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Summary of Contents for Unigas TP90A
- Page 1 TP90A-TP91A TP92A-TP93A TP512A-TP515A TP520A-TP525A Gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039177CA Rev. 0 04/2007...
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Page 2: Table Of Contents
M03177CA TABLE OF CONTENTS WARNINGS ................................3 PART I: INSTALLATION MANUAL .......................... 5 GENERAL FEATURES ................................... 5 How to interpret the burner’s “Performance curve” ......................... 6 BURNERS SPECIFICATIONS ............................... 7 Technical specifications ................................7 Country and usefulness gas categories ............................8 Overall dimensions .................................. -
Page 3: Warnings
WARNINGS 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. - Page 4 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS GENERAL INSTRUCTIONS DEPENDING ON FUEL USED GENERAL 3a) ELECTRICAL CONNECTION The burner shall be installed by qualified personnel and in For safety reasons the unit must be efficiently earthed and compliance with regulations and provisions in force; wrong installed as required by current safety regulations.
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Page 5: Part I: Installation Manual
CIB UNIGAS - M039177CA PART I: INSTALLATION MANUAL GENERAL FEATURES This series of industrial burners is designed for all those applications that require big-sized air fans or air-flue heat exchangers to be installed in sound-proof areas to reduce noise. They can be provided with built-in or separately-mounted control panel (console or wall- mounted). -
Page 6: How To Interpret The Burner's "Performance Curve
CIB UNIGAS - M039177CA How to interpret the burner’s “Performance curve” To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed: fuel furnace input, in kW or kcal/h (kW = kcal/h / 860);... -
Page 7: Burners Specifications
CIB UNIGAS - M039177CA BURNERS SPECIFICATIONS Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type TP90A Model M-. PR. S. *. A. (4) (5) (6) (7) (8) (1) BURNER TYPE... -
Page 8: Country And Usefulness Gas Categories
BURNER TYPE TP512A T515A T520A TP525A 1000 - 6400 2000 - 9750 Output min - max kW 600-4500 770 - 5200 Natural gas Fuel Category (see next paragraph) min.-max. (Stm 63.5 - 476 81.5 - 550 106 - 677 212 - 1032 Gas rate 230V 3~ / 400V 3N~ 50Hz Power supply... -
Page 9: Overall Dimensions
Overall dimensions (mm) COLD AIR ONLY COLD AIR+HOT AIR Fig. 4 Fig. 5: Bellows unit drilling plate Fig. 6Boiler’s drilling plate TP90A TP91A TP92A TP93A... - Page 10 COLD AIR+HOT AIR COLD AIR ONLY Fig. 7 Fig. 8 Fig. 9: Bellows unit drilling plate Fig. 10 - Boiler’s drilling plate TP512A TP515A TP520A TP525A 474* * Fit a counterflange between burner and boiler. As an alternative, make a smaller hole H, but greather than Y and fit the blast tube from the internal side of boiler.
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Page 11: Performance Curves
CIB UNIGAS - M039177CA Performance Curves Output diagram (air temperature = 15°C) TP525A TP520A TP515A TP512A TP93A TP92A TP91A TP90A 2000 4000 6000 8000 10000 12000 14000 16000 Range for burner choosing Campo di scelta bruciatore... -
Page 12: Pressure In The Network / Gas Flow Rate Curves
CIB UNIGAS - M039177CA Pressure in the Network / gas flow rate curves TP90A TP91A Rp 2" (50) DN65 Rp 2" (50) DN65 DN80 DN80 DN100 DN100 90 110 130 150 170 190 210 230 250 TP92A TP93A Rp 2" (50) Rp 2"... -
Page 13: Mounting And Connecting The Burner
CIB UNIGAS - M039177CA MOUNTING AND CONNECTING THE BURNER Packing Fig. 11 The burners are despatched in wooden crates. Their dimensions are: 9xA series: 1740 x 1270 x 1010 (W x H x D) 5xxA series: 1740 x 1420 x 110 (W x H x D) Packing cases of this type are affected by humidity and are not suitable for stacking. -
Page 14: Fitting The Burner To The Boiler
CIB UNIGAS - M039177CA Fitting the burner to the boiler To perform the installation, it is necessary to drill the boiler door as described on paragraph “Overall dimensions”; screw the studbolts (5) on the boiler’s door, according to the drilling plate (see paragraph “Overall dimensions”);... -
Page 15: Matching The Burner To The Boiler
CIB UNIGAS - M039177CA Matching the burner to the boiler The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in dia- meter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with res- pect of the application involved. -
Page 16: Gas Train Connections
CIB UNIGAS - M039177CA 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 in compliance with the current laws. ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL SHUTOFF COCKS ARE CLOSED. -
Page 17: Assembling The Gas Grain
CIB UNIGAS - M039177CA Assembling the gas grain To assemble the gas train, proceed as follows: gas supply network ”direction” arrows for installation Keys 1A..1E Gasket Gas filter Gas valves group Bellow joint Manual cock Fig. 14 - Example of gas train To mount the gas train, proceed as follows: 1-a) in case of threaded joints: use proper seals according to the gas used;... - Page 18 CIB UNIGAS - M039177CA Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure stabiliser) Mounting When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded); to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts;...
- Page 19 CIB UNIGAS - M039177CA MULTIBLOC DUNGS MBC1900-3100-5000SE (Flanged valves group) Mounting 1. Insert setscrews A 2. Insert seals 3. Insert setscrews B 4. Tighten setscrews A + B. Ensure correct seating of the seal! 6. After installation, perform leakage and functional test.
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Page 20: Electrical Connections
CIB UNIGAS - M039177CA ELECTRICAL CONNECTIONS Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse the phase and neutral connections. fit a differential thermal magnet switch adequate for connection to the mains. -
Page 21: Electrical Wiring Diagram For Burners Provided With Printed Circuit (Standard Configuration)
CIB UNIGAS - M039177CA Electrical wiring diagram for burners provided with printed circuit (standard configuration). As far as connections, refer to the terminal block showed on Fig. 23. Fig. 23: Terminal board for connections on printed circuit Connect the signal conductors from the boiler to the burner, as for the next elements (Fig. 24 - Fig. 26):... -
Page 22: Electrical Wiring Diagram For Burners With No Printed Circuit Provided
CIB UNIGAS - M039177CA Electrical wiring diagram for burners with no printed circuit provided If the burner is ordered without printed circuit, follow the next connections diagrams. Fig. 27 - Progressive burners Fig. 29 - Fully modulating burners (**) Probes connection Fig. -
Page 23: Combustion Head Pressure Curves Depending On The Gas Flow Rate
CIB UNIGAS - M039177CA Combustion head pressure curves depending on the gas flow rate Curves are referred to pressure= 0mbar in the combustion head! The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner in the com- bustion stage (3% of O ). -
Page 24: Pressure In Combustion Head - Gas Flow Rate Curves
CIB UNIGAS - M039177CA Pressure in combustion head - gas flow rate curves TP90A TP91A 100 120 140 160 180 200 220 240 260 280 300 Stm3/h Stm3/h TP92A TP93A 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340... -
Page 25: Adjusting Air And Gas Flow Rates
CIB UNIGAS - M039177CA ADJUSTING AIR AND GAS FLOW RATES Keys Gas filter Gas proving system Gas valves Adjusting cam Servocontrol Fig. 31 Gas Filter (Fig. 31 - 1) The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burners, counters and regu- lators) from becoming rapidly blocked. -
Page 26: Air And Gas Flow Rate Adjustements
CIB UNIGAS - M039177CA Air and gas flow rate adjustements ATTENTION: before starting the burner up, be sure that the manual shutoff valves are open and check that the pressure value upstream the gas train matches the value on paragraph “Technical specifications”). - Page 27 CIB UNIGAS - M039177CA startup the burner by turning its main switch A to on: if the burner locks (LED B on in the control panel) press the RESET button (C) on the control panel. The burner is factory-set with the head in its MAX position (maximum outuput).
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Page 28: Adjustment By The Berger Stm30.. Servocontrol
CIB UNIGAS - M039177CA Adjustment by the Berger STM30.. servocontrol once the combustion head is adjusted (see pag. 25), remove the sevocontrol cover and set it to the ignition position, by pressing the MAN/AUTO lever (ignition position= 0° on the air damper index ID1 - see figure on next page) MAN- STM30.. - Page 29 CIB UNIGAS - M039177CA the air and gas rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV adjusting cam as to reach the minimum power point. as for the point-to-point regulation, move the low flame microswitch (cam III) a little lower than the maximum position (90°);...
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Page 30: Adjustment By The Siemens Sql33.. Servocontrol
CIB UNIGAS - M039177CA Adjustment by the Siemens SQL33.. servocontrol once the combustion head is adjusted (see pag. 25), remove the sevocontrol cover and set it to the ignition position, by the MAN/ AUTO selector (ignition position= read on the air damper index ID1 - see figure on pag.28);... - Page 31 CIB UNIGAS - M039177CA the air and gas rate are now adjusted at the maximum output, go on with the point to point adjustment on the SV adjusting cam as to reach the minimum output point. In high flame stage, the servocontrol AB cam does not press the black microswitch C;...
- Page 32 CIB UNIGAS - M039177CA Gas butterfly valve closed Gas butterfly valve open 14 The low flame position must never match the ignition position, (see index ID1 position in figure) that is why cam AB must be set 5° more than the ignition position.
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Page 33: Calibration Of Air And Gas Pressure Switches
CIB UNIGAS - M039177CA Calibration of air and gas pressure switches (Fig. 31- 2 - 5) The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of the control box unlock pushbutton, placed on the burner control panel. -
Page 34: Part Ii: Operation
CIB UNIGAS - M039177CA PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CON- NECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSI- DERED IMPROPER AND THEREFORE DANGEROUS. -
Page 35: Operation
CIB UNIGAS - M039177CA OPERATION ATTENTION: before starting the burner up, be sure that the manual shutoff valves are open and check that the pres- sure value upstream the gas train matches the value on paragraph “Technical specifications”). Check that the mains switch is closed. -
Page 36: Part Iii: Maintenance
CIB UNIGAS - M039177CA PART III: MAINTENANCE At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6 months. - Page 37 CIB UNIGAS - M039177CA Removing the combustion head Remove the cover C. remove the electrodes cables; unscrew the 3 screws V which hold in position the gas manifold G and pull out the complete group as shown in figure. Note: to replace the combustion head reverse the procedure described above having care to place correctly the O ring (OR) between burner and gas manifold.
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Page 38: Adjusting The Electrodes
CIB UNIGAS - M039177CA Adjusting the electrodes Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion head. ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boi- ler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. -
Page 39: Checking The Detection Current
CIB UNIGAS - M039177CA Replacing the detection electrode ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. -
Page 40: Seasonal Stop
CIB UNIGAS - M039177CA Check of the detection current (with printed circuit) Fig. 40 To check the detection signal remove the bridge on “TEST ER” or “TEST FC” and connect a micro ammeter when Fig. 40. If the signal is less than... -
Page 41: Troubleshooting
TROUBLESHOOTING FAULTS SOLUTIONS ● MAIN SWITCH OPEN ● ● LACK OF GAS ● ● MAXIMUM GAS PRESSURE SWITCH DEFECTIVE ● ● ● THERMOSTATS/PRESSURE SWITCHES DEFECTIVES ● OVERLOAD TRIPPED INTERVENTION ● AUXILIARIES FUSE INTERRUPTED ● ● ● ● ● DEFECTIVE FLAME MONITOR DEVICE ●... -
Page 42: Wiring Diagrams
CIB UNIGAS - M039177CA WIRING DIAGRAMS BURNERS FITTED WITH PRINTED CIRCUIT Complete key 21-001/2 MANUAL SWITCH 0)OFF 1)HIGH FLAME 2)LOW FLAME 3)AUTOMATIC FLAME DETECTION ELECTRODE GAS ELECTRO-VALVE UPSTREAM (OR VALVES GROUP) GAS ELECTRO-VALVE DOWNSTREAM (OR VALVES GROUP) AUXILIARY FUSE FAN MOTOR LINE FUSES... - Page 43 CIB UNIGAS - M039177CA Wiring diagram 21-001/2 - Progressive burners...
- Page 44 CIB UNIGAS - M039177CA Wiring diagram 21-001/2 - Fully modulating burners...
- Page 45 CIB UNIGAS - M039177CA Wiring diagram 21-001/2 WIRING DIAGRAM Cod. 09-313 Rev. 1 - Burners type TP525A Mod. M-.PR.x.xx.x.1.xx...
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- Page 49 CIB UNIGAS - M039177CA WIRING DIAGRAM Cod. 09-315/1 - Burners type TP525A Mod. M-.MD.x.xx.x.1.xx...
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Page 53: Spare Parts
CIB UNIGAS - M039177CA SPARE PARTS TP90A - TP91A - TP92A -TP93A Desription Code TP90A TP91A TP92A TP93A GAS FILTER - Rp 2” 2090119 2090119 2090119 2090119 GAS FILTER - DN65 2090117 2090117 2090117 2090117 GAS FILTER - DN80 2090112... -
Page 54: Appendix
CIB UNIGAS - M039177CA TP512A - TP515A - TP520A -TP525A Desription Code TP512A TP515A TP520A TP525A GAS FILTER - Rp 2” 2090119 2090119 2090119 2090119 GAS FILTER - DN65 2090117 2090117 2090117 2090117 GAS FILTER - DN80 2090112 2090112 2090112... - Page 55 CIB UNIGAS - M039177CA...
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