Unigas HR75A LG Series Manual Of Installation - Use - Maintenance Download

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M039315CA Rel. 0.3 07/2015

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

LMV2x

Microprocessor-controlled

Gas - light oil burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

HR75A

Summary of Contents for HR75A LG Series

Page 1: ...M039315CA Rel 0 3 07 2015 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ LMV2x Microprocessor controlled Gas light oil burners MANUAL OF INSTALLATION USE MAINTENANCE HR75A ...

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: ...development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives 2009 142 EC Gas Directive 2006 95 CEC Low Tension Directive 2004 108 EC Electromagnetic compatibility Directive 2006 42 EC Machinery Directive Harmonized standards UNI EN 676 Automatic forced draught burners for gaseous fuels EN 55014 1 Electromagnetic compatibility Requirements for house hold appli...

Page 4: ...ements for house hold appliances electric tools and similar apparatus EN 746 2 Industrial thermoprocessing equipment Part 2 Safety requi rements for combustion and fuel handling systems EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements Burner data plate For the following information please refer to the data plate z burner type and burne...

Page 5: ...l passing through the nozzle The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which a separate regulating valve is provided Other pumps are provided with two pressure regulators one for the high and one for low pressure in double stage systems wi...

Page 6: ...kW 320 2050 Fuel Natural gas Light oil L P G Light oil Category see next paragraph I3B P Gas rate min max Stm3 h 34 217 11 9 77 Gas pressure see Note 2 Power supply 400V 3N 50Hz Total power consumption kW 4 05 Pump motor kW 0 55 Fan motor power consumption kW 3 Light oil rate min max kg h 27 173 Oil viscosity 2 7 4 cSt 40 C Oil density kg m3 840 Approximate weight kg 150 Protection IP40 Operation ...

Page 7: ... Country and usefulness gas categories 1 4 Fuel GAS CATEGORY COUNTRY I2H AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH I2E LU PL I2E R B BE I2L NL I2ELL DE I2Er FR WARNING The burner must be used only with the fuel specified in the burner data plate Type Model Year S Number Output Oil Flow Fuel Category Gas Pressure Viscosity El Supply El Consump ...

Page 8: ...M10 216 250 233 465 127 338 525 608 210 155 1 65 1253 69 550 435 28 305 503 374 750 352 1051 690 361 254 270 282 300 453 M10 216 250 233 535 127 408 565 608 210 155 1 80 1253 69 550 435 28 305 503 374 750 352 1051 690 361 254 270 284 300 453 M10 216 250 233 555 127 428 565 608 210 155 BB CC Z L AE U E D F W G B Y AD AA C A R S Q AB AC J K K O min O max O min O max M H P P N Burner flange Boiler re...

Page 9: ...N 1 Filter 2 Flexible hose 3 Pump and pressure governor 4 Electrical motor 6 Solenoid valve 6 1 Solenoid valve 10 Oil distributor 12 Pressure gauge 13 Pressure governor 15 Pressure switch 16 One way valve 16 1 One way valve 18 Flexible hose 19 Manual valve 20 Pressure gauge MAIN GAS TRAIN 23 Pressure switch PGMIN 24 Safety valve with built in gas governor 25 Proving system pressure switch PGCP 26 ...

Page 10: ...graph Adjusting the combustion head the minimum output point is rea ched setting the combustion 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 To check the proper gas train size it is necessary to...

Page 11: ... know the minimum pressure at the gas train inlet necessary to get the requested gas rate add the pressure value in the combustion chamber to the value read on the y axis GAS PRESSURE IN THE NETWORK mbar HR75A L Gas rate 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 combustion chamber is not included To know the...

Page 12: ... the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge 1 12 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 pressure outlet to get the pressure in the combustion chamber and the other one into the butterfly valve s pressure outlet ...

Page 13: ... 1 14 Pressure rate in combustion head curves LPG Curves are referred to pressure 0 mbar in the combustion chamber Gas pressure in combustion head mbar HR75A M Stm3 h Curves are referred to pressure 0mbar in the combustion chamber Gas pressure in combustion head mbar HR75A L Stm3 h ...

Page 14: ...ng 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 2 1 Packing The burners are despatched in wooden crates whose dimensions are 1672mm x 1072mm x 1016mm L x P x H Packing cases of this type are affected by humidity and are not suit...

Page 15: ...er is designed to work positioned according to the picture below For different installations please contact the Technical Department Keys 1 Burner 2 Fixing nut 3 Washer 4 Ceramic fibre plait 5 Stud bolt 7 Blast tube SIDE UP SIDE DOWN ...

Page 16: ... lenght follow the instructions of the boiler manufacturer 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 com...

Page 17: ...flanged gas trains with Siemens VGD40 3 2 MULTIBLOC DUNGS MB DLE 415 420 Mounting 1 Loosen screws A and B do not unscrew 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 WARNING BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED ATTENTIO...

Page 18: ...ke certain that the O rings and gaskets between the flanges and the double gas valve are 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 ...

Page 19: ...tches 3 5 Gas Filter if provided The gas filters remove the dust particles that are present in the gas and prevent the elements at risk e g burner valves counters and regulators from becoming rapidly blocked The filter is normally installed upstream from all the control and on off devices Fig 14 Siemens SKP actuator Performance range mbar 0 22 15 120 100 250 Spring colour neutral yellow red ATTENT...

Page 20: ...ying circuits NOTE in plants where gravity or ring feed systems are provided install an automatic interception device Fig 15 Gravity circuit Fig 16 Ring circuit Fig 17 Suction circuit Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve ...

Page 21: ...l connections on top and side are reversed 4 3 About the use of fuel pumps 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 avoiding the possibility that ...

Page 22: ...manometer 2 suction M2 G1 4 3 Connection for manometer 3 M3 A Suction connection G1 2 D Direct clockwise I Indirect counter clockwise R By pass connection G1 2 S Delivery connection G1 2 VR After removal of cover screw pressure regulation Connecting the oil flexible hoses to the pump To connect the flexible oil hoses to the pump proceed as follows according to the pump provided 1 remove the closin...

Page 23: ...PART II INSTALLATION 23 on the pump For further information refer to the technical documentation of the pump Suntec E Suntec TA HP Technik UHE A R A R A R A ...

Page 24: ...2 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 25: ...VER 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 ...

Page 26: ... on fully modulating burners Operation selector MAN AUTO operation in manual or automatic mode MIN operation with minimum output 0 Stop MAX operation at the maximum output S4 Fuel selection O1 EVG1 solenoid valve operation LED O2 EVG2 solenoid valve operation LED O3 Pump motor overload tripped LED O4 Oil pump in operation LED A1 Burner Modulator only on fully modulating burners A2 AZL I S1 B1 B2 B...

Page 27: ...tput increasing too much or that the flues temperature gets too low to cause condensation in the chimney 5 4 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 normal c...

Page 28: ... 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 29: ...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 30: ...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 31: ...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 32: ... 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 33: ...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 34: ... RP regulator after slackening the locking screw VB by a number of turns By unscrewing the regulator RP the valve opens screwing the valve closes To set the fast opening remove cover T reverse it upside down and use it as a tool to rotate screw VR Clockwise rotation reduces start flow rate anticlockwise rotation incre ases it Do not use a screwdriver on the screw VR The pressure stabilizer is adju...

Page 35: ...rrectly z Clockwise turn the pressure switch adjusting ring nut as to increase the pressure value until the burner stops z Slowly fully open the manual cutoff valve z Refit the transparent plastic cover on the pressure switch 6 7 Adjusting the maximum gas pressure switch when provided To calibrate the maximum pressure switch proceed as follows according to its mounting position 1 remove the pressu...

Page 36: ...n Siemens LDU LME7x burner control Siemens LMV Bur ner 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 6 10 Adjusting the combustion head The burner is factory adjusted with the combustion head in the MAX position accordingly to the maximum power To operate the bur n...

Page 37: ...hich the burner is designed z For natural gas burners plate holes are fully opened 6 12 HR75A L Center head holes gas flow regulation To adjust the gas flow partially close the holes as follows 1 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 th...

Page 38: ...1 0 12 8 4 5 9 2 9 4 10 0 11 0 11 9 12 9 14 3 15 3 17 2 24 5 24 8 14 1 5 0 10 8 11 0 11 3 11 6 13 0 14 3 15 6 17 0 18 6 24 3 26 2 13 4 5 5 9 7 10 0 10 2 11 1 12 1 13 4 14 8 16 4 18 1 29 7 12 4 6 0 9 2 9 5 9 9 10 0 10 8 12 4 14 1 15 7 17 5 18 9 29 3 33 1 14 8 6 5 10 5 10 8 11 1 11 4 12 1 13 8 15 3 16 5 18 4 20 0 22 4 36 2 36 7 15 5 7 0 8 7 9 4 10 0 11 4 13 2 14 9 17 2 19 6 23 1 25 1 33 2 33 7 15 2 ...

Page 39: ...et 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 governor see chapter on page 38 The flow rate will then be about 95kg h see the example showed on the Bergonzo diagram ...

Page 40: ...is provided set the return pressure at 13bar supply at 20bar on the delivery to get a 110kg h flow rate If the return pressure needed is 5bar instead act on the adjusting screw on the pressure gover nor The flow rate will then be about 55kg h see the example showed on the Bergonzo diagram ...

Page 41: ...PART III OPERATION 41 Fig 25 ...

Page 42: ...t changing the air flow rate set during the gas operation adjustments see previous paragraph checking always the combustion parameters Turn the burner off then start it up again If the adjustment is not correct repeat the previous steps 7 2 Maximum oil pressure switch The oil pressure switch on the return line checks that the pressure does not exceed a default value This value must not be higher t...

Page 43: ... Clean and grease joints and rotating parts IMPORTANT Remove the combustion head before checking the ignition electrode z Remove and clean the compressed air regulator z Remove and clean the oil regulator if provided 8 1 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 cartridge B clean it using water and...

Page 44: ...difference 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 Pa...

Page 45: ...he gas valve group proceed as follows 1 Carefully twist the protection 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...

Page 46: ...g and replacing the detection photocell To clean replace the detection photocell proceed as follows 1 Disconnect the system from the electrical power supply 2 Shut off the fuel supply 3 remove the photocell from its slot see next figure 4 clean the bulbe if dirty taking care not to touch it with bare hands 5 if necessary replace the bulb 6 replace the photocell into its slot ATTENTION avoid the ig...

Page 47: ...he electrode or the detector 8 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 8 11 Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials Device Flame detector Minimum ...

Page 48: ...V MAINTENANCE 48 9 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 49: ... MAIN SWITCH OPEN z LACK OF GAS z z MAXIMUM GAS PRESSURE SWITCH DEFECTIVE IF PROVIDED z z THERMOSTATS PRESSURE SWITCHES DEFECTIVE z z z FAN MOTOR THERMAL CUTOUT INTERVENTION z OVERLOAD TRIPPED INTERVENTION z z AUXILIARY FUSES INTERRUPTED z CONTROL BOX FAULTY z z z z z DEFECTIVE ACTUATOR z z z z AIR PRESSURE SWITCH FAULT OR BAD SETTING z z z z MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIR...

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Page 52: ...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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