CIB UNIGAS Low NOx Series Manual Of Installation - Use - Maintenance Download

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M039308CA Rel. 0.2 05/2015

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Gas burners

Low NOx series

MANUAL OF INSTALLATION - USE - MAINTENANCE

RX92

Summary of Contents for Low NOx Series

Page 1: ...M039308CA Rel 0 2 05 2015 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Gas burners Low NOx series MANUAL OF INSTALLATION USE MAINTENANCE RX92 ...

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: ...r 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 communic...

Page 5: ...in the utilisation limits The electric actuator that moves proportionally the air damper and the gas butterfly valve uses an adjusting cam with variable shape This one allows the optimisation of the gas flue values as to get an efficient combustion The combustion head positioning determines the burner s output The combustion head determines the energetic quality and the geometry of the flame Fuel ...

Page 6: ...ons 50 Rp2 65 DN65 80 DN80 100 DN100 BURNER TYPE RX92 Output min max kW 480 2450 Fuel Natural gas Gas rate see next paragraph Gas rate min max Stm3 h 51 259 Gas pressure see Note 2see Note 2 Power supply 400V 3N 50Hz Power supply kW 3 5 Total power consumption kW 3 Electric motor kg 250 Approximate weight IP40 Protection Progressive Fully modulating Operation ØValves Connection 50 Rp 2 Gas train 5...

Page 7: ...m3 ρ kg Stm3 fQ fp LPG 26 79 2 151 0 353 0 4 Town gas 4 88 0 6023 1 936 3 3 Biogas 6 395 1 1472 1 478 3 5 ATTENTION The combustion head type and the settings depend on the fuel The burner must be used only for its intended purpose specified in the burner data plate ATTENTION The corrective factors in the above table depend on the gas composition so on the calorifc value and the density of the gas ...

Page 8: ...0 649 228 185 65 1421 246 35 564 117 382 441 1005 425 1406 971 435 286 316 228 447 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 80 1421 246 35 579 132 382 441 1005 425 1437 1002 435 286 316 228 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185 100 1421 246 35 592 145 382 441 1005 425 1520 1085 435 286 316 228 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 ...

Page 9: ...o 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...

Page 10: ...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 2 9 Pressure in the Network gas flow rate curves PRESSURE IN COMBUSTION CHAMBER mbar RX92 kW GAS PRESSURE mbar RX92 Stm3 h Caution the gas rate value is quoted on the x axis the related network pressure is quoted on the y axis ...

Page 11: ...n the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement The burner is designed to work positioned according to the picture below For different installations please contact the Technical Department Note the figure is indicative only 2 11 Packing The burners are despatched in wooden crates whose dimensions are series 9x 1672mm...

Page 12: ...r verify the type of the blast tube type 1 or type 2 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 manu facturer In absence of these consider the following z Cast iron boilers thr...

Page 13: ... the gas train proceed as follows WARNING BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED Gas train with valves group VGD 20 40 with built in gas pressure governor PGCP gas leakage pressure switch 1 Burner 2 Butterfly valve 4 Maximum gas pressure switch option 5 Minimum gas pressure switch 6 Gas filter 7 Bellows unit 8 Manual cutoff valve 1...

Page 14: ...low 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 8mm external size pipe supplied loose to the gas pressur...

Page 15: ...nters and regulators from becoming rapidly blocked The filter is normally installed upstream from all the control and on off devices Once the gas train in installed execute the electrical connections for all its items gas valves group gas proving system pressure switches Performance range mbar 0 22 15 120 100 250 Spring colour neutral yellow red ATTENTION it is reccomended to install the filter wi...

Page 16: ...2 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 17: ...re outlet on the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge 5 2 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 press...

Page 18: ...e 0mbar in the combustion chamber Gas pressure in combustion head mbar RX92 Stm3 h WARNING the diagrams refers to natural gas For different type of fuel please refer to the paragraph Fuel at the beginning of this chapter 0 2 4 6 8 10 12 14 16 18 20 22 40 60 80 100 120 140 160 180 200 220 240 260 280 ...

Page 19: ...HE GENERATOR COUPLING FLANGE CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT 1 Turn to the ON position the main switch A on the burner s control panel see 6 0 2 Check the control box is not locked LED B on and eventually release it by means of the pushbutton C reset for more informa tion about the device please refer to the manual s Appendix 3 Check the series of thermostats or pres...

Page 20: ...burners provided with Siemens LDU11 E Gas pressure switch signal LED F Lock out LED for gas proving system G Hi flame operation LED H Lo flame operation LED I Ignition transformer operation LED L EV2 opening LED M EV1 opening LED N Fan motor overload tripped LED O Burner in stand by LED P Burner Modulator only on fully modulating bur ners M F D P A C E L N G H B I O ...

Page 21: ...s by means of Siemens SQM40 Berger STM30 actuator 1 check the fan motor rotation 2 Before starting the burner up drive the high flame actuator microswitch matching the low flame one in order to let the burner ope rates at the lowest output to safely achieve the high flame stage 3 Turn the burner on by means of its main switch A see next picture if the burner locks LED B on in the control panel pre...

Page 22: ...as to get the desired air flow rate moving the rod TR towards the air damper shaft the air damper opens and consequently the air flow rate increases moving it far from the shaft the air damper closes and the air flow rate decreases Note once the procedure is perfomed be sure that the blocking nut RA is fasten Do not change the position of the air damper rods 10 Only if necessary change the combusi...

Page 23: ...ing stages to drive the burner to the high flame stage set CMF 1 to drive it to the low flame stage set CMF 2 6 4 Adjusting the combustion head Burner is factory set according to its combustion head model z The burner is factory set with the head in its all ahead position as for the minimum output To operate at a higher power loosen the VB screw and slightly move the combustion head backwards by s...

Page 24: ...ans of the adjusting ring nut VR set the value read on step 2 increased by the 30 4 replace the plastic cover 6 8 Calibration of low gas pressure switch As for the gas pressure switch calibration proceed as follows z Be sure that the filter is clean z Remove 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 g...

Page 25: ...st time td1 The pressure switch PGCP has not to detect a rise of pressure z Test space filling EV2 opens and keep this position for a preset time td3 in order to fill the test space z Test gas pressure EV2 closes and keep this position for a preset time td2 The pressure switch PGCP has not to detect a pres sure drop down If all of the test phases are passed the proving system test is successful if...

Page 26: ...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 27: ...mbustion head by a compressed air blow or in case of scale scrape it off by a scratchbrush 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 Attention before adjusting the combustion head turn the burner off and wait until it gets cold Key VRT Head adjusting screw AR Threaded rod V Fixing screw G G...

Page 28: ...s see next pictures 5 remove the electrodes and replace them referring to the measures indicated in the previous paragraph 6 reconnect the electrodes cables 7 replace the combustion head 8 replace the burner cover 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 af...

Page 29: ...etection electrode or detector the electrical contacts and if necessary replace the electrode or the detec tor Fig 14 Detection by electrode Fig 15 Detection by photocell QRA 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 sp...

Page 30: ...which it must be replaced 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 replace the photocell into its slot ...

Page 31: ...F 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 ...

Page 32: ...4 2 GAS VALVE HOUSING 14 2 1 DETECTION ELECTRODE 10 DETECTION CABLE 12 4 3 SKP ACTUATOR 14 2 2 IGNITION ELECTRODE 11 1 BURNER HOUSING 12 4 4 SKP ACTUATOR 15 1 FAN WHEEL 11 2 BURNER HOUSING 12 4 5 GAS PROVING SYSTEM 15 2 MOTOR 11 3 COVER 13 1 BUSH 16 1 FRONT CONTROL PANEL 11 4 FLANGE 13 2 BUSH 16 2 BOARD 11 5 NET 13 3 BUSH 16 3 COVER 11 6 CERAMIC FIBRE PLAIT 13 4 ADJUSTING CAM SHAFT 17 1 CONTROL BO...

Page 33: ...PART IV MAINTENANCE 33 ...

Page 34: ...V MAINTENANCE 34 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 ...

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Page 36: ...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 Low NOx Series, Manual Of Installation - Use - Maintenance

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