Unigas HTP512A Installation, User'S, And Maintenance Manual Download

Page: 1 / 60

M039219CA Rev. 0 0

/2008

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Progressive

and fully-modulating

gas - light oil burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

HTP90A - HTP91A
HTP92A - HTP93A

HTP512A - HTP515A
HTP520A - HTP525A

Summary of Contents for HTP512A

Page 1: ... 08 2008 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive and fully modulating gas light oil burners MANUAL OF INSTALLATION USE MAINTENANCE HTP90A HTP91A HTP92A HTP93A HTP512A HTP515A HTP520A HTP525A ...

Page 2: ...ting is the same as delivery mains electricity gas oil or other fuel z 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 stopped When the decision is made to discontinue the use of the burner the user shall have qualified personnel carry out ...

Page 3: ...development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of n...

Page 4: ...ing parameters are needed z fuel z furnace input in kW or kcal h kW kcal h 860 z boiler type z combustione head type reverse flame or three phase z temperature or pressure of the thermal carrier fluid z Comburent air temperature z Air duct positioning z Pressure in the combustion chamber z Elevation altitude of burner installation z Gas train only for gas burners z Pumping unit only for light oil ...

Page 5: ... far as intercepitng the network pressure curve according to the installed gas train DN65 in the example From the inter ception 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 Data requested z furnace input z air temperature z altitude Example z fu...

Page 6: ... switch 8 GAS CONNECTION 50 Rp2 65 DN65 80 DN80 100 DN100 BURNER TYPE HTP90A HTP91A HTP92A HTP93A Output min max kW 320 2300 480 2670 480 3050 550 4100 Fuel Natural gas Light oil Gas category see next paragraph Gas rate min max Stm3 h 34 243 51 283 51 323 58 434 Gas pressure see Note 2 Oil viscosity cSt 40 C 2 7 4 Oil density kg m3 0 84 Light oil rate min max kg h 27 194 40 225 40 257 46 345 Power...

Page 7: ...0Hz 400V 3N 50Hz Pump motor kW 1 1 1 5 1 5 4 Total power consumption kW 1 6 2 2 4 5 Protection IP40 Operation Progressive Fully modulating Gas train 50 ØValves Connection 2 Rp 2 Gas train 65 ØValves Connection 2 1 2 DN65 Gas train 80 ØValves Connection 3 DN80 Gas train 100 ØValves Connection 4 DN100 Operating temperature C 10 50 Storage Temperature C 20 60 Working service Intermittent Note1 all ga...

Page 8: ... 80 1356 490 866 305 1449 959 490 265 295 307 185 360 510 695 M14 424 300 610 300 592 148 444 750 322 875 228 180 HTP91A 100 1356 490 866 305 1539 1049 490 265 295 447 185 360 510 695 M14 424 300 610 300 672 148 524 824 382 875 228 180 HTP92A 50 1356 490 866 305 1342 852 490 269 299 329 185 360 510 695 M14 424 300 610 300 522 148 374 624 216 875 228 180 HTP92A 65 1356 490 866 305 1447 957 490 269 ...

Page 9: ...20 494 185 460 530 715 M14 552 390 693 390 x 643 x 160 483 843 293 945 312 230 HTP515A 80 1491 520 971 314 1583 1084 499 380 420 494 185 460 530 715 M14 552 390 693 390 x 695 x 160 535 875 322 945 312 230 HTP515A 100 1491 520 971 314 1666 1167 499 380 420 494 185 460 530 715 M14 552 390 693 390 x 802 x 160 642 942 382 945 312 230 HTP520A 50 1497 520 977 314 1570 1071 499 400 440 494 185 460 530 71...

Page 10: ...ultiply value in kW by 860 Data are referred to standard conditions 1013mbar 15 C HTP525A HTP520A HTP515A HTP512A HTP93A HTP92A HTP90A HTP91A 0 2000 4000 6000 8000 10000 12000 14000 16000 Campo di scelta bruciatore Output diagram air temperature 15 C Burner performance range ...

Page 11: ...50 200 250 300 Rp 2 50 DN65 DN80 DN100 0 20 40 60 80 100 120 50 100 150 200 250 300 350 Rp2 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 50 100 150 200 50 100 150 200 250 300 350 400 450 500 550 Rp 2 50 DN65 DN80 DN100 0 50 100 150 200 250 50 100 150 200 250 300 350 400 450 500 550 600 650 Rp 2 50 DN65 DN80 DN100 0 50 100 150 200 250 300 3...

Page 12: ...ow rate the temperature the distance between the fan and the burner and according to the fan features as well Packing The burners are despatched in wooden crates Their dimensions are 9xA series 1740mm x 1270mm x 1010mm LW x PH x HD 5xxA series 1740mm x 1420mm x 110mm LW x PH x HD 1 burner with gas train detached 1 gasket to be inserted between the burner and the boiler 2 flexible oil pipes 1 oil f...

Page 13: ...n this case the blast tube must penetrate at least 50 100 mm into combustion chamber in respect to the tube bundle plate The length of the blast tubes does not always allow this requirement to be met and thus it may be necessary to use a suitably sized spacer to move the burner backwards or to design a blast tube tha suites the utilisation please contact the manifacturer Gas train connections The ...

Page 14: ...r pressure governor pressure switch VPS504 gas proving system Gas train 4 Gas train with valves group VGD 20 40 with built in gas pressure governor PGCP gas leakage pressure switch Gas train 5 Rp2 Gas train with valves group MBC 1200SE 2 valves gas filter pressure governor PGCP gas leakage pres sure switch Gas train 6 DN65 80 100 Gas train with valves group MBC 1900 3100 5000SE 2 valves gas filter...

Page 15: ... valve first fit the flanges to the piping and then clean the associated parts z install the valve z the direction of gas flow 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 ...

Page 16: ...nsert MBC SE Note position of O rings see Fig 9 3 Tighten screws A H 4 After installation perform leakage and functional test 5 Disassembly in reverse order Fig 9 Mounting 1 Insert setscrews A 2 Insert seals 3 Insert setscrews B 4 Tighten setscrews A B Ensure correct seating of the seal 6 After installation perform leakage and functional test 7 Disassembly in reverse order Fig 10 BS BS SKP1 SKP2 B...

Page 17: ...l its elements gas valves group pressure switches gas proving system Hydraulic diagrams for light oil supplying circuits DUNGS MBC SE Siemens SKP actuator Performance range mbar 4 20 20 40 40 80 80 150 Spring colour ed 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 4 the gas proving tes...

Page 18: ...ystem The burner is supplied with filter and flexible hoses all the parts upstream the filter must be installed by the customer As far as the hoses connection see the related paragraph Key 1 Burner 2 Flexible hoses fitted 3 Light oil filter fitted 4 Automatic interceptor 5 One way valve 6 Gate valve 7 Quick closing gate valve outside the tank or boiler rooms Only for installations with gravity sip...

Page 19: ...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 formation over time of compounds which may deposit between the gear teeth thus obstructing them z After filling the tank wait before starting the burner This will give any suspended impurities time to deposit on the bottom of the tank thus avo...

Page 20: ...y 2 5 450 cSt Oil temperature 10 160 C Max suction pressure 4 bar Min suction pressure 0 45 bar to avoid gasing Max return pressure 4 bar Rotation speed 3450 rpm max Viscosity 4 800 cSt Oil temperature 0 140 C Minimum suction pressure 0 45 bar to prevent gasing Maximum suction pressure 5 bar Rated speed 3600 rpm max Key 1 To pressure adjusting valve G3 4 2 Pressure vacuum gauge port to measure the...

Page 21: ...n motor thermal cutout Respect the basic safety rules make sure of the connection to the earthing system do not reverse the phase and neutral connections fit a differential thermal magnet switch adequate for connection to the mains ATTENTION before executing the electrical connections pay attention to turn the plant s switch to OFF and be sure that the burner s main switch is in 0 position OFF too...

Page 22: ...er as for the next elements Fig 19 Fig 21 LB Burner s lockout signalling LED LSPG Gas proving system lockout signalling LED 3 In case of modulating burners the 5 6 and 7 terminals on the MA teminal block are already connected to the regulating modula tor mod RWF40 A 4 pole plug coming out from the electrical panel is provided for the temperature and pressure probes connec tions see Fig 20 Note the...

Page 23: ... on the body In the event of wrong rotation reverse the three phase supply and check again the rotation of the motor NOTE except for motors with star delta start up 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 Fig 22 ...

Page 24: ...r 2 Pressure outlet on the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge 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 pres sure outlet Fig 26 2 to get the pressure in the combustion chamber and the other one into the butterf...

Page 25: ... 230 250 0 5 10 15 20 25 30 35 40 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 55...

Page 26: ... cam 5 Actuator VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off valves This check is carried out as soon as the boiler thermostat gives a start signal to the burner creating by means of the diaphragm pump inside it a pressure in the test space of 20 mbar higher than the supply pressure When wishing to monitor the test install a pressure gauge ranged to that...

Page 27: ...gas valves group set the pressure regulator to 1 3 of its stroke using a 2 5 allen key Now adjust the burner according to the actuator model provided The burner is factory set wih the adjusting plate holes fully open and the combustion head at its MAX position so it is fit to work at the maximum output To adjust the gas flow partially close the holes as follows 1 loosen the three V screws that fix...

Page 28: ...ly 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 8 acting on the pressure stabiliser of the valves group adjust the gas flow rate in the high flame stage 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 de...

Page 29: ...mostat series and wait until the pre purge time comes to an end and that the burner starts up 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 previous page 5 disconnect the TAB thermostat removing the wire from the terminal no 6 or by setting MAN on the RWF40 m...

Page 30: ...o the combustion values read 15 Once the cam foil shape is defined reconnect the TAB thermostat reconnecting the wire to the terminal no 6 or setting the RWF40 burner modulator to AUTO or the CMF switch to 3 only for fully modulating burner 16 Turn the burner off then start it up again 17 Once the pre purge time comes to end drive the burner to the high flame stage by the TAB thermostat and check ...

Page 31: ...nt 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 are higher than...

Page 32: ...xt paragraphs Fig 29 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 Bergonzo diagram Fig 29 N...

Page 33: ...econds until the oil circuit is charged 3 bleed the air from the M pressure gauge port Fig 31 by loosing the cap without removing it then release the contactor Fig 31 4 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 achieve safely the high flame stage Fig 30 Suntec TA Danfoss KSM Suntec...

Page 34: ...adjusting screw that refers to a lower position screw V2 to increase the rate unscrew to decrease in order to get the pressure as showed on chart diagram on Adjusting light oil flow rate on page 32 according to the requested rate 14 Move again cam V towards the minimum to meet the next screw on the adjusting cam and repeat the previous step go on this way as to reach the desired low flame point 15...

Page 35: ...y move the adjusting cam in order to adjust each of the V2 screws as to describe the cam foil shape 11 to change the SV2 position set the actuator on 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 ac...

Page 36: ...the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor The solenoid valve 2 set the fuel immission into the combustion chamber The part of fuel that is not burnt goes back to the tank through the return circuit The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see prevoius paragraph Fig 36 Stand by Fig 37 Prepurge Fig...

Page 37: ...urning the A switch on the burner control panel CAUTION if the fuel chosen is light oil be sure the cutoff valves on the feed and return pipes are open z Check the control box is not locked signalling light O on if so reset it by means of the pushbutton C z Check the series of thermostats and pressure switches turn the burner to on Gas operation z Check the gas feeding pressure is sufficient signa...

Page 38: ... 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 time the actuator is in the light oil ignition position the ignition transformer is energised lamp L on the light oil valves open Few seconds after the valves opening the transformer is de energised and lamp L turns off z The burner is now opera...

Page 39: ...lame 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 40: ... 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 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 fil...

Page 41: ...ive cap 1 Screw in the protective cap with the O ring in it 6 Stick the adhesive label for spring identification on the type plate Cleaning and replacing the detection photocell The photocell working life is about 10000 working hours about 1 year at max 50 C after which it must be replaced To clean replace the detection photocell proceed as follows 1 Disconnect the system from the electrical power...

Page 42: ...ng to the laws in force in your country about the Disposal of materials Fig 42 Detection by electrode Fig 43 Detection by photocell QRA To check the detection signal remove the bridge on TEST ER or TEST UV and connect a micro ammeter when Fig 44 If the signal is less than the value indicated check the position of the detection electrode or detector the electrical contacts one ER terminal for the e...

Page 43: ... 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 B...

Page 44: ...69 GAS VALVE GROUP DN100 Siemens VGD40 2190174 2190174 2190174 2190174 GAS VALVE ACTUATOR SKP15 2190181 2190181 2190181 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...

Page 45: ...DN100 Siemens VGD40 2190174 2190174 2190174 2190174 GAS VALVE ACTUATOR SKP15 2190181 2190181 2190181 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 ...

Page 46: ... IN LOW FLAME INDICATOR LIGHT LEV1 INDICATOR LIGHT FOR OPENING OF ELECTRO VALVE EV1 LEV2 INDICATOR LIGHT FOR OPENING OF ELECTRO VALVE EV2 LEVG INDICATOR LIGHT FOR EVG 1 2 OPENING LPGMIN INDICATOR LIGHT FOR PRESENCE OF GAS IN THE NETWORK LS INDICATOR LIGHT FOR BURNER STAND BY LSPG INDICATOR LIGHT FOR LEAKAGE OF VALVES LT INDICATOR LIGHT FOR FAN OVERLOAD TRIPPED LTA IGNITION TRANSFORMER INDICATOR LI...

Page 47: ...C I B UNIGAS M039219CA 47 Wiring diagram 21 002 3 ...

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Page 50: ...C I B UNIGAS M039219CA 50 WIRING DIAGRAM Cod 11 336 2 ...

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Page 53: ...C I B UNIGAS M039219CA 53 WIRING DIAGRAM Cod 11 339 2 ...

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Page 57: ...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 58: ...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 59: ... 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 60: ... 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 ...

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