Unigas HP20, HP30 Manual Of Installation - Use - Maintenance
HP20 - HP30
Progressive, Fully-modulating
Gas - light oil
dual fuel burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -
M039203CC REL. 2.1 11/2012
ГОРЕЛКИ
TABLE OF CONTENTS
WARNINGS ................................................................................................................................................................ 3
PART I: INSTALLATION ........................................................................................................................................... 5
GENERAL FEATURES ................................................................................................................................................................... 5
How to interpret the burner “Performance curve” ........................................................................................................................... 5
Checking the proper gas train size ................................................................................................................................................. 6
Matching the burner to the boiler .................................................................................................................................................... 6
Burner model identification ............................................................................................................................................................. 7
Specifications ................................................................................................................................................................................. 7
Country and usefulness gas categories 8
Overall dimensions ........................................................................................................................................................................ 8
Performance Curves ....................................................................................................................................................................... 9
Pressure in the network - gas rate curves ...................................................................................................................................... 9
MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 10
Packing ......................................................................................................................................................................................... 10
Handling the burner ...................................................................................................................................................................... 10
Fitting the burner to the boiler ....................................................................................................................................................... 10
Gas train connections ................................................................................................................................................................... 11
Assembling the gas grain .............................................................................................................................................................. 12
Hydraulic diagrams for light oil supplying circuits ......................................................................................................................... 13
Light oil piping installation diagram ............................................................................................................................................... 14
About the use of fuel pumps ......................................................................................................................................................... 14
Light oil pumps .............................................................................................................................................................................. 15
Connecting the light oil flexible hoses ........................................................................................................................................... 15
Electrical connections ................................................................................................................................................................... 15
Rotation of fan motor and pump motor ......................................................................................................................................... 16
ADJUSTMENTS ........................................................................................................................................................................... 17
Combustion head gas pressure curves depending on the flow rate ............................................................................................. 17
Measuring the gas pressure in the combustion head ................................................................................................................... 17
Pressure in combustion head - gas rate curves ........................................................................................................................... 17
Gas Filter ..................................................................................................................................................................................... 18
VPS504 Gas proving system ........................................................................................................................................................ 18
Adjustments - brief description ...................................................................................................................................................... 18
Adjustment procedure for gas operation ...................................................................................................................................... 18
Calibration of air and gas pressure switches ................................................................................................................................ 20
Calibration of air pressure switch .................................................................................................................................................. 20
Calibration of low gas pressure switch .......................................................................................................................................... 20
Adjusting the high gas pressure switch (when provided) .............................................................................................................. 21
Fully modulating
Adjustment procedure for light oil operation .................................................................................................................................. 22
Oil Flow Rate Settings .................................................................................................................................................................. 23
Light oil circuit ............................................................................................................................................................................... 25
burners
............................................................................................................................................................... 21
PART II: OPERATION ............................................................................................................................................. 26
OPERATION ................................................................................................................................................................................. 26
Gas operation ............................................................................................................................................................................... 26
Light oil operation .......................................................................................................................................................................... 27
PART III: MAINTENANCE ....................................................................................................................................... 28
ROUTINE MAINTENANCE ........................................................................................................................................................... 28
Light oil filter maintenance ............................................................................................................................................................ 28
Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................. 28
Removing the combustion head ................................................................................................................................................... 29
Cleaning and replacing the detection photocell ............................................................................................................................ 30
Checking the detection current ..................................................................................................................................................... 31
Seasonal stop ............................................................................................................................................................................... 31
Burner disposal ............................................................................................................................................................................. 31
TROUBLESHOOTING.................................................................................................................................................................. 32
SPARE PARTS ............................................................................................................................................................................. 33
BURNER EXPLODED VIEW ........................................................................................................................................................ 34
WIRING DIAGRAMS .................................................................................................................................................................... 36
APENDIX
2
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,
z Observe ca
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
ution with hot burner components. These are, usually,
or other fuel).
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.
3
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 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 (Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements.
Light oil burners
European directives:
- Directive 2006/95/EC on low voltage;
-
Directive 2004/108/
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
European directives:
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-CEI EN 60335-1 Household and similar electrical appliances - SafetyPart
1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
European directives:
- Directive 90/396/CEE Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 Gas Burners
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
European directives:
- Directive 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
CEE on ele
ctromagnetic compatibility
Heavy oil burners
Gas - Light oil burners
Gas - Heavy oil burners
4
C.I.B. UNIGAS - M039203CC
PART I: INSTALLATION
GENERAL FEATURES
This series represents monobloc gas burners made in die-cast aluminium housing, that can burn either gas or light oil, thanks to the
adjustable combustion head which allows a good performance with both fuels. They can be provided in progressive or fully-modulating
version.
Gas operation: 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 actuator moves proportionally the air damper and the gas butterfly valve It drives an adjusting cam with variable shape. This one allows the optimisation of the gas flue values, as to get an efficient combustion.
Light oil operation:the fuel coming from the supply line, is pushed by the pump to the nozzle and then into the combustion chamber,
where the mixture between fuel and air takes place and consequently the flame.
In the burners, the mixture bertween fuel and air, to perform clean and efficient combustion, is activated by atomisation of oil into very
small particles. This process is achieved making pressurised oil passing through the nozzle.
The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pressure,
pumps are provided with a pressure regulator (except for some models for which a separate regulating valve is provided). Other pumps
are provided with two pressure regulators: one for the high and one for low pressure (in double-stage systems with one nozzle).
The adjustable combustion head can improve the burner performance. The combustion head determines the energetic quality and the
geometry of the flame. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion chamber). The control panel, placed on the burner front side, shows each operating stage.
How to interpret the burner “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. 1), 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.
Campo di lavoro bruciatori
Tipo P60 Mod. M-x x.x.IT.A.0.50 - M-.x x.x.IT.A.0.65
8
7
6
5
4
3
2
1
combustione mbar
0
Contropressione in camera di
-1
100 200 300 400 500 600 700 800 900
A
Pote nza kW
Fig. 1
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C
5
C.I.B. UNIGAS - M039203CC
Checking the proper gas train size
To check the proper gas train size, it is necessary to know 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
Tipo / Type P60
M-...50 (Multibloc DUNGS MB-DLE 420 B01)
M-...65 ( Filtro / Filter DN65 + SIEMENS VGD40.065 +SKP1x+S KP2x)
25
20
15
10
pressure (mbar)
5
rete / Minimum inlet gas
Minima pressione gas in
0
100 200 300 400 500 600 700 800 900
gas value, calculated before.
Rp 2" (50)
DN65
Potenza / Output (kW)
Fig. 2
Matching the burner to the boiler
The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose
dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in diameter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with respect of the application involved. To correctly match the burner to the boiler verify the necessary input and the pressure in combustion
chamber are included in the burner performance curve; otherwise the choice of the burner must be revised consulting the burner manufacturer. To choose the blast tube lenght follow the instructions of the boiler manufacturer. In absence of these consider the following:
z Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than 100 mm into
the combustion chamber.
z Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in
respect to the tube bundle plate.
The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitablyspacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).
sized
Fig. 3
Key
a) Heat output in kW
b) Lenght of the flame tube in meters
c) Flame tube firing intensity in MW/m
3
d) Combustion chamber diameter (m)
Fig. 3 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.
6
C.I.B. UNIGAS - M039203CC
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type HP20 Model MG. PR. S. *. A. 0. 25
(1) (2) (3) (4) (5) (6) (7) (8)
(1) BURNER TYPE HP20 - HP30
(2) FUEL M - Natural gas G - Light oil
(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 0 = 2 gas valves
1 = 2 gas valves + gas proving system
7 = 2 gas valves + max. pressure switch
8 = 2 gas valves + gas proving system + max. pressure switch
(8) GAS CONNECTION 25 = Rp1
32 = Rp1
1/4
Specifications
BURNER TYPE HP20 HP30
Output min. - max. kW
Fuel
Gas category (see next paragraph)
Gas rate
Gas pressure
Light oil rate
min.-max. min. - max. Stm
min.- max. mbar
min.- max. kg/h 7.2 - 19.4 5.5 - 29.5
3
/h)
Oil viscosity 2 - 7.4 cSt @ 40°C
Oil density
Power supply 230V 1N ~ 50Hz
Total power consumption
Electric motor
Pump motor
kW 0.75
kW 0.37
kW 0.10
Protection
Approx. weight
kg 60 60
Operation
Gas Train Rp1
Gas Train Rp1
1/4
Valves size / Gas connection 1” / Rp1
Valves size / Gas connection 1” / Rp1
Operating temperature °C
Storage Temperature °C
Working service**
* NOTE ON THE BURNER WORKING SERVICE
z Siemens LGB..: for safety reasons, one controlled shutdown must be performed every 24 hours of continuous operation.
z Siemens LME..: the control box automatically stops after 24h of continuous working. The control box immediately starts
up, automatically.
85 - 230 65 - 350
Natural gas - Light oil
9 - 24.3 7 - 37
(see Note 2)
840 kg/m
3
IP40
Progressive - Fully modulating
/ Rp1
1”
1/4
/ Rp1
1”
1/4
-10 ÷ +50
-20 ÷ +60
Intermittent
1/4
1/4
Note1:
Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC valves)
All gas flow rates are referred to Stm
calorific value H
Minimum gas pressure = see gas curves.
= 34.02 MJ/Stm3).
i
3
/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (net
7
Country and usefulness gas categories
C.I.B. UNIGAS - M039203CC
GAS
CATEGORY
I
2H
I
2E
I
2E( R ) B
I
2L
I
2ELL
I
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------------------------
Overall dimensions (mm)
COUNTRY
A B(*S) B(*L) C(*S) C(*L) D E F G H J K L M N P
HP20 555 173 258 728 813 510 320 830 126 151 178 290 360 M10 370 155
HP30 555 300 - 855 - 510 320 830 150 162 178 290 360 M10 490 155
*S = measure referred to burner fitted with standard blast tube
*L = measure referred to burner fitted with extended blast tube
8
C.I.B. UNIGAS - M039203CC
0
Performance Curves
HP20
8
7
6
5
4
3
2
1
BACK PRESSURE IN
0
40 60 80 100 120 140 160 180 200 220 240 260 28
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 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.
kW
HP30
8
7
6
5
4
3
2
1
0
40 80 120 160 200 240 280 320 360 400
kW
Pressure in the network - gas rate curves
HP20 MG. .. .25
15
10
5
GAS PRESSURE IN
THE NETWORK mbar
0
6 1014182226
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.
Gas rate Stm
HP30 MG. .. .25/32
25
20
15
10
5
0
6 10141822263034 38
3
/h
Rp 1 (25)
Rp 1¼ (32)
Gas rate Stm
3
/h
9
C.I.B. UNIGAS - M039203CC
MOUNTINGS AND CONNECTIONS
Packing
Burners are despatched in cardboard packages whose dimensions are: 1280mm x 850mm x 760mm (L x P x H)
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing case:
z burner with gas train detached;
z gasket to be inserted between the burner and the boiler;
z flexible oil pipes;
z oil filter;
z envelope containing this manual
To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of
H
P
L
materials
Handling the burner
ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these operations are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.
To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).
The unpacked burner must be lifted and moved only by means of a fork lift truck.
The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck: the forks must be inserted into the A
anb B ways. Remove the stirrup only once the burner is installed to the boiler.
A
B
Fitting the burner to the boiler
To install the burner into the boiler, proceed as follows:
1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”;
2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;
3 place the 4 stud bolts (5) on the hole of the boiler’s door, according to the burner’s drilling plate described on paragraph “Overall
dimensions”;
4 fasten the 4 stud bolts;
5 place the gasket on the burner flange;
6 install the burner into the boiler;
7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture.
8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate
insulating material (ceramic fibre cord or refractory cement).
Keys
1 Burner
2 Fixing nut
3Washer
4 Sealing gasket
5 Stud bolt
7Blast tube
The burner is designed to work positioned according to the picture below. For different installations, please contact the Technical
Department.
10
C.I.B. UNIGAS - M039203CC
SIDE UP
SIDE
DOWN
Gas train connections
The next diagrams show the components of the gas train included in the delivery and which must be fitted by the installer.The diagrams
are in compliance with the current laws.
ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE
MANUAL CUTOFF VALVES ARE CLOSED. READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING
OF THIS MANUAL.
Gas train with valves group MB-DLE with built-in gas pressure governor+ VPS504 gas proving system
MANUFACTURER
4
1
2
9
3
4
5
INSTALLER
78
Key
1 Burner
2 Butterfly valve
3 Gas proving system (option)
4 Maximum gas pressure switch (optional*)
5 Minimum gas pressure switch
6 Gas filter
7 Bellow joint
8 Manual cutoff valve
9 MB-DLE Valves group
* Note: the high gas pressure switch can be mounted either upstream the gas valve or downstream the gas valves but upstream the
butterfly gas valve.
11
Assembling the gas grain
”direction” arrows for installation
C.I.B. UNIGAS - M039203CC
gas supply network
1A
5
3
1E
1C
1B
4
Keys
1A..1E Gasket
2 Gas filter
3 Gas valves group
4 Bellow joint
21D
5 Manual valve
Fig. 4 - Example of gas train
To mount the gas train, proceed as follows:
1) in case of threaded joints: use proper seals according to the gas used;
2) fasten all the elements by means of screws, according to the schemes shown, observing the mounting directions for each element.
NOTE: the bellow joint, the manual cock and the gaskets are not part of the standard supply.
ATTENTION: once the gas train is mounted according to the diagram on Fig. 4, the gas proving test mus be performed,
according to the procedure set by the laws in force.
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 train used:
z threaded gas trains with Multibloc Dungs MB-DLE
MULTIBLOC DUNGS MB-DLE 405..412
Mounting
1. Mount flange onto tube lines: use appropriate sealing agent (see Fig. 7);
2. insert MB-DLE: note position of O rings (see Fig. 7);
3. tighten screws A, B, C and D (Fig. 5 - Fig. 6), accordind to the mounting positions (Fig. 8);
4. after installation, perform leakage and functional test;
5. disassembly in reverse order.
A
B
DC
Fig. 5 Fig. 6 Fig. 7 Fig. 8
MOUNTING POSITIONS
Once the train is installed, connect electrically all its elements: gas valves group, pressure switches, gas proving system.
ATTENTION: once the gas train is mounted according to the diagram on Fig. 4, the gas proving test mus be performed,
according to the procedure set by the laws in force.
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C.I.B. UNIGAS - M039203CC
Hydraulic diagrams for light oil supplying circuits
Fig. 9 - Gravity circuit
Fig. 10 - Ring circuit
Fig. 11 - Suction circuit
Key
1 Manual valve
2 Light oil filter
3 Light oil feeding pump
4 One way valve
5 Flexible hoses
6 Relief valve
NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n. 4 - Fig. 12).
13
Light oil piping installation diagram
From tank
To tank
C.I.B. UNIGAS - M039203CC
Fig. 12
Key
1 Burner
2 Flexible hoses (fitted)
3 Light oil filter (fitted)
4 Automatic interceptor (*)
5 One-way valve (*)
(*) Only for installations with gravity, siphon or forced circulation feed systems. If the device installed
is a solenoid valve, a timer must be installed to
delay the valve closing.
The direct connection of the device without a timer
may cause pump breaks.
6 Gate valve
7 Quick-closing gate-valve (not in vicinity of tank or boiler)
The pumps that are used can be installed both into single-pipe and double-pipe systems.
Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is driven to
the nozzle: a part comes out from the nozzle while the othe part goes back to the pump. In this system, the by-pass pulg, if provided,
must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer.
Double-pipe system: as for the single pipe system, a pipe that connects the tank to the pump’s inlet is used besides another pipe that
connects the pum’s return port to the tank, as well. The excess of oil goes back to the tank: this installation can be considered self-bleeding. If provided, the inside by-pass plug must be installed to avoid air and fuel passing through the pump.
Burners come out from the factory provided for double-stage systems. They can be suited for single-pipe system (recommended in the
case of gravity feed) as decribed before.To change from a 1-pipe system to a 2-pipe-system, insert the by-pass plug G (as for ccw-rotation- referring to the pump shaft).
Caution: Changing the direction of rotation, all connections on top and side are reversed.
Bleed
Bleeding in two-pipe operation is automatic : it is assured by a bleed flat on the piston. In one-pipe operation, the plug of a pressure
gauge port must be loosened until the air is evacuated from the system.
About the use of fuel pumps
z Make sure that the by-pass plug is not used in a single pipe installation, because the fuel unit will not function properly and damage
to the pump and burner motor could result.
z Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth,
thus obstructing them.
z After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of the
tank, thus avoiding the possibility that they might be sucked into the pump.
z On initial commissioning a "dry" operation is foreseen for a considerable length of time (for example, when there is a long suction
line to bleed). To avoid damages inject some lubrication oil into the vacuum inlet.
z Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the
joint, noise and overloading the gears.
z Pipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal junc-
tions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of junc-
tions should be kept to a minimum as they are a possible source of leakage.
z Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could depo-
sit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) jun-
ctions if possible.
z An external filter should always be installed in the suction line upstream of the fuel unit.
14
C.I.B. UNIGAS - M039203CC
Light oil pumps
Pump Suntec AL65
2
Viscosity range 2 ÷ 12 (cSt) mm
/s
Oil temperature 0 ÷ 60 °C
Inlet pressure 2 bar
Minimum inlet pressure - 0,45 barto avoid gasing
Maximum return pressure 2 bar
Rated speed 3600 rpm
Keys
1 inlet (suction) G1/4
2 return and internal by-pass plug G1/4
3 outlet to the nozzle G1/8
4 pressure gauge port G1/8
5 vacuum gauge port G1/8
6 pressure adjusting screw
Connecting the light oil flexible hoses
To connect the flexible light oil hoses to the pump, proceed as follows, according to the pump provided:
1 remove the closing nuts A and R on the inlet and return connections of the pump;
2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the inlet and return lines: see
the arrows marked on the pump that show the inlet and the return (see prevoius paragraph).
R A
Electrical connections
Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse the phase and
neutral connections. fit a differential thermal magnet switch adequate for connection to the mains.
ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be
sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the
“Electrical connections” section.
WARNING: The burner is provided with a jumper between terminals 6 and 7; in the event of connecting the high/low
flame thermostat remove this jumper before connecting the thermostat.
IMPORTANT: while connecting electric supply wires to burner’s teminal block be sure that ground wire should be
longer than phase and neutral ones.
WARNING: if the cable that connects the thermostats and the LME.. control box should be longer than 3 meters,
insert a sectioning relay following the attached electrical wiring diagram.
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 motor;
4 refit the panel cover
15
Fig. 13 Progressive burners
C.I.B. UNIGAS - M039203CC
Fig. 14Fully modulating burners
Probes connection by means of the 7-pins plug (Fig. 16) see Fig. 15 and the Electric wiring diagrams for connections.
Fig. 16 Probe connector:
Fig. 15 Probes connection
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C.I.B. UNIGAS - M039203CC
ADJUSTMENTS
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
in the flues as shown in the “Recommended combustion values” table and CO in the standard
2
limits). During this stage, the combustion head, the gas butterfly valve and the servocontrol are at the maximum opening. Refer to Fig.
17, showing the correct way to measure the gas pressure, considering the values of pressure in combustion chamber, surveyed by
means of the pressure gauge or taken from the boiler’s Technical specifications.
1
2
4
3
Fig. 17
Key
1 Generator
2 Pressure outlet on the combustion chamber
3 Gas pressure outlet on the butterfly valve
4 Differential pressure gauge
Measuring the gas pressure in the combustion head
In order to measure the pressure in the combustion head, insert the pressure gauge probes: one into the combustion chamber’s pressure outlet (Fig. 17-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the
burner (Fig. 17-3). On the basis of the measured differential pressure, it is possible to get the maximum flow rate: in the pressure - rate
3
curves (showed on the next paragraph), it is easy to find out the burner’s output in Stm
/h (quoted on the x axis) from the pressure
measured in the combustion head (quoted on the y axis). The data obtained must be considered when adjusting the gas flow rate.
NOTE: THE PRESSURE-RATE CURVES ARE GIVEN AS INFORMATION ONLY; FOR A PROPER SETTING OF THE GAS RATE,
PLEASE REFER TO THE GAS METER READING.
Pressure in combustion head - gas rate curves
HP20
9
8
7
6
5
4
3
2
1
GAS PRESSURE mbar
0
8 101214161820222426283032
Gas rate Stm
HP30
8
7
6
5
4
3
2
1
0
14 16 18 20 22 24 26 28 30 32 34 36 38
3
/h
Gas rate Stm
3
/h
17
C.I.B. UNIGAS - M039203CC
ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the
mains switch is closed.
.ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation
of carbon monoxide); if this should happen, make the gas decrease slowly until the normal combustion values are achieved.
WARNING: NEVER LOOSE THE SEALED SCREWS! OTHERWISE, THE DEVICE WARRANTY WILL BE IMMEDIATELY INVALIDATE!
Gas Filter
The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burners, counters and regulators) from becoming rapidly blocked. The filter is normally installed upstream from all the control and on-off devices.
VPS504 Gas proving system
The VPS504 check the operation of the seal of the gas shut off valves. This check is carried out as soon as the boiler thermostat gives
a start signal to the burner, creating, by means of the diaphragm
pump inside it, a pressure in the test space of 20 mbar higher than
the supply pressure.
When wishing to monitor the test, install a pressure gauge ranged to
that of the pressure supply point PA.
If the test cycle is satisfactory, after a few seconds the consent light
LC (yellow) comes on. In the opposite case the lockout light LB (red)
comes on.
To restart it is necessary to reset the appliance by pressing the illuminated pushbutton LB.
PA
LC
LB
Fig. 18
IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:
Recommended combustion parameters
Fuel
Recommended (%) CO
Recommended (%) O2
2
Natural gas 9 ÷ 10 3 ÷ 4.8
Light oil 11.5 ÷ 13 2.9 ÷ 4.9
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. see “Measuring the gas pressure in the combustion head” on page 17.
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.
Adjustment procedure for gas operation
1 Set GAS fuel by means of the burner CM switch (it is placed on the burner control panel - see page 26)
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 replacement of the coil.
Attention:
z Beger actuator: cams can be moved manually
z Siemens actuator: set the MAN/AUTO lever to MAN to move the cams, rememeber to set it to AUTO once the adjustment
is accomplished.
18
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