Unigas HTP1030, HTP1080, HTP1050, TP1030, TP1050 Installation, User's, And Maintenance Manual
...
HTP1030
HTP1050
HTP1080
Gas - light oil
dual fuel burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -
M039180CC REV. 2 09/2009
ГОРЕЛКИ
TABLE OF CONTENTS
WARNINGS ................................................................................................................................................................ 3
PART I: INSTALLATION 5
GENERAL FEATURES ................................................................................................................................................................... 5
Example of installation .................................................................................................................................................................... 6
How to choose the burner ............................................................................................................................................................... 7
Burner model identification ............................................................................................................................................................. 8
Country and usefulness gas categories .......................................................................................................................................... 8
Overall dimensions ......................................................................................................................................................................... 9
Performance curves ...................................................................................................................................................................... 10
Pressure in the network / gas rate curves ..................................................................................................................................... 11
INSTALLATION ............................................................................................................................................................................ 12
Packing ......................................................................................................................................................................................... 12
Handling the burner ...................................................................................................................................................................... 12
Fitting the burner to the boiler ....................................................................................................................................................... 12
Fan installation .............................................................................................................................................................................. 13
Matching the burner to the boiler .................................................................................................................................................. 13
GAS TRAIN CONNECTIONS ....................................................................................................................................................... 13
Assembling the gas grain .............................................................................................................................................................. 15
Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) ......................................................................... 16
Pressure adjusting range .............................................................................................................................................................. 16
Hydraulic diagrams for light oil supplying circuits ......................................................................................................................... 18
Light oil piping installation diagram ............................................................................................................................................... 19
About the use of fuel pumps ......................................................................................................................................................... 19
Suntec TV Pressure governor ....................................................................................................................................................... 20
Assembling the light oil flexible hoses .......................................................................................................................................... 20
Connecting the burner to the light oil pumping unit ....................................................................................................................... 21
Electrical connections ................................................................................................................................................................... 21
Rotation of fan motor and pump motor ......................................................................................................................................... 21
ADJUSTMENTS ........................................................................................................................................................................... 22
Combustion head gas pressure curves depending on the flow rate ............................................................................................. 22
Measuring the gas pressure in the combustion head ................................................................................................................... 22
Pressure - rate in combustion head curves ................................................................................................................................. 23
Gas Filter ...................................................................................................................................................................................... 24
VPS504 Gas proving system ........................................................................................................................................................ 24
Adjusting the injector gas flow rate: Brahma EG12*R valve and pressure governor .................................................................... 24
Adjustments - brief description ...................................................................................................................................................... 25
Adjustment procedure ................................................................................................................................................................... 25
Calibration of air pressure switch.............................................................................................
Calibration of low gas pressure switch .......................................................................................................................................... 27
Adjusting the high gas pressure switch (when provided) .............................................................................................................. 28
PGCP Gas leakage pressure switch (witn SiemensLDU/Siemens LMV burner control).............................................................. 28
Fully modulating burners ............................................................................................................................................................... 28
Adjustment for light oil operation ................................................................................................................................................... 29
Oil circuit ....................................................................................................................................................................................... 33
..................................................... 27
PART II: OPERATION ............................................................................................................................................. 34
OPERATION ................................................................................................................................................................................. 35
PART III: MAINTENANCE ....................................................................................................................................... 36
ROUTINE MAINTENANCE ........................................................................................................................................................... 36
Gas filter maintenance .................................................................................................................................................................. 36
Replacing the spring in the gas valve group ................................................................................................................................. 37
Light oil filter maintenance ............................................................................................................................................................ 37
Removing the combustion head ................................................................................................................................................... 37
Adjusting the ignition electrode ..................................................................................................................................................... 38
Replacing the ignition electrode .................................................................................................................................................... 39
Cleaning and replacing the detection photocell ............................................................................................................................ 40
Seasonal stop ............................................................................................................................................................................... 40
TROUBLESHOOTING .................................................................................................................................................................. 41
SPARE PARTS ............................................................................................................................................................................. 42
APPENDIX
2
WARNINGS
THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE
USER.
INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.
THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION
OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
1) GENERAL INTRODUCTION
z The equipment must be installed in compliance with the regulations
in force, following the manufacturer’s instructions, by qualified personnel.
z Qualified personnel means those having technical knowledge in the
field of components for civil or industrial heating systems, sanitary
hot water generation and particularly service centres authorised by
the manufacturer.
z Improper installation may cause injury to people and animals, or
damage to property, for which the manufacturer cannot be held liable.
z Remove all packaging material and inspect the equipment for inte-
grity.
In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devices, plastic
bags, foamed polystyrene, etc), should not be left within the reach of children, as they may prove harmful.
z Before any cleaning or servicing operation, disconnect the unit from
the mains by turning the master switch OFF, and/or through the cut-
out devices that are provided.
z Make sure that inlet or exhaust grilles are unobstructed.
z In case of breakdown and/or defective unit operation, disconnect the
unit. Make no attempt to repair the unit or take any direct action.
Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly authorised
by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair the unit’s
safety.
To ensure equipment efficiency and proper operation, it is essential that
maintenance operations are performed by qualified personnel at regular
intervals, following the manufacturer’s instructions.
z When a decision is made to discontinue the use of the equipment,
those parts likely to constitute sources of danger shall be made har-
mless.
z In case the equipment is to be sold or transferred to another user, or
in case the original user should move and leave the unit behind,
make sure that these instructions accompany the equipment at all
times so that they can be consulted by the new owner and/or the
installer.
z For all the units that have been modified or have options fitted then
original accessory equipment only shall be used.
z This unit shall be employed exclusively for the use for which it is
meant. Any other use shall be considered as improper and, there-
fore, dangerous.
The manufacturer shall not be held liable, by agreement or otherwise, for
damages resulting from improper installation, use and failure to comply
with the instructions supplied by the manufacturer.
2) SPECIAL INSTRUCTIONS FOR BURNERS
z The burner should be installed in a suitable room, with ventilation
openings complying with the requirements of the regulations in force,
and sufficient for good combustion.
z Only burners designed according to the regulations in force should
be used.
z This burner should be employed exclusively for the use for which it
was designed.
z Before connecting the burner, make sure that the unit rating is the
same as delivery mains (electricity, gas oil, or other fuel).
z Observe caution with hot burner components. These are, usually,
near to the flame and the fuel pre-heating system, they become hot
during the unit operation and will remain hot for some time after the
burner has stopped.
When the decision is made to discontinue the use of the burner, the user
shall have qualified personnel carry out the following operations:
a Remove the power supply by disconnecting the power cord from the
mains.
b) Disconnect the fuel supply by means of the hand-operated shut-off
valve and remove the control handwheels from their spindles.
Special warnings
z Make sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.
z Before the burner is started and, thereafter, at least once a year,
have qualified personnel perform the following operations:
a set the burner fuel flow rate depending on the heat input of the
appliance;
b set the flow rate of the combustion-supporting air to obtain a combu-
stion efficiency level at least equal to the lower level required by the
regulations in force;
c check the unit operation for proper combustion, to avoid any harmful
or polluting unburnt gases in excess of the limits permitted by the
regulations in force;
d make sure that control and safety devices are operating properly;
e make sure that exhaust ducts intended to discharge the products of
combustion are operating properly;
f on completion of setting and adjustment operations, make sure that
all mechanical locking devices of controls have been duly tightened;
g make sure that a copy of the burner use and maintenance instruc-
tions is available in the boiler room.
z In case of a burner shut-down, reser the control box by means of the
RESET pushbutton. If a second shut-down takes place, call the
Technical Service, without trying to RESET further.
z The unit shall be operated and serviced by qualified personnel only,
in compliance with the regulations in force.
3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED
3a) ELECTRICAL CONNECTION
z For safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.
z It is vital that all saftey requirements are met. In case of any doubt,
ask for an accurate inspection of electrics by qualified personnel,
since the manufacturer cannot be held liable for damages that may
be caused by failure to correctly earth the equipment.
z Qualified personnel must inspect the system to make sure that it is
adequate to take the maximum power used by the equipment shown
on the equipment rating plate. In particular, make sure that the
system cable cross section is adequate for the power absorbed by
the unit.
z No adaptors, multiple outlet sockets and/or extension cables are per-
mitted to connect the unit to the electric mains.
z An omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.
z The use of any power-operated component implies observance of a
few basic rules, for example:
- do not touch the unit with wet or damp parts of the body and/or with
bare feet;
- do not pull electric cables;
- do not leave the equipment exposed to weather (rain, sun, etc.)
unless expressly required to do so;
- do not allow children or inexperienced persons to use equipment;
z The unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact qualified
personnel to replace.
When the unit is out of use for some time the electric switch supplying all
the power-driven components in the system (i.e. pumps, burner, etc.)
should be switched off.
3
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
GENERAL
z The burner shall be installed by qualified personnel and in com-
pliance with regulations and provisions in force; wrong installation
can cause injuries to people and animals, or damage to property, for
which the manufacturer cannot be held liable.
z Before installation, it is recommended that all the fuel supply system
pipes be carefully cleaned inside, to remove foreign matter that might
impair the burner operation.
z Before the burner is commissioned, qualified personnel should ins-
pect the following:
a the fuel supply system, for proper sealing;
b the fuel flow rate, to make sure that it has been set based on the
firing rate required of the burner;
c the burner firing system, to make sure that it is supplied for the desi-
gned fuel type;
d the fuel supply pressure, to make sure that it is included in the range
shown on the rating plate;
e the fuel supply system, to make sure that the system dimensions are
adequate to the burner firing rate, and that the system is equipped
with all the safety and control devices required by the regulations in
force.
z When the burner is to remain idle for some time, the fuel supply tap
or taps should be closed.
SPECIAL INSTRUCTIONS FOR USING GAS
Have qualified personnel inspect the installation to ensure that:
a the gas delivery line and train are in compliance with the regulations
and provisions in force;
b all gas connections are tight;
c the boiler room ventilation openings are such that they ensure the air
supply flow required by the current regulations, and in any case are
sufficient for proper combustion.
z Do not use gas pipes to earth electrical equipment.
z Never leave the burner connected when not in use. Always shut the
gas valve off.
z In case of prolonged absence of the user, the main gas delivery
valve to the burner should be shut off.
Precautions if you can smell gas
a do not operate electric switches, the telephone, or any other item
likely to generate sparks;
b immediately open doors and windows to create an air flow to purge
the room;
c close the gas valves;
d contact qualified personnel.
z Do not obstruct the ventilation openings of the room where gas
appliances are installed, to avoid dangerous conditions such as the
development of toxic or explosive mixtures.
DIRECTIVES AND STANDARDS
Gas burners
European directives:
- Directive 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 (Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements.
Light oil burners
European directives:
- Directive 2006/95/EC on low voltage;
-
Directive 2004/108/CEE 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/CEE on electromagnetic compatibility
Harmonised standards :
-CEI EN 60335-1 Household and similar electrical appliances - SafetyPart
1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Gas - Light oil burners
European directives:
- Directive 90/396/CEE Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 Gas Burners
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Gas - Heavy oil burners
European directives:
- Directive 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
4
CIB UNIGAS - M039180CC
PART I: INSTALLATION
GENERAL FEATURES
This series of industrial burners is designed for all those applications that require big-sized air fans or air-flue heat exchangers to be
installed in sound-proof areas to reduce noise. They can be provided with built-in or separately-mounted control panel (console or wallmounted).
10
9
8
7
11
12
6
5
1
2
4
Fig. 1
1 Adjusting cam
2 Actuator
3 Bellows
4 Air inlet flange
5 Junction box
6 Combustion head adjusting screw
7 Gas filter
8 Gas valves group
9 Cover
10 Ignitor gas train
11 Combustion head-blast tube ass.y
12 Burner flange
Gas operation: the gas coming from the supply line, passes through the valves group provided with filter and stabiliser. This one for-
ces the pressure in the utilisation limits. The actuator (2) moves proportionally the air damper and the gas butterfly valve It drives an
adjusting cam (1) with variable shape. This one allows the optimisation of the gas flue values, as to get an efficient combustion.
Light oil operation:the fuel coming from the supply line, is pushed by the pump to the nozzle and then into the combustion chamber,
where the mixture between fuel and air takes place and consequently the flame.
In the burners, the mixture bertween fuel and air, to perform clean and efficient combustion, is activated by atomisation of oil into very
small particles. This process is achieved making pressurised oil passing through the nozzle.
The pump (8) main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pressure,
pumps are provided with a pressure regulator (except for some models for which a separate regulating valve is provided). Other pumps
are provided with two pressure regulators: one for the high and one for low pressure (in double-stage systems with one nozzle).
The adjustable combustion head can improve the burner performance. The combustion head (11) determines the energetic quality and
the geometry of the flame. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion
chamber).
3
5
Example of installation
CIB UNIGAS - M039180CC
Burner
Gas train
Pumping unit
Fan
Electric panel
Note: the picture shows one of the possible installations. Fan, electrical panel and pumping unit can be placed according to the customer needs.
6
CIB UNIGAS - M039180CC
How to choose the burner
To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed:
z fuel
z furnace input, in kW or kcal/h (kW = kcal/h / 860);
z boiler type;
z combustione head type (reverse flame or three phase)’
z temperature or pressure of the thermal carrier fluid
z Comburent air temperature
z Air duct positioning
z Pressure in the combustion chamber
z Elevation (altitude) of burner installation
z Gas train (only for gas burners)
z Pumping unit (only for light-oil or heavy-oil burners)
z Air fan
z Bilt-in or separated control panel
z backpressure (data are available on the boiler’s ID plate or in the user’s manual).
Burners provided with built-in control panel are designed for IP40 index of protection. For other values of IP, please contact the manifacturer Technical Dpt.
Data requested:
z furnace input;
Power output diagram at 15àC air temperature
TP1050
TP1030
TP525A
TP520A
TP515A
TP512A
TP93A
TP92A
TP91A
TP90A
0 2000 4000 6000 8000 10000 12000 14000 16000
Burner performance range
z air temperature
z altitude
z generator pressure or temperature
Example:
z furnace input: 9600kW
z air temperature: 15°C
z altitude: 0m
Fig. 2
See the diagram in Fig. 2, as to find the burners that better suite the power range requested in the exmple (9600kW). Once the models
are founded out, the choice regards technical and economical features. Technical features can be summarised in a higher modulation
ratio (fewer start-ups, less consumption, fewer swigings in the generator temperature and pressure values.
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 pgas. Draw a vertical line matching the furnace input value (600kW, in the example),
quoted on the x-axis, as far as intercepitng the network pressure curve, according to the installed gas train (DN65, in the example).
From the interception point, draw an horizontal line as far as matching, on the y-axis, the value of pressure necessary to get the requested furnace input. This value must be lower or equal to the p
Tipo / Type P6 0
M-. ..50 ( Multib loc DUNGS MB- DLE 420 B01)
M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)
25
20
15
10
pressure (mbar)
5
rete / Minimum inlet gas
Minima pressione gas in
0
100 200 300 400 500 600 700 80 0 900
gas value, calculated before.
Rp 2" (50)
DN65
Fig. 3
Potenza / Output (kW)
7
CIB UNIGAS - M039180CC
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type HTP1030 Model M-. PR. S. *. A. 1. 80
(1) (2) (3) (4) (5) (6) (7) (8)
(1) BURNER TYPE HTP1030 - HTP1050 - HTP1080
(2) FUEL MG - Natural gas-light oil
(3) OPERATION Available versions PR - Progressive MD - Fully modulating
(4) BLAST TUBE S - Standard
(5) DESTINATION COUNTRY
* - see data plate
(6) BURNER VERSION A - StandardY - Special
(7) EQUIPMENT 1 = 2 valves + gas proving system
8 = 2 valves + gas proving system + high gas pressure switch
(8) GAS CONNECTION 80 = DN80 100 = DN100 125 = DN125
Technical specifications
BURNER TYPE
Output
Fuel
Gas category (see next paragraph)
Gas rate
Oil Density
Oil Viscosity
Light oil rate
Power supply
Total power consumption
Total power consumption
Protection
Operation
Gas pressure (see Note 2)
Gas train 80
Gas train 100
Gas train 125
Weight
Operating temperature °C
Storage Temperature °C
Working service*
Note1:
Note2: Maximum gas pressure = 500mbar (with Siemens VGD gas valves).
all gas flow rates are referred to Stm
ral gas (nett calorific value H
Minimum gas pressure = see gas curves.
= 34.02 MJ/Stm3).
i
min - max kW
3
min.- max.(Stm
min.-max. kg/h
kW
kW
Ø
Valves Connection
Valves Connection
Ø
Valves Connection
Ø
3
/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 natu-
/h)
kg
*NOTE ON THE BURNER WORKING SERVICE: for safety reasons, one controlled shutdown must be performed every 24 hours of
continuous operation.
HTP1030 HTP1050 HTP1080
2550-13000 3500-15500 4500-19000
Natural gas-light oil
270-1376 370-1641 476-2010
840 kg/m3
2 - 7.4 cSt@ 40°C
215 - 1095 295 - 1306 380 - 1600
400V 3N~ 50
5.5
6
IP40
Progressive - Fully modulating
80 / DN80
100 / DN100
125 / DN125
300
-10 ÷ +50
-20 ÷ +60
Internittent
Country and usefulness gas categories
GAS
CATEGORY
I
2H
I
2E
I
2E( R ) B
I
2L
I
2ELL
I
2Er
COUNTRY
AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH
LUPL-----------------------
BE------------------------
NL------------------------
DE------------------------
FR------------------------
8
Overall dimensions (mm)
9
CIB UNIGAS - M039180CC
Air inlet flange
DN A B C CC D E F G H J JJ K KK L M N O OO P Q R RR S SS TT U V W Y Z
HTP1030 80 1864 544 1320 348 1898 1301 597 464 504 710 185 660 660 845 M16 651 460 1000 460 936 200 265 736 80 587 1092 322 1175 372 330
HTP1030 100 1864 544 1320 348 1914 1317 597 464 504 710 185 660 660 845 M16 651 460 1000 460 842 200 265 642 80 587 1092 382 1175 372 330
HTP1050 80 1864 544 1320 348 1898 1301 597 489 539 710 185 660 660 845 M16 651 460 1000 460 936 200 265 736 80 587 1092 322 1175 408 330
HTP1050 100 1864 544 1320 348 1914 1317 597 489 539 710 185 660 660 845 M16 651 460 1000 460 842 200 265 642 80 587 1092 382 1175 408 330
HTP1080 100 1864 544 1320 348 1914 1317 597 514 564 710 185 660 660 845 M16 651 460 1000 460 842 200 265 642 80 587 1092 382 1175 408 330
HTP1080 125 1864 544 1320 348 1946 1349 597 514 564 710 185 660 660 845 M16 651 460 1000 460 954 200 265 754 80 587 1192 480 1175 408 330
Boiler recommended drilling jig
Burner flange
Performance curves
HTP1030
CIB UNIGAS - M039180CC
2000 4000 6000 8000 10000 12000 14000
HTP1050
2000 4000 6000 8000 10000 12000 14000 16000
HTP1080
kW
kW
4000 6000 8000 10000 12000 14000 16000 18000 20000
Performance range
To get the input in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: 1013mbar, 15°C.
10
kW
Pressure in the network / gas rate curves
HTP1030
450
400
350
300
250
200
15 0
10 0
GAS PRESSURE IN
THE NETWORK mbar
HTP1050
50
0
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
CIB UNIGAS - M039180CC
DN80
DN100
DN125
Gas rate Stm3/h
500
400
300
200
GAS PRESSURE IN
THE NETWORK mbar
10 0
0
300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
HTP1080
450
400
350
300
250
200
15 0
GAS PRESSURE IN
THE NETWORK mbar
10 0
50
0
400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
DN80
DN100
DN125
Gas rate Stm3/h
DN100
DN125
Gas rate Stm3/h
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.
11
CIB UNIGAS - M039180CC
INSTALLATION
Packing
The burners are despatched in wodden crates whose dimensions are:
HTP1030 - HTP1050: 2180 mm x 1180 mm x 1210 mm (L x P x H)
HTP1080: 2180 mm x 1580 mm x 1560 mm (L x P x H)
Packing cases of this type are affected by humidity and are not suitable for stacking.
In each packing case, find:
1 burner with gas train detached;
1 gasket to be inserted between the burner and the boiler;
2 flexible oil pipes;
1 oil filter;
1 envelope containing this manual
To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials.
H
P
Handling the burner
ATTENTION! Handling operations must be performed by trained personnel specialised on handling loads. If these
operations are not carried out correctly, the residual risk for the machine to overturn and fall down remains.
To handle the machine, use means suitable to handle requested loads (see par. “Technical specifications”).”
The burner is provided with eye-bolts for lifting.
Eye-bolts
L
Fitting the burner to the boiler
1 To perform the installation, it is necessary to drill the boiler door as described on paragraph “Overall dimensions”;
2 screw the studbolts (5) on the boiler door, according to the drilling plate (see paragraph “Overall dimensions”);
3 move the burner towards the boiler: lift the burner by means of the eyebolts placed on its top side;
4 remove the balst tube, by loosening the three screws beside the burner flange;
5 place the the ceramic fibre plait on the burner flange;
6 replace the blast tube: before fastening completely the screws, avoid any misalignement between the blast tube axis and the com-
bustion head axis;
7 install the burner to the boiler;
8 fix the burner to the stud bolts, by means of the fixing nuts, according to Fig. 4.
9 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).
12
CIB UNIGAS - M039180CC
Keys
4
1Burner
2 Fixing nut
7
3 Washer
4 Ceramic fibre plait
5 Stud bolt
7Blast tube
Fig. 4
Fan installation
Pay attention when designing the air duct: dimensioning must be performed according to the flow rate, the temperature, the distance
between the fan and the burner and according to the fan features as well.
ATTENTION! The bellows unit provided is made of canvas and is provided with blocking spacers to avoid breaking it during
installation: first place the bellows unit between flanges, then remove the spacers. Canvas has to be stretched after the installation, but not stressed.
Matching the burner to the boiler
To correctly match the burner to the boiler verify the necessary input and the pressure in combustion chamber are included in the burner performance curve; otherwise the choice of the burner must be revised consulting the burner manufacturer.
To choose the blast tube lenght follow the instructions of the boiler manufacturer. In absence of these consider the following:
z Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than 100 mm into
the combustion chamber.
z Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in
respect to the tube bundle plate.
The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably-sized
spacer to move the burner backwards.
GAS TRAIN CONNECTIONS
The diagrams show the components of the gas trai 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.
Gas train - 1 (DN80/100): Gas train with valves group VGD40 with built-in gas pressure governor + VPS504 gas proving
system
4
MANUFACTURER
45
INSTALLER
1
2
678
11
5
3
14
15 15
78
13
CIB UNIGAS - M039180CC
Gas train 2 (DN80/100): Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor +
pressure switch) + LDU gas proving system
MANUFACTURER
INSTALLER
4
19
45
1
2
5
6
14
7
8
3
7
8
15 15
Key
1 Burner
2 Butterfly valve
3 Gas proving system
4 High gas pressure switch (option*)
5 Low gas pressure switch
8 Manual cutoff valve
11 VGD Valves group
14 Pressure governor with filter
15 Ignitor gas valve
19 MBC Valves group (DN80/100)
6 Gas filter
7 Bellow joint
Gas train - 3: Gas train with valves group VGD 40 with built-in gas pressure governor + gas leakage pressure switch (PGCP)
for Siemens LDU/LMV burner control
MANUFACTURER
4
1
2
16
45
6
INSTALLER
7
8
11
5
15 15
14
78
Key
1 Burner
2 Butterfly valve
4 High gas pressure switch (option*)
5 Low gas pressure switch
6 Gas filter
8 Manual cutoff valve
11 VGD Valves group
14 Pressure governor with filter
15 Ignitor gas valve
16 PGCP (leakage control pressure switch)
7 Bellow joint
* Note: the high gas pressure switch can be mounted either upstream the gas valve or downstream the gas valves but upstream the
butterfly gas valve.
14
CIB UNIGAS - M039180CC
The pilot gas train is already installed to the burner, the following connections must be executed:
z connection from the filter with stabiliser to the gas supply network
z connection from the valve to the main gas train, by means of the pipe provided with the burner.
connection from the pilot gas train to the gas valves
group of the main train
connection to the gas supply network
3
SIEMENS VGD40..
Fig. 5 - pipe port (3) for connecting the pilot gas train to the valves group of the main gas train
-
Assembling the gas grain
To assemble the main gas train, proceed as follows:
”direction” arrows for installation
3
1E
21D
DUNGS MBC3100-5000SE
gas supply network
1A
5
1B
Keys
1A..1E Gasket
4
1C
2 Gas filter
3 Gas valves group
4 Bellow joint
5 Manual cock
Fig. 6 - Example of gas train
1) in case of flanged joints: place a gasket (no. 1A..1E - Fig. 6) between the elements
2) fasten all the items by means of screws, according to the shcemes showed before, obesrving the mounting direction for each
item.
15
CIB UNIGAS - M039180CC
NOTE: the bellow joint, the manual valve and the gaskets are not part of the standard supply.
ATTENTION: once the gas train is mounted according to the diagram on Fig. 6, 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 showed in the next paragraphs, according to the gas train used:
z flanged gas trains with Multibloc Dungs MBC..SE 1900-3100-5000 or Siemens VGD40.. (flanged valves group)
Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor)
Mounting
z When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded);
z to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts;
z install the valve;
z the direction of gas flow must be in accordance with the direction of the arrow on the valve body;
z ensure that the bolts on the flanges are properly tightened;
z ensure that the connections with all components are tight;
z make certain that the O-rings and gaskets between the flanges and the double gas valve are fitted.
z
Connect the reference gas pipe (TP in figure), to the gas pressure nipples placed on the gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size .
Leave the blowhole free (SA in figure). Should the spring fitted not permit satisfactory regulation, ask one of our service centres for a
suitable replacement.
WARNING: removing the four screws BS causes the device to be unserviceable!
SIEMENS VGD..MOUNTING
POSITIONS
BS
BS
SKP1. SKP2.
BS
BS
SA
TP
Fig. 7
Fig. 8
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
njo/!6!y!EO
2
10 = pulse lines
21
22
7631z05/0101
Fig. 9
#
#
#
"
"
EO
Fig. 10
#
"
"
Pressure adjusting range
The pressure adjusting range, downstream the gas valves group, changes according to the spring provided with the valve group.
16
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