Unigas HRX515 Manual Of Installation - Use - Maintenance Download

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Summary of Contents for HRX515

Page 1: ...M039334CA Rel 0 10 2014 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Gas light oil dual fuel burners Progressive Fully modulating MANUAL OF INSTALLATION USE MAINTENANCE HRX515 ...

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: ...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: ... 1 2 3 4 5 6 7 8 1 BURNER TYPE HRX515 2 FUEL M Natural 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 SpecialeSpecial 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 DN100 ...

Page 7: ... 13 Electric motor kW 11 Pump motor kW 1 5 Protection IP40 Operation Progressive Fully modulating Gas train 50 Valves size Gas connection 50 Rp2 Gas train 65 Valves size Gas connection 65 DN65 Gas train 80 Valves size Gas connection 80 DN80 Gas train 100 Valves size Gas connection 100 DN100 Operating temperature C 10 50 Storage Temperature C 20 60 Working service Intermitent Note1 All gas flow rat...

Page 8: ... 150 605 843 216 852 328 270 65 1731 323 910 475 35 415 612 118 530 508 1201 446 1691 1049 642 305 345 494 540 582 M14 552 390 390 633 150 483 843 292 852 328 270 80 1731 323 910 475 35 415 626 132 530 508 1201 446 1725 1084 642 305 345 494 540 582 M14 552 390 390 685 150 535 875 322 852 328 270 100 1731 323 910 475 35 415 639 145 530 508 1201 446 1809 1167 642 305 345 494 540 582 M14 552 390 390 ...

Page 9: ...ulic diagram 9 8 PS PSH PSH PSL M PS M S PS PI PI 1 2 3 6 50 4 20 52 53 18 16 12 15 19 1 19 10 54 7 11 VGD 44 47 41 40 42 45 43 46 M 51 13 5 17 ON BOARD ITEMS SUPPLIED LOOSE ITEMS oil inlet oil outlet gas inlet combustion air BY BURNER CONSTRUCTOR BY OTHERS ...

Page 10: ...e switch PGMIN 5 Flexible hose 44 Safety valve with built in gas governor 6 Solenoid valve 45 Proving system pressure switch PGCP 7 Flexible hose 46 Pressure switch PGMAX 8 3 way solenoid valve 47 Butterfly valve 9 Flexible hose COMBUSTION AIR TRAIN 10 Oil distributor 50 Air damper 11 Flexible hose 51 Actuator 12 Pressure gauge 52 Pressure switch PA 13 Pressure governor 53 Draught fan with electro...

Page 11: ...ph Adjusting the 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 To check the proper gas train size it is necessary to th...

Page 12: ... 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 5 Note the figure is indicative only Key 1 Generator 2 Pressure outlet on the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge GAS PRESSURE mbar HRX515 Stm3 ...

Page 13: ...t the maximum flow rate in the pressure rate curves showed on the next paragraph it is easy to find out the burner s output in Stm3 h quoted on the x axis from the pressure measured in the combustion head quoted on the y axis The data obtained must be considered when adjusting the gas flow rate 1 11 Pressure rate in combustion head curves natural gas ATTENTION THE BURNED GAS RATE MUST BE READ AT T...

Page 14: ... 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 carried out by specialised an...

Page 15: ... 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 16: ...ites the utilisation please contact the manifacturer Fig 6 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 6 Firing intensity diameter and lenght of the test flame tube as a function of the heat input in kW ...

Page 17: ...K 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 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 PS PSH S P...

Page 18: ...n 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 downstream...

Page 19: ... be closed z Test space evacuating EV1 valve burner side opens and keep this position 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...

Page 20: ... 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 PS EV1 EV2 PGCP ...

Page 21: ...NNECTIONS 3 6 Hydraulic diagrams for light oil supplying circuits Fig 12 Gravity circuit Fig 13 Ring circuit Fig 14 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 22: ...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 23: ...ept 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 suctio...

Page 24: ...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 25: ... 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 26: ...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 TECHNICAL SE...

Page 27: ...the burner staring cycle begins in case of leakage in a valve the gas proving system stops the burner and the lamp B1 turns on NOTE if the burner is fitted with Dungs VPS504 the pre purgue phase starts once the gas proving system is successfully performed Since the pre purgue phase must be carried out with the maximum air rate the control box drives the actuator opening and when the maximum openin...

Page 28: ...turns off z The burner is now operating meanwhile the actuator goes to the high flame position after some seconds the two stage operation 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 LED B2 on the burner control panel The fuel is pushed into the pump to the nozzle at the delivery pressure set...

Page 29: ... adjusting 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 opera...

Page 30: ...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 31: ...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 32: ...ter 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 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 increa...

Page 33: ...tion turn slowly the 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 ...

Page 34: ...once the adjustmet is performed fasten the V screws The adjusting plate correct position must be regulated in the plant during the commissioning The factory setting depends on the type of fuel for which the burner is designed z For biogas natural gas and town gas burners plate holes are fully opened z For LPG burners plate holes are opened about 1 5mm 9x series or 1 3 5xx series WARNING please rea...

Page 35: ...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 A3 20 11 13 6 recommended MONARCH NOZZLE Tab 8 Fig 16 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 4...

Page 36: ... 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 37: ...PART III OPERATION 37 Fig 18 ...

Page 38: ...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 39: ...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 40: ...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 41: ...s 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 cap 1 Screw in the protective cap with the O ring in it 6 Stick the adhe...

Page 42: ...ffuser edge the other four lean out 72mm Attention If it is necessary to change the head position repeat the air and gas adjustments described at staps 1 9 in paragraph related to air fuel ratio adjustments according to the actuator model Attention before adjusting the combustion head turn the burner off and wait until it gets cold When changing the nozzles position pay attention that the smallest...

Page 43: ...rected towards the flame axis while the biggest ones main holes are directed outwards As for a finest adjustment in the plant please contact the Technical service The nozzles can be adjusted as follows back and forth adjustment by means of V1 screws up and down adjustment by means of V2 screws V1 V2 ...

Page 44: ...n 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 Fig 23 Key VRT Head adjusting screw AR Threaded rod V Fixing screw G Gas manifold OR O ring C Cover CAUTIO...

Page 45: ...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 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 v...

Page 46: ... OPERATION URNS OF AND REPEATS CYCLE DURING OPERATION URNS OF AND REPEATS CYCLE DURING OPERATION 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 PRES...

Page 47: ...PART IV MAINTENANCE 47 11 0 BURNER EXPLODED VIEW NOTE combustion head is indicative only ...

Page 48: ...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 ...

Page 49: ...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 50: ... 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 51: ...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...

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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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