAFT 12.7 INSPECTION GLASS 15.5.1 IGNITION ELECTRODES

7.6 LEVERAGE 12.8 BRACKET 15.5.2 ADJUSTING BUSH

7.7.1 ADJUSTING CAM 12.9.1 THREADED GAS PIPE 15.5.3 FALSE GUN

7.7.2 ADJUSTING CAM FOIL 12.9.2 AIR PRESSURE SWITCH 15.5.4.1 OIL GUN HOLDER

7.8 ACTUATOR 12.9.3 PRESSURE SWITCH BRACKET 16.1 FRONT CONTROL PANEL

7.9 ROD 12.10.1 AIR DAMPER SILENCER 16.2 BOARD

7.10 CAM 12.10.2 AIR INTAKE DAMPER 16.3 COVER

7.11 LEVERAGE 12.11.1 SPACER 17.1 CONTROL BOX

7.12 ROD 12.11.2 SILENCER 17.2 IGNITION TRANSFORMER

7.13 JOINT 12.11.3 SILENCER 17.3 PRINTED CIRCUIT BOARD

7.14 JOINT 13.1 GAS FILTER

7.15 ACTUATOR SHAFT 13.2 REVERSIBLE PIPE

7.16 BRACKET 13.3 FLANGED REVERSIBLE CURVE

7.17 BRACKET 13.4.1 GAS PRESSURE

PART IV: MAINTENANCE

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 t he 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 waitin g the resp onse 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 tim e 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 a t

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

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

Note: specifications and data subject to change. Errors and omissions exceptd.

CIB UNIGAS R91A, R520A, R525A, R92A, R93A Manual Of Installation - Use - Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual