Unigas P20 User Manual Download

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Technical Documentation

CIB Unigas

- Campodarsego (PD) - Italy

MANUAL OF
- INSTALLATION
- OPERATION
- MAINTENANCE

GAS BURNERS

P20
P30
P45
P50
P65

TOWN GAS VERSION

M03980CA Rev. 00 01/02

Summary of Contents for P20

Page 1: ...Technical Documentation CIB Unigas Campodarsego PD Italy MANUAL OF INSTALLATION OPERATION MAINTENANCE GAS BURNERS P20 P30 P45 P50 P65 TOWN GAS VERSION M03980CA Rev 00 01 02 ...

Page 2: ...ssory equipment only shall be used This unit shall be employed exclusively for the use for which it is meant Any other use shall be considered as improper and therefore dangerous The manufacturer shall not be held liable by agreement or otherwise for damages resulting from improper installation use and failure to comply with the instructions supplied by the manufacturer 2 SPECIAL INSTRUCTIONS FOR ...

Page 3: ...mals or damage to property for which the manufacturer cannot be held liable Before installation it is recommended that all the fuel sup ply system pipes be carefully cleaned inside to remove foreign matter that might impair the burner operation Before the burner is commissioned qualified personnel should inspect the following a the fuel supply system for proper sealing b the fuel flow rate to make...

Page 4: ...Rp 1 Rp 11 4 Rp 11 4 Rp2 Rp 11 2 Operation single stage single stage single stage single stage Destination country BURNERS TYPE MODEL P45 C 50 P50 C 40 P50 C 50 P50 C 65 Input min kW 240 350 350 350 max kW 520 523 860 860 min kcal h 206 400 301 000 301 000 301 000 max kcal h 447 200 449 700 739 600 739 600 Fuel Town gas Town gas Town gas Town gas Category I2h I2h I2h I2h Gas flow rate min max m3 h...

Page 5: ...50 650 650 900 Electric motor 2800 rpm W 370 370 370 620 Protection IP40 IP40 IP40 IP40 Weight Kg 30 30 30 58 Gas train size 1 1 1 2 1 1 2 2 1 1 2 Gas connections Rp 1 Rp 11 4 Rp 11 4 Rp1 Rp 11 2 Operation double stage progressive fully modulating double stage progressive fully modulating double stage progressive fully modulating double stage progressive fully modulating Destination country BURNER...

Page 6: ...ailable versions 0 2 Valves 1 2 Valves leakage control optional if burner input 1200 kW 8 GAS TRAIN SIZE See Technical data 25 Rp1 40 Rp11 2 50 Rp2 65 DN65 BL Long blast tube OVERALL DIMENSIONS IN mm Fig 4a Fig 4b Boiler plate drilling template Make 4 M10 threaded holes A B BL C CL D E F G K J L N P20 555 210 295 765 850 510 200 710 126 290 178 360 370 P30 555 230 330 785 885 510 200 710 148 290 1...

Page 7: ... COMBUSTION CHAMBER mbar P20 C AB 40 C PR 40 C MD 40 kW P45 C AB xx C PR xx C MD xx kW Fig 8 0 1 2 3 4 5 6 7 8 40 60 80 100 120 140 160 180 200 220 240 260 280 0 1 2 3 4 5 6 7 100 140 180 220 260 300 340 380 420 0 1 2 3 4 5 6 7 8 40 60 80 100 120 140 160 180 200 220 240 260 280 0 1 2 3 4 5 6 7 0 40 80 120 160 200 240 280 320 360 400 80 120 160 200 240 280 320 360 0 1 2 3 4 5 6 7 8 0 40 80 120 160 ...

Page 8: ...bar P50 C TN 40 kW P65 C AB xx C PR xx C MD xx kW Fig 9 BACK PRESSURE IN COMBUSTION CHAMBER mbar P50 C TN 50 C TN 65 kW Fig 10 0 1 2 3 4 5 6 7 8 300 340 380 420 460 500 540 580 0 1 2 3 4 5 6 7 8 9 200 300 400 500 600 700 800 900 1000 0 1 2 3 4 5 6 7 8 300 400 500 600 700 800 900 ...

Page 9: ...Gas pressure port on butterfly valve 3 Sightglass cooling port 4 Water column pressure gauge Curves are referred to a null pressure in combustion head NOTE THE PRESSURE RATE CURVES ARE INDICATIVE FOR A PROPER SETTING OF THE GAS RATE PLEASE REFER TO THE GAS METER READING INLET PRESSURE IN COMBUSTION HEAD mbar P20 NATURAL GAS FLOW RATE Stm3 h Fig 12 INLET PRESSURE IN COMBUSTION HEAD mbar P30 NATURAL...

Page 10: ...MBUSTION HEAD mbar P50 NATURAL GAS FLOW RATE Stm3 h Fig 15 INLET PRESSURE IN COMBUSTION HEAD mbar P65 NATURAL GAS FLOW RATE Stm3 h Fig 16 0 5 10 15 20 25 30 35 40 45 50 55 60 2 3 4 5 6 7 8 20 30 40 50 60 70 80 90 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 110 WARNING THESE DIAGRAMS ARE VALID ONLY FOR NATURAL GAS BURNER ...

Page 11: ...ambers that comply with EN676 regulation and whose dimensions are described in the diagram in Fig 18 In case the burner must be coupled with boilers with a combustion chamber smaller in diameter 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...

Page 12: ...31 Diagrams for burners WITH printed circuit WARNING The burners with high low flame operation are fitted with an electrical bridge between terminals 6 and 7 in the event of connecting the high low flame thermostat remove this bridge before connecting the thermostat IMPORTANT In connecting electric supply wires to burner teminal block be sure that ground wire should be longer than phase and neutra...

Page 13: ...er supply terminal board three phase burners Terminal block for connections on printed circuit Fig 20a Power supply terminal board for mono phase burners type P45 Fig 20b Fig 21 Fig 22a Type P20 P30 C TN Fig 23a Type P50 C TN Fig 22b Type P20 P30 C AB Fig 23b Type P65 C AB ...

Page 14: ...E the burners are supplied for three phase 400 V supply and in the case of three phase 230 V supply it is necessary to modify the electrical connections inside the terminal box of the electric motor and replace the thermal cutout relay Fig 24a Type P20 P30 C MD PROBE CONNECTION ON FULLY MODULATING BURNERS Fig 25 Fig 24b Type P45 C MD Fig 24c Type P65 C MD RESPECT THE BASIC SAFETY RULES MAKE SURE O...

Page 15: ... equipped with DUNGS MBDLE valves group 2 valves filter governor pressure switch Fig 26b Burner equipped with 2 gas val ves one of which is equipped with pressure governor gas filter and pressure switch Fig 26c Key 1 Burner 2 Gas valve EV2 3 Gas valve EV1 4 Minimum gas pressure switch 5 Governor with filter 6 Manually operated shut off valve 7 Bellow joint 8 Leakage control optional if output is g...

Page 16: ...ontrol device VPS504 Optional The VPS504 check the operation of the seal of the gas shut off valves costituting the MB DLE This check carried out as soon as the boiler thermostat gives a start signal to the burner crea tes 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...

Page 17: ...Landis gas valves Version with SKP20 with incorporated pressure governor To increase or decrease gas pressure and therefore gas flow rate remove the cap T and use a screwdriver to adjust the regulator screw VR Turn clockwise to increase the flow anti clockwise to reduce it Connect up the gas tubing to the gas pressure nipple TP in figure Leave the blowhole free SA in figure Should the spring fitte...

Page 18: ...back in place making sure that the O Ring 2 is in its seat and that the filter cartridge 3 fits neatly between the guides 6 on the cover 1 the same as those on the bottom 5 Threaded fittings Fig 31b and Fig 31c After having ensured that there is no pressurised gas inside the filter remove the cover 5 by unscrewing the fastening screws 1 Remove the filter cartridge 3 wash it in soap and water blow ...

Page 19: ...the posi tions of high and low flame During testing in the factory the throttle valve air damper and low flame are set to average values using cams of the servocontrol To change the settings of the burner during testing in the plant proceed as follow 1 Turn on the burner and drive it to high flame 2 Adjust the gas flow rate to the required value by means of the pressure governor or the valve regul...

Page 20: ...o adjust burner capacity at low flame move the servocontrol cam accordingly page 21 3 Adjust the gas flow rate in the low flame position same position as the ingition by means of the adjustable screws V Fig 37 to change the opening angle of the throttle valve Fig 36 rotate clockwise to increase the flow rate or anticlockwise to decrease it 4 Turn off the burner and turn it on again If the gas flow...

Page 21: ... other servocontrols Landis SQN30 151 hi lo flame burners Landis SQN30 251 progressive and fully modulating burners Berger STA6 B 3 41 hi lo flame burners Berger STA12B3 41 progressive and fully modulating burners Berger STA15B3 41 progressive and fully modulating burners Fig 38a Fig 38b Landis SQN70 224A20 hi lo flame burners Landis SQN70 424A20 progr and fully modulating burners Berger STA4 5BO ...

Page 22: ...ve the transparent plastic cap With the burner in operation test the pressure on the pressure port at the input of the gas filter slowly close the manual shut off valve n 6 in Fig 26a Fig 26b and Fig 26c until the detected pressure is reduced by 50 Fully open the manual shut off valve WARNING carry out this operation ONLY with the burner turned off Refit the transparent plastic cover on the pressu...

Page 23: ...ORRECT AND SAFE FUNCTIO NING OF THE BURNER THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLA TION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE E G DISCONNEC TION 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 MA...

Page 24: ... EV1 and EV2 are energized lights L and I on the front panel 3 seconds after the opening of the valves the ignition transformer comes off and the lamp H turns off subsequently Single stage burners the burner is on at the maximum power the lights F and G are on High low flame burners the burner is on in low flame light G is on 8 seconds later the high flame operation begins and the burner switches ...

Page 25: ...tating parts Removal of the combustion head N B All operations on the burner must be carried out with the power disconnected NOTE The check on the ignition and detection electrodes is carried out after removing the combustion head Fig 42 Burners P20 P30 P45 P50 Remove the lid C Unscrew the 2 screws S which hold in position the washer unscrew then the screw VRT to free the threaded rod AR Unscrew t...

Page 26: ...47 If the signal is less than the value shown check the position of the detection electrode the electrical contacts and if necessary replace the detection electrode Fig 46 Fig 47 Flame control device Minimum detection signal Landis LGB21 22 3 µA Landis LMG21 22 3 µA Detection electrode Ignition electrode Earth electrode Detection electrode Ignition electrode Earth electrode TERMINAL BLOCK MA SCALE...

Page 27: ...YCLE BURNER DOESN T SWITCH TO HIGH FLAME BURNER S LOCKOUT DURING OPERATION BURNER STOPS AND REPEATS CYCLE DURING OPERATION BURNER S LOCKOUT AFTER START THE FLAME CONTROL DEV REPEATS THE CYCLE WITHOUT GIVE CONSENT MAINS SWITCH OPEN ABSENCE OF GAS MINIMUM GAS PRESSURE SWITCH FAULT OR BAD SETTING BOILER THERMOSTATS OPEN OVERLOAD TRIPPED INTERVENTION FUSES INTERVENTION AIR PRESSURE SWITCH FAULT OR BAD...

Page 28: ...r supply connection MV Fan motor N Neutral PA Air pressure switch PE Earth connection PGMAX Maximum gas pressure switch optional if fitted remove the bridge in the connector PG Minimum gas pressure switch PS Reset pushbutton for flame control device SQN30 151 Landis servocontrol for air damper hi lo flame burners SQN30 251 Landis servocontrol for air damper progressive burners SQN70 224A20 Landis ...

Page 29: ...PART II OPERATION 29 ELECTRICAL DIAGRAMS Electrical diagram code 18 009 Rev 1 Burners P20 P30 C TN C AB C PR P50 C TN P65 C AB ...

Page 30: ...PART II OPERATION 30 Electrical diagram code 18 020 Burners P45 C TN C AB C PR ...

Page 31: ...essure switch PS Flame reset pushbutton Pt100 Connection for thermoresistor Pt 100 RWF40 000 Landis modulator SD 0 4 20mA Probe connection with signal 0 20mA 4 20mA SD 0 10V Probe connection with signal 0 10V SD PRESS 3 terminals pressure probe connection LANDIS QBE620 SD TEMP 2 terminals themperature probe connection Pt1000 o LANDIS QAE2 QAC2 SQN30 251 Landis servocontrol for air damper alternate...

Page 32: ...PART II OPERATION 32 Electrical diagram code 04 622 Burners P20 P30 C MD ...

Page 33: ...PART II OPERATION 33 Electrical diagram 04 642 Burners P45 C MD ...

Page 34: ...PART II OPERATION 34 Electrical diagram code 05 615 Burner P65 C MD ...

Page 35: ...PART II OPERATION 35 SPARE PARTS ...

Page 36: ...PART II OPERATION 36 SPARE PARTS Burners P20 P30 C TN C AB ...

Page 37: ...080202 2080202 12 IGNITION CABLE 6050108 6050108 6050108 6050108 6050108 6050108 13 GASKET 2110004 2110004 2110004 2110004 2110004 2110004 14 O RING 2250001 2250001 2250001 2250001 2250001 2250001 15 THROTTLE VALVE HI LO FLAME 2460221 2460221 2460221 2460221 2460221 2460221 15A THROTTLE VALVE SINGLE STAGE 2460201 2460201 2460201 2460201 2460201 2460201 17 AIR DAMPER 2140005 2140005 2140005 2140005...

Page 38: ...PART II OPERATION 38 SPARE PARTS Burners P45 C TN C AB P50 C TN P65 C AB ...

Page 39: ...HEAD 306 00 C1 306 00 C1 306 00 C1 306 00 C1 306 00 78 306 00 78 306 00 78 306 00 C2 306 00 C2 19 IGNITION ELECTRODE 208 02 02 208 02 02 208 02 02 208 02 02 208 02 02 208 02 02 208 02 02 208 02 02 208 02 02 20 IGNITION CABLE 605 01 08 605 01 08 605 01 08 605 01 08 605 01 08 605 01 08 605 01 08 605 01 08 605 01 08 21 GASKET 211 00 13 211 00 13 211 00 13 211 00 13 211 00 13 211 00 13 211 00 13 211 0...

Page 40: ...PART II OPERATION 40 SPARE PARTS Burners P20 P30 C MD ...

Page 41: ...5 00 01 225 00 01 15 THROTTLE VALVE 246 02 21 246 02 21 246 02 21 246 02 21 246 02 21 246 02 21 17 AIR DAMPER 214 00 05 214 00 05 214 00 05 214 00 05 214 00 05 214 00 05 18 SERVOCONTROL SUPPORT BRACKET 305 00 11 305 00 11 305 00 11 305 00 11 305 00 11 305 00 11 19 SERVOCONTROL BERGER 248 00 53 248 00 53 248 00 53 248 00 53 248 00 53 248 00 53 20 ADJUSTABLE CAM 244 00 29 244 00 29 244 00 29 244 00 ...

Page 42: ...PART II OPERATION 42 SPARE PARTS Burners P45 P65 C MD ...

Page 43: ...8 605 01 08 605 01 08 21 GASKET 211 00 13 211 00 13 211 00 33 211 00 33 22 OR RING FOR THROTTLE VALVE 225 00 03 225 00 03 225 00 03 225 00 03 23 THROTTLE VALVE 246 02 22 246 02 22 246 02 22 246 02 24 24 GAS PRESSURE SWITCH 216 00 10 216 00 10 216 00 10 216 00 10 26 INTERNAL AIR DAMPER 214 00 07 214 00 07 214 00 22 214 00 22 26A EXTERNAL AIR DAMPER 214 00 23 214 00 23 27 SERVOCONTROL SUPPORT BRACKE...

Page 44: ...TROLLER 45 LANDIS LMG21 22 25 FLAME CONTROLLER 48 GAS MULTIBLOC REGULATOR DUNGS MB DLE 405 407 410 412 415 420 50 VALVE PROVING SYSTEM DUNGS VPS504 50 SAFETY SOLENOID VALVES DUNGS MV 5 MVD 5 MVDLE 5 SINGLE STAGE 50 LANDIS VALVES 51 APPENDIX COMPONENTS CHARACTERISTICS ...

Page 45: ...on AGK11 s socket Command signal from flame control Input signals Conditions for starting up the burner The burner control must not be locked out The contacts of the gas pressure switch GP the temperature or pressure switch W and the controller R must be closed Start up programme A Start up command controlled start up The regulator R supplies due to terminal 12 the mechanism the fan starts up for ...

Page 46: ...liance is located a plexiglass lunette under which there is the indicator disc of programme s progress In the event of safety stop the programmer stops The disc shows as follows the position of the programme at which the interruption occur red no start up the command ring is open interval tw or t10 on LGB21 tw or t11 on LGB22 air damper open LGB22 safety stop block through absence of the air press...

Page 47: ...ostat or pressostat W Safety thermostat or pressostat Z Ignition transformer LGB21 Key programmer s diagram A start up command from regulator R AR main relay B burner operation C program start position start up FR flame relay tw waiting time t1 preventilation time t2 safety time t3 pre ignition time t4 interval of time BV1 BV2 or BV1 LR t10 waiting time for confirmation of air pressure t11 air dam...

Page 48: ...ion time t3n Ignition time during TSA t4 Interval BV BV2 or BV1 LR t10 Specified time for air pressure signal t11 Programmed opening time for actuator SA t12 Programmed closing time for actuator SA Startup program A Start up controlled by LR fan command after the waiting time tw for LMG21 25 or after the period t11 for LMG22 tw Waiting time During this time the air pressure switch and the flame re...

Page 49: ...d lamp switched on Release of the flame control device Press the release button for 0 5 3 seconds Diagnosis of troubles Wait at least 10s Press the release button for 3s Count the number of flashing of the green lamp and compare with the Diagnosis Table Internal diagram LMG21 25 Diagnosis table Number of flashing Possible causes 2 flashing No flame at the end of the Safety time Detection electrode...

Page 50: ...izontally as well as its intermediate positions VALVE PROVING SYSTEM DUNGS VPS504 Specifications Operating pressure max 500 mbar 50 kPa Test volume 4 0 l Pressure increase by motor pump20 mbar Nominal voltage AC 230V 15 240V 10 DC 24V Frequency 50 Hz Rating requirement during pumping timeapprox 60 VA in operation 17 VA Prefuse provided by the customer 10 A quick acting fuse or 6 3 slow blow fuse F...

Page 51: ... are identical In this position the opening of the bypass is such that the retum flow through the bypass corresponds to the current oil output of the pump The control characteristic is that of a P controller with a very small proportional band Inspite of this the control stability is good since the piston velocities are small Design Features Servocontrol The electro hydraulic actuator consists of ...

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