Unigas HR512A Manual Of Installation, Use And Maintenance Download Page 56

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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: [email protected]

Note: specifications and data subject to change. Errors and omissions exceptd.

Summary of Contents for HR512A

Page 1: ...l 3 2 03 2015 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Gas light oil dual fuel burners Progressive Fully modulating MANUAL OF INSTALLATION USE MAINTENANCE HR91A HR92A HR93A HR512A HR515A HR520A HR525A ...

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: ...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 main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pres...

Page 6: ...x kW 480 2670 480 3050 550 4100 Fuel Natural gas Light oil Category see next paragraph Gas rate Natural gas min max Stm3 h 51 283 51 323 58 434 Gas pressure mbar see Note 2 Light oil rate min max kg h 40 225 40 257 46 345 Oil viscosity cSt 40 C 2 7 4 Oil density kg m3 840 Light oil train inlet pressure bar max 2 Power supply 230V 3 400V 3N 50Hz Total power consumption kW 5 6 7 1 9 1 Electric motor...

Page 7: ...utput min max kW 600 4500 770 5200 1000 6400 2000 6700 2000 8000 Fuel Natural gas Light oil Category see next paragraph Gas rate Natural gas min max Stm3 h 63 476 81 550 106 677 212 709 212 847 Gas pressure mbar see Note 2 Light oil rate min max kg h 50 379 65 438 84 539 168 564 168 674 Oil viscosity 2 7 4 cSt 40 C Oil density kg m3 840 Light oil train inlet pressure bar max 2 Power supply 230V 3 ...

Page 8: ...sive Fully modulating Gas train 50 Valves size Gas connection 50 Rp2 50 Rp2 50 Rp2 50 Rp2 Gas train 65 Valves size Gas connection 65 DN65 65 DN65 65 DN65 65 DN65 Gas train 80 Valves size Gas connection 80 DN80 80 DN80 80 DN80 80 DN80 Gas train 100 Valves size Gas connection 100 DN100 100 DN100 100 DN100 100 DN100 Operating temperature C 10 50 Storage Temperature C 20 60 Working service Intermitent...

Page 9: ...8 185 65 1535 242 831 327 35 300 564 117 490 441 1045 421 1406 971 435 269 299 228 447 360 523 M12 424 280 310 300 632 148 484 846 292 708 228 185 80 1535 242 831 327 35 300 579 132 490 441 1045 421 1437 1002 435 269 299 228 447 360 523 M12 424 280 310 300 683 148 535 875 313 708 228 185 100 1535 242 831 327 35 300 592 145 490 441 1045 421 1520 1085 435 269 299 228 447 360 523 M12 424 280 310 300 ...

Page 10: ...830 310 270 100 1723 320 928 371 35 333 639 145 530 517 1193 446 1726 1082 644 380 420 494 540 560 M14 552 390 390 791 149 642 942 353 830 310 270 HR520A 50 1723 320 928 371 35 333 595 100 530 517 1193 446 1590 946 644 400 440 494 540 560 M14 552 390 390 763 149 614 845 190 830 328 270 65 1723 320 928 371 35 333 611 117 530 517 1193 446 1613 969 644 400 440 494 540 560 M14 552 390 390 636 149 487 ...

Page 11: ...ible hose 12 Pressure gauge 13 Pressure governor 15 Pressure switch 16 One way valve 16 1 One way valve 17 Flexible hose 18 Flexible hose 19 Manual valve 20 Pressure gauge MAIN GAS TRAIN 23 Pressure switch PGMIN 24 Safety valve with built in gas governor 25 Proving system pressure switch PGCP 26 Pressure switch PGMAX 40 Manual valve 41 Bellows unit 42 Filter 43 Pressure switch PGMIN 44 Safety valv...

Page 12: ...valve 9 Flexible hose 10 Oil distributor 11 Flexible hose 12 Pressure 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 switc...

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: ...s 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 HR91A kW HR92A kW BACK PRESSURE IN COMBUSTION CHAMBER mbar HR93A kW HR512A kW BACK PRESSURE IN COMBUSTION CHAMBER mbar HR515A kW HR520A kW BACK PRESSURE IN COMBUSTION CHAMBER mbar ...

Page 15: ... h HR520A MG Stm3 h GAS PRESSURE mbar HR525A MG Rp2 Stm3 h HR525A MG DN65 80 100 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 val...

Page 16: ... Stm3 h GAS PRESSURE mbar HR520A LG 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 ...

Page 17: ... the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge 1 12 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 ...

Page 18: ...0 40 60 80 100 120 140 160 180 200 220 240 260 280 300 0 5 10 15 20 25 30 35 40 45 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 0 5 10 15 20 25 30 35 40 45 50 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 0 5 10 15 20 25 30 35 50 100 150 200 250 300 350 400 450 500 0 5 10 15 20 25 30 35 40 50 100 150 200 250 300 350 400 450 500 550 600 0 5 10 15 20 25 30 35 40 4...

Page 19: ...Stm3 h HR93A LG Stm3 h Gas pressure in combustion head HR512A LG Stm3 h GAS PRESSURE mbar HR520A LG Stm3 h 0 2 4 6 8 10 12 14 16 18 20 22 24 26 10 20 30 40 50 60 70 80 90 100 110 0 10 20 30 40 50 60 70 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 0 5 10 15 20 25 30 35 40 20 40 60 80 100 120 140 160 180 0 5 10 15 20 25 30 35 40 45 50 25 50 75 100 125 150 175 200 225 250 ...

Page 20: ...e placed 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 lhandling operations must be carri...

Page 21: ... 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 type 1 or type 2 Verify the necessary input and the pressure in ...

Page 22: ...ites the utilisation please contact the manifacturer Fig 7 Key a Heat output in kW b Lenght of the flame tube in meters c Flame tube firing intensity in MW m3 d Combustion chamber diameter m Fig 7 Firing intensity diameter and lenght of the test flame tube as a function of the heat input in kW ...

Page 23: ...g direction for each item NOTE the bellows unit the manual cutoff valve and the gaskets are not part of the standard supply ATTENTION BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED Gas train with valves group VGD with built in gas pressure governor gas leakage pressure switch PGCP 1 Filter 6 Butterfly valve 2 Pressure switch PGMIN 8 Main b...

Page 24: ...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 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 suitab...

Page 25: ...on for a preset time td4 in order the bring the test space to ambient pressure Test atmospheric pressure EV1 closes and keep this position for a preset time test 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...

Page 26: ...ying circuits NOTE in plants where gravity or ring feed systems are provided install an automatic interception device 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: ...lled 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 connecti...

Page 28: ...pt 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 always be installed in the suction...

Page 29: ...sing nuts A on the pump inlet and R from pump to the burner 2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the lines see the arrows marked on the pump For further information refer to the technical documentation of the pump 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 ...

Page 30: ... 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 31: ...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 32: ... provided B1 Lock out LED B2 Hi flame operation LED B3 Lo flame operation 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 O5 Oil valve EVG operation signalling lamp A1 Burner ...

Page 33: ... requirements Operation in high or low flame is signalled by lamp B2 on the frontal panel 4 4 Light oil operation z The fan motor starts and the pre purge phase as well Since the pre purge phase must be carried out at the maximum air rate the control box drives the actuator opening and when the maximum opening position is reached the pre purge time counting starts z At the end of the pre purge tim...

Page 34: ...g cam sets the air gas ratio in those points regulating the opening closing of the throttle gas valve z 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 WARNING During commissioning operations do not let the burner operate with i...

Page 35: ...it upside down and use it as a tool to rotate screw VR Clockwise rotation reduces start flow rate anticlockwise rotation increases it Do not use a screwdriver on the screw VR Note the screw VSB must be removed only in case of replacemente of the coil 3 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 lowe...

Page 36: ...inimum output point 12 as for the point to point regulation move the gas low flame microswitch a little lower than the maximum position 90 13 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position 14 move the gas low flame microswitch to the minimum to move the actuator towards the low flame until the two bearings find the adjusting scre...

Page 37: ...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 38: ...adjusting 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 6 9 PGCP Gas leakage pressure switch witn Siemens LDU LME7x burner control ...

Page 39: ...urner is designed z For natural gas burners plate holes are fully opened 6 12 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 it move CW CCW as to open close the holes 3 once the adjustmet is performed fasten the V sc...

Page 40: ...n angle according to the return pressure _________ Flow rate ATTENTION To achieve the maximum flow rate close completely the return line 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 48 145 160 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 16...

Page 41: ...O 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 The flow rate will then be about 95kg h see the example showed on the Bergonzo diagram ...

Page 42: ...PART III OPERATION 42 Fig 18 ...

Page 43: ...graph 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 picture when the cam has reached the high flame position 10 once the...

Page 44: ...ecks 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 pressure recorded during the combustion adjustment It is recommend...

Page 45: ...ason z Clean and grease joints and rotating parts IMPORTANT Remove the combustion head before checking the ignition electrode z Remove and clean the compressed air regulator z Remove and clean the oil regulator 9 1 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 ...

Page 46: ...escribed above 9 5 Electrodes Adjustment 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 ring 2 in protective ...

Page 47: ...t the nozzle position according to the air pipe by means of the VU screw ance the VL screw is fastened 9 7 Checking the detection current To check the detection signal follow the scheme in the picture below 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 ATTENTION...

Page 48: ...ean 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 9 9 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 9 10 Burner disposal In case of disposal follow the instructions ac...

Page 49: ...V MAINTENANCE 49 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 50: ... 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 DIR...

Page 51: ...PART IV MAINTENANCE 51 12 0 BURNER EXPLODED VIEW ...

Page 52: ...ONT CONTROL PANEL 2 2 FAN WHEEL 10 2 LIGHT 3 1 STANDARD COMBUSTION HEAD 10 3 LIGHT 3 2 STANDARD COMPLETE OIL GUN 10 4 SWITCH 3 2 1 1 SOLENOID VALVE 10 5 LOCK OUT RESET BUTTON 3 2 1 2 ONE WAY VALVE 10 6 PROTECTION 3 2 2 NOZZLE 11 1 PRESSURE GOVERNOR 3 3 IGNITION ELECTRODE 11 2 PRESSURE GAUGE 3 4 GAS MANIFOLD 13 AIR INLET CONE 3 5 O RING 14 BUTTERFLY GAS VALVE 3 7 O RING 14 1 O RING 4 1 COUPLING 14 ...

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Page 56: ...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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Unigas HR512A, Manual Of Installation, Use And Maintenance

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