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Unigas R91A, Manual Of Installation - Use - Maintenance

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Unigas R91A Manual Of Installation - Use - Maintenance Download Page 13

C.I.B. UNIGAS

 - M039231CB

13

Key

* Note: the high gas pressure switch can be mounted either upstream the gas valve or downstream the gas valves but upstream the
butterfly gas valve.* 

 

Gas train - 2

 (Rp2)

Gas train with valves group MBC 1200SE (2  gas  pressure governor) +  VPS504 gas proving system

Gas train - 3

(DN65/80/100)

Gas train with valves group MBC 1900/3100/5000SE (2  gas  pressure governor) +  VPS504 gas proving system

1

Burner

2

Butterfly valve

4

Maximum gas pressure switch (optional)

5

Minimum gas pressure switch

6

Gas filter

7

Bellows unit

8

Manual cutoff valve

10

VGD Valves group 

16

PGCP - gas leakage pressure switch

18

MBC Valves group (2” with filter provided)

19

MBC Valves group (DN65/80/100)

1

2

5

4

7

8

18

16

4

MANUFACTURER

INSTALLER

1

2

5

4

7

8

18

16

4

MANUFACTURER

INSTALLER

Summary of Contents for R91A

Page 1: ...M039231CB Rel 1 0 05 2010 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Microprocessor controlled gas burners MANUAL OF INSTALLATION USE MAINTENANCE R91A R92A R93A ...

Page 2: ...enu 21 Phases list 22 Entering the Parameter levels 23 Info level 23 Service level 25 Adjusting air and gas flow rates 26 Adjustments brief description 26 Adjusting procedure 27 Adjusting the combustion head 28 Calibration of air and gas pressure switches 28 Calibration of air pressure switch 28 Calibration of low gas pressure switch 29 PGCP Gas leakage pressure switch witn Siemens LDU burner cont...

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 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 CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric...

Page 5: ... of the Siemens LMV central unit that performs all the burner control functions and of the Siemens AZL local programming unit that interfaces the system with the user Fig 1 Keys 1 Burner 2 AZL2 3 Air actuator 4 Fuel actuator 5 LMV2 PART I INSTALLATION MANUAL 3 4 1 2 5 2 ...

Page 6: ...er and the valves group provided with stabiliser This one forces the pres sure in the utilisation limits The actuators proportionally move the air damper and the gas butterfly valve microprocess controlled in order to optimise the gas flue values as to get an efficient combustion The combustion head positioning determines the burner s output Fuel and comburent are routed into separated ways as far...

Page 7: ...know the available gas pressure value upstream the burner s gas valve Then subtract the backpressure The result is called pgas Draw a vertical line matching the furnace input value 600kW in the example quoted on the x axis as far as intercepitng the network pressure curve according to the installed gas train DN65 in the example From the interception point draw an horizontal line as far as matching...

Page 8: ...ATION EA Burner equipped with LMV2 EB Burner equipped with LMV37 BURNER TYPE R91A R92A R93A Output min max kW 480 2670 480 3050 550 4100 Fuel Natural gas Gas category see next paragraph Gas rate min max Stm3 h 51 283 51 323 58 434 Pressure mbar see Note 2 Power supply 230V 3 400V 3N 50Hz Total power consumption kW 4 5 6 8 Electric motor kW 4 5 5 7 5 Protection IP40 Operation Progressive Fully modu...

Page 9: ...4 269 299 329 360 464 M12 417 280 310 295 522 148 374 624 216 649 240 185 R92A 65 1333 242 490 419 843 422 1309 875 434 269 299 288 360 464 M12 417 280 310 295 551 148 403 750 292 649 240 185 R92A 80 1333 242 490 419 843 422 1311 877 434 269 299 307 360 464 M12 417 280 310 295 592 148 444 750 322 649 240 185 R92A 100 1333 242 490 419 843 422 1401 967 434 269 299 447 360 464 M12 417 280 310 295 672...

Page 10: ...output may be different from the Per formance curve minimum Pressure in the Network gas flow rate curves PRESSURE IN COMBUSTION CHAMBER mbar R91A kW R92A kW PRESSURE IN COMBUSTION CHAMBER mbar R93A kW GAS PRESSURE mbar R91A Stm3 h R92A Stm3 h GAS PRESSURE mbar R93A Stm3 h Caution the gas rate value is quoted on the x axis the related network pressure is quoted on the y axis pressure value in the c...

Page 11: ... gap between the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement Packing The burners are despatched in wooden crates whose dimensions are 1730mm x 1280mm x 1020mm L x P x H Packing cases of this type are affected by humidity and are not suitable for stacking The following are placed in each packing case z burner with gas t...

Page 12: ...st tube must protrude no more than 100 mm into the combustion chamber z Pressurised boilers with flame reversal in 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 backward...

Page 13: ...s train 3 DN65 80 100 Gas train with valves group MBC 1900 3100 5000SE 2 valves gas filter pressure governor VPS504 gas proving system 1 Burner 2 Butterfly valve 4 Maximum gas pressure switch optional 5 Minimum gas pressure switch 6 Gas filter 7 Bellows unit 8 Manual cutoff valve 10 VGD Valves group 16 PGCP gas leakage pressure switch 18 MBC Valves group 2 with filter provided 19 MBC Valves group ...

Page 14: ...s trains with Multibloc Dungs MBC SE 1200 or Siemens VGD20 z flanged gas trains with Multibloc Dungs MBC SE 1900 3100 5000 or Siemens VGD40 MULTIBLOC DUNGS MBC300 700 1200SE Threaded valves group ATTENTION once the gas train is mounted according to the diagram on Fig 5 the gas proving test mus be performed according to the procedure set by the laws in force Mounting 1 Mount flange onto tube lines ...

Page 15: ...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 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 r...

Page 16: ...nstalled connect electrically all its elements gas valves group pressure switches gas proving system Fig 13 DUNGS MBC SE Siemens SKP actuator Performance range mbar 4 20 20 40 40 80 80 150 Spring colour red 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 5 the gas proving test mus be per...

Page 17: ...oard and the earth terminal an RC Siemens RC466890660 filter must be inserted Key C Capacitor 22nF 250V LMV Siemens BMS Burner Management System R Resistor 1Mohm RC466890660 RC Siemens filter Fig 14 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 th...

Page 18: ... Key 1 Generator 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 15 2 to get the pressure in the combustion chamber and the other one i...

Page 19: ...essure 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 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 ...

Page 20: ...s contemporarly the code message will appear by entering the proper password it is possible to access the Service mode Info and Enter keys Used for Info and Service menues Used as Enter key in the setting modes Used as Reset key in the burner operation mode Used to enter a lower level menu Key Used to decrease a a value Used to enter Info and Serivce during the curve adjustments Key Used to increa...

Page 21: ...0 Informazioni generali General OEM Service Info 200 Controllo bruciatore Burner control OEM Service 400 Curve rapporto Ratio curves OEM Service 500 Controllo rapporto Ratio control OEM Service 600 Servocomandi Actuators OEM Service 700 Storico errori Error history OEM Service Info 900 Dati di processo Process data OEM Service Info P V h min s Lock unlock codes Flame Open valves Fan motor energise...

Page 22: ...42 tempo preaccensione 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 intervallo2 t52 interval 2 Ph60 Funzionamento 1 stazionario Operation 1 stationary Ph62 t62 massimo tempo bassa fiamma funzionamento 2 in preparazione per spegnimento verso bassa fiamma t62 max time lo...

Page 23: ...m will start again the display will show OFF 2 until the display 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 compl...

Page 24: ... flash 10 Press InFo for more than three seconds or for more than three seconds orto return to the normal display If a message like the one below is shown during operation it means that the burner is locked out and the Errore code is shown in the example error code 4 this message is alternating with Parameter Description 167 Cubic meters of fule resettable 162 Operating hours resettable 163 Device...

Page 25: ...set 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 press InFo until the display will show The service level shows all the information about flame intensity actuators position number and lock codes 1 the first parameter will be 954 the percentage of flame is shown on the right By pressinf or it is possible to scro...

Page 26: ...hen adjust the combustion values by setting the air gas ratio curvepoints see the LMV2 related manual z Set now the low flame output 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 ATTENTION before starting the burner up be sure that the manual cutoff valves are open and check that the pres sure upstream the...

Page 27: ...e next figure Dungs MBC SE valves group act on its pressure governor to increase or decrease the pressure and consequently the gas rate Now adjust the pressure switches see next par Fully modulating burners To adjust the fully modulating burners use the CMF switch on the burner control panel see Fig 16 instead of the TAB thermostat as described on the previous paragraphs about the progressive burn...

Page 28: ...ccording to the actuator model provided Calibration of air and gas pressure switches The air pressure switch locks the control box if the air pressure is not the one requested If it happens unlock the burner by means of the control box unlock pushbutton placed on the burner control panel The gas pressure switches check the pressure to avoid the burner operate when the pres sure value is not in the...

Page 29: ...trol Siemens LMV Burner Management System z remove the pressure switch plastic cover z adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch z replace the plastic cover Adjusting the high gas pressure switch when provided To calibrate the high pressure switch proceed as follows according to its mounting position 1 remove the pressure switch plastic cover 2 if th...

Page 30: ...THE GENERATOR COUPLING FLANGE CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT OPERATION z Set to on the B switch on the burner control panel z Check that the contrl box is not in the lockout position light B on in case unlock it by pressing the Enter InFo key for further infor mation on the LMV2 see the related manual z Check that the pressure switches thermostats series enables the...

Page 31: ...ystem E Gas pressure switch enabling signal F Lock out light for gas proving system G Hi flame operation light H Lo flame operation light I Ignition transformer operation light L EV2 opening light M EV1 opening light N Fan motor overload tripped light O Burner in stand by light P Burner Modulator only on fully modula ting burners M F P A C E L N G H B I O Q R ...

Page 32: ...place the cover fastening by the proper screws A Inspection and replacement of the MULTIBLOC DUNGS MBC SE filter Threaded valves group WARNING ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL ATTENTIONwhen servicing if it was necessary to disassemble the...

Page 33: ...w in the protective cap with the O ring in it 6 Stick the adhesive label for spring identification on the type plate Removing the combustion head 1 Remove the cover C 2 remove the electrodes cables 3 unscrew the 3 screws V which hold in position the gas manifold G and pull out the complete group as shown in figure Note to replace the combustion head reverse the procedure described above having car...

Page 34: ...the outside and remove the combustion head D 6 loose the screw of th eignition electrodes support E 7 remove the electrodes and replace them paying attention to the measures showed in figure F G ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc otherwise the bur ner operation would be compromised Check the electrodes position after any intervention...

Page 35: ...combustion head 2 by means of an allen key loose the fixing screws of the detection electrode ER and replace it 3 replace the combustion head E F G ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc otherwise the boi ler s operation would be compromised Check the electrodes position after any intervention on the combustion head 528 528 7 4 8 ER ER ...

Page 36: ...the safety phase One repetition is permitted This means that if the error occurs again the next time the system is shut down the unit initiates lockout 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 Burner disposal In case of disposal follow the instructi...

Page 37: ...0087 2160087 IGNITION TRANSFORMER 2170140 2170140 2170140 MOTOR 2180276 2180277 2180206 GAS VALVE GROUP Rp2 Siemens VGD20 2190171 2190171 2190171 GAS VALVE GROUP DN65 Siemens VGD40 2190172 2190172 2190172 GAS VALVE GROUP DN80 Siemens VGD40 2190169 2190169 2190169 GAS VALVE GROUP DN100 Siemens VGD40 2190174 2190174 2190174 GAS VALVE ACTUATOR SKP15 2190181 2190181 2190181 GAS VALVE ACTUATOR SKP25 21...

Page 38: ...C I B UNIGAS M039231CB 38 WIRING DIAGRAMS ATTENTION 1 Power supply 400V 50Hz 3N a c and 230V 50Hz 1N a c 2 Don t reverse phase and neutral 3 Ensure the burner is properly earthed ...

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Page 55: ...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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