Unigas HP60, HP72, HP73A, HP65 Manual Of Installation - Use - Maintenance

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Progressive

and fully-modulating

gas - light oil burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

HP60 - HP65

HP72 - HP73A

M03957CI Rel. 8.2 02/2010

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 caution w

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

ith 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.

2

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 elec

Gas - Light oil burners

Gas - Heavy oil burners

tromagnetic compatibility

Heavy oil burners

3

C.I.B. UNIGAS - M03957CI

PART I: INSTALLATION

9

5

7

6

4

3

2

1

8

10

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.

Fig. 1

1 Mimic panel with startup switch
2 Gas proving system
3 Gas valve group
4 Burner flange
5 Blast tube-Combustion head ass.y
6 Cover
7 Light oil pump
8 Pump motor
9 Gas adjusting cam
10 Actuator

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 (10) moves proportionally the air damper and the gas butterfly valve It drives an
adjusting cam (13) 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 (8) 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 (8) 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 (5) 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 (1), 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. 2), draw a vertical line matching the furnace input value and an horizontal line matching the

backpressure value. The burner is suitable if the intersection point A is inside the performance curve.

4

C.I.B. UNIGAS - M03957CI

()

0

5

10

15

20

25

100 200 300 400 500 600 700 800 900

Potenza / Output (kW)

Minima pressione gas in

rete / Minimum inlet gas

pressure (mbar)

Rp 2" (50)

DN65

Camp o di lav o ro bruciat o ri

Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.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. 2

Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C

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

gas. Draw a vertical line matching the furnace input value (600kW, in the example),

gas value, calculated before.

Fig. 3

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.

z 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-

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

Key

a) Heat output in kW
b) Lenght of the flame tube in meters

c) Flame tube firing intensity in MW/m

3

d) Combustion chamber diameter (m)

Fig. 4 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.

Fig. 4

sized

5

C.I.B. UNIGAS - M03957CI

Burner model identification

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

Type HP60 Model MG. PR. S. *. A. 1. 50
(1) (2) (3) (4) (5) (6) (7) (8)
(1) BURNER TYPE HP60
(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

Y - Speciale

(7) EQUIPMENT 0 = 2 gas valves

1 = 2 gas valves + gas proving system
7 = 2 gas valves + maximum gas pressure switch
8 = 2 gas valves + gas proving system + maximum gas pressure switch

(8) GAS CONNECTION
see Specifications

40 = Rp1

50 = Rp2

1/2

65 = DN65 80 = DN80

Specifications

BURNER TYPE HP60...0.40 HP60...0.50 HP60...0.65

Output min. - max. kW
Fuel
Gas category (see next paragraph)
Gas rate
Gas pressure
Oil train inlet pressure
Light oil rate

min. - max. (Stm

min. - max. mbar

max. bar

min. - max.kg/h 14 - 44 14 - 74 14 - 74

3

/h)

Oil viscosity 2 - 7.4 cSt @ 40°C
Oil density 840 kg/m3
Power supply 230V 3~ / 400V 3N ~ 50Hz
Total power consumption
Fan motor
Pump motor

kW 2.15
kW 1.1
kW 0.55

Protection
Approx. weight

kg 65 70 80

Operation
Gas Train

Valves size / Gas connection

Operating temperature °C
Storage Temperature °C
Working service*

170 - 523 170 - 880 170 - 880

Natural gas - Light oil

18 - 55 18 - 93 18 - 93

(see Note 2)

1

IP40

Progressive - Fully modulating

40 50 65

/ Rp1

1”

1/2

1/2

2” / Rp2

-10 ÷ +50

-20 ÷ +60

Intermittent

2”

/ DN65

1/2

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

Country and usefulness gas categories

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------------------------

COUNTRY

6

C.I.B. UNIGAS - M03957CI

BURNER TYPE HP65...0.50 HP65...0.65

Output min. - max. kW

Fuel

270 - 970

Nat. gas - Light oil

Gas category (see next paragraph)

Gas rate

Gas pressure

Oil train inlet pressure

Light oil rate

min. - max. kW (Stm3/h)

min. - max. mbar

max. bar

min.- max.kg/h 23 - 82

29 - 103

(see Note 2)

1

Oil viscosity 2 - 7.4 cSt @40°C

Oil density 840 kg/m3

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

Total power consumption

Fa motor

Pump motor

Protection

Approx. weight

Operation

Gas Train

Valves size / Gas connection

Operating temperature °C

Storage Temperature °C

Working service*

kW 2.6

kW 1.5

kW 0.55

IP40

kg 105 115

Progressive - Fully modulating

50 65

2” / Rp2

2”

1/2

-10 ÷ +50

-20 ÷ +60

Intermittent

/ DN65

BURNER TYPE HP72...0.50 HP72...0.65 HP72...0.80

Output min. - max. kW

Fuel

330 - 1200

Nat. gas - Light oil

Gas category (see next paragraph)

Gas rate

Gas pressure

Oil train inlet pressure

Light oil rate

3

min.- max. (Stm

/h)

min. - max. mbar (see Note 2)

max. bar

min.- max. kg/h 28 - 101

35 - 127

1

Oil viscosity 2 - 7.4 cSt @40°C

Oil density 0.84 kg/m3

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

Total power consumption

Fan motor

Pump motor

Protection

Approx. weight

Operation

Gas Train

Valves size / Gas connection

Operating temperature °C

Storage Temperature °C

Working service*

kW 3.25

kW 2.2

kW 0.55

IP40

kg 110 120 130

Progressive - Fully modulating

50 65 80

/ DN65

2” / Rp2

2”

1/2

-10 ÷ +50

-20 ÷ +60

Intermittent

3” / DN80

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

7

C.I.B. UNIGAS - M03957CI

BURNER TYPE HP72...1.50 HP72...1.65 HP72...1.80

Output min. - max. kW
Fuel

330 - 1550

Nat. gas - Light oil

Gas category (see next paragraph)
Gas rate
Gas pressure
Oil train inlet pressure
Light oil rate

min. - max. (Stm

3

/h)

min.- max. mbar (see Note 2)

max. bar

min.- max. kg/h 28 - 131

35 - 164

1

Oil viscosity 2 - 7.4 cSt @40°C
Oil density 840 kg/m3
Power supply 230V 3~ / 400V 3N ~ 50Hz
Total power consumption
Fan motor
Pump motor
Protection
Approx. weight
Operation
Gas Train

Valves size / Gas connection

Operating temperature °C
Storage Temperature °C
Working service*

kW 3.25
kW 2.2
kW 0.55

IP40

kg 110 120 130

Progressive - Fully modulating

50 65 80

/ DN65

2” / Rp2

2”

1/2

-10 ÷ +50

-20 ÷ +60

Intermittent

3” / DN80

BURNER TYPE

HP73A

MG..x.50

HP73A

MG..x.65

HP73A

MG..x.80

Output min. - max. kW 320 - 2300
Fuel Nat. gas - Light oil

Gas category

Gas rate
Gas pressure
Oil train inlet pressure
Light oil rate

min.- max. (Stm

3

/h)

34 - 243 34 - 243 34 - 243

min.- max. mbar (see Note 2)

max. bar

min.-max. kg/h

27 - 194 27 - 194 27 - 194

(see next paragraph)

1

Oil viscosity 2 - 7.4 cSt @40°C
Oil density 840 kg/m3

Power supply
Total power consumption
Fan motor
Pump motor
Index of Protection
Approx. weight

kW 4.05
kW 3
kW 0.55

kg 115 125 135

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

IP40

Operation Progressive - Fully modulating

Gas train 50 65 80

2”

Valves size/Gas connection 2” / Rp2

1/2

/ DN65

3” / DN80

Storage Temperature °C -10 ÷ +50
Working service* °C -20 ÷ +60
Operating temperature

Intermttent

Note1:

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

All gas flow rates are referred to Stm
calorific value H

= 500mbar (with Dungs MBC and Siemens VGD gas valves).

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

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

8

Overall dimensions (mm)

Boiler recommended drilling template

9

C.I.B. UNIGAS - M03957CI

DNAAABBBCCCD E F G H J K L M NO - minO - maxP Q R S U V W Y Z

HP60 MG..0.40 40 1119 99 383 314 736 362 930 500 430 240 280 210 240 344 M10 269 190 190 190 445 112 327 444 x 464 162 120

HP60 MG.. 0.50 50 1119 99 383 314 736 362 930 500 430 240 280 210 240 344 M10 269 190 190 190 445 112 335 444 x 464 162 120

HP60 MG.. 0.65 65 1119 99 383 314 736 362 1115 685 430 240 280 250 240 420 M10 269 190 190 190 845 112 403 540 313 540 162 120

HP65 MG.. 0.50 50 1156 139 362 347 794 382 1022 568 454 240 280 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 162 155

HP65 MG..1.50 50 1156 139 362 347 794 382 1148 694 454 240 280 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 162 155

HP65 MG..0.65 65 1156 139 362 347 794 382 1120 666 454 240 280 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 162 155

HP65 MG..1.65 65 1156 139 362 347 794 382 1226 772 454 240 280 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 162 155

HP72 MG.. 0.50 50 1299 139 505 373 794 382 1022 568 454 300 340 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 155

HP72 MG..1.50 50 1299 139 505 373 794 382 1148 694 454 300 340 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 155

HP72 MG..0.65 65 1299 139 505 373 794 382 1120 666 454 300 340 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 155

HP72 MG..1.65 65 1299 139 505 373 794 382 1226 772 454 300 340 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 155

HP72 MG.. 0.80 80 1299 139 505 373 794 382 1120 666 454 300 340 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 155

HP72 MG..1.80 80 1299 139 505 373 794 382 1228 774 454 300 340 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 155

HP72 MG..0.100 100 1299 139 505 373 794 382 1395 941 454 300 340 434 300 579 M10 330 216 250 233 653 130 523 824 405 734 198 155

HP72 MG..1.100 100 1299 139 505 373 794 382 1503 1049 454 300 340 434 300 579 M10 330 216 250 233 653 130 523 824 405 734 198 155

HP73A MG..1.50 50 1294 139 500 373 794 382 1148 694 454 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 155

HP73A MG..1.65 65 1294 139 500 373 794 382 1226 772 454 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 155

10

HP73A MG..1.80 80 1294 139 500 373 794 382 1228 774 454 234 264 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 155

HP73A MG..1.100 100 1294 139 500 373 794 382 1503 1049 454 234 264 434 300 579 M10 330 216 250 233 653 130 523 824 405 734 198 155

C.I.B. UNIGAS - M03957CI

*DN = gas valves size

HP60 - HP72:

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

Performance Curves

-2

-1

0

1

2

3

4

5

6

7

8

100 200 300 400 500 600

-2

-1

0

1

2

3

4

5

6

7

8

100 200 300 400 500 60 0 700 800 900

0

1

2

3

4

5

6

7

8

9

200 300 400 500 600 700 800 900 1000

-2

0

2

4

6

8

10

12

14

0 200 400 600 800 1000 1200 1400

-2

0

2

4

6

8

10

12

200 400 600 800 1000 1200 1400 1600 1800

0

2

4

6

8

10

12

0 500 1000 1500 2000 2500

HP60 MG.xx.x.xx.A.0.40

BACK PRESSURE IN

C.I.B. UNIGAS - M03957CI

HP60 MG....50/65

COMBUSTION CHAMBER mbar

HP65 MG....50/65

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

HP72 MG.....1...

kW

HP72 MG.....0...

kW

HP73A ..1...

kW

kW

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 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

kW

11

Pressure in the network - gas rate curves

0

5

10

15

20

25

10 20 30 40 50 60 70 80 90

DN50

DN65

DN40

0

5

10

15

20

25

30

20 30 40 50 60 70 80 90 100 110 120

DN50

DN65

Rp2(50)

0

10

20

30

40

20 40 60 80 100 120 140

DN50

DN65

DN80

0

10

20

30

40

50

60

70

20 40 60 80 100 120 140 160 180

Rp 2" (50)

DN65

DN80

0

25

50

75

100

125

0 50 100 150 200 250

Rp 2" (50)

HP60

GAS PRESSURE IN

THE NETWORK mbar

Gas rate Stm

HP72...0.xx

C.I.B. UNIGAS - M03957CI

HP65

3

/h

HP72...1.xx

Gas rate Stm3/h

GAS PRESSURE IN

THE NETWORK mbar

HP73A

GAS PRESSURE IN

THE NETWORK mbar

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 Stm3/h

DN65

DN80

Gas rate Stm3/h

Gas rate Stm

3

/h

12

C.I.B. UNIGAS - M03957CI

H

PL

A

B

Keys

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

SIDE UP

SIDE DOWN

MOUNTINGS AND CONNECTIONS

Packing

Burners are despatched in cardboard packages and whose dimensions: 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 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.

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’s drilling template 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).

The burner is designed to work positioned according to the picture below. For different installations, please contact the Technical
Department.

13

C.I.B. UNIGAS - M03957CI

1

2

3

4

5

78

9

4

MANUFACTURER

INSTALLER

1

2

54

6

78

10

4

MANUFACTURER

INSTALLER

1

2

3

4

5

78

18

4

MANUFACTURER

INSTALLER

1

2

3

4

78

5

6

19

4

MANUFACTURER

INSTALLER

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 - 1 Gas train with valves group MB-DLE with built-in gas pressure governor + VPS504 gas proving system

Gas train - 2

Gas train - 3

Gas train - 4 Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor) + VPS504 gas proving

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

Gas train with valves group MBC 1200SE (2 valves + gas filter + pressure governor) + VPS504 gas proving system

system

Key

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

8 Manual cutoff valve
9 MB-DLE Valves group
10 VGD Valves group
18 MBC Valves group (2” with filter provided)

19 MBC Valves group (DN65/80/100)
6 Gas filter
7 Bellow joint

*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.

14

C.I.B. UNIGAS - M03957CI

1A

5

1B

4

1C

21D

1E

3

”direction” arrows for installation

gas supply network

Keys

1A..1E Gasket
2 Gas filter
3 Gas valves group
4 Bellow joint
5 Manual cock

A

B

C

D

C

B

D

A

MOUNTING POSITIONS

Assembling the gas grain

Fig. 5 - Example of gas train

To mount the gas train, proceed as follows:
1-a) in case of threaded joints: use proper seals according to the gas used;
1-b) in case of flanged joints: place a gasket (no. 1A..1E - Fig. 5) between the elements

NOTE: the bellow joint, the manual valve and the gaskets are not part of the standard supply.

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

according to the procedure set by the laws in force.

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, MBC..SE 700 or Siemens VGD20..
z flanged gas trains with Multibloc Dungs MBC..SE 1900-3100-5000 or Siemens VGD40..

MULTIBLOC DUNGS MB-DLE 415..420

Mounting

1. Loosen screws A and B do not unscrew (Fig. 6 - Fig. 7).

2. unscrew screws C and D (Fig. 6 - Fig. 7).

3. Remove MultiBloc between the threaded flanges (Fig. 7).

4. After mounting, perform leakage and functional tests.

Fig. 6 Fig. 7 Fig. 8 Fig. 9

15

C.I.B. UNIGAS - M03957CI

MOUNTING

POSITIONS

OPTION

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





S

%U

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

S

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

S

%U



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

S

%U

PLQ['1

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£

Ó

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#

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Fig. 10

Mounting positions OPTION

10 = pulse lines

njo/!6!y!EO

EO

2

22

21

"

#
#

"

#
#

"

"

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

Mounting

1. Mount flange onto tube lines. Use appropriate sealing agent (see Fig. 10)

2. Insert MBC...SE. Note position of O rings (see Fig. 11).

3. Tighten screws A – H

4. After installation, perform leakage and functional test.

5. Disassembly in reverse order

MULTIBLOCDUNGS MBC1900-3100-5000SE (Flanged valves group)

Mounting

1. Insert setscrews A

2. Insert seals

3. Insert setscrews B

4. Tighten setscrews A + B.
Ensure correct seating of the seal!

6. After installation, perform leakage and functional test.

7. Disassembly in reverse order.

Fig. 11

Fig. 12

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

Mounting

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

z

Connect the reference gas pipe (TP in figure), 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. 15).

16

C.I.B. UNIGAS - M03957CI

BS

BS

SKP1. SKP2.

BS

BS

SA

TP

D

7631z05/0101



1

2

2

1

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

SIEMENS VGD..MOUNTING
POSITIONS

Fig. 16

Fig. 13

Fig. 14 Fig. 15

Pressure adjusting range

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

DUNGS MBC..SE Siemens SKP actuator

Keys

1 spring
2 cap

DUNGS MBC valves:

Performance range

Spring colour - red black green

Siemens VGD valves with SKP actuator

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

Spring colour neutral yellow red

Once the train is installed, connect electrically all its elements: gas valves group, pressure switches, gas proving system.

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

according to the procedure set by the laws in force.

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

:

17

C.I.B. UNIGAS - M03957CI

Hydraulic diagrams for light oil supplying circuits

Fig. 17 - Gravity circuit

Fig. 18 - Ring circuit

Fig. 19 - 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. 20).

18