Unigas R75A Installation, Use & Maintenance Manual Download

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Summary of Contents for R75A

Page 1: ...M039318CD Rel 0 3 02 2015 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ LMV2x Microprocessor controlled gas burners MANUAL OF INSTALLATION USE MAINTENANCE R75A RX75 RX75R ...

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: ... pressure in the utilisation limits The actuators move proportionally the air damper and the gas butterfly valve in order to achieve the optimisation of the gas flue values as to get an efficient combustion The adjustable combustion head can improve the burner performance The combustion head determines the energetic quality and the geometry of the flame Fuel and comburent are routed into separated...

Page 6: ...ut inverter EB micro processor control with inverter BURNER TYPE RX75R M 0 xx RX75 M 1 xx Output min max kW 270 1200 300 1800 Fuel Natural gas Natural gas Category see next paragraph see next paragraph Gas flow rate min max Stm3 h 29 127 32 190 Gas pressure min max mbar see Note 2 see Note 2 Electric supply 230V 3 400V 3N 50Hz 230V 3 400V 3N 50Hz Total power consumption kW 2 7 3 5 Fan motor kW 2 2...

Page 7: ...as connection 65 2 1 2 DN65 Valves size Gas connection 80 3 DN80 Valves size Gas connection 100 DN100 Operating temperature C 10 50 Storage TemperatureStorage Temperature C 20 60 Working service Intermittent Note1 All gas flow rates are referred to Stm3 h 1013 mbar absolute pressure 15 C temperature and are valid for G20 gas net calorific value Hi 34 02 MJ Stm3 Note2 Maximum gas pressure 360mbar w...

Page 8: ...358 483 374 770 352 979 618 361 270 290 235 330 453 M10 250 250 250 485 147 338 525 618 210 165 1 65 1162 1287 89 48 358 483 374 770 352 1051 690 361 270 290 282 330 453 M10 250 250 250 555 147 408 565 618 210 165 1 80 1162 1287 89 48 358 483 374 770 352 1051 690 361 270 290 284 330 453 M10 250 250 250 555 147 428 565 618 210 165 Boiler recommended drilling template Burner flange P11 P13 330 330 2...

Page 9: ... 525 608 210 155 1 65 1162 1287 69 28 378 503 374 750 352 1051 690 361 250 270 282 300 453 M10 216 250 233 535 127 408 565 608 210 155 1 80 1162 1287 69 28 378 503 374 750 352 1051 690 361 250 270 284 300 453 M10 216 250 233 555 127 428 565 608 210 155 DN A AS AA AD B BS BB C CC D E EE F G H J K L M Omin Omax P Q R S U W Y Z R75A 1 50 1253 69 28 503 374 750 352 979 618 361 254 270 235 300 453 M10 ...

Page 10: ...he performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests but does not represent the regulation range of the machine On this diagram the maximum output point is usually reached by adj suting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is rea ched setting the combust...

Page 11: ...e example From the interception 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 calcula ted before GAS PRESSURE IN THE NETWORK mbar RX75 Gas rate Stm3 h RX75R Gas rate Stm3 h GAS PRESSURE IN THE NETWORK mbar R75A M Gas rate Stm3 h WARNING the diagrams refers to natu...

Page 12: ...o 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 4 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 IN THE NETWORK mbar R75A L Gas rate...

Page 13: ...sure 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 14 Pressure rate in combustion head curves ATTENTION THE BURNED GAS RATE MUST BE READ AT THE GAS FLOW METER WHEN IT IS NOT POSSIBLE THE U...

Page 14: ...PART I SPECIFICATIONS 14 1 15 Pressure rate in combustion head curves LPG Curves are referred to pressure 0mbar in the combustion chamber Gas pressure in combustion head mbar R75A L Stm3 h ...

Page 15: ... following are placed in each packing case z burner with gas train z ceramic fibre plait to be inserted between the burner and the boiler z envelope containing this manual 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 and trained personnel If these opera tions are not...

Page 16: ...ensions 4 fasten the 4 stud bolts 5 place the gasket on the burner flange 6 install the burner into the boiler 7 fix the burner to the stud bolts by means of the fixing nuts according to the next picture 8 After fitting the burner to the boiler ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement...

Page 17: ...llow the instructions of the boiler manu facturer In absence of these consider the following z Cast iron boilers three pass flue boilers with the first pass in the rear part the blast tube must protrude no more than Dist 100 mm into the combustion chamber please see the picture below z Pressurised boilers with flame reversal in this case the blast tube must penetrate Dm 50 100 mm into combustion c...

Page 18: ...e governor Gas train with valves group MB DLE 2 valves gas filter pressure governor pressure switch gas leakage pressure switch PGCP 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...

Page 19: ...s are showed in the next paragraphs according to the gas train used z threaded gas trains with Siemens VGD20 Multibloc Dungs MB DLE z flanged gas trains with Siemens VGD40 ATTENTION once the gas train is mounted according to the diagram on Fig 6 the gas proving test mus be per formed according to the procedure set by the laws in force ATTENTION it is recommended to mount filter and gas valves to a...

Page 20: ...ounting positions Fig 10 4 after installation perform leakage and functional test 5 disassembly in reverse order 2 3 3 MULTIBLOC DUNGS MB DLE 415 420 Mounting 1 Loosen screws A and B do not unscrew Fig 11 Fig 12 2 unscrew screws C and D Fig 11 Fig 12 3 Remove MultiBloc between the threaded flanges Fig 12 4 After mounting perform leakage and functional tests Fig 7 Fig 8 Fig 9 Fig 10 Fig 11 Fig 12 F...

Page 21: ...ed 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 suitable replacement Siemens VGD valves with SKP actuator The pressure adjusting range upstr...

Page 22: ...ssure 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 preset time td2 The pressure switch PGCP has not to detect a pres sure drop down If all of the tes...

Page 23: ... 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 24: ...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 25: ... an error code on the AZL display z At the beginning of the start up cycle the actuator drives the air damper to the maximum opening position then the fan motor starts up the pre purge phase begins During the pre purge phase the air damper complete opening is signalled by the light B2 on see front panel z At the end of the pre purge the air damper is driven to the ignition position the ignition tr...

Page 26: ...flame output increasing too much or that the flues temperature gets too low to cause condensation in the chimney 5 2 User interface The AZL2x display is shown below The keys functions are the following WARNING During commissioning operations do not let the burner operate with insufficient air flow danger of formation of carbon monoxide if this should happen make the fuel decrease slowly until the ...

Page 27: ... Serivce during the curve adjustments Key Used to increase a a value Used to enter Info and Serivce during the curve adjustments Keys ESC By pressing and at the same time the ESCAPE function is perfomed to enter a lower level menu Bloc Descrizione Description Password 100 Informazioni generali General OEM Service Info 200 Controllo bruciatore Burner control OEM Service 400 Curve rapporto Ratio cur...

Page 28: ...rasformatore accen sione ON TSA1 1st safety time ignition transformer ON Ph42 TSA1 primo tempo sicurezza trasformatore accen sione OFF TSA1 1st safety time ignition transformer OFF t42 preignition time OFF Ph44 t44 intervallo 1 t44 interval 1 Ph50 TSA2 secondo tempo sicurezza TSA2 2nd safety time Ph52 t52 intervallo 2 t52 interval 2 Ph60 Funzionamento 1 stazionario Operation 1 stationary Ph62 t62 ...

Page 29: ...isplay will show InFo Press the enter InFo key 3 then il will show the first code 167 flashing on the right side it will show the data entered By pressing or it is possible to scroll up or down the parameter list 4 If a dot line is shown on the right there is no enough room for complete visualisation press enter again the data will be completely shown for 1 to 3 seconds By pressing enter or and at...

Page 30: ...e or by pressing ESC or InFo for more seconds the display will show 9 Once the last parameter is accessed 143 by pressing the End message will flash 10 Press InFo for more than three seconds or for more than three seconds orto return to the normal display Parameter Description 167 Cubic meters of fule resettable 162 Operating hours resettable 163 Device operating hours 164 Burners start ups resett...

Page 31: ... the reset press InFo for one second The unit displays an event which does not lead to shutdown The display shows current error code c alternating with diagnostic code d Press InFo to return to the display of phases Example Error code 111 diagnostic code 0 To reset press InFo for a second Record the codes and check the Error List to find the type of faults Service level To enter the Service mode p...

Page 32: ...143 by pressing the End message will blink 3 Press InFo for more than three seconds or for more than three seconds orto return to the normal display For further nformation see tha LMV2 related manual Parameter Description 954 Flame intensity 121 output if set automatic operation 922 Actuators position 00 combustibile 01 aria 161 Lock outs number 701 725 Lock outs History see chapter 23 in the LMV2...

Page 33: ... the cover C By screwing down the pressure is increased and by unscrewing it is reduced Note the screw VSB must be removed only in case of replacemente of the coil Fig 21 Fig 22 Key 1 Electrical connection for valves 2 Operation display optional 3 Pressure governor closing tap 4 Start setting cap 5 Hydraulic brake and rate regulator 6 Coil 7 Test point connection G 1 8 8 Test point connection G 1 ...

Page 34: ...e ID index shows how much the combustion head moved Fig 23 RX75 RX75R The burner is factory set with the head in its all ahead position as for the minimum output To operate at a higher power slightly move the combustion head backwards turning clockwise the screw VRT CAUTION perform these adjustments once the burner is turned off and cooled Attention if it is necessary to change the head position r...

Page 35: ... 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 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 LPG ...

Page 36: ... purge phase o the operation 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 5 12 Calibration of low gas pr...

Page 37: ...ream the gas governor gas valves group and upstream the butterfly valve light the burner adjust it according to the procedure in the previous paragrph Then measure the gas pressure at the operating flow rate downstream the gas governor gas valves group and upstream the butterfly valve by means of the adjusting ring nut VR set the value read on step 2 increased by the 30 4 replace the plastic cover...

Page 38: ... 1 and 3 Fig 25 Fig 26 is Δp 10 mbar z Change the filter if the pressure difference between pressure connection 1 and 3 Fig 25 Fig 26 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 4 using the Allen key n 3 and remove filter cover 5 in Fig 27 3 Remove the filter 6 and replace w...

Page 39: ...erence between pressure connection 1 and 2 Fig 28 Fig 29 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 30 3 Change filter insert 4 Re insert filter housing screw in screws 1 6 without using any force and fasten 5 Perform leakage and functional test pmax 360 mbar 6 Pay at...

Page 40: ...on 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 adhesive label for spring identification on the type plate ATTENTIO...

Page 41: ...lows 1 remove the burner cover 2 disconnect the electrodes cables 3 loose the screw VB that fasten the electrodes group to the combustion head 4 remove the electrodes and replace them paying attention to the measures showed in previous paragraph Reassemble the burner by fllowing the procedure in the reversed order ATTENTION avoid the ignition and detection electrodes to contact metallic parts blas...

Page 42: ...PART IV MAINTENANCE 42 RX75 RX75R Fig 32 R75A Fig 33 Detection electrode VB ...

Page 43: ...tor the electrical contacts and if necessary replace the electrode or the detector 6 10 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 6 11 Burner disposal In case of disposal follow the instructions according to the laws in force in your country about th...

Page 44: ...V MAINTENANCE 44 7 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 45: ...F 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 ...

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Page 48: ...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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