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3

DANGERS, WARNINGS AND NOTES OF CAUTION

THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE
USER.
INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO-
DUCT INSTALLATION AND MAINTENANCE.
THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION
OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.

1)

GENERAL INTRODUCTION

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The equipment must be installed in compliance with the regulations
in force, following the manufacturer’s instructions, by qualified per-
sonnel.

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Qualified personnel means those having technical knowledge in the
field of components for civil or industrial heating systems, sanitary
hot water generation and particularly service centres authorised by
the manufacturer.

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Improper installation may cause injury to people and animals, or
damage to property, for which the manufacturer cannot be held lia-
ble.

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Remove all packaging material and inspect the equipment for inte-
grity.

In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devices, plastic
bags, foamed polystyrene, etc), should not be left within the reach of chil-
dren, as they may prove harmful.

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Before any cleaning or servicing operation, disconnect the unit from
the mains by turning the master switch OFF, and/or through the cut-
out devices that are provided.

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Make sure that inlet or exhaust grilles are unobstructed.

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In case of breakdown and/or defective unit operation, disconnect the
unit. Make no attempt to repair the unit or take any direct action.

Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly authorised
by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair the unit’s
safety.
To ensure equipment efficiency and proper operation, it is essential that
maintenance operations are performed by qualified personnel at regular
intervals, following the manufacturer’s instructions.

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When a decision is made to discontinue the use of the equipment,
those parts likely to constitute sources of danger shall be made har-
mless.

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In case the equipment is to be sold or transferred to another user, or
in case the original user should move and leave the unit behind,
make sure that these instructions accompany the equipment at all
times so that they can be consulted by the new owner and/or the
installer.

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For all the units that have been modified or have options fitted then
original accessory equipment only shall be used.

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This unit shall be employed exclusively for the use for which it is
meant. Any other use shall be considered as improper and, there-
fore, dangerous.

The manufacturer shall not be held liable, by agreement or otherwise, for
damages resulting from improper installation, use and failure to comply
with the instructions supplied by the manufacturer.The occurrence of any
of the following circustances may cause  explosions, polluting unburnt
gases (example: carbon monoxide CO), burns, serious harm to people,
animals and things: 
- Failure to comply with one of the WARNINGS in this chapter 
- Incorrect handling, installation, adjustment or maintenance  of the burner
- Incorrect use of the burner or incorrect use of its parts or optional supply

2)

SPECIAL INSTRUCTIONS FOR BURNERS

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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.

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Only burners designed according to the regulations in force should
be used.

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This burner should be employed exclusively for the use for which it

was designed.

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Before connecting the burner, make sure that the unit rating is the
same as delivery mains (electricity, gas oil, or other fuel).

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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

Remove the power supply by disconnecting the power cord from the
mains.

b) Disconnect the fuel supply by means of the hand-operated shut-off

valve and remove the control handwheels from their spindles.

Special warnings

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Make sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.

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Before the burner is started and, thereafter, at least once a year,
have qualified personnel perform the following operations:

a

set the burner fuel flow rate depending on the heat input of the
appliance;

b

set the flow rate of the combustion-supporting air to obtain a combu-
stion efficiency level at least equal to the lower level required by the
regulations in force;

c

check the unit operation for proper combustion, to avoid any harmful
or polluting unburnt gases in excess of the limits permitted by the
regulations in force;

d

make sure that control and safety devices are operating properly;

e

make sure that exhaust ducts intended to discharge the products of
combustion are operating properly;

f

on completion of setting and adjustment operations, make sure that
all mechanical locking devices of controls have been duly tightened;

g

make sure that a copy of the burner use and maintenance instruc-
tions is available in the boiler room.

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In case of a burner shut-down, reser the control box by means of the
RESET pushbutton. If a second shut-down takes place, call the
Technical Service, 

without trying to RESET further

.

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The unit shall be operated and serviced by qualified personnel only,
in compliance with the regulations in force.

3)

GENERAL INSTRUCTIONS DEPENDING ON FUEL USED 

3a) ELECTRICAL CONNECTION

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For safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.

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It is vital that all saftey requirements are met. In case of any doubt,
ask for an accurate inspection of electrics by qualified personnel,
since the manufacturer cannot be held liable for damages that may
be caused by failure to correctly earth the equipment.

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Qualified personnel must inspect the system to make sure that it is
adequate to take the maximum power used by the equipment shown
on the equipment rating plate. In particular, make sure that the
system cable cross section is adequate for the power absorbed by
the unit.

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No adaptors, multiple outlet sockets and/or extension cables are per-
mitted to connect the unit to the electric mains.

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An omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.

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The use of any power-operated component implies observance of a
few basic rules, for example:

-

do not touch the unit with wet or damp parts of the body and/or with

bare feet;

-

do not pull electric cables;

Содержание R1025

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

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

Страница 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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Страница 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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