Unigas HTP1030 Installation, User'S, And Maintenance Manual Download

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MANUAL OF INSTALLATION - USE - MAINTENANCE

HTP1030
HTP1050
HTP1080

Gas - light oil

dual fuel burners

M039180CC REV. 2 09/2009

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Summary of Contents for HTP1030

Page 1: ...MANUAL OF INSTALLATION USE MAINTENANCE HTP1030 HTP1050 HTP1080 Gas light oil dual fuel burners M039180CC REV 2 09 2009 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ ...

Page 2: ...r and pump motor 21 ADJUSTMENTS 22 Combustion head gas pressure curves depending on the flow rate 22 Measuring the gas pressure in the combustion head 22 Pressure rate in combustion head curves 23 Gas Filter 24 VPS504 Gas proving system 24 Adjusting the injector gas flow rate Brahma EG12 R valve and pressure governor 24 Adjustments brief description 25 Adjustment procedure 25 Calibration of air pr...

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: ...stion Light oil operation the fuel coming from the supply line is pushed by the pump to the nozzle and then into the combustion chamber where the mixture between fuel and air takes place and consequently the flame In the burners the mixture bertween fuel and air to perform clean and efficient combustion is activated by atomisation of oil into very small particles This process is achieved making pr...

Page 6: ...CC 6 Example of installation Note the picture shows one of the possible installations Fan electrical panel and pumping unit can be placed according to the custo mer needs Burner Fan Gas train Electric panel Pumping unit ...

Page 7: ...less consumption fewer swigings in the generator temperature and pressure values Checking the proper gas train size To check the proper gas train size it is necessary to 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 ...

Page 8: ...0 3500 15500 4500 19000 Fuel Natural gas light oil Gas category see next paragraph Gas rate min max Stm3 h 270 1376 370 1641 476 2010 Oil Density 840 kg m3 Oil Viscosity 2 7 4 cSt 40 C Light oil rate min max kg h 215 1095 295 1306 380 1600 Power supply 400V 3N 50 Total power consumption kW 5 5 Total power consumption kW 6 Protection IP40 Operation Progressive Fully modulating Gas pressure see Note...

Page 9: ...1864 544 1320 348 1898 1301 597 489 539 710 185 660 660 845 M16 651 460 1000 460 936 200 265 736 80 587 1092 322 1175 408 330 HTP1050 100 1864 544 1320 348 1914 1317 597 489 539 710 185 660 660 845 M16 651 460 1000 460 842 200 265 642 80 587 1092 382 1175 408 330 HTP1080 100 1864 544 1320 348 1914 1317 597 514 564 710 185 660 660 845 M16 651 460 1000 460 842 200 265 642 80 587 1092 382 1175 408 33...

Page 10: ...To get the input in kcal h multiply value in kW by 860 Data are referred to standard conditions 1013mbar 15 C Performance range 2000 4000 6000 8000 10000 12000 14000 kW 2000 4000 6000 8000 10000 12000 14000 16000 kW 4000 6000 8000 10000 12000 14000 16000 18000 20000 kW ...

Page 11: ...r 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 50 1 00 1 50 200 250 300 350 400 450 200 300 400 500 600 700 800 900 1 000 1 1 00 1 200 1 300 1 400 DN80 DN100 DN125 0 1 00 200 300 400 500 300 400 500 600 700 800 900 1 000 1 1 00 1 200 1 300 1 400 1 500 1...

Page 12: ...ner to the boiler 8 fix the burner to the stud bolts by means of the fixing nuts according to Fig 4 9 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 Packing The burners are despatched in wodden crates whose dimensions are HTP1030 HTP1050 2180 mm x 1180...

Page 13: ...t 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 backwards GAS TRAIN CONNECTIONS The diagrams show the components of the gas trai included in the delivery and which must be fitted by the installer The diagrams are...

Page 14: ...w joint 8 Manual cutoff valve 11 VGD Valves group 14 Pressure governor with filter 15 Ignitor gas valve 19 MBC Valves group DN80 100 Gas train 3 Gas train with valves group VGD 40 with built in gas pressure governor gas leakage pressure switch PGCP for Siemens LDU LMV burner control 1 Burner 2 Butterfly valve 4 High gas pressure switch option 5 Low gas pressure switch 6 Gas filter 7 Bellow joint 8...

Page 15: ...gas grain To assemble the main gas train proceed as follows 1 in case of flanged joints place a gasket no 1A 1E Fig 6 between the elements 2 fasten all the items by means of screws according to the shcemes showed before obesrving the mounting direction for each item connection to the gas supply network connection from the pilot gas train to the gas valves group of the main train 3 SIEMENS VGD40 DU...

Page 16: ...z Connect the reference gas pipe TP in figure to the 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 WARNING removing the four screws ...

Page 17: ...re switches gas proving system 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 6 the gas proving test mus be performed according to the procedure set by the laws in force 1 2 2 1 ...

Page 18: ...lants where gravity or ring feed systems are provided install an automatic interception device see n 4 Fig 14 Fig 11 Gravity circuit Fig 12 Ring circuit Fig 13 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 19: ...e of fuel pumps z Make sure that the by pass plug is not used in a single pipe installation because the fuel unit will not function properly and damage to the pump and burner motor could result 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 burne...

Page 20: ...ctions of the pump 2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the inlet and return lines see the arrows marked on the pump that show the inlet and the return see prevoius paragraph Viscosity 4 800 cSt Oil temperature 0 140 C Minimum suction pressure 0 45 bar to prevent gasing Maximum suction pressure 5 bar Rated speed 3600 rpm max Key 1 To pres...

Page 21: ...rection of the fan motor see next pargraph 4 refit the panel cover Rotation of fan motor and pump motor Once the electrical connection of the burner is executed remember to check the rotation of the motor The motor should rotate accor ding to the indication on the body In the event of wrong rotation reverse the three phase supply and check again the rotation of the motor Respect the basic safety r...

Page 22: ...chamber s pres sure outlet Fig 16 2 to get the pressure in the combustion chamber and the other one into the butterfly valve s pressure outlet of the burner Fig 16 3 On the basis of the measured differential pressure it is possible to get the maximum flow rate in the pressure 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...

Page 23: ...sted according to the in the following chart Recommended combustion parameters Fuel Recommended CO2 Recommended O2 Natural gas 9 10 3 4 8 Light oil 11 5 13 2 9 4 9 0 20 40 60 80 100 120 140 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 0 10 20 30 40 50 60 70 80 90 100 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 0 20 40 60 80 1 00 1 20 1 40 1 60 400 500 600 700 80...

Page 24: ...a screwdriver on the screw TR as shown in the picture below Screw to increase the pressure unscrew to decrease once the regulation is performed replace cap T Fig 17 Keys 1 Gas filter 2 Gas proving system 3 Gas valves 4 Adjusting cam 5 Actuator VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off val ves This check is carried out as soon as the boiler thermostat ...

Page 25: ...ation in the chimney Now adjust the burner according to the actuator model provided Adjustment procedure To change the burner setting during the testing in the plant follow the next procedure 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 Before starting the burner up drive the high flame actuator microswitch matching the low flame one ...

Page 26: ...djusting screw to increase or decrease the pressure and conse quently the gas rate screwind VR the rate increases unscrewing it decreases see next figure Dungs MBC SE valves group act on its pressure governor to increase or decrease the pressure and consequently the gas rate 9 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 mov...

Page 27: ...pre 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 Calibration of low gas pres...

Page 28: ... ring nut VR set the value read on step 2 increased by the 30 4 replace the plastic cover PGCP Gas leakage pressure switch witn SiemensLDU Siemens LMV burner control 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 Fully modulating burners To adjust the fully modulating burners use the...

Page 29: ...LE DELIVERY PRESSURE bar RETURN PRESSURE MAX bar RETURN PRESSURE MIN bar FLUIDICS WR2 BERGONZO B BERGONZO C 25 20 7 recommended Tab 1 Fig 20 Atomisation angle according to the return pressure ______ Flow rate FLOW RATE kg h DIMENSIONS Min Max 40 13 40 50 16 50 60 20 60 70 23 70 80 26 80 90 30 90 100 33 100 115 38 115 130 43 130 145 48 145 160 53 160 180 59 180 200 66 200 225 74 225 250 82 250 275 ...

Page 30: ...e adjusted turn the burner off turn the burner on again by means of the CM selector to switch to the light oil operation OIL on the burner control panel 2 with the electrical panel open prime the oil pump acting directly on the related CP contactor see next picture check the pump Pump flow rate Nozzle flow rate ...

Page 31: ... comes to an end and that the bruner starts up 7 drive the burner to high flame stage by means fo the thermostat TAB 8 Then move progressively the microswitch to higher values until it reaches the high flame position always check the combustion values and eventually adjusting the oil pressure see next step 9 the nozzle supply pressure is already factory set and must not be changed Only if necessar...

Page 32: ...rds the minimum to move the actuator towards the low flame until the two bearings find the adju sting screw that refers to a lower position screw V2 to increase the rate unscrew to decrease in order to get the pressure as showed on chart diagram on Adjustment for light oil operation on page 29 according to the requested rate 14 Move again cam V towards the minimum to meet the next screw on the adj...

Page 33: ...e tank through the return circuit The spill back nozzle is feeded at constant pressure while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see prevoius paragraph Fig 25 Stand by Fig 26 Prepurge Fig 27 Low flame Fig 2...

Page 34: ...ANTEES CORRECT 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 T...

Page 35: ...is is achieved the ignition transformer is energised the ignitor gas valves and the main gas valves open z Few seconds after the valves opening the transformer is de energised and lamp L turns off z The burner is now operating meanwhile the actuator goes to the high flame position and after some seconds the two stage ope ration begins the burner is driven automatically to high flame or low flame a...

Page 36: ... the fuel nozzle Important cleaning must be performed using solvent not metal tools At the end of maintenance operations after the burner reassembly light the flame and check its shape replacing the nozzle whenever a questio nable flame shape appears Whenever the burner is used intensely we recommend preventively replacing the nozzle at the start of each heating season z Clean and grease sliding a...

Page 37: ... photoresistance out of its housing 3 Unscrew the V screws that block the gas collector G loosen the three joints E and remove the ass y as shown on the following picture 4 Clean the combustion head by means fo a vacuum cleaner scrape off the scale by means fo a metallic brush Note to remount the burner floow the same procedure in the reversed order DUNGS MBC SE SKP Siemens actuator Light oil filt...

Page 38: ...ilot P and ignition elecctrode E Fig 30 Detailed view of the combustion head with pilot P and ignition elecctrode E Observe the values quoted on figure Fig 31 ATTENTION avoid the ignition electrode to contact metallic parts blast tube head etc otherwise the boiler s operation would be compromised Check the electrode position after any intervention on the combustion head E P E P 5mm P E ...

Page 39: ...par Removing the combustion head 4 loose screw B that fasten the ignition electrode E to the burner pilot P 5 remove the electrode and replace it referring to the values quoted on Fig 31 ATTENTION avoid the ignition electrode to contact metallic parts blast tube head etc otherwise the boiler s operation would be compromised Check the electrode position after any intervention on the combustion head...

Page 40: ... its slot Checking the detection current To check the detection signal follow the scheme in Fig 32 If the signal is lower than the value quoted check the position of the UV detector photocell the electrical contacts and if necessary replace the UV detector Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner s main switch to 0 Off position 2 disconnect the pow...

Page 41: ... z HIGH GAS PRESSURE SWITCH DEFECTIVE z DEFECTIVE THERMOSTAT z OVERLOAD TRIPPED INTERVENTION z AUXILIARIES FUSES INTERRUPTED z DEFECTIVE AIR PRESSURE SWITCH z DEFECTIVE CONTROL BOX z z z DEFECTIVE ACTUATOR z z z z AIR PRESSURE SWITCH FAULT OR BAD SETTING z GAS PRESSURE SWITCH BAD SETTING z IGNITION TRANSFORMER FAULT z z z z DETECTION ELECTRODE BAD POSITION z BUTTERFLY VALVE BAD SETTING z DEFECTIVE...

Page 42: ...M7 GAS VALVE GROUP DUNGS MBC5000SE DN100 21903M8 21903M8 21903M8 PILOT GAS ELECTROVALVE 2190502 2190502 2190502 OIL SOLENOID VALVE PARKER 2190750 2190750 2190750 OIL SOLENOID VALVE L338 2190437 2190437 2190437 GAS PROVING SYSTEM VPS504 2191604 2191604 2191604 FLEXIBLE HOSE L 1500 2340004 2340004 2340004 FLEXIBLE HOSE L 600 2340059 2340059 2340059 FLEXIBLE HOSE L 385 2340088 2340088 2340088 FLEXIBL...

Page 43: ...ctivated terminals 22 and 23 or 23 4 for the detector test and the paracitic light test Where the burners do not have dampers or have an independent 00 damper control mechanism there must be a bridge between terminals 6 and 8 otherwise the mechanism will not start up the burner For a burner to start up the following conditions must be met z Mechanism not blocked reset z Damper closed Limit contact...

Page 44: ... because during this period an NTC in the circuit acts as retarder This means that brief unscheduled influences can not cause a block Times t3 t2 and t4 only apply only to safety devices in the series 01 Specifications Mains voltage 220V 15 240V 10 Frequency 50Hz 6 60Hz 6 Absorbed capacity 3 5 VA Built in fuse T6 3 250E slow action DIN41571 No 451915070 External fuse max 16A Interference N VDE0875...

Page 45: ...lot burner fuel valve for mono tube burners for twin tube burners 1 input for raising QRA detector voltage to test level 2 input for excitation of flame relay during flame detector test circuit contact XIV and during safety time contact IV 3 Do not press EK for more than 10 seconds Programmer diagram t1 pre ventilation time t2 safety time t2 1st safety time t3 pre ignition time t3 pre ignition tim...

Page 46: ...nts given on Connection examples with vent pipe to the atmosphere Gas valve proving is initiated automatically with every burner startup using one or two standard pressure monitors either z prior to burner startup z during the pre purge time if it lasts at least 60 s z immediately after the controlled shutdown or z on completion of the burner control s control program e g on comple tion of the pos...

Page 47: ...ng mechanism of the control unit returns to its start position where it switches itself off During these idle steps the position of the control contacts of the pro gramming mechanism remains unchanged Program and lockout indicator When the unit goes to lockout the programming mechanism stops and also the position indicator fitted to the spindle of the mechanism The symbol that stops above the read...

Page 48: ...terfere with or modify the unit z Check wiring carefully before putting the unit into operation z Check all safety functions when putting the unit into operation or after replacing a fuse z Ensure protection against electric shock hazard on the unit and at all electrical connections through appropriate mounting z Electromagnetic emissions must be checked from an application point of view z The reg...

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Page 52: ... and data subject to change Errors and omissions exceptd 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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Unigas HTP1030, Installation, User'S, And Maintenance Manual

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