Unigas R512A Instruction Manual Download

Page: 1 / 56

M039240CA

/2009

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

LMV2..

Microprocessor-controlled

gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

R512A - R515A
R520A - R525A

Summary of Contents for R512A

Page 1: ...M039240CA 12 2009 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ LMV2 Microprocessor controlled gas burners MANUAL OF INSTALLATION USE MAINTENANCE R512A R515A R520A R525A ...

Page 2: ... 20 Setting menu 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 27 Adjusting procedure 27 Adjusting the combustion head 28 Calibration of air and gas pressure switches 29 Calibration of air pressure switch 29 Calibration of low gas pressure switch 29 Adjusting the high gas pressure switch when prov...

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: ...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 flue gas 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 geometry of the flam...

Page 6: ...vailable 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 of the heat generator 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...

Page 7: ...t min max kW 600 4500 770 5200 1000 6400 2000 6700 2000 8000 Fuel Natural gas Gas category see next paragraph Gas rate min max Stm3 h 63 5 476 81 5 550 106 677 212 709 212 847 Pressure mbar see Note 2 Power supply 230V 3 400V 3N 50Hz 400V 3N 50Hz Total power consumption kW 9 7 11 5 15 5 19 19 Electric motor kW 9 2 11 15 18 5 18 5 Protection IP40 Operation Progressive Fully modulating Gas train 50 ...

Page 8: ...15A 80 1475 323 530 508 945 446 1727 1084 643 380 420 494 540 628 M14 552 390 390 685 150 535 875 323 898 328 270 R515A 100 1475 323 530 508 945 446 1810 1167 643 380 420 494 540 641 M14 552 390 390 792 150 642 942 384 911 328 270 R520A 50 1475 323 530 508 945 446 1714 1071 643 400 440 494 540 597 M14 552 390 390 755 150 605 843 195 867 328 270 R520A 65 1475 323 530 508 945 446 1692 1049 643 400 4...

Page 9: ... 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 PRESSURE IN COMBUSTION CHAMBER mbar R512A kW R515A kW PRESSURE IN COMBUSTION CHAMBER mba...

Page 10: ... 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 50 100 150 200 50 100 150 200 250 300 350 400 450 500 550 Rp 2 50 DN65 DN80 DN100 0 50 100 150 200 250 50 100 150 200 250 300 350 400 450 500 550 600 650 Rp 2 50 DN65 DN80 DN100 0 50 100 150 200 250 300 350 400 100 150 200 250 300 350 ...

Page 11: ...ign a blast tube tha suites the utilisation please contact the manifacturer Handling the burner The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck the forks must be inserted into the A anb B ways Remove the stirrup only once the burner is installed to the boiler The burner is designed to work positioned according to the picture below For different ins...

Page 12: ...ler s door according to the burner s drilling plate described on paragraph Overall dimensions 4 fasten the 4 stud bolts 5 place the ceramic fibre plait 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 refra...

Page 13: ...es group VGD 20 40 with built in gas pressure governor PGCP gas leakage pressure switch Gas train 5 Rp2 Gas train with valves group MBC 1200SE 2 valves gas filter pressure governor PGCP gas leakage pressure switch Gas train 6 DN65 80 100 Gas train with valves group MBC 1900 3100 5000SE 2 valves gas filter pressure governor PGCP gas leakage pressure switch 1 Burner 2 Butterfly valve 3 Gas proving s...

Page 14: ...paragraphs according to the gas train used z threaded gas 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 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 ATTENTION it is recommended to mount fil...

Page 15: ...e fitted 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 Mounting 1 Mount flange ...

Page 16: ...lled connect electrically all its elements gas valves group pressure switches gas proving system Fig 9 Fig 10 SIEMENS VGD MOUNTING POSITIONS Fig 11 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 ...

Page 17: ...V three phase or 230V phase phase without a neutral with the Siemens LME2 control box between the terminal 2 on the board and the earth terminal an RC Siemens RC466890660 filter must be inserted Key C Capacitor 22nF 250V LME Siemens control box R Resistor 1Mohm RC466890660 RC Siemens filter Fig 12 Respect the basic safety rules make sure of the connection to the earthing system do not reverse the ...

Page 18: ...13 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 13 2 to get the pressure in the combustion chamber and the other one...

Page 19: ...led upstream from all the control and on off devices Gas pressure in combustion head mbar R512A Stm3 h R515A Stm3 h Gas pressure in combustion head mbar R520A Stm3 h R525A Stm3 h 0 5 10 15 20 25 30 35 50 100 150 200 250 300 350 400 450 500 0 5 10 15 20 25 30 35 40 50 100 150 200 250 300 350 400 450 500 550 600 0 5 10 15 20 25 30 35 40 45 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700 0 ...

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: ...ord 100 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 en...

Page 22: ...en 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 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 low fire operati...

Page 23: ...me time then the program 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...

Page 24: ...ng 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 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 hour...

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: ... value quoted on paragraph Technical specifications Be sure that the mains switch is closed ATTENTION 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 gas decrease slowly until the normal combustion values are achieved WARNING NEVER LOOSE THE SEALED SCREWS OTHERWISE THE DEVICE WARRANTY WIL...

Page 27: ... on adjusting the burner observing the procedure on the LMV2 related manual By following the air gas ratio curvepoints setting procedure on the LMV2 manual adjusting the air and gas flow rates check conti nuosly the flue gas analisys as to avoid combustion with little air dose the air according to the gas flow rate change following the steps quoted below acting on the pressure stabiliser of the va...

Page 28: ...ctory set wih the D adjusting plate holes fully open and the combustion head at its MAX position so it is fit to work at the maximum output 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 fas...

Page 29: ...e is reduced by 50 Pay attention that the CO value in the flue gas does not increase if the CO values are higher than the limits laid down by law slowly open the cutoff valve as to get values lower than these limits z Check that the burner is operating correctly z Clockwise turn the pressure switch adjusting ring nut as to increase the pressure value until the burner stops z Slowly fully open the ...

Page 30: ...T 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 THE MAIN SWITC...

Page 31: ... the front panel z Few seconds after the gas valves opening the ignition transformer is de energised and light H turns to off The burner operates in the low flame stage few seconds later the two stages opertaion begins and the burner output increases or decreases driven by the external thermostats progressive burners or by the modulator P in Fig 14 fully modulating burners Fig 14 Burner control pa...

Page 32: ...t 4 be sure to replace the O ring into its place C and replace 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 ATTEN...

Page 33: ...ring OR between burner and gas manifold Adjusting the electrodes Important Note Check the ignition and detection electrodes after removing adjusting the combustion head The gap between the ignition electrodes must be 4mm see picture below Fig 16 Key VRT Head adjusting screw AR Threaded rod V Fixing screw G Gas manifold OR O ring C Cover ATTENTION avoid the ignition and detection electrodes to cont...

Page 34: ...ection electrode To replace the detection electrode proceed as follows 1 remove the combustion head according to the procedure on paragraph Removing the 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 ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc other...

Page 35: ...ght Extraneous light during standby phase 12 leads to start prevention followed by a restart Extraneous light during the prepurge phase leads to immediate lockout If extraneous light occurs during the shutdown phase the system switches to 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 ...

Page 36: ...209 2180278 2180289 GAS VALVE GROUP Rp2 Siemens VGD20 2190171 2190171 2190171 2190171 GAS VALVE GROUP DN65 Siemens VGD40 2190172 2190172 2190172 2190172 GAS VALVE GROUP DN80 Siemens VGD40 2190169 2190169 2190169 2190169 GAS VALVE GROUP DN100 Siemens VGD40 2190174 2190174 2190174 2190174 GAS VALVE ACTUATOR SKP15 2190181 2190181 2190181 2190181 GAS VALVE ACTUATOR SKP25 2190183 2190183 2190183 219018...

Page 37: ...CA 37 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 SE05 844 PROGRESSIVE BURNERS SE05 848 FULLY MODULATING BURNERS ...

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Page 56: ...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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