Unigas HP91A Manual Of Installation - Use - Maintenance Download | Manualshive

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C.I.B. UNIGAS - M039140CE

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Electrical Wiring Diagram for Burners Fitted with Printed Circuit

Rotation of fan motor and pump motor

Once the electrical connection of the burner is executed, remember to check the rotation of the motor. The motor should rotate accor-
ding to the indication on the body. In the event of wrong rotation, reverse the three-phase supply and check again the rotation of the
motor.

NOTE (exceptHP525A): burners are supplied for three-phase 400V supply, and in the case of three-phase 230V supply it is
necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped
relay.

High-low flame burners

Electric motor connection

Probes connection

Fully modulating burners

Power supply terminal board

Terminal board for connections on printed circuit

CAUTION: check the motor thermal cut-out adjustment

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Summary of Contents for HP91A

Page 1: ...E Rev 4 12 2009 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive and fully modulating gas light oil burners MANUAL OF INSTALLATION USE MAINTENANCE HP91A HP92A HP93A HP512A HP515A HP520A HP525A ...

Page 2: ...be employed exclusively for the use for which it was designed Before connecting the burner make sure that the unit rating is the same as delivery mains electricity gas oil or other fuel Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stoppe...

Page 3: ...mixtures DIRECTIVES AND STANDARDS Gas burners European directives Regulation 2016 426 UE appliances burning gaseous fuels 2014 35 UE Low Tension Directive 2014 30 UE Electromagnetic compatibility Directive 2006 42 EC Machinery Directive Harmonized standards UNI EN 676 Automatic forced draught burners for gaseous fuels EN 55014 1 Electromagnetic compatibility Requirements for house hold appliances ...

Page 4: ...equipment of machi nes EN 60335 2 Electrical equipment of non electric appliances for house hold and similar purposes Safety requirements Burner data plate 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 repor ted in any communication with the supplier date of productio...

Page 5: ... coming from the supply line is pushed by the pump 10 to the nozzle and then into the combustion cham ber 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 ...

Page 6: ...cording 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 pgas value calculated before Fig 3 Burner model identification Burners are identified by burner type and model Burner model identification is described ...

Page 7: ...15A HP520A HP525A 50 HP525A xx Output min max kW 770 5200 1000 6400 2000 6700 2000 8000 Fuel Natural gas Light oil Category see next paragraph Gas rate min max Stm3 h 81 550 106 677 212 709 212 847 Gas pressure mbar see Note 2 Light oil rate min max kg h 65 438 84 539 168 564 168 674 Oil viscosity cSt 40 C 2 7 4 Oil density kg m3 840 Power supply 230V 3 400V 3N 50Hz Total power consumption kW 13 1...

Page 8: ... 624 216 651 228 185 HP92A 65 1455 242 490 419 918 422 1544 957 587 269 299 288 360 466 M12 417 280 310 295 551 148 403 750 292 651 228 185 HP92A 80 1455 242 490 419 918 422 1546 959 587 269 299 307 360 466 M12 417 280 310 295 592 148 444 750 322 651 228 185 HP92A 100 1455 242 490 419 918 422 1636 1049 587 269 299 447 360 592 M12 417 280 310 295 672 148 524 824 382 777 228 185 HP93A 50 1460 242 49...

Page 9: ... 160 403 750 292 733 328 235 HP515A 80 1608 332 520 511 1021 455 1636 959 677 380 420 354 460 498 M14 552 390 390 604 160 444 750 322 733 328 235 HP515A 100 1608 332 520 511 1021 455 1726 1049 677 380 420 392 460 498 M14 552 390 390 684 160 524 824 382 733 328 235 HP520A 50 1608 332 520 511 1021 455 1615 938 677 400 450 337 460 498 M14 552 390 390 685 160 525 710 216 733 340 235 HP520A 65 1608 332...

Page 10: ...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 HP91A kW HP92A kW BACK PRESSURE IN COMBUSTION CHAMBER mbar HP93A kW HP512A kW BACK PRESSURE IN COMBUSTION CHAMBER mbar HP515A kW HP520A kW BACK PRESSURE IN COMBUSTION CHAMBER mbar HP...

Page 11: ... value in the combustion chamber to the value read on the y axis 0 10 20 30 40 50 60 70 80 90 100 50 100 150 200 250 300 Rp 2 50 DN65 DN80 DN100 0 20 40 60 80 100 120 140 50 100 150 200 250 300 350 Rp 2 50 DN100 DN80 DN65 0 40 80 120 160 200 50 100 150 200 250 300 350 400 450 500 Rp 2 50 DN65 DN80 DN100 0 40 80 120 160 200 50 100 150 200 250 300 350 400 450 500 550 Rp 2 50 DN65 DN80 DN100 0 50 100...

Page 12: ...cribed on paragraph Overall dimensions 2 place the burner to the boiler lift it up and handle it according to the procedure described on paragraph Handling the burner 3 place the 4 stud bolts 5 on boiler s door according to the burner s drilling template described on paragraph Overall dimensions 4 fasten the 4 stud bolts 5 place the gasket on the burner flange 6 install the burner into the boiler ...

Page 13: ...t 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 res...

Page 14: ...valves group VGD 20 40 with built in gas pressure governor VPS504 gas proving system Gas train 2Gas train with valves group MBC 1200SE 2 valves gas filter pressure governor VPS504 gas proving system Gas train 3 DN65 80 100 Gas train with valves group MBC 1900 3100 5000SE 2 valves gas filter pressure governor VPS504 gas proving system 1 Burner 2 Butterfly valve 3 Gas proving system 4 Maximum gas pr...

Page 15: ...group ATTENTION once the gas train is mounted according to the diagram on Fig 5 the gas proving test mus be performed according to the procedure set by the laws in force ATTENTION it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the valves during maintenance and cleaning operation of the filters both the filters outside the valves group and the ones b...

Page 16: ...uble 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 pres sure must be measured at a distance that must be at least 5 times the pipe size Leave the blowhole free SA in figure Should the spring fitted not permit satisfactory regulation ask one of our service centres for a suitable replacement Caution...

Page 17: ...is installed connect electrically all its elements gas valves group pressure switches gas proving system DUNGS MBC SE Siemens SKP actuator Performance range mbar 4 20 20 40 40 80 80 150 Spring colour red black green Performance range mbar 0 22 15 120 100 250 Spring colour neutral yellow red ATTENTION once the gas train is mounted according to the diagram on Fig 5 the gas proving test mus be perfor...

Page 18: ...plants where gravity or ring feed systems are provided install an automatic interception device see n 4 Fig 16 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 19: ...eed flat on the piston In one pipe operation the plug of a pressure gauge port must be loosened until the air is evacuated from the system About the use of fuel pumps z Make sure that the by pass plug is not used in a single pipe installation because the fuel unit will not function properly and damage to the pump and burner motor could result z Do not use fuel with additives to avoid the possible ...

Page 20: ...tion line upstream of the fuel unit Light oil pumps Keys 1 Pressure regulator 2 Pressure Vacuum gauge port to measure inlet pressure vacuum 3 Pressure gauge port 5 Suction 7 To the nozzle 8 Return Suntec T pump Note pump with C rotation 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 Rotatio...

Page 21: ...e lock nut 4 To increase pressure turn adjusting screw 3 clockwise To decrease the pressure turn screw anticlockwise Tight the lock nut 4 refit the gasket 2 and the cap nut 1 Key 1 Cap nut 2 Gasket 3 Adjusting screw 4 Lock nut 5 Gasket Suntec TA Danfoss KSM Suntec T Respect the basic safety rules make sure of the connection to the earthing system do not reverse the phase and neutral connections fi...

Page 22: ...heck again the rotation of the motor NOTE exceptHP525A burners are supplied for three phase 400V supply and in the case of three phase 230V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay High low flame burners Electric motor connection Probes connection Fully modulating burners Power supply terminal boa...

Page 23: ...mbustion values table and CO in the standard limits During this stage the combustion head the gas butterfly valve and the actuator are at the maximum opening Refer to Fig 18 showing the correct way to measure the gas pressure considering the values of pressure in combustion chamber surveyed by means of the pressure gauge or taken from the boiler s Technical specifications Fig 18 Key 1 Generator 2 ...

Page 24: ...OR A PROPER SETTING OF THE GAS RATE PLEASE REFER TO THE GAS METER READING Pressure in combustion head gas rate curves Gas pressure in combustion head HP91A Stm3 h HP92A Stm3 h Gas pressure in combustion head HP93A Stm3 h HP512A Stm3 h GAS PRESSURE mbar HP515A Stm3 h HP520A Stm3 h GAS PRESSURE mbar HP525A Rp2 Stm3 h HP525A DN65 80 100 Stm3 h 0 5 10 15 20 25 30 35 40 40 60 80 100 120 140 160 180 200...

Page 25: ... THE SEALED SCREWS OTHERWISE THE DEVICE WARRANTY WILL BE INVALIDATE Fig 19 Keys 1 Gas filterl 2 Gas proving system 3 Gas valves 4 Air pressure switch 5 Oil Adjusting cam 6 Fuel pump 7 Actuator 8 Gas Adjusting cam VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off val ves This check is carried out as soon as the boiler thermostat gives a start signal to the bur...

Page 26: ...o much or that the flues temperature gets too low to cause condensation in the chimney Adjustment procedure To change the burner setting during the testing in the plant follow the next procedure On the DUNGS MBC SE gas valves group set the pressure regulator to 1 3 of its stroke using a 2 5 allen key The burner is factory set wih the adjusting plate holes fully open and the combustion head at its ...

Page 27: ... as to meet the values requested by the boiler utilisation Siemens VGD valves group remove cap T and act on the VR adjusting screw to increase or decrease the pressure and conse quently the gas rate screwind VR the rate increases unscrewing it decreases see next figure Dungs MBC SE valves group act on its pressure governor to increase or decrease the pressure and consequently the gas rate 9 To adj...

Page 28: ...mes to an end 4 the burner starts up with the actuator on the ignition position set it to the MAN manual mode by the MAN AUTO selector ignition position read on the air damper index ID1 see picture on pag 27 5 disconnect the TAB thermostat removing the wire from the terminal no 6 or by setting MAN on the RWF40 modulatore or by set ting 0 by means of the CMF switch only for fully modulating burners...

Page 29: ...cribed on the next steps 12 to change the SV1 position set the actuator on the manual mode MAN turn the adjusting cam SV1 and set again the actuator to the AUTO mode to lock the adjusting cam 13 act on the V1 screw that mathces the bearings referring to the adjusting cam position 14 to adjust the next screw set again the actuator mode to MAN turn the adjusting cam and set the actuator to AUTO mode...

Page 30: ...er is operating correctly z Clockwise turn the pressure switch adjusting ring nut as to increase the pressure value until the burner stops z Slowly fully open the manual cutoff valve z Refit the transparent plastic cover on the pressure switch Adjusting the high gas pressure switch when provided To calibrate the high pressure switch proceed as follows according to its mounting position 1 remove th...

Page 31: ...o drive the burner to the high flame stage set CMF 1 to drive it to the low flame stage set CMF 2 To move the adjusting cam set CMF 1 or 2 and then CMF 0 CMF CMF 0 stop at the current position CMF 1 high flame operation CMF 2 low flame operation CMF 3 automatic operation ...

Page 32: ...ecific gravity of the light oil 0 840kg dm3 Example Bergonzo if a 220kg h flow rate BERGONZO nozzle is provided set the return pressure at 11bar supply at 20bar on the delivery to get a 220kg h flow rate If the return pressure needed is 5bar instead act on the V adjusting screw on the pressure gover nor see chapter on page 32 The flow rate will then be about 95kg h see the example showed on the Be...

Page 33: ...S 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 48 145 160 53 160 180 59 180 200 66 200 225 74 225 250 82 250 275 91 275 300 99 300 330 109 330 360 119 360 400 132 400 450 148 450 500 165 500 550 181 550 600 198 600 650 214 650 700 231 700 750 250 750 800 267 800 Pressure at nozzle 357psi Pressure on return Pressure on return Up to 100kg hUp Ove...

Page 34: ...the bruner starts up 7 drive the burner to high flame stage by means fo the thermostat TAB high low flame thermostat see Wiring diagrams as far as fully modulating burners see related paragraph 8 Then move progressively the microswitch to higher values until it reaches the high flame position always check the combustion values and eventually adjusting the oil pressure see next step Then move progr...

Page 35: ...urn the burner off then start it up again If the adjustment is not correct repeat the previous steps Adjustment by the Siemens SQL33 actuator 1 Once the air and gas flow rates are adjusted turn the burner off switch the CM switch to the heavy oil operation OIL on the bur ner control panel see page 39 2 with the electrical panel open prime the oil pump acting directly on the related CP contactor se...

Page 36: ...n the manual mode MAN turn the adjusting cam SV2 and set again the actuator to the AUTO mode to lock the adjusting cam 12 act on the V2 screw that mathces the bearings referring to the adjusting cam position 13 to adjust the next screw set again the actuator mode to MAN turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw adjust it and go on this way...

Page 37: ...ozzle is feeded at constant pressure while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see prevoius paragraph Fig 28 Stand by Fig 29 Prepurge Fig 30 Low flame Fig 31 High flame Key 1 Light oil pump 2 Light oil sole...

Page 38: ...T AND SAFE FUNCTIONING OF THE BURNER THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE E G DISCONNECTION EVEN PARTIAL OF THE ELECTRICAL LEADS OPENING THE GENERATOR DOOR DISMANTLING OF PART OF THE BURNER NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE OPERATE ONLY THE MAIN SWITC...

Page 39: ...LED L is on z Few seconds after the gas valves opening the transformer is de energised and lamp L turns off z The 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 N ...

Page 40: ...rovided E Gas proving system lockout signalling lamp F Gas valves EV1 EV2 operation signalling lamp G Gas pressure switch signal lamp H Oil valve EVG operation signalling lamp I Thermal cutout intervention signalling light CTV L Ignition transformer operation signalling lamp M Low flame operation signalling lamp N High flame operation signalling lamp O Burner lockout signalling lamp P Stand by sig...

Page 41: ...ame and check its shape replacing the nozzle whenever a questio nable flame shape appears Whenever the burner is used intensely we recommend preventively replacing the nozzle at the start of each heating season z Clean and grease sliding and rotating parts 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 ...

Page 42: ...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 procedure Caution adjust the nozzle position according to the air pipe by means of the VU screw ance the VL screw is fastened Inspect the filter at least once a year z Change the filter if pressure value between ...

Page 43: ...eplace the photocell into its slot Checking the detection current To check the detection current follow the diagram on Fig 35 If the signal is less than the value indicated check the position of the detection electrode or detector the electrical contacts and if necessary replace the electrode or the detector Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner...

Page 44: ... 21 3 1 LIGHT 12 AIR PRESSURE SWITCH 15 3 THREADED PIPE 21 3 2 LIGHT 13 1 AIR INTAKE 15 4 GAS FILTER 21 3 3 LOCK OUT RESET BUTTON 13 2 LOUVER SHAFT 16 1 FAIRLEAD 21 3 4 PROTECTION 13 3 LOUVER SHAFT 16 2 FAIRLEAD 21 3 5 SWITCH 13 4 AIR INTAKE DAMPER 17 1 PRESSURE GOVERNOR 22 1 CONTROL BOX SOCKET 13 5 AIR INTAKE DAMPER 17 2 PRESSURE GAUGE 22 2 IGNITION TRANSFORMER 13 6 PIN 18 1 OIL MANIFOLD 22 3 CON...

Page 45: ...C I B UNIGAS M039140CE 45 ...

Page 46: ...90174 GAS VALVE ACTUATOR SKP15 2190181 2190181 2190181 GAS VALVE ACTUATOR SKP25 2190183 2190183 2190183 GAS VALVE GROUP Rp2 Dungs MBC1200SE 21903M5 21903M5 21903M5 GAS VALVE GROUP DN65 Dungs MBC1900SE 21903M6 21903M6 21903M6 GAS VALVE GROUP DN80 Dungs MBC3100SE 21903M7 21903M7 21903M7 GAS VALVE GROUP DN100 Dungs MBC5000SE 21903M8 21903M8 21903M8 GAS PROVING SYSTEM 2190403 2190403 2190403 GAS PROVI...

Page 47: ...0181 2190181 GAS VALVE ACTUATOR SKP25 2190183 2190183 2190183 2190183 GAS VALVE GROUP Rp2 Dungs MBC1200SE 21903M5 21903M5 21903M5 21903M5 GAS VALVE GROUP DN65 Dungs MBC1900SE 21903M6 21903M6 21903M6 21903M6 GAS VALVE GROUP DN80 Dungs MBC3100SE 21903M7 21903M7 21903M7 21903M7 GAS VALVE GROUP DN100 Dungs MBC5000SE 21903M8 21903M8 21903M8 21903M8 OIL SOLENOID VALVE 2190403 2190403 2190403 2190750 GAS...

Page 48: ...MAIN SWITCH OPEN z LACK OF GAS z z MAXIMUM GAS PRESSURE SWITCH DEFECTIVE IF PROVIDED z z THERMOSTATS PRESSURE SWITCHES DEFECTIVE z z z FAN MOTOR THERMAL CUTOUT INTERVENTION z OVERLOAD TRIPPED INTERVENTION z z AUXILIARY FUSES INTERRUPTED z CONTROL BOX FAULTY z z z z z DEFECTIVE ACTUATOR z z z z AIR PRESSURE SWITCH FAULT OR BAD SETTING z z z z MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIRT...

Page 49: ...rminals 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 switchZ must be in the CLOSED position and allow current to flow between terminals 11 and 8 z Any contacts checking that the fuel valve bv is closed or other con tacts with similar functions must be closed bet...

Page 50: ...tection IP40 Permitted ambient temp 20 60 C Min temperature trans storage 50 C Weight apparatus approx 1 000g base approx 165g Ionisation monitor voltage in detector electrode normal working 330V 10 test 380V 10 short circuit current max 0 5 mA Ionisation current min request 6 µA max permitted length for connecting cables normal cable laid separately 80m armoured cable high frequency protection at...

Page 51: ... for creating current between terminals 17 and 19 t5 interval for creating current between terminals 19 and 20 t6 post ventilation time t7 interval between startup consent and current created at terminal 7 t8 duration of start up t9 2nd safety time t10 interval before air pressure monitoring begins t11 damper opening travel time t12 damper closure travel time t13 permissible post combustion time t...

Page 52: ... and data subject to change Errors and omissions exceptd C I B UNIGAS S p A 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 ...

Page 53: ...E039140CA Rev 0 12 2009 WIRING DIAGRAMS ...

Page 54: ...y 400V 50 Hz 3N a c 2 Don t reverse phase with neutral 3 Ensure burner is properly hearted WIRING DIAGRAM Cod 21 019 WIRING DIAGRAMHP525 MG PR Cod 11 336 1 Progressive burners WIRING DIAGRAM HP525 MG MD Cod 11 339 1 Fully modulating burners ...

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Page 72: ...C I B UNIGAS S p A 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 ...

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