Unigas R1025 Manual Download

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M03996CI Rel. 8.1 03/2015

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Gas burners

Progressive / Fully modulating

MANUAL OF INSTALLATION - USE - MAINTENANCE

R1025
R1030
R1040

Summary of Contents for R1025

Page 1: ...M03996CI Rel 8 1 03 2015 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Gas burners Progressive Fully modulating MANUAL OF INSTALLATION USE MAINTENANCE R1025 R1030 R1040 ...

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: ...essure in the utilisation limits The electric actuator that moves proportionally the air damper and the gas butterfly valve uses an adjusting cam with variable shape This one allows the optimisation of the gas flue values as to get an efficient combustion The combustion head positioning determines the burner s output The combustion head determines the energetic quality and the geo metry of the fla...

Page 6: ...1030 M 1 xx R1040 M 1 xx Output min max kW 2550 8700 2550 9500 2550 10600 2550 13000 Fuel M Natural gas Gas category see next paragraph Gas rate min max Stm3 h 270 921 270 1000 270 1122 270 1376 Power supply 400V 3N 50 400V 3N 50 400V 3N 50 400V 3N 50 Total power consumption kW 19 22 5 22 5 30 5 Electric motor kW 18 5 22 22 30 Protection IP40 Operation Progressive Fully modulating Pressure see Not...

Page 7: ...sive Fully modulating Pressure see Note 2 Gas train 65 ØValves Connection 2 1 2 DN65 2 1 2 DN65 2 1 2 DN65 Gas train 80 ØValves Connection 3 DN80 3 DN80 3 DN80 3 DN80 Gas train 100 ØValves Connection 4 DN100 4 DN100 4 DN100 4 DN100 Gas train 125 ØValves Connection 5 DN125 Operating temperature C 10 50 Storage Temperature C 20 60 Working service Intermitent Note1 All gas flow rates are referred to ...

Page 8: ...20 709 660 831 M16 651 460 460 922 204 269 718 80 1092 289 1161 372 330 R1030 80 1890 377 30 841 132 542 657 1348 680 2041 1219 822 454 504 520 709 660 831 M16 651 460 460 944 204 269 740 80 1092 310 1161 372 330 R1030 100 1890 377 30 854 145 542 657 1348 680 2057 1235 822 454 504 520 709 660 831 M16 651 460 460 848 204 269 644 80 1092 350 1161 372 330 R1040 80 1920 377 30 841 132 542 664 1378 680...

Page 9: ...o 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 on...

Page 10: ...mum 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 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 d...

Page 11: ... M 1 xx Gas rate Stm3 h GAS PRESSURE IN THE NETWORK mbar R1040 M 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 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...

Page 12: ... the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge 1 10 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: ...ate in combustion head curves natural gas Curves are referred to pressure 0mbar in the combustion chamber Gas pressure in combustion head R1025 M Gas rate Stm3 h Gas pressure in combustion head R1030 M Gas rate Stm3 h R1040 M Gas rate Stm3 h ...

Page 14: ...7 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 2280 x 1730 x 1360 L x P x H Packing cases of this type are affected by humidity and are not suitable for stacking The followi...

Page 15: ...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 chamber in respect to the ...

Page 16: ...kets are not part of the standard supply ATTENTION BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED 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 s...

Page 17: ...tted 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 rep...

Page 18: ...he following scheme valid for LPG In case of natural gas connect the pressure goveror pos 3 to the natural gas line maximum input pressure 1 bar Fig 11 Key 1 Gas valves 2 Minimum gas pressure switch 3 Gas pressure governor with filter 4 Bellow joint 5 Manual cutoff valve 6 Pressure governor 7 Tank The pilot gas train is already installed into the burner the connection from the filter with stabilis...

Page 19: ...the filter with stabiliser to the gas supply network Fig 12 pipe port 3 for connecting the pilot gas train to the valves group of the main gas train ATTENTION once the gas train is mounted according to the diagram on Fig 11 the gas proving test mus be per formed according to the procedure set by the laws in force connection to the gas supply network connection to the gas supply network 3 to the bu...

Page 20: ...st 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 test phases are passed the proving system test is successful if...

Page 21: ...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 22: ...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 23: ...on the gas valves open z Few seconds after the valves opening the transformer is de energised and lamp B4 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 according to the plant requirements Operation in high or low flame is signalled by...

Page 24: ...time comes to an end and that the burner starts up 4 drive the burner to high flame stage by means fo the thermostat TAB 5 Then move progressively the microswitch to higher values until it reaches the high flame position always check the combustion values and eventually adjusting the gas by means of the valves group stabiliser 6 go on adjusting air and gas flow rates check continuosly the flue gas...

Page 25: ...inimum output point 11 as for the point to point regulation move the gas low flame microswitch a little lower than the maximum position 90 12 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position 13 move the gas low flame microswitch to the minimum to move the actuator towards the low flame until the two bearings find the adjusting scre...

Page 26: ...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 diagram until the detected pressure is reduced by 50 Pay attention that the CO value in the flue gas does not increase if the CO values ar...

Page 27: ...hase 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 9 PGCP Gas leakage pressure switch w...

Page 28: ...l gas burners plate holes are fully opened 5 12 Center head holes gas flow regulation LPG burners 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 the V screws The adjusting plate corre...

Page 29: ...follows 1 remove the cap unscrewing the fixing screws A 2 remove the filtering cartridge B clean it using water and soap blow it with compressed air or replace it if necessary 3 replace the cartridge in its proper position taking care to place it inbetween the guides as not to hamper the cap replacement 4 be sure to replace the O ring into its place C and replace the cover fastening by the proper ...

Page 30: ...orrectly the O ring OR between burner and gas manifold To replace the spring in the 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 ...

Page 31: ...iled view of the combustion head with pilot P and ignition elecctrode E Observe the values shown on next picture Fig 17 ATTENTION avoid the electrode to get in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the electrode position after any intervention on the combustion head E P E P 5mm P E ...

Page 32: ...ector the electrical contacts and if necessary replace the electrode or the detector 6 7 Cleaning 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 ha...

Page 33: ... 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 9 Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials ...

Page 34: ...V MAINTENANCE 34 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 35: ...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 BU...

Page 36: ...PART IV MAINTENANCE 36 8 0 BURNER EXPLODED VIEW ...

Page 37: ...COVER 6 4 LEVERAGE 10 2 4 GAS VALVE HOUSING 13 4 1 CONTROL BOX SOCKET 6 5 LEVERAGE 10 2 5 GAS PRESSURE 13 4 2 TIME COUNTER 6 6 ACTUATOR 10 3 FLANGED REVERSIBLE CURVE 13 4 3 BIMETAL RELAY 6 7 LEVER 10 4 REVERSIBLE PIPE 13 4 4 CONTROL BOX 6 8 INDEX LABEL 10 5 FLANGED PIPE 13 4 5 IGNITION TRANSFORMER 6 9 CONNECTOR 10 6 GASKET 6 10 ADJUSTING CAM 11 1 MOTOR 6 11 BRACKET 11 2 FAN WHEEL 6 12 BRACKET 12 1...

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Page 40: ...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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