Unigas H455A Manual Download

Page: 39 / 44

PART IV: MAINTENANCE

TROUBLESHOOTNG GUIDE Gas operation

TROUBLESHOOTNG GUIDE Light oil operation

BURNER DOESN'T LIGHT

* No electric power supply

* Restore power supply

* Main switch open

* Close switch

* Thermostats open

* Check set points and thermostat connections

* Bad thermostat set point or broken thermostat

* Reset or replace the thermostat

* No gas pressure

* Restore gas pressure

* Safety devices (manually operated safety thermostat,

pressure switches and so on) open

* Restore safety devices; wait till boiler reaches operating

temperature then check safety device functionality.

* Broken fuses

* Replace fuses. Check current absorption

* Fan thermal contacts open (three phases motors only) * Reset contacts and check current absorption
* Burner control lock out

* Reset and check its functionality

* Burner control damaged

* Replace burner control

GAS LEAKAGE: BURNER LOCKS OUT

(NO FLAME)

* Gas flow is too low

* Increase the gas flow
* Check gas filter cleanness
* Check butterfly valve opening when burner is starting

(only Hi-Low flame and progressive)

* Ignition electrodes discharge to ground because dirty or

broken

* Clean or replace electrodes

* Bad electrodes setting

* Check electrodes position referring to instruction

manual

* Electrical ignition cables damaged

* Replace cables

* Bad position of cables in the ignition transformer or into

the electrodes

* Improve the installation

* Ignition transformer damaged

* Replace the transformer

BURNER LOCKS OUT WITH FLAME PRESENCE

* Wrong setting of flame detector

* Adjust flame detector

* Flame detector damaged

* Replace flame detector

* Bad cables of flame detector

* Check cables

* Burner control damaged

* Replace burner control

* Phase and neutral inverted

* Adjust connections

* Ground missing or damaged

* Check ground continuity

* Voltage on neutral

* Take off tension on neutral

* Too small flame (due to not much gas)

* Adjust gas flow
* Check gas filter cleanness

* Too much combustion air

* Adjust air flow rate

only FOR LME22: BURNER CONTINUES TO PER-

FORM ALL ITS FEATURES WITHOUT IGNITING
THE BURNER

* Air pressure switch damaged or bad links

* Check air pressure switch functions and links

* Burner control damaged

* Replace burner control

BURNER LOCKS OUT WITHOUT ANY GAS FLOW

* Gas valves don’t open

* Check voltage on valves; if necessary replace valve or

the burner control

* Check if the gas pressure is so high that the valve

cannot open

* Gas valves completely closed

* Open valves

* Pressure governor too closed

* Adjust the pressure governor

* Butterfly valve closed

* Open the butterfly valve

* Maximum pressure switch open.

* Check connection and functionality

* Air pressure switch doesn’t close the NO contact

* Check connections
* Check pressure switch functionality

THE BURNER IS BLOCKED AND THE EQUIPMENT

PROVIDES A LOCK CODE "CAUSE AIR PRESSURE
SWITCH FAULT"

* Air pressure switch damaged (it keeps the stand-by

position or badly set)

* Check air pressure switch functionality

* Reset air pressure switch

* Air pressure switch connections wrong

* Check connections

* Air fan damaged

* Replace motor

* No power supply

* Reset power supply

* Air damper too closed

* Adjust air damper position

BURNER LOCKS OUT DURING NORMAL RUNNING

* Flame detector circuit interrupted

* Check wiring
* Check photocell

* Burner control damaged

* Replace burner control

* Maximum gas pressure switch damaged or badly set

* Reset pressure switch or replace it

THE BURNER STARTS AND AFTER A WHILE IT

REPEATS THE STARTING CYCLE.

* Gas pressure switch badly set

* Reset the pressure switch

* Gas filter dirty

* Clean gas filter

* Gas governor too low or damaged

* Reset or replace the governor

BURNER STANDS WHILE RUNNING WITHOUT ANY

SWITCHING OF THERMOSTATS

* Thermal contacts of fan motor open

* Reset contacts and check values
* Check current absorption

FAN MOTOR DOESN'T START

* Internal motor wiring broken

* Replace wiring or complete motor

* Fan motor starter broken

* Replace starter

* Fuses broken (three phases only)

* Replace fuses and check current absorption

BURNER DOESN'T SWITCH TO HIGH FLAME

* Hi-low flame thermostat badly set or damaged

* Reset or replace thermostat

* Servomotor cam badly set

* Reset servomotor cam

mechanical only

: SOMETIMES THE SERVOMOTOR

RUNS IN THE WRONG WAY

* Servomotor capacitor damaged

* Replace capacitor

PHASE-TO-PHASE SUPPLY OR PRESENCE OF

VOLTAGE ON NEUTRAL*

* Lights up and freezes

* In such cases, insert an RC circuit (our code 2531003).

Summary of Contents for H455A

Page 1: ...M039618CA 0 3 09 2022 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ MANUAL OF INSTALLATION USE MAINTENANCE H455A H630A H685A Gas light oil burners ...

Page 2: ...anufacturer declines all responsibility for non compliance with this manual Personnel training The user is the person organisation or company that has acquired the appliance and intends to use it for the specific purpose The user is responsible for the appliance and for training the personnel that operate it The user Undertakes to entrust the machine to suitably trained and qualified per sonnel Mu...

Page 3: ... compliance with the regulations in force GENERAL INSTRUCTIONS DEPENDING ON FUEL USED 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 liabl...

Page 4: ...nt and risk reduction For the following information please refer to the data plate Burner type and burner model must be reported in any communication with the supplier Burner ID serial number must be reported in any communication with the supplier Date of production year and month Information about fuel type and network pressure Consump WARNING Failure to observe the warning may result in irrepara...

Page 5: ... 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 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 generat...

Page 6: ...te Natural gas min max Stm3 h 79 481 74 667 78 725 Gas pressure mbar see Note 2 see Note 2 see Note 2 Light oil rate min max Stm3 h 63 384 59 531 62 578 63 384 59 531 62 578 63 384 59 531 62 578 LPG rate min max Stm3 h 28 170 26 235 28 256 Off gas rate min max Stm3 h 154 932 143 1291 152 1404 Oil viscosity cSt 40 C 2 7 4 Oil density kg m3 840 Light oil train inlet bar max 2 Power supply triphase 2...

Page 7: ...13 845 190 856 270 H630A 65 1747 295 35 611 117 530 488 1217 511 1584 969 615 340 380 494 480 586 M14 552 390 390 390 634 150 484 845 294 856 270 H630A 80 1747 295 35 626 132 530 488 1217 511 1617 1002 615 340 380 494 480 586 M14 552 390 390 390 686 150 535 875 313 856 270 H630A 100 1747 295 35 639 145 530 488 1217 511 1697 1082 615 340 380 494 480 586 M14 552 390 390 390 791 150 642 942 353 856 2...

Page 8: ...ssure gauge 13 Pressure governor 15 Pressure switch 16 One way valve 17 Flexible hose 18 Flexible hose 19 Manual valve 19 1 Manual valve 20 Pressure gauge MAIN GAS TRAIN 40 Manual valve 41 Bellows unit 42 Filter 43 Pressure switch PGMIN 44 Safety valve with built in gas governor 45 Proving system pressure switch PGCP 46 Pressure switch PGMAX 47 Butterfly valve COMBUSTION AIR TRAIN 50 Air damper 51...

Page 9: ...vailable 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 ...

Page 10: ...st 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 COMBUSTION CHAMBER mbar H455A M kW H630A M kW PRESSURE IN COMBUSTION CHAMBER mbar H685A M kW The values in the diagrams refer to natural gas with a calorific value of 8125 kcal ...

Page 11: ...al gas WARNING the diagrams refers to natural gas For different type of fuel please refer to the paragraph Fuel at the beginning of this chapter GAS PRESSURE IN THE NETWORK mbar H455A Gas rate Stm3 h H630A Gas rate Stm3 h GAS PRESSURE IN THE NETWORK mbar H685A Gas rate Stm3 h ...

Page 12: ...en from the boiler s Technical specifications Measuring 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 the burner On the basis of the measured differential pressu...

Page 13: ...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 Packing The burners are despatched in wooden crates whose dimensions are series 1810mm x 1310mm x 1060mm L x P x H Packing cases of this type are affected by humidity and are not suitable for stacking The fol...

Page 14: ...iagram In case the burner must be coupled with boilers with a combustion chamber smaller in dia meter 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 type of the blast tube Verify the necessary input and the pressure in combustion ...

Page 15: ...ount the gas train proceed as follows NOTE the bellows unit the manual cutoff valve and the gaskets are not part of the standard supply WARNING before executing the connections to the gas pipe network be sure that the manual cutoff valves are closed ATTENTION it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the valves during maintenance and cleaning o...

Page 16: ...n gas governor 8 Main burner 4 Proving system pressure switch PGCP 9 Antivibration joint optional 5 Pressure switch PGMAX mandatory for MBE optional for VGD and MB DLE 10 Manual valve optional MULTIBLOC DUNGS MB DLE 405 412 MB DLE 415 420 Mounting 1 Mount flange onto tube lines use appropriate sealing agent 2 Insert MB DLE note position of O rings 3 Remove MultiBloc between the threaded flanges 4 ...

Page 17: ... filters outside the valves group and the ones built in the gas valves WARNING Slowly open the fuel cock to avoid breaking the pressure regulator Attention In the case of the MBE valve a pressure limit switch downstream of the safety valve is mandatory ALLA V FARFALLA GAS BRUCIATORE ø185 501939 PGMAX PGCP PGMI EV1 EV2 S EV2 EV1 PGMAX PGMIN VD R PGCP VD V VD V VD R PS PS pressure sensor Gas filter ...

Page 18: ...ccording to MBE Pipe fitting with female thread size mount sensor with seal observe torque 3 The pressure sensor includes a vent limiter according to UL 353 and ANSI Z21 18 CSA 6 3 No venting required in loca tions where vent limiters are accepted by the jurisdiction 4 Only PS pressure sensors specified by DUNGS are authorised to be connected to the VD R s M12 interface 5 Only PS cables specified ...

Page 19: ... Plug connection End of stroke Plug connection Actuator connection A Valve closed only with SKPxx xx1xx 1 2 2 1 1 3 2 Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve NOTE in plants where gravity or ring feed systems are provided install an automatic interception device RING CIRCUIT GRAVITY CIRCUIT SUCTION CIRCUIT ...

Page 20: ... 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 connections on top and side are reversed HP UHE series pumps a kit Art Nr 0841211 is required for the transition from 2 pipe to 1 pipe ...

Page 21: ...he nozzle reducing efficiency Always use O Rings or mechanical seal copper or aluminium gaskets jun ctions if possible An external filter should always be installed in the suction line upstream the fuel unit 1 Connection for manometer 1 delivery M1 G1 4 2 Connection for manometer 2 suction M2 G1 4 3 Connection for manometer 3 M3 A Suction connection G1 2 D Direct clockwise I Indirect counter clock...

Page 22: ... careful to avoid exchanging the lines see the arrows marked on the pump For further information refer to the technical documentation of the pump Diesel filters Suntec TA Oil viscosity 3 75 cSt Oil temperature 0 150 C Min suction pressure 0 45 bar to avoid gasing Max suction pressure 5 bar Max return pressure 5 bar Rotation speed 3600 rpm max Suntec T TV HP Technik UHE A Suntec TA R A R A R A Item...

Page 23: ...inal 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 diffe...

Page 24: ...HE 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 TECHNICAL SERVICE WITHOUT TRYING TO RESE...

Page 25: ...imum opening position is reached the pre purge time counting starts At the end of the pre purge time the actuator is in the light oil ignition position the ignition transformer is energised lamp B4 on the ignitor gas valves if provided and the light oil valves open Few seconds after the valves opening the transformer is de ener gised and lamp B4 turns off The burner is now operating meanwhile the ...

Page 26: ...oints regulating the opening closing of the air damper Set now the low flame output acting on the low flame microswitch of the actuator 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 To change the burner setting during the testing in the plant follows the next procedure according to the model provided WARNI...

Page 27: ...n values and eventually adjusting the gas by means of the valves group stabiliser 10 go on adjusting 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 SQM40 265 CSV Actuator cams 11 acting on the pressure stabiliser of the valves group adjust the gas flow rate in ...

Page 28: ...me microswitch towards the minimum to meet the next screw on the adjusting cam and repeat the pre vious step go on this way as to reach the desired low flame point 19 Now adjust the pressure switches Fully modulating burners To adjust the fully modulating burners use the CMF switch on the burner control panel see next picture instead of the TAB thermo stat as described on the previous paragraphs a...

Page 29: ...djustments do not exceed a value that creates a hazardous condition to the burner Adjusting output pressure for positive pressure systems requires PS 10 40 or PS 50 200 Outlet pressure MIN 10 25 50 75 MAX PS 10 40 4 mbar 0 4 kPa 2 w c 10 mbar 1 0 kPa 4 w c 25 mbar 2 5 kPa 10 w c 50 mbar 5 0 kPa 20 w c 75 mbar 7 5 kPa 30 w c 100 mbar 10 0 kPa 40 w c PS 50 200 20 mbar 2 0 kPa 8 w c 50 mbar 5 0 kPa 2...

Page 30: ...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 upstre...

Page 31: ...the plant during the commissioning The factory setting depends on the type of fuel for which the burner is designed For natural gas burners plate holes are fully opened Center head holes gas flow regulation LPG burners 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 ...

Page 32: ...ATE kg h Indicative pessure on return bar Min Max 40 13 40 19 50 16 50 22 60 20 60 20 70 23 70 23 80 26 80 23 90 30 90 22 100 33 100 22 115 38 115 21 130 43 130 22 145 48 145 21 160 53 160 21 180 59 180 22 200 66 200 21 225 74 225 22 250 82 250 22 275 91 275 22 300 99 300 23 330 109 330 23 360 119 360 22 400 132 400 22 450 148 450 22 500 165 500 22 550 181 550 22 600 198 600 23 650 214 650 23 700 ...

Page 33: ... VR Pressure values are indicated at the beginning of this paragraph 9 in order to get the maximum oil flow 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 pictu...

Page 34: ...pressure switch The oil pressure switch on the return line checks that the pressure does not exceed 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 press...

Page 35: ...rease joints and rotating parts IMPORTANT Remove the combustion head before checking the ignition electrode Remove and clean the compressed air regulator Remove and clean the oil regulator if provided Gas filter maintenance 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 c...

Page 36: ...t direction or any references on the cover and tray 7 Replace the filter by following the reverse order operations 8 Make sure there is no leakage and give the power to any electrical equipmente on the filter MultiBloc MBEMultiBloc VD Mounting Thecnical procedure of self cleaning filters substitution valid for all models WARNING Drain the system by unscrewing the drain screw on the bottom of the s...

Page 37: ...e prevoius paragraph 2 loosen the VL screw and remove the oil gun and the electrodes check the oil gun replace it if necessary 3 after removing the oil gun unscrew the nozzle and replace it if necessary 4 in order to replace the electrodes unscrew the VE fixing screws and remove them place the new electrodes being careful to observe the measures showed on pag reassemlbe following the reversed proc...

Page 38: ...n 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 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 ...

Page 39: ... Check air pressure switch functions and links Burner control damaged Replace burner control BURNER LOCKS OUT WITHOUT ANY GAS FLOW Gas valves don t open Check voltage on valves if necessary replace valve or the burner control Check if the gas pressure is so high that the valve cannot open Gas valves completely closed Open valves Pressure governor too closed Adjust the pressure governor Butterfly v...

Page 40: ...nition transformer or into the electrodes Improve the installation Ignition transformer damaged Replace the transformer PUMP TOO NOISY Suction too high over 0 35 bar dirty filters check valve in the tank locked and so on Clean filters Replace check valve in the tank Flexible hoses damaged Replace flexible hoses Air infiltration in the pipes Take off all infiltration Pipe too long or too narrow Inc...

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Page 44: ...ia 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 excepted ...

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