Unigas R91A, R93A, R92A Manual Of Installation - Use - Maintenance
R91A
R92A
R93A
Microprocessor-controlled
gas burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -
M039231CB Rel.1.0 05/2010
TABLE OF CONTENTS
WARNINGS ................................................................................................................................................................ 3
PART I: INSTALLATION MANUAL .......................................................................................................................... 5
GENERAL FEATURES ................................................................................................................................................................... 5
How to interpret the burner’s “Performance curve” ......................................................................................................................... 7
BURNER FEATURES..................................................................................................................................................................... 8
Technical Specifications ................................................................................................................................................................. 8
Country and usefulness gas categories .......................................................................................................................................... 8
Overall dimensions ......................................................................................................................................................................... 9
Pressure in the Network / gas flow rate curves ............................................................................................................................ 10
MOUNTING AND CONNECTING THE BURNER ........................................................................................................................ 11
Packing ......................................................................................................................................................................................... 11
Handling the burner ...................................................................................................................................................................... 11
Fitting the burner to the boiler ....................................................................................................................................................... 11
Matching the burner to the boiler .................................................................................................................................................. 12
GAS TRAIN CONNECTIONS ....................................................................................................................................................... 12
Assembling the gas grain .............................................................................................................................................................. 14
Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) ......................................................................... 15
Pressure adjusting range .............................................................................................................................................................. 16
ELECTRICAL CONNECTIONS .................................................................................................................................................... 17
Rotation of fan motor .................................................................................................................................................................... 17
ADJUSTING AIR AND GAS FLOW RATES ................................................................................................................................. 18
Combustion head gas pressure curves depending on the flow rate ............................................................................................. 18
Measuring the gas pressure in the combustion head ................................................................................................................... 18
User interface ................................................................................................................................................................................ 20
Setting menu ................................................................................................................................................................................. 21
Phases list ..................................................................................................................................................................................... 22
Entering the Parameter levels ....................................................................................................................................................... 23
Info level ........................................................................................................................................................................................ 23
Service level .................................................................................................................................................................................. 25
Adjusting air and gas flow rates .................................................................................................................................................... 26
Adjustments - brief description ...................................................................................................................................................... 26
Adjusting procedure ...................................................................................................................................................................... 27
Adjusting the combustion head ..................................................................................................................................................... 28
Calibration of air and gas pressure switches ................................................................................................................................ 28
Calibration of
Calibration of low gas pressure switch .......................................................................................................................................... 29
PGCP Gas leakage pressure switch (witn Siemens LDU burner control/Siemens LMV Burner Management System) ............. 29
Adjusting the high gas pressure switch (when provided) .............................................................................................................. 29
air pressure s
witch .................................................................................................................................................. 28
PART II: OPERATION ............................................................................................................................................. 30
OPERATION ................................................................................................................................................................................. 30
PART III: MAINTENANCE ....................................................................................................................................... 32
ROUTINE MAINTENANCE ........................................................................................................................................................... 32
Gas filter maintenance .................................................................................................................................................................. 32
Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group) ............................................ 32
Replacing the spring in the gas valve group ................................................................................................................................. 33
Removing the combustion head ................................................................................................................................................... 33
Adjusting the electrodes position .................................................................................................................................................. 34
Replacing the ignition electrodes .................................................................................................................................................. 34
Replacing the detection electrode ................................................................................................................................................. 35
Checking the detection current ..................................................................................................................................................... 36
Extraneous light ............................................................................................................................................................................ 36
Seasonal stop ............................................................................................................................................................................... 36
Burner disposal ............................................................................................................................................................................. 36
SPARE PARTS............................................................................................................................................................................. 37
WIRING DIAGRAMS .................................................................................................................................................................... 38
2
WARNINGS
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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
The equipment must be installed in compliance with the regulations
in force, following the manufacturer’s instructions, by qualified personnel.
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.
Improper installation may cause injury to people and animals, or
damage to property, for which the manufacturer cannot be held liable.
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.
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.
Make sure that inlet or exhaust grilles are unobstructed.
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.
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.
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.
For all the units that have been modified or have options fitted then
original accessory equipment only shall be used.
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
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.
Only burners designed according to the regulations in force should
be used.
This burner should be employed exclusively for the use for which it
was designed.
Before connecting the burner, make sure that the unit rating is the
same as delivery mains (electricity, gas oil, or other fuel).
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
Make sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.
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.
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.
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
For safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.
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.
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.
No adaptors, multiple outlet sockets and/or extension cables are per-
mitted to connect the unit to the electric mains.
An omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.
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;
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.
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3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
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GENERAL
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 liable.
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.
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.
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.
Do not use gas pipes to earth electrical equipment.
Never leave the burner connected when not in use. Always shut the
gas valve off.
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.
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;
-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/EC on electromagnetic compatibility
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
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 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
-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 :
-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
d similar purposes
an
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
. Safety requirements.
;
4
C.I.B. UNIGAS - M039231CB
PART I: INSTALLATION MANUAL
GENERAL FEATURES
The control system is made of the Siemens LMV central unit that performs all the burner control functions and of the Siemens AZL local
programming unit that interfaces the system with the user.
1
2
4
Keys
1 Burner
2 AZL2..
3 Air actuator
4 Fuel actuator
5LMV2..
3
5
2
Fig. 1
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C.I.B. UNIGAS - M039231CB
8
6
5
4
3
2
1
14
13
1 Control panel with startup switch
2 RWF Regulating modulator (only for fully--modulating burners)
3 AZL2x user interface
4 Gas filter
5 Gas valves group
6 Electrical panel
7 Burner cover
8 Flange
9 Blast tube (combustion head inside)
10 Gas butterfly valve
11 Air pressure switch
12 Air inlet
13 Air actuator
14 Combustion head adjusting screw
7
9
10
11
12
The gas coming from the supply line, passes through the filter and the valves group provided with stabiliser. This one forces the pressure in the utilisation limits. The actuators proportionally move the air damper and the gas butterfly valve, microprocess-controlled in
order to optimise the gas flue values, as to get an efficient combustion. The combustion head positioning determines the burner’s
output. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion chamber).
The control panel, placed on the burner’s front side, shows each operating stage.
They can be provided in progressive or fully-modulating version.
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C.I.B. UNIGAS - M039231CB
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Tipo / Type P6 0
M-...50 (Multibloc DUNGS MB-DLE 420 B01)
M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)
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
How to interpret the burner’s “Performance curve”
To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed:
furnace input, in kW or kcal/h (kW = kcal/h / 860);
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.
Campo di lavoro bruciatori
Tipo P60 Mod. M-x x.x.IT.A.0.50 - M-.x x.x.IT.A.0.65
8
7
6
5
4
3
2
1
combustione mbar
0
Contropressione in camera di
-1
100 200 300 400 500 600 700 800 900
A
Pote nza kW
Fig. 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
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C.I.B. UNIGAS - M039231CB
BURNERS FEATURES
Burner model identification
Type R91A Model M-. PR. S. *. A. 1. 80. EA
(1) (2) (3) (4) (5) (6) (7) (8) (9)
(1) BURNER TYPE R91A
(2) FUEL M - Natural gas
(3) OPERATION (Available versions) PR - Progressive MD - Fully modulating
(4) BLAST TUBE S - Standard L - Extended
(5) DESTINATION COUNTRY
(6) BURNER VERSION A - Standard
(7) EQUIPMENT 1 = 2 valves + gas proving system
(8) GAS CONNECTION
(see Specifications)
(9)MICROPROCESSOR-CONTROLLED REGULATION EA = Burner equipped with LMV2
Burners are identified by burner type and model. Burner model identification is described as follows.
* - see data plate
8 = 2 valves + gas proving system
50 = Rp2
65 = DN65
80 = DN80 100 = DN100
EB = Burner equipped with LMV37
Technical Specifications
BURNER TYPE R91A R92A R93A
Output min - max kW
Fuel
Gas category (see next paragraph)
Gas rate
Pressure mbar (see Note 2)
Power supply
Total power consumption
Electric motor
Protection IP40
Operation
Gas train 50
Gas train 65 2”1/2 / DN65
Gas train 80 3” / DN80
Gas train 100 4” / DN100
Operating temperature °C
Storage Temperature °C
Working service *
min.- max. (Stm
ØValves / Connection
kW
kW
3
/h)
480 - 2670 480 - 3050 550 - 4100
Natural gas
51 - 283 51 - 323 58 - 434
230V 3~ / 400V 3N~ 50Hz
4.5 6 8
45.57.5
Progressive - Fully modulating
2” / Rp 2
-10 ÷ +50
-20 ÷ +60
mittent
Inter
Note1:
Note2: Maximum gas pressure = 500mbar (with Siemens VGD gas valves / Dungs MBC.. gas valves).
all gas flow rates are referred to Stm
(net calorific value H
Minimum gas pressure = see gas curves.
= 34.02 MJ/Stm3).
i
3
/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas
*NOTE ON THE BURNER WORKING SERVICE: the control box automatically stops after 24h of continuous working. The control box
immediately starts up, automatically.
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
8
Overall dimensions (mm)
BOILER RECOMMENDED
DRILLING TEMPLATE
9
DN* A AA BS BB C CC D E F G H J K L M N Omin Omax P Q R S U V W Y Z
R91A 50 1333 242 490 419 843 422 1159 725 434 265 295 329 360 464 M12 417 280 310 295 522 148 374 624 216 649 240 185
R91A 65 1333 242 490 419 843 422 1309 875 434 265 295 288 360 464 M12 417 280 310 295 551 148 403 750 292 649 240 185
R91A 80 1333 242 490 419 843 422 1311 877 434 265 295 307 360 464 M12 417 280 310 295 592 148 444 750 322 649 240 185
R91A 100 1333 242 490 419 843 422 1401 967 434 265 295 447 360 464 M12 417 280 310 295 672 148 524 824 382 649 240 185
R92A 50 1333 242 490 419 843 422 1159 725 434 269 299 329 360 464 M12 417 280 310 295 522 148 374 624 216 649 240 185
R92A 65 1333 242 490 419 843 422 1309 875 434 269 299 288 360 464 M12 417 280 310 295 551 148 403 750 292 649 240 185
R92A 80 1333 242 490 419 843 422 1311 877 434 269 299 307 360 464 M12 417 280 310 295 592 148 444 750 322 649 240 185
R92A 100 1333 242 490 419 843 422 1401 967 434 269 299 447 360 464 M12 417 280 310 295 672 148 524 824 382 649 240 185
R93A 50 1338 242 495 460 843 422 1159 725 434 304 344 329 360 464 M12 417 280 310 295 522 148 374 624 216 649 240 185
R93A 65 1338 242 495 460 843 422 1309 875 434 304 344 288 360 464 M12 417 280 310 295 551 148 403 750 292 649 240 185
R93A 80 1338 242 495 460 843 422 1311 877 434 304 344 307 360 464 M12 417 280 310 295 592 148 444 750 322 649 240 185
R93A 100 1338 242 495 460 843 422 1401 967 434 304 344 447 360 464 M12 417 280 310 295 672 148 524 824 382 649 240 185
C.I.B. UNIGAS - M039231CB
*DN = gas valves size
NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves.
Performance Curves
0
2
4
6
8
10
12
14
16
400 800 1200 1600 2000 2400 2800
0
2
4
6
8
10
12
14
16
400 800 1200 1600 2000 2400 2800 3200 3600
0
10
20
30
40
50
60
70
80
90
50 100 150 200 250 300
Rp 2" (50)
DN65
DN80
DN100
0
20
40
60
80
100
120
50 100 150 200 250 300 350
Rp 2" (50)
DN100
DN80
DN65
0
40
80
120
160
200
50 100 150 200 250 300 350 400 450 500
Rp 2" (50)
C.I.B. UNIGAS - M039231CB
R91A
R92A
PRESSURE IN
COMBUSTION CHAMBER (mbar)
kW
kW
R93A
16
14
12
10
8
6
PRESSURE IN
4
2
0
500 1500 2500 3500 4500
COMBUSTION CHAMBER (mbar)
kW
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.
Pressure in the Network / gas flow rate curves
R91A
R92A
GAS PRESSURE (mbar)
R93A
GAS PRESSURE (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.
Stm3/h
DN65
DN80
DN100
Stm3/h
Stm3/h
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C.I.B. UNIGAS - M039231CB
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MOUNTING AND CONNECTING THE BURNER
Packing
The burners are despatched in wooden crates whose dimensions are:
1730mm x 1280mm x 1020mm (L x P x H)
Packing cases of this type are affected by humidity and are not suitable for stacking.
The following are placed in each packing case:
burner with gas train detached but electrically connected to the burner;
gasket to be inserted between the burner and the boiler;
envelope containing this manual and other documents.
To get rid of the burner’s packing and in the event of scrapping of the latter, follow the
procedures laid down by current laws on disposal of materials.
H
P
L
Handling the burner
ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these operations are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.
To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).
The unpacked burner must be lifted and moved only by means of a fork lift truck.
The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck: the forks must be inserted into the A
anb B ways. Remove the stirrup only once the burner is installed to the boiler.
A
B
Fitting the burner to the boiler
To install the burner into the boiler, proceed as follows:
1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)
2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;
3 place the 4 stud bolts (5) on 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).
Keys
1 Burner
2 Fixing nut
3 Washer
4 Sealing gasket
5 Stud bolt
7Blast tube
11
C.I.B. UNIGAS - M039231CB
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SIDE UP
SIDE
DOWN
1
2
5
4
6
7
8
11
16
4
The burner is designed to work positioned according to the picture below. For different installations, please contact the Technical
Department.
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:
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.
Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in
respect to the tube bundle plate.
The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitablyspacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).
Key
a) Heat output in kW
b) Length of the flame tube in meters
c) Flame tube firing intensity in MW/m
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.
3
sized
Fig. 4
GAS TRAIN CONNECTIONS
The 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 VGD 20/40.. with built-in gas pressure governor + VPS504 gas proving system
MANUFACTURER
INSTALLER
12
C.I.B. UNIGAS - M039231CB
1
2
54
78
18
16
4
MANUFACTURER
INSTALLER
1
2
54
78
18
16
4
MANUFACTURER
INSTALLER
Gas train - 2 (Rp2)
Gas train with valves group MBC 1200SE (2 valves + gas filter + pressure governor) + VPS504 gas proving system
Gas train - 3(DN65/80/100)
Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor) + VPS504 gas proving system
Key
1 Burner
2 Butterfly valve
4 Maximum gas pressure switch (optional)
5 Minimum gas pressure switch
6 Gas filter
8 Manual cutoff valve
10 VGD Valves group
16 PGCP - gas leakage pressure switch
18 MBC Valves group (2” with filter provided)
19 MBC Valves group (DN65/80/100)
7 Bellows unit
* 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.*
13
Assembling the gas grain
z
z
1A
5
1B
4
1C
21D
1E
3
Keys
1A..1E Gasket
2 Gas filter
3 Gas valves group
4 Bellows unit
5 Manual valve
”direction” arrows for installation
gas supply network
S
%U
S
%U
S
%U
S
%U
PLQ['1
'1
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S
%U
#
&
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$
C.I.B. UNIGAS - M039231CB
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
2) fasten all the items by means of screws, according to the diagrams shown, observing the mounting direction for each item;
NOTE: the bellows unit, the manual cutoff valve and the gaskets are not part of the standard supply.
ATTENTION: once the gas train is mounted according to the diagram on Fig. 5, the gas proving test mus be performed,
according to the procedure set by the laws in force.
The procedures of installation fo the gas valves are shown in the next paragraphs, according to the gas train used:
threaded gas trains with Multibloc Dungs MBC..SE 1200 or Siemens VGD20..
flanged gas trains with Multibloc Dungs MBC..SE 1900-3100-5000 or Siemens VGD40..
MULTIBLOC DUNGS MBC300-700-1200SE (Threaded valves group)
Mounting
1. Mount flange onto tube lines. Use appropriate sealing agent (see Fig. 6)
2. Insert MBC...SE. Note position of O rings (see Fig. 7).
3. Tighten screws A – H
Fig. 6
4. After installation, perform leakage and functional test.
5. Disassembly in reverse order
MOUNTING
POSITIONS
OPTION
Fig. 7
14
C.I.B. UNIGAS - M039231CB
z
z
z
z
z
z
z
z
10 = pulse lines
njo/!6!y!EO
EO
2
22
21
"
#
#
"
#
#
"
"
BS
BS
SKP1. SKP2.
BS
BS
SA
TP
7631z05/0101
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.
Mounting positions OPTION
Fig. 8
Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor)
Mounting
When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded);
to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts;
install the valve;
the direction of gas flow must be in accordance with the direction of the arrow on the valve body;
ensure that the bolts on the flanges are properly tightened;
ensure that the connections with all components are tight;
make certain that the O-rings and gaskets between the flanges and the double gas valve are fitted.
Connect the reference gas pipe (TP in figure; 8mm-external size pipe supplied loose), to the gas pressure nipples placed on the
gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size.
Leave the blowhole free (SA in figure). Should the spring fitted not permit satisfactory regulation, ask one of our service centres for a
suitable replacement.
Caution: the SKP2 diaphragm D must be vertical (see Fig. 11).
WARNING: removing the four screws BS causes the device to be unserviceable!
Fig. 9
SIEMENS VGD..MOUNTING
POSITIONS
D
Fig. 12
Fig. 10 Fig. 11
15
C.I.B. UNIGAS - M039231CB
TP
Fig. 13
Pressure adjusting range
The pressure adjusting range, downstream the gas valves group, changes according to the spring provided with the valve group.
1
1
2
2
DUNGS MBC..SE Siemens SKP actuator
Keys
1 spring
2 cap
DUNGS MBC valves:
Performance range (mbar) 4 - 20 20 - 40 40 - 80 80 - 150
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.
16
C.I.B. UNIGAS - M039231CB
ELECTRICAL CONNECTIONS
Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse the phase and
neutral connections. fit a differential thermal magnet switch adequate for connection to the mains.
ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be
sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the
“Electrical connections” section.
WARNING: The burner is provided with an electrical bridge between terminals 6 and 7; when connecting the high/
low flame thermostat, remove this bridge before connecting the thermostat.
IMPORTANT: Connecting electrical supply wires to the burner teminal block MA, be sure that the ground wire is
longer than phase and neutral ones.
Wiring diagram keys on page 38.
Rotation of fan motor
Once the electrical connection of the burner is executed, remember to check the rotation of the fan motor. The motor should rotate
according to the indication on the body. In the event of wrong rotation, reverse the three-phase supply and check again the rotation of
the motor.
NOTE: the burners are supplied for three-phase 400V supply, and in the case of three-phase 230V supply it is necessary to
modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay.
Note on elecrtical supply
If the power supply to the burner is 230V three-phase or 230V phase-phase (without a neutral), with the Siemens LME2... control box,
between the terminal 2 on the board and the earth terminal, an RC Siemens RC466890660 filter must be inserted.
Key
C - Capacitor (22nF/250V)
LMV - Siemens BMS (Burner Management System)
R - Resistor (1Mohm)
RC466890660 - RC Siemens filter
SIEMENS
LMV2..
X03-4 (N)
Fig. 14
17
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