Unigas R91A, R93A, R92A Manual Of Installation - Use - Maintenance

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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

WARNINGS

z z

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.

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

z z

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

National standards :

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

and test methods

. Safety requirements.

;

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.

Keys

1 Burner 2 AZL2.. 3 Air actuator 4 Fuel actuator 5LMV2..

Fig. 1

C.I.B. UNIGAS - M039231CB

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

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.

C.I.B. UNIGAS - M039231CB

Tipo / Type P6 0 M-...50 (Multibloc DUNGS MB-DLE 420 B01) M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)

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

combustione mbar

Contropressione in camera di

-1 100 200 300 400 500 600 700 800 900

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

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

/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).

/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

2E( R ) B

2ELL

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

Overall dimensions (mm)

BOILER RECOMMENDED

DRILLING TEMPLATE

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

400 800 1200 1600 2000 2400 2800

400 800 1200 1600 2000 2400 2800 3200 3600

50 100 150 200 250 300

Rp 2" (50)

DN65

DN80

DN100

100

120

50 100 150 200 250 300 350

Rp 2" (50)

DN100

DN80

DN65

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)

R93A

PRESSURE IN

500 1500 2500 3500 4500

COMBUSTION CHAMBER (mbar)

To get the input in kcal/h, multiply value in kW by 860. Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory

tests, but does not represent the regulation range of the machine. On this diagram the maximum output point is usually reached by adjsuting the combustion head to its “MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is reached setting the combustion head to its “MIN” position. During the first ignition, the combustion head is set in order to find a compromise between the burner output and the generator specifications, that is why the minimum output may be different from the Performance curve minimum.

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

C.I.B. UNIGAS - M039231CB

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.

Handling the burner

ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these operations are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.

To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).

The unpacked burner must be lifted and moved only by means of a fork lift truck.

The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck: the forks must be inserted into the A anb B ways. Remove the stirrup only once the burner is installed to the boiler.

Fitting the burner to the boiler

To install the burner into the boiler, proceed as follows: 1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) 2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; 3 place the 4 stud bolts (5) on boiler’s door, according to the burner’s drilling template described on paragraph “Overall dimensions”; 4 fasten the 4 stud bolts; 5 place the gasket on the burner flange; 6 install the burner into the boiler; 7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture. 8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate

insulating material (ceramic fibre cord or refractory cement).

Keys

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

C.I.B. UNIGAS - M039231CB

SIDE UP

SIDE

DOWN

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.

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

C.I.B. UNIGAS - M039231CB

MANUFACTURER

INSTALLER

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.*

Assembling the gas grain

21D

Keys

1A..1E Gasket 2 Gas filter 3 Gas valves group 4 Bellows unit 5 Manual valve

”direction” arrows for installation

gas supply network

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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

C.I.B. UNIGAS - M039231CB

10 = pulse lines

njo/!6!y!EO

# #

SKP1. SKP2.

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

Fig. 12

Fig. 10 Fig. 11

C.I.B. UNIGAS - M039231CB

Fig. 13

Pressure adjusting range

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



DUNGS MBC..SE Siemens SKP actuator

Keys

1 spring 2 cap

DUNGS MBC valves:

Performance range (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.

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

C.I.B. UNIGAS - M039231CB

ADJUSTING AIR AND GAS FLOW RATES

Combustion head gas pressure curves depending on the flow rate

Curves are referred to pressure = 0mbar in the combustion head!

The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner properly adjusted (percentage of residual O limits). During this stage, the combustion head, the gas butterfly valve and the actuator are at the maximum opening. Refer to Fig. 15, 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.

in the flues as shown in the “Recommended combustion values” table and CO in the standard

Fig. 15

Key

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

Measuring the gas pressure in the combustion head

In order to measure the pressure in the combustion head, insert the pressure gauge probes: one into the combustion chamber’s pressure outlet (Fig. 15-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig. 15-3). 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 measured in the combustion head (quoted on the y axis). The data obtained must be considered when adjusting the gas flow rate.

NOTE: THE PRESSURE-RATE CURVES ARE GIVEN AS INFORMATION ONLY; FOR A PROPER SETTING OF THE GAS RATE, PLEASE REFER TO THE GAS METER READING.

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

C.I.B. UNIGAS - M039231CB

40 60 80 100 120 140 160 180 200 220 240 260 280 300

40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340

50 75 100 125 150 17 5 200 225 250 275 300 325 350 375 400 425 450

Pressure in combustion head - gas flow rate curves”

R91A

Gas pressure in

combustion head (mbar)

R93A

Stm

R92A

Stm3/h

Gas pressure in

combustion head (mbar)

Stm

User interface

d/00

The AZL2x.. display is shown below:

C.I.B. UNIGAS - M039231CB

The keys functions are the following:

Key F

Used to adjust the “fuel” actuator position (Fuel): : While pressing the F key, the “fuel” actuator position can be changed by means of the + and - keys.

Key A

Used to adjust the “air” actuator position (Air): While pressing the A key, the “air” actuator position can be changed by means of the + and - keys.

Key F + A

While pressing the two keys contemporarly, the code message will appear: by entering the proper password it is possible to access the Service mode.

VSD

hmin

ESC

nfo

Info and Enter keys

Used for Info and Service menues Used as Enter key in the setting modes Used as Reset key in the burner operation mode Used to enter a lower level menu

Key -

Used to decrease a a value Used to enter Info and Serivce during the curve adjustments

Key +

Used to increase a a value Used to enter Info and Serivce during the curve adjustments

Keys (+ & - )= ESC

By pressing + and - at the same time, the ESCAPE function is perfomed:

to erase a entered value to enter a lower level menu

C.I.B. UNIGAS - M039231CB

mi n

The display will show these data:The display will show these data:

Lock+unlock codes

Flame

Open valves

Ignition transformers energised

Fan motor energised

Oil pre-heater energised

Plant heat request

Parametere setting mode

Info mode

Service mode

Closing actuator

Opening actuator

Unit measure

Setting menu

The setting menu is divided into different blocks:

Block Description Password

100

Informazioni generali General OEM / Service / Info

200

Controllo bruciatore Burner control OEM / Service

400

Curve rapporto Ratio curves OEM / Service

500

Controllo rapporto Ratio control OEM / Service

600

Servocomandi Actuators OEM / Service

700

Storico errori Error history OEM / Service / Info

900

Dati di processo Process data OEM / Service / Info

The accesses to the various blocks are allowed by passwords. Passwords are divided into three levels:

User level (info): no password needed Service level (Service) Manifacturer level (OEM)

C.I.B. UNIGAS - M039231CB

PHASES LIST

During operation, the following program phases are shown. The meaning for each phase is quoted in the table below.

Phase Funzione Function

Ph00 Fase blocco Lockout phase

Ph01 Fase di sicurezza Safety phase

Ph10 t10 = tempo raggiungimento posizione riposo t10 = home run

Ph12 Pausa Standby (stationary)

Ph22

t22 = tempo di salita ventilatore (fmotore ventilatore = ON, valvola intercettazione di sicurezza = ON)

Ph24 Verso posizione preventilazione Traveling to the prepurge position

Ph30 t1 = tempo preventilazione t1 = prepurge time

Ph36 Verso posizione accensione Traveling to the ignition position

Ph38 t3 = tempo preaccensione t3 = preignition time

Ph40

TSA1 = primo tempo sicurezza (trasformatore accensione ON)

TSA1 = primo tempo sicurezza (trasformatore accen-

Ph42

sione OFF) t42 = tempo preaccensione OFF

Ph44 t44 = intervallo 1 t44 = interval 1

Ph50 TSA2 = secondo tempo sicurezza TSA2 = 2nd safety time

Ph52 t52 = intervallo2 t52 = interval 2

Ph60 Funzionamento 1 (stazionario) Operation 1 (stationary)

Ph62

t62 = massimo tempo bassa fiamma (funzionamento 2, in preparazione per spegnimento, verso bassa fiamma)

Ph70 t13 = tempo postcombustione t13 = afterburn time

Ph72 Verso posizione postcombustione Traveling to the postpurge position

Ph74 t8 = tempo postventilazione t8 = postpurge time

Ph80 t80 = tempo evacuazione controllo tenuta valvole t80 = valve proving test evacuation time

Ph81

t80 = tempo perdita pressione atmosferica, prova atmosferica

Ph82 t82 = testa perdita, test riempimento t82 = leakage test filling test, filling

Ph83 t80 = tempo perdita pressione gas, test pressione

Ph90 Tempo attesa “mancanza gas” Gas shortage waiting time

t22 = fan ramp up time (fan motor = ON, safety shutoff valve = ON)

TSA1= 1st safety time (ignition transformer ON)

TSA1 = 1st safety time (ignition transformer OFF), t42 = preignition time OFF

t62 = max. time low-fire (operation 2, preparing for shutdown, traveling to low-fire)

t81 = leakage time test time atmospheric pressure, atmospheric test

t83 = leakage test time gas pressure, pres sure test

C.I.B. UNIGAS - M039231CB

Entering the Parameter levels

By means of a proper use of the keys, it is possible to enter the various level parameters, as shown in the following flow chart:

The burner and consequently the LMV2x.. are factory set; the air and fuel curves as set as well.

Info level

To enter the Info level, proceed as follows: 1 in any menu position, press keys + and - at the same time, then the program will start again: the display will show OFF.

2 until the display will show InFo, Press the enter (InFo) key

3 then il will show the first code (167) flashing, on the right side it will show the data entered. By pressing + or - it is possible to scroll

(up or down) the parameter list.

4 If a dot-line is shown on the right, there is no enough room for complete visualisation: press enter again the data will be completely

shown for 1 to 3 seconds. By pressing enter or + and- at the same time, the system will exit the parameter visualisation and go back to the flashing number.

The Info level shows some basic parameters as:

C.I.B. UNIGAS - M039231CB

Parameter Description

167 Cubic meters of fule (resettable)

162 Operating hours (resettable)

163 Device operating hours

164 Burners start-ups (resettable)

166 Total number of start-ups

113 Burner number (i.e. serial number)

107 Software version

102 Software date

103 Device serial number

104 Parameter set preassignment: Customer code

105 Parameter set preassignment: Version

143 Free

5 Example: choose parameter 102 to show the date

the display shows parameter 102 flashing on the left and characters ._._ on the right. 6 press InFo for 1-3 seconds: the date will appear 7 press InFo to go back to parameter “102” 8 by pressing + / -, it is possible to scroll up/down the parameter list (see table above), or, by pressing ESC or InFo for more seconds,

the display will show

9 Once the last parameter is accessed (143) by pressing + , the End message will flash.

10 Press InFo

for more than three seconds or for more than three seconds orto return to the normal display.

If a message like the one below is shown during operation,

it means that the burner is locked out and the Errore code is shown (in the example “error code:4”); this message is alternating with

C.I.B. UNIGAS - M039231CB

another message

Diagnostic code (in the example “diagnostic code:3”). Record the codes and find out the fault in the Error table. To perform the reset, press InFo for one second:

The unit displays an event which does not lead to shutdown. The display shows current error code c: alternating with diagnostic code d:

. Press InFo to return to the display of phases. Example: Error code 111 / diagnostic code 0

To reset, press InFo for a second. Record the codes and check the Error List to find the type of faults.

Service level

To enter the Service mode, press InFo until the display will show:

The service level shows all the information about flame intensity, actuators position, number and lock codes:

Parameter Description

954 Flame intensity

121 % output, if set = automatic operation

922 Actuators position, 00=combustibile; 01= aria

161 Lock-outs number

701..725 Lock-outs History (see chapter 23 in the LMV2x manual)

1 the first parameter will be “954”: the percentage of flame is shown on the right. By pressinf + or - it is possible to scroll up/down the

C.I.B. UNIGAS - M039231CB

parameter list.

2 Once the last parameter is accessed (143) by pressing + , the End message will blink.

3Press InFo

for more than three seconds or for more than three seconds orto return to the normal display.

Adjusting air and gas flow rates

ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres-

sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed.

ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide); if this should happen, make the gas decrease slowly until the normal combustion values are achieved.

WARNING: NEVER LOOSE THE SEALED SCREWS! OTHERWISE, THE DEVICE WARRANTY WILL BE IMMEDIATELY INVALIDATE!

IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:

Fuel

Recommended combustion parameters

Recommended (%) CO

Recommended (%) O2

Natural gas 9 ÷ 10 3 ÷ 4.8

During the factory test, the gas butterfly valve, air damper in low flame and sevocontrol are set to average values.

Adjustments - brief description

The air and fuel rates adjustments must be performed at the maximum ouptput first (“high flame”): see the LMV2.. related manual..

Check that the combustion parameters are in the suggested limits.

Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a differential pressure gauge, as described on par. “Measuring the gas pressure in the combustion head” on page 18.

Then, adjust the combustion values by setting the “air/gas ratio” curvepoints (see the LMV2.. related manual). Set, now, the low flame output, in order to avoid the low flame output increasing too much or that the flues temperature gets too low

to cause condensation in the chimney.

C.I.B. UNIGAS - M039231CB

Pressure setting

Adjusting procedure

If the burner is provided with the DUNGS MBC..SE gas valves group, set the pressure regulator to 1/3 of its stroke, using a 2.5 allen key.

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go on adjusting the burner, observing the procedure on the LMV2.. related manual.

By following the “fuel/air ratio” curvepoints setting procedure on the LMV2.. manual, adjusting the air and gas flow rates: check, continuosly, the flue gas analisys, as to avoid combustion with little air; dose the air according to the gas flow rate change following the steps quoted below.

Acting on the pressure governor of the valves group, adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler/utilisation:

- Siemens VGD valves group: remove cap T and act on the VR adjusting screw to increase or decrease the pressure and consequen-

tly the gas rate; screwind VR the rate increases, unscrewing it decreases (see next figure).

- Dungs MBC..SE valves group: act on its pressure governor to increase or decrease the pressure and consequently the gas rate.

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Siemens VGD..

$IJBWFFTBHPOBMFDBWBOS

Dungs MBC..SE

Now adjust the pressure switches (see next par.).

Fully modulating burners

To adjust the fully-modulating burners, use the CMF switch on the burner control panel (see Fig. 16), instead of the TAB thermostat as described on the previous paragraphs about the progressive burners. Go on adjusting the burner as described before, paying attention to use the CMF switch intead of TAB.

The CMF position sets the oprating stages: to drive the burner to the high-flame stage, set CMF=1; to drive it to the low-flame stage, set CMF=2. To move the adjusting cam set CMF=1 or 2 and then CMF=0.

CMF = 0 stop at the current position CMF = 1 high flame operation CMF = 2 low flame operation CMF = 3 automatic operation

As far as fully-modulating burners, see the Siemens RWF40.. manual.

C.I.B. UNIGAS - M039231CB

Adjusting the combustion head

CAUTION: perform these adjustments once the burner is turned off and cooled.

The burner is factory-set wih the D adjusting plate holes fully open, and the combustion head at its MAX position, so it is fit to work at the maximum output.

To adjust the gas flow, partially close the holes, as follows: 1 loosen the three V screws that fix the adjusting plate D; 2 insert a screwdriver on the adjusting plate notches and let it move CW/CCW as to open/close the holes; 3 once the adjustmet is performed, fasten the V screws.

open holes

closed holes

To let the burner operate at a lower output, loose the VB screw and move progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when the adjustment is accomplished.

“MAX” head position

VRT

“MIN” head position

Attention! Change the combustion head position only if necessary. If so, repeat the air and gas adjustments described above.Now, adjust the burner according to the actuator model provided.

Calibration of air and gas pressure switches

The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of the control box unlock pushbutton, placed on the burner control panel.

The gas pressure switches check the pressure to avoid the burner operate when the pressure value is not in the requested pressure range.

Calibration of air pressure switch

To calibrate the air pressure switch, proceed as follows:

Remove the transparent plastic cap. Once air and gas setting have been accomplished, startup the burner. During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout,

then read the value on the pressure switch scale and set it to a value reduced by 15%. Repeat the ignition cycle of the burner and check it runs properly.

C.I.B. UNIGAS - M039231CB

Refit the transparent plastic cover on the pressure switch.

Calibration of low gas pressure switch

As for the gas pressure switch calibration, proceed as follows:

Remove the transparent plastic cap. While the burner is operating at the maximum output, test the gas pressure on the low gas pressure switch port. Slowly close the manual shut-off valve (placed upstream the pressure switch, see gas train installation diagram), until the measu-

red pressure is reduced by 50%. Pay attention that the CO value in the flue gas does not increase. Check that the burner is operating correctly. Screw down the pressure switch adjusting ring nut until the burner lockout. Fully open the manual shut-off valve. Refit the transparent plastic cover on the pressure switch.

PGCP Gas leakage pressure switch (witn Siemens LDU burner control/Siemens LMV Burner Management System)

remove the pressure switch plastic cover; adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch; replace the plastic cover.

Adjusting the high gas pressure switch (when provided)

To calibrate the high pressure switch, proceed as follows according to its mounting position: 1 remove the pressure switch plastic cover; 2 if the maximum pressure switch is mounted upstreaam the gas valves: measure the gas pressure in the network, when flame is off;

by means of the adjusting ring nut VR, set the value read, increased by the 30%.

3 if the maximum pressure switch is mounted downstream the “gas governor-gas valves” group and upstream the butterfly valve:

light the burner, adjust it according to the procedure in the previous paragrph. Then, measure the gas pressure at the operating flow rate, downstream the “gas governor-gas valves” group and upstream the butterfly valve; by means of the adjusting ring nut VR, set the value read on step 2, increased by the 30%;

4 replace the plastic cover.

C.I.B. UNIGAS - M039231CB

PART II: OPERATION

LIMITATIONS OF USE

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.

THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER.

A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER.

THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER).

NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.

OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON.

IN CASE OF A BURNER SHUT-DOWN, RESET 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.

WARNING: DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR (COUPLING FLANGE) CAN BECOME VERY HOT, AVOID TOUCHING THEM SO AS NOT TO GET BURNT.

OPERATION

ATTENTION: BEFORE STARTING THE BURNER UP, BE SURE THAT THE MANUAL CUTOFF VALVES ARE OPEN AND CHECK THAT THE PRESSURE VALUE UPSTREAM THE GAS TRAIN MATCHES THE VALUE ON PARAGRAPH “TECHNICAL SPECIFICATIONS”). CHECK THAT THE MAINS SWITCH IS CLOSED. CAREF

Set to “on” the B switch on the burner control panel. Check that the contrl box is not in the lockout position (light B on); in case unlock it by pressing the Enter/InFo key (for further infor-

mation on the LMV2.., see the related manual). Check that the pressure switches/thermostats series enables the burner operation. Check that the gas pressure is sufficient (signalled by an error code on the AZL2.. display). At the beginning of the startup cycle, the actuator drives the air damper to the maximum opening position, then the fan motor starts

up: the prepurge phase begins. During the prepurge phase, the air damper complete opening si signalled by the light F on (see front panel).

At the end of the prepurge, the air damper is driven to the ignition position, the ignition transformer is energised (signalled by the light H on the front panel) then, few seconds later, the EV1 and EV2 gas valves are energised (light L and I on the front panel).

Few seconds after the gas valves opening, the ignition transformer is de-energised and light H turns to off.

The burner operates in the low flame stage; few seconds later the two-stages opertaion begins and the burner output increases or decreases, driven by the external thermostats (progressive burners) or by the modulator (P in Fig. 16, fully-modulating burners).

C.I.B. UNIGAS - M039231CB

Key

A Main switch

B Lock-out light

C Reset pushbutton for control box

D Reset pushbutton for gas proving system

E Gas pressure switch enabling signal

F Lock-out light for gas proving system

G Hi-flame operation light

H Lo-flame operation light

I Ignition transformer operation light

L EV2 opening light

M EV1 opening light

N Fan motor overload tripped light

O Burner in stand-by light

P Burner Modulator (only on fully modula-

ting burners)

Fig. 16 - Burner control panel

C.I.B. UNIGAS - M039231CB

PART III: MAINTENANCE

At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6 months.

WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED!

ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL..

ROUTINE MAINTENANCE

Clean and examining the gas filter cartdrige, if necessary replace it (see next paragraphs). Remove, check and clean the combustion head.

Check the ignition and detection electrodes, clean and adjust if necessary (see page 34). In case of doubt, check the detection current according to the schemes on page 35.

Cleaning and greasing of sliding and rotating parts.

ATTENTIONwhen servicing, if it was necessary to disassemble the gas train parts, remember to execute the gas proving test, once the gas train is reassembled, according to the procedure imposed by the law in force.

Gas filter maintenance

ATTENTION: Before opening the filter, close the manual cutoff valve downstream the filter and bleed the gas; check that inside the filter there is no pressurised gas.

To clean or remove the filter, proceed as follows: 1 remove the cap unscrewing the fixing screws (A); 2 remove the filtering cartridge (B), clean it using water and soap, blow it with compressed air(or replace it, if necessary) 3 replace the cartridge in its proper position taking care to place it inbetween the guides as not to hamper the cap replacement; 4 be sure to replace the “O” ring into its place (C) and replace the cover fastening by the proper screws (A).

Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group)

Inspect the filter at least once a year.

Change the filter, if pressure value between pressure connections 1 and 2 is greather than 10 mbar.

Change the filter, if pressure value between pressure connections 1 and 2 is twice as high compared to the last inspection.

1. Interrupt gas supply: close ball valve

2. Remove screws 1-2

3. Replace the filter insert 3

4. Screw in screws 1-2 without use force to fasten.

5. Perform leakage and funcion test.

6. Pay attention that dirt does not fall inside the valve.

Space requirements for fitting filter, A: from 150 to 230 mm.

Fig. 17

C.I.B. UNIGAS - M039231CB



Replacing the spring in the gas valve group

To replace the spring in the gas valve group,proceed as follows: 1 Carefully twist the protection cap 1 and the O-ring 2. 2 remove the “set value” spring 3 from housing 4. 3 Replace spring 3. 4 Carefully insert the new “set value” spring. Pay attention to mount properly. First insert the spring part with smaller diameter in the

housing. 5 Place O-ring 2 in protective cap 1. Screw in the protective cap with the O-ring in it. 6 Stick the adhesive label for spring identification on the type plate.

DUNGS MBC..SE SKP Siemens actuator

Removing the combustion head

1 Remove the cover C. 2 remove the electrodes cables; 3 unscrew the 3 screws V which hold in position the gas manifold G and pull out the complete group as shown in figure. Note: to replace the combustion head reverse the procedure described above having care to place correctly the O ring (OR) between

burner and gas manifold.

VRT

GAR

Keys

VRT Head adjusting screw

AR Threaded rod

V Fixing screw

G Gas manifold

OR “O” ring

CCover

Fig. 19

Fig. 18

C.I.B. UNIGAS - M039231CB

528 528

AR G

Adjusting the electrodes position

Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion head.

ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the bur-

ner operation would be compromised. Check the electrodes position after any intervention on the combustion head.

Replacing the ignition electrodes

ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head.

To replace the ignition electrodes, proceed as follows: 1 remove the burner cover 2 loose the nuts that fasten;the electrodes group to the combustion head (A); 3 disconnect the electrodes cables (B); 4 loose the security dowes of the adjusting ring nut (C); 5 shift the electrodes group back to the outside and remove the combustion head (D), 6 loose the screw of th eignition electrodes support (E); 7 remove the electrodes and replace them paying attention to the measures showed in figure (F-G).

C.I.B. UNIGAS - M039231CB

528 528

Replacing the detection electrode

To replace the detection electrode, proceed as follows: 1 remove the combustion head according to the procedure on paragraph “Removing the combustion head”;

2 by means of an allen key, loose the fixing screws of the detection electrode ER and replace it;

3 replace the combustion head.

C.I.B. UNIGAS - M039231CB

Protective earth PE

Ionization probe (ION)

QRB.../ QRC... signal voltage

QRB... GND

X10-05

Checking the detection current

To check the detection signal follow the scheme in Fig. 20. If the signal is less than the value indicated, check the position of the detection electrode or detector, the electrical contacts and, if necessary, replace the electrode or the detector.

NOTE: there is no linear relation between the flame percentage shown on display (parameter no. 954) and the detection signal values.

Device

Minimum detection signal

Siemens LMV2 4 μA (values on display: 30%)

Error code Diagnostic code Actions

93 3 Sensor short-circuit

QRA... (-)

QRA... (+)

X10-06

Fig. 20

CAUTION: Permissible length of flame detector cable (laid separately): 3 m (core-earth 100 pF / m).

Extraneous light

Extraneous light during standby (phase 12) leads to start prevention, followed by a restart. Extraneous light during the prepurge phase leads to immediate lockout. If extraneous light occurs during the shutdown phase, the system switches to the safety phase. One repetition is permitted. This means that if the error occurs again the next time the system is shut down, the unit initiates lockout.

Seasonal stop

To stop the burner in the seasonal stop, proceed as follows: 1 turn the burner main switch to 0 (Off position) 2 disconnect the power mains 3 close the fuel valve of the supply line

Burner disposal

In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”.

C.I.B. UNIGAS - M039231CB

SPARE PARTS

Desription Code

P91A P92A P93A

BURNER CONTROLLER - SIEMENS LMV20 2020474 2020474 2020474 USER INTERFACE - SIEMENS AZL23 2022115 2022115 2022115 DETECTION ELECTRODE 2080107 2080107 2080107 IGNITION ELECTRODE 2080291 2080291 2080291 IGNITION ELECTRODSE 2080292 2080292 2080292 GAS FILTER - Rp 2 2090119 2090119 2090119 GAS FILTER - DN65 2090117 2090117 2090117 GAS FILTER - DN80 2090112 2090112 2090112 GAS FILTER - DN100 2090113 2090113 2090113 GASKET 2110048 2110048 2110048 FAN WHEEL 2150009 2150028 2150010 AIR PRESSURE SWITCH 2160065 2160065 2160065 GAS PRESSURE SWITCH - DUNGS GW50 A5 2160076 2160076 2160076 GAS PRESSURE SWITCH - DUNGS GW150 A5 2160077 2160077 2160077 GAS PRESSURE SWITCH - DUNGS GW150 A6 2160086 2160086 2160086 GAS PRESSURE SWITCH - DUNGS GW500 A6 2160087 2160087 2160087 IGNITION TRANSFORMER 2170140 2170140 2170140 MOTOR 2180276 2180277 2180206 GAS VALVE GROUP - Rp2 - Siemens VGD20.. 2190171 2190171 2190171 GAS VALVE GROUP - DN65 - Siemens VGD40.. 2190172 2190172 2190172 GAS VALVE GROUP - DN80 - Siemens VGD40.. 2190169 2190169 2190169 GAS VALVE GROUP - DN100 - Siemens VGD40.. 2190174 2190174 2190174 GAS VALVE ACTUATOR SKP15 2190181 2190181 2190181 GAS VALVE ACTUATOR SKP25 2190183 2190183 2190183 GAS VALVE GROUP - Rp2 - Dungs MBC1200SE 21903M5 21903M5 21903M5 GAS VALVE GROUP - DN65 - Dungs MBC1900SE 21903M6 21903M6 21903M6 GAS VALVE GROUP - DN80 - Dungs MBC3100SE 21903M7 21903M7 21903M7 GAS VALVE GROUP - DN100 - Dungs MBC5000SE 21903M8 21903M8 21903M8 BUTTERFLY VALVE ACTUATOR - SIEMENS SQM33.410A9-1.2NM 2480092 2480092 2480092 AIR DAMPER ACTUATOR - SIEMENS SQM33.510A9-3NM 2480094 2480094 2480094 BURNER MODULATOR 2570112 2570112 2570112 COMBUSTION HEAD 30600R3 30600R3 30600R3 BLAST TUBE 30900M3 30900M4 30900M6 IGNITION CABLE 6050160 6050160 6050160 DETECTION CABLE 6050206 6050206 6050206