Unigas HR91A, HR92A, HR520A, HR525A, HR512A Manual Of Installation, Use And Maintenance

...

M039213CD Rel. 3.2 03/2015

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Gas / light oil dual fuel burners Progressive - Fully modulating

MANUAL OF INSTALLATION - USE - MAINTENANCE

HR91A - HR92A - HR93A

HR512A -HR515A

HR520A - HR525A

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 harmful

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

regulations in force; d make sure that control and safety devices are operating properly; e make sure that exhaust ducts intended to discharge the products of

combustion are operating properly; f on completion of setting and adjustment operations, make sure that

all mechanical locking devices of controls have been duly tightened; g make sure that a copy of the burner use and maintenance instruc-

tions is available in the boiler room. z In case of a burner shut-down, reser the control box by means of the

RESET pushbutton. If a second shut-down takes place, call the

Technical Service, without trying to RESET further. z The unit shall be operated and serviced by qualified personnel only,

in compliance with the regulations in force.

3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED

3a) ELECTRICAL CONNECTION

z For safety reasons the unit must be efficiently earthed and installed

as required by current safety regulations. z It is vital that all saftey requirements are met. In case of any doubt,

ask for an accurate inspection of electrics by qualified personnel,

since the manufacturer cannot be held liable for damages that may

be caused by failure to correctly earth the equipment. z Qualified personnel must inspect the system to make sure that it is

adequate to take the maximum power used by the equipment shown

on the equipment rating plate. In particular, make sure that the

system cable cross section is adequate for the power absorbed by

the unit. z No adaptors, multiple outlet sockets and/or extension cables are per-

mitted to connect the unit to the electric mains. z An omnipolar switch shall be provided for connection to mains, as

required by the current safety regulations. z The use of any power-operated component implies observance of a

few basic rules, for example:

- do not touch the unit with wet or damp parts of the body and/or with

bare feet;

- do not pull electric cables;

- do not leave the equipment exposed to weather (rain, sun, etc.)

unless expressly required to do so;

- do not allow children or inexperienced persons to use equipment;

z The unit input cable shall not be replaced by the user. In case of damage to the cable, switch off the unit and contact qualified personnel to replace. When the unit is out of use for some time the electric switch supplying all the power-driven components in the system (i.e. pumps, burner, etc.) should be switched off.

3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS

GENERAL

z The burner shall be installed by qualified personnel and in com-

pliance with regulations and provisions in force; wrong installation can cause injuries to people and animals, or damage to property, for which the manufacturer cannot be held liable.

z Before installation, it is recommended that all the fuel supply system

pipes be carefully cleaned inside, to remove foreign matter that might impair the burner operation.

z Before the burner is commissioned, qualified personnel should

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

2004/108/EC on electromagnetic compatibility

Harmonised standards :

-EN 55014-1Electromagnetic compatibility - Requirements for household appliances, electric tools and similar apparatus.

-UNI EN 676 (Gas Burners;

-CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements;

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

National standards :

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

Industrial burners

European directives:

- Directive 2009/142/EC - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC on electromagnetic compatibility

Harmonised standards :

-EN 55014-1Electromagnetic compatibility - Requirements for household appliances, electric tools and similar apparatus.

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

-UNI EN 746-2: Industrial thermoprocessing equipment

Burner data plate

For the following information, please refer to the data plate:

z burner type and burner model: must be

reported in any communication with the supplier

z burner ID (serial number): must be 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!

Failure to observe the warning may result in irreparable damage to the unit or damage to the environment

DANGER!

Failure to observe the warning may result in serious injuries or death.

WARNING!

Failure to observe the warning may result in electric shock with lethal consequences

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. --

PART I: SPECIFICATIONS

1.0 BURNERS FEATURES

Note: the figure is indicative only

Keys

1 Mimic panel with startup switch 2 Gas filter 4 Gas valve group 5 Cover 6 Flange 7 Blast tube-Combustion head group 8 Oil pressure governor 9 Actuator 10 Adjusting cams 11 Air intake 12 Air pressure switch 13 Oil manifold 14 Head adjusting ring nut 15 Pump

Gas operation: the gas coming from the supply line, passes through the valves group provided with filter and governor. This one forces the pressure in the utilisation limits. The actuators move proportionally the air damper and the gas butterfly valve, in order to achieve the optimisation of the gas flue values, as to get an efficient combustion.

Light oil operation:the fuel coming from the supply line, is pushed by the pump to the nozzle and then into the combustion chamber, where the mixture between fuel and air takes place and consequently the flame. In the burners, the mixture bertween fuel and air, to perform clean and efficient combustion, is activated by atomisation of oil into very small particles. This process is achieved making pressurised oil passing through the nozzle. The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pressure, pumps are provided with a pressure regulator (except for some models for which a separate regulating valve is provided). Other pumps are provided with two pressure regulators: one for the high and one for low pressure (in double-stage systems with one nozzle).

The adjustable combustion head can improve the burner performance. The combustion head determines the energetic quality and the geometry of the flame. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion chamber). The control panel, placed on the burner front side, shows each operating stage.

PART I: SPECIFICATIONS

1.1 Burner model identification

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

1.2 Technical Specifications

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

Type HR512A Model MG. MD. S. *. A. 1. 80.

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

1 BURNER TYPE HR91A, HR92A, HR93A, HR512A, HR515A, HR520A, HR525A 2 FUEL M - Natural gas

L - LPG G - Light oil

3 OPERATION (Available versions) PR - Progressive

MD - Fully modulating 4 BLAST TUBE S - Standard 5 DESTINATION COUNTRY * - see data plate 6 BURNER VERSION A - Standard

Y - SpecialeSpecial 7 EQUIPMENT 1 = 2 gas valves + gas proving system

8 = 2 gas valves + gas proving system + maximum gas pressure switch 8 GAS CONNECTION 50 = Rp2 65 = DN65

80 = DN80 100 = DN100

BURNER TYPE HR91A MG.. HR92A MG.. HR93A MG..

Output min. - max. kW

480 - 2670 480 - 3050 550 - 4100

Fuel

Natural gas - Light oil

Category

(

see next paragraph)

Gas rate-

Natural gas

min.- max. (Stm3/h)

51 - 283 51 - 323 58 - 434

Gas pressure mbar

(

see Note 2)

Light oil rate

min.-max. kg/h

40 - 225 40 - 257 46 - 345

Oil viscosity

cSt @ 40°C

2 - 7.4

Oil density

kg/m

840

Light oil train inlet pressure

bar max

Power supply

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

Total power consumption

5.6 7.1 9.1

Electric motor

45.57.5

Pump motor

1.1 1.1 1.1

Protection

IP40

Operation

Progressive - Fully modulating

Gas train 50

Valves size / Gas connection 50 / Rp 2

Gas train 65

Valves size / Gas connection 65 / DN65

Gas train 80

Valves size / Gas connection 80 / DN80

Gas train 100

Valves size / Gas connection 100 / DN100

Operating temperature °C

-10 ÷ +50

Storage Temperature °C

-20 ÷ +60

Working service (*) Intermitent

Note1:

All gas flow rates are referred to Stm

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

(net calorific value H

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

Note2: Maximum gas pressure = 500mbar (with Siemens VGD)

Minimum gas pressure = see gas curves.

PART I: SPECIFICATIONS

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

BURNER TYPE HR91A LG.. HR92A LG.. HR93A LG..

Output min. - max. kW

480 - 2670 480 - 3050 550 - 4100

Fuel

L.P.G. - Light oil

Category

3B/P

Gas rate- LPG

min.- max. (Stm3/h)

17.9 - 100 17.9 - 114 20 - 153

Gas pressure mbar

(

see Note 2)

Light oil rate

min.-max. kg/h

40 - 225 40 - 257 46 - 345

Oil viscosity

cSt @ 40°C

2 - 7.4

Oil density

kg/m

840

Light oil train inlet pressure

bar max

Power supply

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

Total power consumption

5.6 7.1 9.1

Electric motor

45.57.5

Pump motor

1.1 1.1 1.1

Protection

IP40

Operation

Progressive - Fully modulating

Gas train 50

Valves size / Gas connection 50 / Rp 2

Gas train 65

Valves size / Gas connection 65 / DN65

Gas train 80

Valves size / Gas connection 80 / DN80

Gas train 100

Valves size / Gas connection 100 / DN100

Operating temperature °C

-10 ÷ +50

Storage Temperature °C

-20 ÷ +60

Working service (*) Intermitent

BURNER TYPE HR512A MG.. HR515A MG.. HR520A MG..

HR525A...50

MG..

HR525A...xx

MG..

Output min. - max. kW

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

Fuel

Natural gas - Light oil

Category

(

see next paragraph)

Gas rate-

Natural gas

min.- max. (Stm3/h)

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

Gas pressure mbar

(

see Note 2)

Light oil rate

min.-max. kg/h

50 - 379 65 - 438 84 - 539 168 - 564 168 - 674

Oil viscosity

2 - 7.4 cSt @ 40°C

Oil density

kg/m

840

Light oil train inlet pressure

bar max

Power supply

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

Total power consumption

10.8 13 17 22 22

Electric motor

9.2 11 15 18.5 18.5

Pump motor

1.1 1.5 1.5 3 3

Protection

IP40

Operation

Progressive - Fully modulating

Gas train 50

Valves size / Gas connection

50 / Rp2

50 / Rp2 50 / Rp2 50 / Rp2

Gas train 65

Valves size / Gas connection

65 / DN65

65 / DN65 65 / DN65

- 65 / DN65

Gas train 80

Valves size / Gas connection

80 / DN80 80 / DN80 80 / DN80 - 80 / DN80

Gas train 100

Valves size / Gas connection

100 / DN100

100 / DN100 100 / DN100 - 100 / DN100

Operating temperature °C

-10 ÷ +50

Storage Temperature °C

-20 ÷ +60

Working service (*) Intermitent

Note1:

All gas flow rates are referred to Stm

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

(net calorific value H

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

Note2: Maximum gas pressure = 500mbar (with Siemens VGD)

Minimum gas pressure = see gas curves.

PART I: SPECIFICATIONS

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

1.3 Country and usefulness gas categories

1.4 Fuel

BURNER TYPE HR512A LG.. HR515A LG.. HR520A LG..

HR525A...50

LG..

HR525A...xx

LG..

Output min. - max. kW

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

Fuel

L.P.G. - Light oil

Category

3B/P

Gas rate- LPG

min.- max. (Stm3/h)

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

Gas pressure mbar

(

see Note 2)

Light oil rate

min.-max. kg/h

50 - 379 65 - 438 84 - 539 168 - 564 168 - 674

Oil viscosity

2 - 7.4 cSt @ 40°C

Oil density

kg/m

840

Light oil train inlet pressure

bar max

Power supply

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

Total power consumption

10.8 13 17 22 22

Electric motor

9.2 11 15 18.5 18.5

Pump motor

1.1 1.5 1.5 3 3

Protection

IP40

Operation

Progressive - Fully modulating

Gas train 50

Valves size / Gas connection

50 / Rp2

50 / Rp2 50 / Rp2 50 / Rp2

Gas train 65

Valves size / Gas connection

65 / DN65

65 / DN65 65 / DN65

- 65 / DN65

Gas train 80

Valves size / Gas connection

80 / DN80 80 / DN80 80 / DN80 - 80 / DN80

Gas train 100

Valves size / Gas connection

100 / DN100

100 / DN100 100 / DN100 - 100 / DN100

Operating temperature °C

-10 ÷ +50

Storage Temperature °C

-20 ÷ +60

Working service (*) Intermitent

Note1:

All gas flow rates are referred to Stm

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

(net calorific value H

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

Note2: Maximum gas pressure = 500mbar (with Siemens VGD)

Minimum gas pressure = see gas curves.

GAS

CATEGORY

COUNTRY

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

2E( R ) B

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

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

2ELL

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

2Er

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

ATTENTION! The burner must be used only with the fuel specifie d in the burner data plate .

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

PART I: SPECIFICATIONS

1.5 Overall dimensions (mm)

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

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

HR91A

50 1535 242 831 327 35 300 550 100 490 441 1045 421 1160 725 435 265 295 228 450 360 523 M12 424 280 310 300 532 148 384 624 190 708 228 185 65 1535 242 831 327 35 300 564 117 490 441 1045 421 1406 971 435 265 295 228 447 360 523 M12 424 280 310 300 632 148 484 846 292 708 228 185 80 1535 242 831 327 35 300 579 132 490 441 1045 421 1437 1002 435 265 295 228 447 360 523 M12 424 280 310 300 683 148 535 875 313 708 228 185

100 1535 242 831 327 35 300 592 145 490 441 1045 421 1520 1085 435 265 295 228 447 360 523 M12 424 280 310 300 790 148 642 942 353 708 228 185

HR92A

50 1535 242 831 327 35 300 550 100 490 441 1045 421 1160 725 435 269 299 228 450 360 523 M12 424 280 310 300 532 148 384 624 190 708 228 185 65 1535 242 831 327 35 300 564 117 490 441 1045 421 1406 971 435 269 299 228 447 360 523 M12 424 280 310 300 632 148 484 846 292 708 228 185 80 1535 242 831 327 35 300 579 132 490 441 1045 421 1437 1002 435 269 299 228 447 360 523 M12 424 280 310 300 683 148 535 875 313 708 228 185

100 1535 242 831 327 35 300 592 145 490 441 1045 421 1520 1085 435 269 299 228 447 360 523 M12 424 280 310 300 790 148 642 942 353 708 228 185

HR93A

50 1540 242 835 327 35 300 550 100 495 460 1045 421 1160 725 435 304 344 228 450 360 523 M12 424 280 310 300 532 148 384 624 190 708 228 185 65 1540 242 835 327 35 300 564 117 495 460 1045 421 1406 971 435 304 344 228 447 360 523 M12 424 280 310 300 632 148 484 846 292 708 228 185 80 1540 242 835 327 35 300 579 132 495 460 1045 421 1437 1002 435 304 344 228 447 360 523 M12 424 280 310 300 683 148 535 875 313 708 228 185

100 1540 242 835 327 35 300 592 145 495 460 1045 421 1520 1085 435 304 344 228 447 360 523 M12 424 280 310 300 790 148 642 942 353 708 228 185

O max

O min

Boiler recommended drilling tem-

plate

Burner flange

PART I: SPECIFICATIONS

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

DN* A AA AB AC AD AE 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

HR512A

50 1723 320 924 364 35 326 595 100 530 517 1193 446 1590 946 644 340 380 494 540 560 M14 552 390 390 763 149 614 845 190 830 307 270 65 1723 320 924 364 35 326 611 117 530 517 1193 446 1613 969 644 340 380 494 540 560 M14 552 390 390 636 149 487 845 292 830 307 270 80 1723 320 924 364 35 326 626 132 530 517 1193 446 1646 1002 644 340 380 494 540 560 M14 552 390 390 687 149 538 875 310 830 307 270

100 1723 320 924 364 35 326 639 145 530 517 1193 446 1726 1082 644 340 380 494 540 560 M14 552 390 390 791 149 642 942 353 830 307 270

HR515A

50 1723 320 928 371 35 333 595 100 530 517 1193 446 1590 946 644 380 420 494 540 560 M14 552 390 390 763 149 614 845 190 830 310 270 65 1723 320 928 371 35 333 611 117 530 517 1193 446 1613 969 644 380 420 494 540 560 M14 552 390 390 636 149 487 845 292 830 310 270 80 1723 320 928 371 35 333 626 132 530 517 1193 446 1646 1002 644 380 420 494 540 560 M14 552 390 390 687 149 538 875 310 830 310 270

100 1723 320 928 371 35 333 639 145 530 517 1193 446 1726 1082 644 380 420 494 540 560 M14 552 390 390 791 149 642 942 353 830 310 270

HR520A

50 1723 320 928 371 35 333 595 100 530 517 1193 446 1590 946 644 400 440 494 540 560 M14 552 390 390 763 149 614 845 190 830 328 270 65 1723 320 928 371 35 333 611 117 530 517 1193 446 1613 969 644 400 440 494 540 560 M14 552 390 390 636 149 487 845 292 830 328 270 80 1723 320 928 371 35 333 626 132 530 517 1193 446 1646 1002 644 400 440 494 540 560 M14 552 390 390 687 149 538 875 310 830 328 270

100 1723 320 928 371 35 333 639 145 530 517 1193 446 1726 1082 644 400 440 494 540 560 M14 552 390 390 791 149 642 942 353 830 328 270

HR525A

50 1723 205 884 580 35 350 595 100 530 650 1193 570 1590 946 644 434 484 494 540 604 M14 552 390 390 763 149 614 845 190 874 328 270 65 1723 205 884 580 35 350 611 117 530 650 1193 570 1613 969 644 434 484 494 540 604 M14 552 390 390 636 149 487 845 292 874 328 270 80 1723 205 884 580 35 350 626 132 530 650 1193 570 1646 1002 644 434 484 494 540 604 M14 552 390 390 687 149 538 875 310 874 328 270

100 1723 205 884 580 35 350 639 145 530 650 1193 570 1726 1082 644 434 484 494 540 604 M14 552 390 390 791 149 642 942 353 874 328 270

E F

Boiler recommended drilling tem-

Burner flange

PART I: SPECIFICATIONS

HR91A - HR92A - HR93A

Fig. 4 - 3I2MG-09 v1 Hydraulic diagram

PSPSH PSL

oil inlet

oil outlet

gas inlet

combustion air

BY BURNER CONSTRUCTOR

BY OTHERS

According to the gas train size and the burner type, MB-DLE safety valves are supplied. In this case, the item 42 is integrated in the valves. See the following drawing.

LEGEND

POS OIL TRAIN

1 Filter 2 Flexible hose 3 Pump and pressure governor 4 Electrical motor 5 Flexible hose 6 Solenoid valve

6.1 Solenoid valve 7 Flexible hose

10 Oil distributor 11 Flexible hose 12 Pressure gauge 13 Pressure governor 15 Pressure switch 16 One-way valve

16.1 One-way valve 17 Flexible hose 18 Flexible hose 19 Manual valve 20 Pressure gauge

MAIN GAS TRAIN

23 Pressure switch - PGMIN 24 Safety valve with built in gas governor 25 Proving system pressure switch - PGCP 26 Pressure switch - PGMAX 40 Manual valve 41 Bellows unit 42 Filter 43 Pressure switch - PGMIN 44 Safety valve with built in gas governor 45 Proving system pressure switch - PGCP 46 Pressure switch - PGMAX 47 Butterfly valve

COMBUSTION AIR TRAIN

50 Air damper

51 Actuator

52 Pressure switch - PA 53 Draught fan with electromotor 54 Burner

Note: The following POS are optional: 19, 20, 26, 40, 41, 46 Note: The following POS are included only on certain types of burner: 5,7,11,17

PART I: SPECIFICATIONS

HR512A - HR515A - HR520A - HR525A

Fig. 5 - 3I2MG-24 v0 Hydraulic diagram

PSH

PSL

19.1

VGD

454

346

oil inlet

oil outlet

gas inlet

combustion air

BY BURNER CONSTRUCTOR

BY OTHERS

3I2MG24

rev.0

LEGEND

POS OIL TRAIN

1 Filter 2 Flexible hose 3 Pump and pressure governor 4 Electrical motor 5 Flexible hose 6 Solenoid valve 7 Flexible hose 8 3-way solenoid valve

9 Flexible hose 10 Oil distributor 11 Flexible hose 12 Pressure gauge 13 Pressure governor 15 Pressure switch 16 One-way valve 17 Flexible hose 18 Flexible hose 19 Manual valve

19.1 Manual valve 20 Pressure gauge

MAIN GAS TRAIN

40 Manual valve 41 Bellows unit 42 Filter 43 Pressure switch - PGMIN 44 Safety valve with built in gas governor 45 Proving system pressure switch - PGCP 46 Pressure switch - PGMAX 47 Butterfly valve

COMBUSTION AIR TRAIN

50 Air damper 51 Actuator 52 Pressure switch - PA 53 Draught fan with electromotor 54 Burner

Note: The following POS are optional: 19, 19.1, 20, 40, 41, 46 Note: The following POS are included only on certain types of burner: 5,7,9,11,17

PART I: SPECIFICATIONS

1.6 How to read 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 ID plate or in the

user’s manual). Example: Furnace input: 600kW Backpressure: 4mbar In the “Performance curve” diagram, draw a vertical line matching the

furnace input value and an horizontal line matching the backpressure value. The burner is suitable if the intersection point A is inside the performance curve. Data are referred to standard conditions: atmospheric pressure at

1013mbar, ambient temperature at 15°C.

1.7 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.

Campo di lavoro bruciatori

Tipo P60 Mod. M-x x.x.IT.A.0.50 - M-.xx.x.IT.A.0.6 5

-1

100 200 300 400 500 600 700 800 900

Pote nza k W

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" (5 0)

DN65

Power kW

minimum gas pressure in

the network mbar

PART I: SPECIFICATIONS

1.8 Performance Curves

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.

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

HR91A

HR92A

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

HR93A

HR512A

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

HR515A

HR520A

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

HR525A Rp2

HR525A DN65-80-100

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

PART I: SPECIFICATIONS

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

GAS PRESSURE mbar

HR91A MG..

Stm

HR92A MG..

Stm3/h

GAS PRESSURE mbar

HR93A MG..

Stm

HR512A MG..

Stm3/h

GAS PRESSURE mbar

HR515A MG..

Stm

HR520A MG..

Stm3/h

GAS PRESSURE mbar

HR525A MG.. Rp2

Stm

HR525A MG.. DN65-80-100

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 include d). 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.

PART I: SPECIFICATIONS

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

GAS PRESSURE mbar

HR91A LG..

Stm

GAS PRESSURE mbar

HR93A LG..

Stm

GAS PRESSURE mbar

HR512A LG..

Stm

GAS PRESSURE mbar

HR520A LG..

Stm

PART I: SPECIFICATIONS

1.11 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 O

in the flues as shown in the “Recommended combustion values” table and CO in the standard limits). During this stage, the combustion head, the gas butterfly valve and the actuator are at the maximum opening. Refer to Fig. 6, 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.

Fig. 6

Note: the figure is indicative only.

Key

1 Generator 2 Pressure outlet on the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge

1.12 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

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

combustion head (quoted on the y axis). The data obtained must be considered when adjusting the gas flow rate.

ATTENTION: THE BURNED GAS RATE MUST BE READ AT THE GAS FLOW METER. WHEN IT IS NOT POSSIBLE, THE USER CAN REFERS TO THE PRESSURE-RATE CURVES AS GENERAL INFORMATION ONLY.

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Unigas HR91A, HR92A, HR520A, HR525A, HR512A Manual Of Installation, Use And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual