CIB UNIGAS HR1025 Manual Download Page 46

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PART IV: MAINTENANCE

9.0 TROUBLESHOOTING

9.1 Heavy oil operation

THE BU

RNER

DOESN’T STAR

THE BU

RNER

REPEATS PRE-

PURGE

NOISY FUEL

PUMP

THE BU

RNER

DOESN’T STAR

AND STOPS

THE BU

RNER

STARTS AND

STOPS

THE BU

RNER

DOESN’T SWITCH

TO HIGH FL

AME

THE BU

RNER

STOPS DURING

OPERATION

THE BURNER STOPS

AND REP

EATS THE

CYC

E DURING

OPE-

MAIN SWITCH OPEN

LINE FUSE INTERVENTION

MAX. PRESSURE SWITCH FAULT

FAN THERMAL CUTOUT INTERVENTION

AUXILIARY RELAIS FUSES INTERVENTION

CONTROL BOX FAULT

SERVOCONTROL FAULT

SMOKEY FLAME

IGNITION TRANSFORMER FAULT

IGNITION ELECTRODE DIRTY OR WRONG
POSITIONED

DIRTY NOZZLE

FUEL SOLENOID VALVE DEFECTIVE

PHOTORESISTOR DIRTY OR DEFECTIVE

HI-LO FLAME THERMOSTAT DEFECTIVE

WRONG POSITION OF SERVOCONTROL
CAMS

FUEL PRESSURE TOO LOW

DIRTY FUEL FILTERS

Summary of Contents for HR1025

Page 1: ...M039115CF Rel 5 0 12 2014 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive and fully modulating gas light oil burners MANUAL OF INSTALLATION USE MAINTENANCE HR1025 HR1030 HR1040 ...

Page 2: ...UCTIONS 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 t...

Page 3: ...nditions such as the development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 2009 142 EC Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners EN 55014 1Electromagnetic compatibility Requirements for household appliances electric tools and similar ap...

Page 4: ... apparatus EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements UNI EN 746 2 Industrial thermoprocessing equipment Burner data plate For the following information please refer to the data plate z burner type and burner model must be reported in any communication with the supplier z burner ID serial number must be repor ted in any communica...

Page 5: ...ed by atomisation of oil into very small particles This process is achieved making pressurised oil passing through the nozzle The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which a separate regulating valve is provided Other pumps are provided ...

Page 6: ...YPE HR1025 HR1030 HR1040 2 FUEL G Light oil M Natural gas B Biogas L LPG C Town gas 3 OPERATION Available versions PR Progressive MD Fully modulating 4 BLAST TUBE S Standard 5 DESTINATION COUNTRY see data plate 6 BURNER VERSION A Standard Y Special 7 EQUIPMENT 1 2 gas valves gas proving system 8 2 gas valves gas proving system maximum gas pressure switch 8 GAS CONNECTION 50 Rp2 65 DN65 80 DN80 100...

Page 7: ... power consumption kW 23 23 26 5 26 5 36 Electric motor kW 18 5 18 5 22 22 30 Pump motor kW 4 4 4 4 5 5 Protection IP40 Operation Progressive Fully modulating Gas train 50 ØValves Connection 50 Rp 2 Gas train 65 ØValves Connection 2 1 2 DN65 2 1 2 DN65 2 1 2 DN65 Gas train 80 ØValves Connection 3 DN80 3 DN80 3 DN80 Gas train 100 ØValves Connection 4 DN100 4 DN100 4 DN100 Gas train 125 ØValves Conn...

Page 8: ... 65 2088 377 1452 651 25 585 827 118 544 657 1544 680 21211299 822 454 504 709 660 816 M16 651 460 460 914 200 265 714 80 1092 142 292 1146 372 330 HR1030 80 2088 377 1452 651 25 585 841 132 544 657 1544 680 21231301 822 454 504 709 660 816 M16 651 460 460 936 200 265 736 80 1092 142 322 1146 372 330 HR1030 100 2088 377 1452 651 25 585 854 145 544 657 1544 680 21391317 822 454 504 709 660 816 M16 ...

Page 9: ...I2MG 17 v1 Hydraulic diagram nozzle M3 PS PS PSL PSH M M M PI PI PSL PS PI ON BOARD ITEMS SUPPLIED LOOSE ITEMS oil inlet oil outlet gas inlet LPG inlet combustion air LPG gas out of Cib Unigas scope of supply BY CIB UNIGAS BY OTHERS ...

Page 10: ...ith manual valve 27 Butterfly valve 9 One way valve COMBUSTION AIR TRAIN 10 Flexible hose 30 Air damper 11 Pressure gauge with manual valve 31 Actuator 12 Pressure governor 32 Pressure switch PA 14 Pressure switch 33 Draught fan with electromotor 15 One way valve 34 Burner 16 Flexible hose PILOT GAS TRAIN 17 3 way solenoid valve 40 Pressure governor with filter 18 Flexible hose 41 Pressure switch ...

Page 11: ...2MG 18 v1 Hydraulic diagram nozzle type G PS PS PSL PSH M M M PI PI PSL PS PI ON BOARD ITEMS SUPPLIED LOOSE ITEMS oil inlet oil outlet gas inlet LPG inlet combustion air LPG gas out of Cib Unigas scope of supply BY CIB UNIGAS BY OTHERS ...

Page 12: ...ith manual valve 27 Butterfly valve 9 One way valve COMBUSTION AIR TRAIN 10 Flexible hose 30 Air damper 11 Pressure gauge with manual valve 31 Actuator 12 Pressure governor 32 Pressure switch PA 14 Pressure switch 33 Draught fan with electromotor 15 One way valve 34 Burner 16 Flexible hose PILOT GAS TRAIN 17 3 way solenoid valve 40 Pressure governor with filter 18 Flexible hose 41 Pressure switch ...

Page 13: ...to the available gas pressure value upstream the burner s gas valve Then subtract the backpressure The result is called pgas Draw a vertical line matching the furnace input value 600kW in the example quoted on the x axis as far as intercepitng the network pressure curve according to the installed gas train DN65 in the example From the interception point draw an horizontal line as far as matching o...

Page 14: ...he combustion head the minimum output point is rea ched 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 Per formance curve minimum BACK PRESSURE IN COMBUSTION CHAMBER mbar HR1025 2 kW HR1025 DN65 DN80 ...

Page 15: ...M 1 xx Gas rate Stm3 h GAS PRESSURE IN THE NETWORK mbar HR1040 M 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...

Page 16: ...e combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge 1 9 Measuring the gas pressure in the combustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one into the combustion chamber s pressure outlet to get the pressure in the combustion chamber and the other one into the butterfly valve s pressure outlet of t...

Page 17: ... rate in combustion head curves natural gas Curves are referred to pressure 0mbar in the combustion chamber Gas pressure in combustion head HR1025 Gas rate Stm3 h Gas pressure in combustion head HR1030 Gas rate Stm3 h HR1040 Gas rate Stm3 h ...

Page 18: ...in each packing case z burner with detached gas train z gasket or ceramic fibre plait according to burner type to be inserted between the burner and the boiler z envelope containing this manual and other documents z oil flexible hoses To get rid of the burner s packing follow the procedures laid down by current laws on disposal of materials ATTENTION The handling operations must be carried out by ...

Page 19: ... place the ceramic fibre plait on the burner flange 5 install the burner into the boiler 6 fix the burner to the stud bolts by means of the fixing nuts according to the picture below 7 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 The burner is design...

Page 20: ...ast tube lenght follow the instructions of the boiler manu facturer 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 Dist 100 mm into the combustion chamber please see the picture below z Pressurised boilers with flame reversal in this case the blast tube must penetrate Dm 50 100 mm...

Page 21: ...h PGMIN 8 Main burner 3 Safety valve with built in gas governor 9 Bellows unit optional 4 Proving system pressure switch if present PGCP 10 Manual valve optional 5 Pressure switch PGMAX optional Gas train with valves group VGD with built in gas pressure governor gas proving system VPS504 1 Filter optional 6 Butterfly valve 2 Pressure switch PGMIN 7 Main burner 3 Safety valve with built in gas gove...

Page 22: ...ready installed to the burner the following connections must be executed z connection from the filter with stabiliser to the gas supply network ATTENTION once the gas train is mounted according to the diagram on Fig 1 the gas proving test mus be per formed according to the procedure set by the laws in force ATTENTION it is recommended to mount filter and gas valves to avoid that extraneous materia...

Page 23: ...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 8mm external size pipe supplied loose to the gas pressure nipples placed on the gas pipe do...

Page 24: ...articles that are present in the gas and prevent the elements at risk e g burner valves counters and regulators from becoming rapidly blocked The filter is normally installed upstream from all the control and on off devices Fig 9 Fig 10 Fig 11 Performance range mbar 0 22 15 120 100 250 Spring colour neutral yellow red ATTENTION it is reccomended to install the filter with gas flow parallel to the ...

Page 25: ... test phases are passed the proving system test is successful if not a burner lockout happens On LMV5x and LMV2x 3x and LME73 except LME73 831BC the valve proving can be parameterized to take place on startup shut down or both On LME73 831BC the valve proving is parameterized to take place on startup only 3 5 Gas Proving System VPS504 Option The VPS504 check the operation of the seal of the gas sh...

Page 26: ...NNECTIONS 4 1 Hydraulic diagrams for light oil supplying circuits Fig 13 Gravity circuit Fig 14 Ring circuit Fig 15 Suction circuit Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve ...

Page 27: ... installed to avoid air and fuel passing through the pump Burners come out from the factory provided for double pipe systems They can be suited for single pipe system recommended in the case of gravity feed as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rota tion referring to the pump shaft Caution Changing the direction of rotation all co...

Page 28: ...e number of jun ctions should be kept to a minimum as they are a possible source of leakage z Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation These could depo sit on the pump filter or the nozzle reducing efficiency Always use O Rings or mechanical seal copper or aluminium gaskets jun ctions if possible z An external filter should...

Page 29: ... terminal X3 04 4 in case of LMV2x LMV3x LMV5x LME7x on the board and the earth terminal an RC Siemens RC466890660 filter must be inserted For LMV5 control box please refer to the clabeling recommendations avaible on the Siemens CD attached to the burner WARNING Respect the basic safety rules make sure of the connection to the earthing system do not reverse the phase and neutral connections fit a ...

Page 30: ...ER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE EXCEPT FOR ITS MAINTENANCE TO SECURE THE MACHINE ACT ON THE ISOLATOR SWITCH IN CASE OF ANOMALIES THAT REQUIRED A SHUT DOWN OF THE BURNER IT S POSSIBLE TO ACT ON THE AUXILIARY LINE SWITCH LOCATED ON THE BURNER FRONT PANEL 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 T...

Page 31: ...ion LED B4 Ignition transformer operation LED B5 Fan motor overload tripped LED B6 Stand by signalling lamp G1 Gas valves EV2 operation signalling lamp G2 Gas valves EV1 operation signalling lamp G3 Gas pressure switch signal lamp G4 Gas proving system lockout signalling lamp A1 Burner Modulator only on fully modulating burners P1 Gas in the network signalling LED pilot P2 Solenoid valve EVP opera...

Page 32: ...he burner is now operating meanwhile the actuator goes to the high flame position and after some seconds the two stage ope ration begins the burner is driven automatically to high flame or low flame according to the plant requirements Operation in high or low flame is signalled by lamp B2 on the frontal panel 5 4 Light oil operation z The fan motor starts and the pre purge phase as well Since the ...

Page 33: ...re purge time comes to an end and that the burner starts up 4 drive the burner to high flame stage by means fo the thermostat TAB 5 Then move progressively the microswitch to higher values until it reaches the high flame position always check the combustion values and eventually adjusting the gas by means of the valves group stabiliser 6 go on adjusting air and gas flow rates check continuosly the...

Page 34: ...nimum output point 11 as for the point to point regulation move the gas low flame microswitch a little lower than the maximum position 90 12 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position 13 move the gas low flame microswitch to the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw...

Page 35: ...the transparent plastic cap z While the burner is operating at the maximum output test the gas pressure on the pressure port of the minimum gas pressure switch z Slowly close the manual cutoff valve placed upstream the pressure switch see gas train installation diagram until the detected pressure is reduced by 50 Pay attention that the CO value in the flue gas does not increase if the CO values ar...

Page 36: ...usting ring nut VR in the clockwise direction to increase the adju sting pressure until the burner lockout then read the value on the pressure switch scale and set it to a value reduced by 15 z Repeat the ignition cycle of the burner and check it runs properly z Refit the transparent plastic cover on the pressure switch 5 14 PGCP Gas leakage pressure switch witn Siemens LDU LME7x burner control Si...

Page 37: ...OZZLE NOZZLE SUPPLY PRESSURE bar HIGH FLAME RETURN PRESSURE bar LOW FLAME RETURN PRESSURE bar FLUIDICS WR2 UNIGAS M3 25 19 20 7 recommended BERGONZO B 25 18 21 7 recommended MONARCH NOZZLE Tab 7 Fig 18 Atomisation angle according to the return pressure _________ Flow rate FLOW RATE kg h DIMENSIONS Min Max 40 13 40 50 16 50 60 20 60 70 23 70 80 26 80 90 30 90 100 33 100 115 38 115 130 43 130 145 48...

Page 38: ...PART III OPERATION 38 Fig 19 Bergonzo B nozzle example with 850kg h nozzle Pump flow rate Nozzle flow rate ...

Page 39: ...rate adjust the pressure reading its value on the PG pressure gauge without changing the air flow rate set during the gas operation adjustments see previous paragraph checking always the combustion parameters the adjustment is to be performed by means of the SV2 adjusting cam screw see picture when the cam has reached the high flame position 10 once the oil rate is adjusted at the maximum output t...

Page 40: ...d a default value This value must not be higher than the maximum acceptable pressure on the return line this value is reported on the specification table A pressure change on the return line could affect the combustion parameters for this reason the pressure switch must be set say at 20 over the pressure recorded during the combustion adjustment It is recommended to verify that the combustion para...

Page 41: ...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 ...

Page 42: ... cleaner scrape off the scale by means of a metallic brush 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 rin...

Page 43: ...iled view of the combustion head with pilot P and ignition elecctrode E Observe the values shown on next picture Fig 26 ATTENTION avoid the electrode to get in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the electrode position after any intervention on the combustion head E P E P 5mm P E ...

Page 44: ...ry replace the electrode or the detector 8 7 Cleaning and replacing the detection photocell To clean replace the detection photocell proceed as follows 1 Disconnect the system from the electrical power supply 2 Shut off the fuel supply 3 remove the photocell from its slot see next figure 4 clean the bulbe if dirty taking care not to touch it with bare hands 5 if necessary replace the bulb 6 replac...

Page 45: ... 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 8 9 Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials ...

Page 46: ...DURING OPE RATION MAIN SWITCH OPEN z LINE FUSE INTERVENTION z MAX PRESSURE SWITCH FAULT z z FAN THERMAL CUTOUT INTERVENTION z AUXILIARY RELAIS FUSES INTERVENTION z CONTROL BOX FAULT z z z z z SERVOCONTROL FAULT z SMOKEY FLAME z z IGNITION TRANSFORMER FAULT z IGNITION ELECTRODE DIRTY OR WRONG POSITIONED z DIRTY NOZZLE z z FUEL SOLENOID VALVE DEFECTIVE z z PHOTORESISTOR DIRTY OR DEFECTIVE z z HI LO ...

Page 47: ... GAS z z MAXIMUM GAS PRESSURE SWITCH DEFECTIVE z z THERMOSTATS PRESSURE SWITCHES DEFECTIVES z z z OVERLOAD TRIPPED INTERVENTION z AUXILIARIES FUSE INTERRUPTED z DEFECTIVE CONTROL BOX z z z z z DEFECTIVE ACTUATOR z z z AIR PRESSURE SWITCH FAULT OR BAD SETTING z z z z MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIRTY z z z z z IGNITION TRANSFORMER FAULT z IGNITION ELECTRODES BAD POSITION z B...

Page 48: ...V MAINTENANCE 48 10 0 WIRING DIAGRAMS Refer to the attached wiring diagrams WARNING 1 Electrical supply 230V 50Hz 1 a c 400V 50Hz 3N a c 2 Do not reverse phase with neutral 3 Ensure burner is properly earthed ...

Page 49: ...FAN WHEEL 8 5 ACTUATOR 11 5 1 SILENCER 17 1 BOARD 8 6 INDEX LABEL 11 5 2 AIR DAMPER SILENCER 17 2 COVER 8 7 ACTUATOR SHAFT 11 6 NAME PLATE 17 3 1 FRONT CONTROL PANEL 8 8 BRACKET 11 7 INDEX LABEL 17 3 2 LIGHT 8 9 BRACKET 11 8 AIR DAMPER INDEX 17 3 3 LIGHT 8 10 BUSH 12 1 GAS PRESSURE 17 3 4 LOCK OUT RESET BUTTON 8 11 ADJUSTING CAM 12 2 GAS SOLENOID VALVE 17 3 5 PROTECTION 8 11 1 ADJUSTING CAM FOIL 1...

Page 50: ...PART IV MAINTENANCE 50 10 5 2 1 1 ...

Page 51: ...ctivated terminals 22 and 23 or 23 4 for the detector test and the paracitic light test Where the burners do not have dampers or have an independent 00 damper control mechanism there must be a bridge between terminals 6 and 8 otherwise the mechanism will not start up the burner For a burner to start up the following conditions must be met z Mechanism not blocked reset z Damper closed Limit contact...

Page 52: ... because during this period an NTC in the circuit acts as retarder This means that brief unscheduled influences can not cause a block Times t3 t2 and t4 only apply only to safety devices in the series 01 Specifications Mains voltage 220V 15 240V 10 Frequency 50Hz 6 60Hz 6 Absorbed capacity 3 5 VA Built in fuse T6 3 250E slow action DIN41571 No 451915070 External fuse max 16A Interference N VDE0875...

Page 53: ...lot burner fuel valve for mono tube burners for twin tube burners 1 input for raising QRA detector voltage to test level 2 input for excitation of flame relay during flame detector test circuit contact XIV and during safety time contact IV 3 Do not press EK for more than 10 seconds Programmer diagram t1 pre ventilation time t2 safety time t2 1st safety time t3 pre ignition time t3 pre ignition tim...

Page 54: ......

Page 55: ...Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it Note specifications and data subject to change Errors and omissions exceptd ...

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CIB UNIGAS HR1025, Manual, Page: 46 / 55

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