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Unigas P60 Series, Installation, Use And Maintenance Manual

The SPYKER P60 Series Operator's Manual is an essential companion for owners of these exceptional products. Offering detailed instructions and guidelines, this manual ensures optimal performance and safety. Download it for free from our website and gain access to the invaluable information you need to operate your SPYKER P60 Series equipment with confidence.

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TABLE OF CONTENTS

WARNINGS ................................................................................................................................................................ 3

PART I: INSTALLATION MANUAL  .......................................................................................................................... 5

Burner model identification  ............................................................................................................................................................. 5
Specifications .................................................................................................................................................................................. 5
Country and usefulness gas categories .......................................................................................................................................... 6
Overall dimensions  ......................................................................................................................................................................... 7
Performance curves ...................................................................................................................................................................... 10

MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 12

Packing ......................................................................................................................................................................................... 12
Fitting the burner to the boiler  ....................................................................................................................................................... 12
Matching the burner to the boiler  .................................................................................................................................................. 12
Gas train connections ...................................................................................................................................................................  13
Assembling the gas grain .............................................................................................................................................................. 14
Siemens VGD20.. and VGD40..  gas valves - with SKP2.. (pressure governor)   ......................................................................... 16
Pressure adjusting range  .............................................................................................................................................................. 16
Gas Proving System VPS504  ....................................................................................................................................................... 17
Electrical connections  ................................................................................................................................................................... 18
Rotation of fan motor  .................................................................................................................................................................... 19

ADJUSTMENTS ........................................................................................................................................................................... 20

Combustion head gas pressure curves depending on the flow rate  ............................................................................................. 20
Measuring the gas pressure in the combustion head  ................................................................................................................... 20
Gas pressure in combustion head vs. gas flow rate curves .......................................................................................................... 21
Adjusting air and gas flow rates  .................................................................................................................................................... 22
Startup Output ............................................................................................................................................................................... 22
Adjustments - brief description ...................................................................................................................................................... 22
Adjusting procedure  ...................................................................................................................................................................... 22
Progressive burners ...................................................................................................................................................................... 26
Fully modulating burners ............................................................................................................................................................... 27
Calibration of air and gas pressure switches  ................................................................................................................................ 27
Calibration of air pressure switch .................................................................................................................................................. 27
Calibration of low gas pressure switch .......................................................................................................................................... 27
Adjusting the high gas pressure switch (when provided) .............................................................................................................. 27

PART II: OPERATION  ............................................................................................................................................. 28

OPERATION.................................................................................................................................................................................  29

PART III: MAINTENANCE.......................................................................................................................................  31

ROUTINE MAINTENANCE ........................................................................................................................................................... 31

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 ............................................................................................. 31
Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group)  ............................................ 32
Gas filter maintenance  .................................................................................................................................................................. 32
Removing the combustion head  ................................................................................................................................................... 32
Adjusting the electrodes ................................................................................................................................................................ 33
Replacing the electrodes  .............................................................................................................................................................. 34
Checking the detection current  ..................................................................................................................................................... 34
Seasonal stop  ............................................................................................................................................................................... 35
Burner disposal  ............................................................................................................................................................................. 35

TROUBLESHOOTING .................................................................................................................................................................. 36

SPARE PARTS.............................................................................................................................................................................  37

BURNER EXPLODED VIEW ......................................................................................................................................................... 38

WIRING DIAGRAMS  .................................................................................................................................................................... 42

APPENDIX

Summary of Contents for P60 Series

Page 1: ...M03956CR 12 2009 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Gas burners MANUAL OF INSTALLATION USE MAINTENANCE P60 P65 P72 P73A ...

Page 2: ...bustion head vs gas flow rate curves 21 Adjusting air and gas flow rates 22 Startup Output 22 Adjustments brief description 22 Adjusting procedure 22 Progressive burners 26 Fully modulating burners 27 Calibration of air and gas pressure switches 27 Calibration of air pressure switch 27 Calibration of low gas pressure switch 27 Adjusting the high gas pressure switch when provided 27 PART II OPERATI...

Page 3: ...ains 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 the following operations a Rem...

Page 4: ...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 non electric ...

Page 5: ...5 80 DN80 BURNER TYPE P60 M 0 40 P60 M 0 50 P60 M 0 65 P65 M 50 P65 M 65 Output min max kW 160 523 160 800 160 800 270 970 Fuel Natural gas Category see next paragraph Gas flow rate min max Stm3 h 17 56 17 84 7 17 84 7 28 6 103 28 6 103 Gas pressure min max mbar see Note 2 Electric supply 230V 3 400V 3N 50Hz Total power consumption kW 1 6 2 Fan motor kW 1 1 1 5 Protection IP40 Weight kg 55 55 70 8...

Page 6: ...e Intermittent BURNER TYPE P73A M 1 50 P73A M 1 65 P73A M 1 80 Output min max kW 320 2300 Fuel Natural gas Category see next paragraph Gas flow rate min max Stm3 h 34 243 Gas pressure min max mbar see Note 2 Electric supply 230V 3 400V 3N 50Hz Total power consumption kW 3 5 Fan motor kW 3 Protection IP40 Weight kg 90 110 120 Operation Double stages Progressive Fully modulating Valves size Gas conn...

Page 7: ...99 99 343 433 314 666 298 812 500 312 184 204 210 240 344 M10 269 190 190 439 112 327 444 464 162 120 P60 PR 0 50 50 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 447 112 335 444 464 162 120 P60 MD 0 50 50 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 447 112 335 444 464 162 120 P60 AB 0 50 50 1009 1099 99 343 433 314 666 298 81...

Page 8: ... 465 130 335 465 531 162 155 P65 MD 0 50 50 1129 1219 130 326 416 373 803 316 900 568 332 184 228 208 300 376 M10 330 216 250 233 465 130 335 465 531 162 155 P65 MD 1 50 50 1129 1219 130 326 416 373 803 316 1026 694 332 184 228 208 300 376 M10 330 216 250 233 465 130 335 465 531 162 155 P65 PR 0 65 65 1129 1219 130 326 416 373 803 316 998 666 332 184 228 273 300 393 M10 330 216 250 233 533 130 403...

Page 9: ...3 565 313 548 198 212 155 P72 PR 0 80 80 1188 1298 130 385 495 373 803 316 998 666 332 234 264 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 212 155 P72 PR 1 80 80 1188 1298 130 385 495 373 803 316 1106 774 332 234 264 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 212 155 P72 AB 0 80 80 1118 1228 130 385 495 373 733 316 998 666 332 234 264 275 300 407 M10 330 216 250 23...

Page 10: ...n 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 BACK PRESSURE IN COMBUSTION CHAMBER mbar P60 M xx x IT A 0 40 kW P60 M xx x IT A 0 50 65 kW BACK PRESSURE IN COMBUSTION CHAMBER mbar P65 kW P72M 0 ...

Page 11: ...elated 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 reque sted gas rate add the pressure value in the combustion chamber to the value read on the y axis 0 5 10 15 20 25 10 20 30 40 50 60 70 80 0 5 10 15 20 25 10 20 30 40 50 60 70 80 90 Rp 2 50 DN65 0 5 10 15 20 25 30 20 30 ...

Page 12: ...propriate insulating material ceramic fibre cord or refractory cement The burner is designed to work positioned according to the picture below For different installations please contact the Technical Department Matching the burner to the boiler The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose dimensions are described in the ...

Page 13: ...and lenght of the test flame tube as a function of the heat input in kW ATTENTION BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNING OF THIS MANUAL Rp1 1 2 Rp2 Gas train with valves group MB DLE 2 valves gas filter pressure governor pressure switch leakage control VPS504 Rp2 DN65 DN80 Gas tr...

Page 14: ... Key 1 Burner 2 Butterfly valve 3 Gas proving system option 4 Maximum gas pressure switch option 5 Minimum gas pressure switch 6 Gas filter 7 Bellow joint 8 Manual valve 9 MB DLE Valves group 10 VGD Valves group 18 Valves group MBC 2 provided with filter 19 Valves group MBC an external filter must be installed ATTENTION once the gas train is mounted according to the diagram Fig 5 the gas proving t...

Page 15: ... Fig 6 Fig 7 2 unscrew screws C and D Fig 6 Fig 7 3 Remove MultiBloc between the threaded flanges Fig 7 4 After mounting perform leakage and functional tests MULTIBLOC DUNGS MBC300 700 1200SE Threaded valves group Fig 6 Fig 7 Fig 8 Fig 9 Mounting 1 Mount flange onto tube lines Use appropriate sealing agent see Fig 10 2 Insert MBC SE Note position of O rings see Fig 11 3 Tighten screws A H 4 After ...

Page 16: ...he 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 the SKP2 diaphragm D must be vertical see Fig 15 WARNING removing the four ...

Page 17: ...ert sealing rings 10 5 x 2 25 into VPS 504 Fig 17 B Fig 18 5 Torque screws 3 4 5 6 M4 x16 Fig 18 C Only use screws with metric thread on reassembly modification repair 6 On completion of work perform a leak and functional test When wishing to monitor the test install a pressure gauge ranged to that of the pressure supply point PA Fig 18 If the test cycle is satisfactory after a few seconds the con...

Page 18: ... the gas proving test mus be performed according to the procedure set by the laws in force 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 OF...

Page 19: ...on of the motor NOTE the 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 20 Probes connection scheme for modulating burners Fig 21 Power supply terminal block Fig 22 CAUTION check the motor thermal cut out adjustment...

Page 20: ...rator 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 23 2 to get the pressure in the combustion chamber and the other one into the but...

Page 21: ...e in combustion head P72 M 0 xx Gas rate Stm3 h P72 M 1 xx Gas rate Stm3 h Gas pressure in combustion head P73A M 1 xx Gas rate Stm3 h 0 1 2 3 4 5 6 15 20 25 30 35 40 45 50 55 60 0 1 2 3 4 5 6 7 8 9 15 25 35 45 55 65 75 85 95 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 110 0 2 4 6 8 30 40 50 60 70 80 90 100 110 120 130 0 2 4 6 8 10 12 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 0 5...

Page 22: ... To change the burner setting during the testing in the plant follows the next procedure according to the model provided Adjusting procedure The burner is factory set with the combustion head at the position that refers to the MAX output The maximum output setting refers to the fully ahead position of the combustion head As for fully ahead position it means that the head is towards the boiler full...

Page 23: ...ase of replacemente of the coil see picture on page 24 On the DUNGS MBC SE gas valves group set the pressure regulator to 1 3 of its stroke using a 2 5 allen key 1 Turn the burner on by means of its main switch A if the burner locks LED B on in the control panel press the RESET button C on the control panel Fig 25 See chapter Operation for further details 2 check the fan motor rotation see Rotatio...

Page 24: ... act on its pressure governor to increase or decrease the pressure and consequently the gas rate Pressure governor is factory set The setting values must be locally adapted to machine conditions Important Follow the instruc tions carefully 8 To adjust the air flow rate in the high flame stage loose the RA nut and screw VRA as to get the desired air flow rate moving the rod T towards the air damper...

Page 25: ...tion cam position that is why it must be set at about 30 more than the ignition cam 13 Turn the burner off and then start it up again If the adjustment is not correct repeat the previous steps Berger STA12 a key is provided to move the cams Siemens SQN72 a key is provided to move cams I and IV the other cams can be moved by means of screws On the BERGER STA12B3 41 actuator the manual air damper co...

Page 26: ...xt screw on the adjusting cam and repeat the previous step go on this way as to reach the desired low flame point 13 Now adjust the pressure switches see page 27 14 If it is necessary to change the burner output in the low flame stage move the low flame cam the low flame position matches the ignition position As far as burners fitted with Dungs MBC gas valves the low flame cam does not match the i...

Page 27: ...ation of low gas pressure switch As for the gas pressure switch calibration proceed as follows z Be sure that the filter 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...

Page 28: ...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 29: ... z At the end of the pre purgue phase the air damper goes to the ignition position the ignition transformer turns on signalled by the lamp H and few seconds later the solenoid valves EV1 and EV2 are energized lights I and L on the front panel z Few seconds after the opening of the valves the ignition transformer turns off and the lamp H turns off subsequently Double stage burners the burner is on ...

Page 30: ...rgue phase G Low flame operation indicator light H Ignition tranformer operation indicator light I Valve in operation indicator light for EV2 L Valve in operation indicator light for EV1 M Indicator light for fan motor overload tripped only three phase burners to reset the overload tripped the electrical board must be opened P Modulator fitted only on fully modulating burners Q Operation manual se...

Page 31: ...e filter if the pressure difference between pressure connection 1 and 2 Fig 26 Fig 27 p 10 mbar z Change the filter if the pressure difference between pressure connection 1 and 2 Fig 26 Fig 27 is twice as high compared to the last check You can change the filter without removing the fitting 1 Interrupt the gas supply closing the on off valve 2 Remove screws 1 6 Fig 28 3 Change filter insert 4 Re i...

Page 32: ...f pressure value between pressure connections 1 and 2 is twice as high compared to the last inspection 1 Interrupt gas supply close ball valve 2 Remove screws 1 2 3 Replace the filter insert 3 4 Screw in screws 1 2 without use force to fasten 5 Perform leakage and funcion test 6 Pay attention that dirt does not fall inside the valve Space requirements for fitting filter A from 150 to 230 mm Fig 29...

Page 33: ... settings P73A Type P65 P72 P73A z Remove the lid C z Unscrew the screws V holding in position the manifold G and pull out the complete group as shown in figure Note for the subsequent assembly carry out the above described operations in the reverse order checking the correct position of the OR ring Fig 31 ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube h...

Page 34: ...ld be compromised Check the electrodes position after any intervention on the combustion head To measure the detection signals refer to the diagrams in Fig 36 and Fig 37 If the signal is less than the indicated value check the position of the detection electrode the electrical contacts and if necessary replace the detection electrode Fig 36 VB VB Control box Minimum detection signal Siemens LME21 ...

Page 35: ...he power mains 3 close the fuel cock of the supply line Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials Test point on burners fitted with printed circuit To check the detection current remove the jumper between termi nals and connect the microamperemeter see Fig 37 Fig 37 ...

Page 36: ...AS z z MAXIMUM GAS PRESSURE SWITCH DEFECTIVE IF PROVIDED z z THERMOSTATS PRESSURE SWITCHES DEFECTIVE z z z OVERLOAD TRIPPED INTERVENTION z AUXILIARIES FUSE INTERRUPTED z CONTROL BOX FAULTY z z z z z DEFECTIVE SERVOCONTROL IF PROVIDED 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 ELECT...

Page 37: ...P Rp11 2 DUNGS MB DLE415 21903L3 VALVE GROUP Rp2 DUNGS MB DLE420 21903L4 21903L4 21903L4 21903L4 VALVE GROUP DN65 SIEMENS VGD40 2190172 2190172 2190172 2190172 VALVE GROUP DN80 SIEMENS VGD40 2190169 2190169 2190169 ACTUATOR SKP15 2190181 2190181 2190181 2190181 ACTUATOR SKP25 2190183 2190183 2190183 2190183 ACTUATOR double stage BERGER STA 2480042 2480042 2480042 2480042 ACTUATOR progressive and f...

Page 38: ...R PRESSURE SWITCH PIPE 11 10 ACTUATOR PIVOT 7 PLEXYGLASS 11 11 CONNECTING ROD 8 BLAST TUBE 11 12 ROD 9 AIR PRESSURE SWITCH 11 13 ROD 10 1 OR RING 11 14 JOINT 10 2 BUTTERFLY VALVE 11 15 ROD JOINT 10 3 GAS MANIFOLDC 12 PREMOUNTED HEAD ADJUSTING SCREWS 11 1 1 COMPLETE MOUNTED LEVERAGE 13 1 WIRED FRONT PANEL 11 1 2 BIG HEXAG VARYING SECTOR 13 2 M BOARD S ELECTRICAL PANEL 11 1 3 ACTUATOR 13 3 M PANEL S...

Page 39: ...C I B UNIGAS M03956CR 39 ...

Page 40: ...ING NUT 12 2 3 TRANSMISSION AIR ADJUSTING CAM 2 5 GAS MANIFOLD 12 2 4 CONNECTING ROD 3 1 FAN 12 2 5 TENSION ROD 3 2 MOTOR 12 2 6 JOINT 4 1 GAS FILTER 12 2 7 JOINT FOR ROD 4 2 BUTTERFLY VALVE FANGE 12 3 INNER AIR DAMPER 4 3 PIPE 12 4 INNER AIR DAMPER 4 4 1 PRESSURE SWITCH 12 5 BOX 4 4 2 VALVE 12 6 ACTUATOR PIVOT 4 4 3 ACTUATOR SKP15 12 7 ACTUATOR PIVOT 4 4 4 ACTUATOR SKP25 12 8 CONNECTING ROD 4 4 5...

Page 41: ...C I B UNIGAS M03956CR 41 ...

Page 42: ...y 400V 50Hz 3N a c three phase and 230V 50Hz 1N a c monophase 2 Don t reverse phase and neutral 3 Ensure the burner is properly earthed Burners provided with Dungs MBC valves diagram SE18 164 Burners provided with Dungs MB DLE or Siemens VGD valves diagram SE18 165 ...

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Page 51: ...ting time air pressure monitor LP and flame relay FR are tested for correct contact positions t11 Programmed opening time for actuator SA Only with LME22 The air damper opens until the nominal load position is reached Only then will fan motor M be switched on t10 Specified time for air pressure signal On completion of this period of time the set air pressure must have built up or else lockout will...

Page 52: ...ed time for air pressure signal t11 Programmed opening time for actuator SA t12 Programmed closing time for actuator SA SB R W GP AL M LP BV1 Z FS tw t1 t3n TSA t4 7 t10 EK2 12 10 3 7 4 6 1 8 t3 A B B C D 11 SB R W GP AL LP SA BV1 LR BV2 Z FS tw t1 t3n TSA t4 7101d02 0606 t11 t12 EK2 12 10 3 7 4 5 6 1 8 A B B C D 9 t3 t10 LK M I 11 SB R W GP AL LP BV1 LR BV2 Z FS tw t1 t3n t4 7101d05 0206 12 10 3 ...

Page 53: ...t W Limit thermostat pressure switch Z Ignition transformer LME22 connection diagram NT PC control RESET EK FSV ION 1 2 3 M 4 BV1 5 7 Z 10 AL T 12 R W GP STB 9 7101 24 0606 pa 6 LP 8 EK 11 K1 K2 1 K3 K2 2 H Si L N NT RESET EK FSV ION 1 2 3 M 4 BV1 5 BV2 7 Z 10 AL T 12 R W GP STB 9 pa 6 LP 8 EK 11 K1 K2 1 K3 K4 K2 2 H Si L N PC control NT PC control RESET EK FSV ION 1 2 3 M 4 BV1 5 BV2 7 Z 10 AL T ...

Page 54: ...ult status is showed by the red LED inside the LME s lockout reset buttonaccording to the Error code table RESETTING THE BURNER CONTROL When lockout occurs the burner control can immediately be reset by pressing the lockout reset button for about 1 3 seconds The LME can only be reset when all contacts in the line are closed and when there is no undervoltage LIMITATION OF REPETITIONS only for LME11...

Page 55: ......

Page 56: ...d and data subject to change Errors and omissions excepted 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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