Unigas HS5, HS10, HS18 Installation & Operation Manual
Documentazione Tecnica
CIB Unigas
- Campodarsego (PD)
Complying with
90 / 396 / CEE
GAS DIRECTIVE
MANUAL OF
- INSTALLATION
- OPERATION
- MAINTENANCE
DUAL FUEL BURNERS
L.P.G. - LIGHT OIL
HS5
HS10
HS18
M039131AA Rev. 0 07/04
NOTICES2
NOTICES
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 knowle-
dge in the field of components for civil or industrial heating
systems, sani tary hot water generation and particularly service centres authorised by the manufacturer.
z Improper installation may cause injury to people and ani-
mals, or damage to property, for which the manufacturer
cannot be held liable.
z Remove all packaging material and inspect the equipment
for integrity.
In case of any doubt, do not use the unit - cont act 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 har mful.
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 qualifi ed personnel only.
Units shall be repaired exclusively by a servicing centre, duly
authorised by the ma nufacturer, with original spare parts.
Failure to comply wit h 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 dan-
ger shall be made harmless.
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 m odified or hav e options fit -
ted 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, therefore, 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, wi th ven-
tilation openings complying with the requirements of the
regulations in force, and sufficient for good combustio n.
z Only burners designed according to the regulati ons 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 t he 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 qual if ied personnel perf orm the following ope ra-
tions:
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 combustion 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 combust ion are operating pro perl y;
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
instructions is available in the boi ler room.
z In case of repeated burner shut-downs, do not continue re-
setting the unit manually. Contact qualified personnel to
take care of such defects.
z The unit shall be operated and serviced by qualified per-
sonnel only, in compliance with the regulat ions in force.
NOTICES 3
3) GENERAL INSTRUCTIONS DEPENDING ON FUEL
USED
3a) ELECTRICAL CONNECTION
z For safety reasons the unit must be efficiently earthed and
installed as requi red by current safety regul ations.
z It is vital that all saf tey requi rem ents 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 ratin g plate. In particular, make sure that the system cable cross section is adequate for the power absorbe d by the uni t.
z No adaptors, multiple outlet sockets and/or extension
cables are permitted 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 obser-
vance 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 requir ed to do so;
◆ do not allow children or inexperienced persons to use
equipment;
z The unit input cable shal l 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, et c.) 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
compliance 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 l iable.
z Before installation, it is recommended that all the fuel sup-
ply 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 seal ing;
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 suppl ied for
the designed 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 devi-
ces 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 regula-
tions, and in any case are sufficient for proper combustion.
z Do not use gas pipes t o earth electrical equi pm ent.
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 likel y 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 dangero us conditions
such as the development of toxic or explosive mixtures.
4
SPECIFICATIONS
Note: all gas flow rates (Stm
3
/h) are referred to standard gas conditions: 1013 mbar pressure, 15 °C temperature.
Flow rates are referred to G20 natural gas (nett calor ifi c value: 34.0 2 MJ/Stm
3
), if G25 is used (n.c.v .: 29.25 MJ/Stm3), flow rates
must be multiplied by 1.16 factor.
* Minimum pressure to get the maximum rate with any value of back pressure in combustion chamber. The bur ner operates cor-
rectly also with lower pressures but these must guarantee the needed rate.
BURNER MODEL IDENTIFICATION
Burners are identified by burner type and model. Burner model identification is described here following.
Type: HS5 Model: LG. PR. S. *. A. 0. 40
(1) (2) (3) (4) (5) (6) (7) (8)
(1) BURNER TYPE
(2) FUEL LG - L.P.G. / Light oil
(3) OPERATION Available versions TN - Single stage
(4) BLAST TUBE LENGHT (see overall dimensions)
Available versions S - Standard
L - Long
(5) DESTINATION COUNTRY * - see data plate
(6) SPECIAL VERSIONS A - Standard
(7) EQUIPMENT Available versions 0 - 2 Valves
1 - 2 Valves + leak detection monitor (on request if output < 1200 kW)
(8) GAS TRAIN SIZE (see specifications)
15= Rp1/2 20=Rp3/4 25= Rp1
BURNER MODEL HS5 HS10 HS18
Output min. kW 35 65 80
max. kW 70 140 200
Fuel
L.P.G.
Light oil
L.P.G.
Light oil
L.P.G.
Light oil
Category
I
3+
I
3+
I
3+
Gas rate min - max
Stm
3
/h
1.3 - 2.7 2.5 - 5.4 3 - 8
Light oil rate min - max Kg/h 3 - 6 5.5 - 12 7 - 17
Gas pressure min.* - max. mbar 20 - 200 20 - 200 20 - 200
Power supply - frequency 230 V - 50 Hz 230 V - 50 Hz 230 V - 50 Hz
Fan motor kW 0.1 0.15 0.15
Pump motor kW 0.1 0.1 0.1
Total power consumption kW 0.25 0.25 0.25
Protection IP40 IP40 IP40
Weight Kg 20 27 27
Valv es size 1/2” 3/4” 1”
Gas connection Rp1/2 Rp3/4 Rp1
Operation single stage single stage single stage
Destination country * * *
PART I: INSTALLATION MANUAL
5
OVERALL DIMENSIONS
Fig. 1
PERFORMANCE CURVES
ABBLCCLDEGKHPminPmaxM
HS5
320 60 160 380 480 400 230 80 19 90 92 134 M8
HS10
350 160 255 510 605 430 255 108 210 115 105 134 M8
HS18
350 175 265 525 615 430 255 125 210 135 105 134 M8
BACK PRESSURE IN
CONBUSTION CHAMBER mbar
HS5
kW
HS10
kW
Fig. 2a Fig. 2b
BACK PRESSURE IN
CONBUSTION CHAMBER mbar
HS18
kW
Fig. 3a
Dima di foratura
piastra calda ia
0
0,5
1
1,5
2
2,5
28 32 36 40 44 48 52 56 60 64 68 72 76
0
0,5
1
1,5
2
2,5
3
3,5
4
50 60 70 80 90 100 110 120 130
0
1
2
3
4
5
60 80 100 120 140 160 180 200 220
6
MOUNTINGS AND CONNECTIONS
Packing
The burners are despatched in cardboard packages of dimensions:
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing
case.
1 burner with detached gas train
1 gasket to be inserted between the burner and the boiler;
1 envelope containing this manual
To get rid of the burner’s packing and in the event of scrappi ng of the latter, follow the procedures lai d down by curr ent laws on
disposal of materials.
Type Model L A P
HS5 L-.TN.S.*.A.0.15 360 460 300
HS5 L-.TN.L.*.A.0.15 360 560 300
HS10 L-.TN.S.*.A.0.20 420 620 340
HS10 L-.TN.L.*.A.0.20 420 700 340
HS18 L-.TN.S.*.A.0.25 420 620 340
HS18 L-.TN.L.*.A.0.25 420 700 340
Fitting the burner to the boil er
Fix the flange of the burner to the boiler as shown in Fig. 4.
This allow a correct inclination towards the combustion cham-
ber. If necessary, after fitting the burner to the boiler, seal the
space between the blast tube and the refractory lining with
appropriate insulating material (ceramic fibre cord or refractory
cement).
Fig. 4
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 Fig. 5. 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 revi sed consulting the burn er manufacturer.
To choose the blast tube lenght follow the instr uctions of the boiler manufacturer. In abse nce of these consider the foll owing:
z Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): th e blast tube must protrude no more than 100
mm into the combusti on cham ber.
The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitablysized spacer to move the burner backwards.
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.
Key
a) Heat input Q in kW
b) Lenght of the flame tube in meters
c) Flame tube firin g intensity in MW/m
3
d) Combustion chamber diameter (m)
Fig. 5 - Firing i ntens ity, diamet er and l enght of the test fl ame tube
as a function of the heat input Q.
7
ELECTRICAL CONNECTIONS
GAS TRAIN INSTALLATION DIAGRAM
The diagram in Fig. 7 shows the components of the gas train which are included in the delivery and those which must be fitted
by the installer . The di agrams complies with regulations in force
Key
1 Burner
2 Manual shut-off valve
3 Bellow joint
4 Multibloc valves group
5 Leakage control device
z Remove the burner cover.
z Carry out the electrical connections to the power supply con-
nector as shown in Fi g. 6.
z Refit the burner cover.
Fig. 6
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.
Fig. 7
Burners fitted with Multibloc DUN GS MBDLE... (2 valves + pres su re switch + filte r +
pressure governor)
14 3
2
5
MANUFACTURER INSTALLER
8
SETTINGS
Gas settings
WARNING!
THE SEALED SCREWS MUST NOT BE UNLOOSED!
IN A SUCH CASE THE DEVICE WARRANTY IS IMMEDIATELY INVALIDATE!
Fig. 8 - Multibloc MB-DLE - VPS504
The multibloc unit is a compact unit consisting of two valves, gas
pressure switch, pressure stabilizer and gas filter. It can be paired
jointly to the Dungs VPS504 sealing controls.
The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns. By unscrewing the
regulator RP the valv e opens, screwing the valve closes.
To set the fast opening remove cover T, reverse it upsi de 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!
The pressure stabilizer is adjusted by operating the screw VS loca-
ted under the cover C. By screwing down the pressur e is increased
and by unscrewing it is r educed.
Note: the screw VSB must be removed only in case of replacemente of the coil.
Leakage control device VPS504 (Optional)
The VPS504 check the operation of the seal of the gas shut off valves costituting the MB-DLE. This check, carried out as soon as the
boiler thermostat gives a start signal to the burner, creates, by
means of the diaphragm pump inside it, a pressure in the test
space of 20 mbar higher than the s upply 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 nece ssary to reset the appliance by pressing the illuminated pushbutt on LB.
.
Fig. 8
C
VS T(VR)
RP
LC LB
PA
VB
VSB
9
Light oil settings
Light oil piping installation diagram
Monotube systen
The burners leave the factory equipped for twin-tube feed. They can be adapted for a mono-tube system (recommended in the
case of gravity feed). Refer to the Appendix for further details.
Fig. 9
Key
1 Burner
2 Flexible hoses (fitted)
3 Light oil filter (fitted)
4 Automatic interceptor (*)
5 One-way val ve (*)
6 Gate valve
7 Quick- closing gate-val ve (not in vicinity of ta nk or boi ler)
(*) 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 opening.
The direct connection of the device without a timer
may cause pump breaks
Sizing the light oil pipel ine
Fig. 10
Tab. 1 Tab. 2 Tab. 3
H
(m)
L (m)
H
(m)
L (m)
H
(m)
L (m)
Ø 6 Ø 8 Ø 10 Ø 6 Ø 8 Ø 10 Ø 12 Ø 6 Ø 8 Ø 10 Ø 12
0 41 100 100 0 19 77 100 100 0 18 73 100 100
0.5 70 100 100 1 24 90 100 100 0.5 15 66 100 100
1 100 100 100 2 30 100 100 100 1 13 59 100 100
1.5 100 100 100 3 34 100 100 100 1.5 10 52 100 100
2 100 100 100 4 39 100 100 100 2 7 44 100 100
2.5 100 100 100 5 44 100 100 100 2.5 5 44 100 100
3 100 100 100 6 48 100 100 100 2.5 - 37 100 100
3.5 100 100 100 7 52 100 100 100 3 - 30 85 100
4 100 100 100 8 56 100 100 100 3.5 - 23 68 100
4.5 100 100 100 9 55 100 100 100 4 - - - 100
5 100 100 100 10 51 100 100 100 4.5 - - - -
From tank
To tank
10
SETTINGS
Oil rate adjustment
The oil rate is set choosing a properly sized nozzle and adjusting the feeding pressure to the nozzle, in the pump (see principle
diagram of the light oil ri ng in Fig. 9).
To choose the proper nozzle refer to Tab. 4; to set the pump pressure see technical data on Page 11. For further informations
on oil pumps see the appendix.
Starting the pump
Before carrying out the adjustment it is nece ssary to start up the oil pump proceeding as follows:
z before operating the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would cause the
pump seal to break.
z Start the burner, light up the photoresistan ce after opening t he solenoid valve and let the air escape from the pressure gauge
connection.
Tab. 4
Key
EV1 Light oil solenoid valve
EV2 Light oil solenoid valve
M Pressure gauge
PPump
Fig. 11
Burners HS5 - HS10
Pump pressure
HS5 - HS10
12 bar
HS18
first stage, 8 bar
second stage, 18 bar
Fig. 12
Burners HS18
PUMP PRESSURE Bar
Nozzle
G.P.H.
8 9 10 11 12 13 14 15 16 17 18
0.40 1.36 1.44 1.52 1.59 1.66 1.73 1.80 1.86 1.92 1.98 2.04
0.50 1.70 1.80 1.90 1.99 2.08 2.17 2.25 2.33 2.40 2.48 2.55
0.60 2.04 2.16 2.28 2.39 2.50 2.60 2.70 2.79 2.88 2.97 3.06
0.65 2.21 2.34 2.47 2.59 2.70 2.82 2.92 3.02 3.12 3.22 3.31
0.75 2.55 2.70 2.85 2.99 3.12 3.25 3.37 3.49 3.60 3.71 3.82
0.85 2.89 3.06 3.23 3.39 3.54 3.68 3.82 3.95 4.08 4.21 4.33
1.00 3.40 3.60 3.80 3.98 4.16 4.33 4.49 4.65 4.80 4.95 5.10
1.10 3.74 3.96 4.18 4.38 4.58 4.76 4.94 5.12 5.29 5.45 5.61
1.20 4.08 4.32 4.56 4.78 4.99 5.20 5.39 5.58 5.77 5.94 6.12
1.25 4.25 4.50 4.75 4.98 5.20 5.41 5.62 5.82 6.01 6.19 6.37
1.35 4.59 4.86 5.13 5.38 5.62 5.85 6.07 6.28 6.49 6.69 6.88
1.50 5.10 5.41 5.70 5.98 6.24 6.50 6.74 6.98 7.21 7.43 7.64
1.65 5.61 5.95 6.27 6.57 6.87 7.15 7.42 7.68 7.93 8.17 8.41
1.75 5.95 6.31 6.65 6.97 7.28 7.58 7.87 8.14 8.41 8.67 8.92
2.00 6.80 7.21 7.60 7.97 8.32 8.66 8.99 9.30 9.61 9.91 10.19
2.25 7.64 8.11 8.55 8.96 9.36 9.74 10.11 10.47 10.81 11.14 11.47
2.50 8.49 9.01 9.50 9.96 10.40 10.83 11.24 11.63 12.01 12.38 12.74
3.00 10.19 10.81 11.40 11.95 12.48 12.99 13.48 13.96 14.41 14.86 15.29
3.50 11.89 12.61 13.29 13.94 14.56 15.16 15.73 16.28 16.82 17.33 17.84
EV
P
M
EV2
EV1
P
M
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