Related Manuals for Unigas HTP1030
Summary of Contents for Unigas HTP1030
- Page 1 HTP1030 HTP1050 HTP1080 Gas - light oil dual fuel burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039180CC REV. 2 09/2009...
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Page 2: Table Of Contents
TABLE OF CONTENTS WARNINGS ................................3 PART I: INSTALLATION 5 GENERAL FEATURES ................................... 5 Example of installation ..................................6 How to choose the burner ................................7 Burner model identification ................................8 Country and usefulness gas categories ............................8 Overall dimensions ..................................9 Performance curves .................................. -
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 DIRECTIVES AND STANDARDS 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS Gas burners GENERAL European directives: The burner shall be installed by qualified personnel and in com- - Directive 90/396/CEE - Gas Appliances; pliance with regulations and provisions in force; wrong installation Directive 2006/95/EC on low voltage;...
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Page 5: Part I: Installation
CIB UNIGAS - M039180CC PART I: INSTALLATION 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: Example Of Installation
CIB UNIGAS - M039180CC Example of installation Burner Gas train Pumping unit Electric panel Note: the picture shows one of the possible installations. Fan, electrical panel and pumping unit can be placed according to the custo- mer needs. -
Page 7: How To Choose The Burner
CIB UNIGAS - M039180CC How to choose the burner 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 8: Burner Model Identification
Burners are identified by burner type and model. Burner model identification is described as follows. Type HTP1030 Model M-. PR. (7) (8) (1) BURNER TYPE HTP1030 - HTP1050 - HTP1080 (2) FUEL MG - Natural gas-light oil (3) OPERATION Available versions PR - Progressive MD - Fully modulating... -
Page 9: Overall Dimensions
Overall dimensions (mm) Air inlet flange Burner flange Boiler recommended drilling jig HTP1030 1864 544 1320 348 1898 1301 1000 460 936 200 587 1092 322 1175 372 HTP1030 100 1864 544 1320 348 1914 1317 1000 460 842 200... -
Page 10: Performance Curves
CIB UNIGAS - M039180CC Performance curves HTP1030 2000 4000 6000 8000 10000 12000 14000 HTP1050 2000 4000 6000 8000 10000 12000 14000 16000 HTP1080 4000 6000 8000 10000 12000 14000 16000 18000 20000 Performance range To get the input in kcal/h, multiply value in kW by 860. -
Page 11: Pressure In The Network / Gas Rate Curves
CIB UNIGAS - M039180CC Pressure in the network / gas rate curves HTP1030 DN80 DN100 1 50 1 00 DN125 1 000 1 1 00 1 200 1 300 1 400 Gas rate Stm HTP1050 DN80 DN100 DN125 1 00... -
Page 12: Installation
The burners are despatched in wodden crates whose dimensions are: HTP1030 - HTP1050: 2180 mm x 1180 mm x 1210 mm (L x P x H) HTP1080: 2180 mm x 1580 mm x 1560 mm (L x P x H) Packing cases of this type are affected by humidity and are not suitable for stacking. -
Page 13: Fan Installation
CIB UNIGAS - M039180CC Keys Burner Fixing nut Washer Ceramic fibre plait Stud bolt Blast tube Fig. 4 Fan installation Pay attention when designing the air duct: dimensioning must be performed according to the flow rate, the temperature, the distance between the fan and the burner and according to the fan features as well. - Page 14 CIB UNIGAS - M039180CC Gas train 2 (DN80/100): Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor + pressure switch) + LDU gas proving system MANUFACTURER INSTALLER Burner Manual cutoff valve Butterfly valve VGD Valves group...
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Page 15: Assembling The Gas Grain
CIB UNIGAS - M039180CC The pilot gas train is already installed to the burner, the following connections must be executed: connection from the filter with stabiliser to the gas supply network connection from the valve to the main gas train, by means of the pipe provided with the burner. -
Page 16: Siemens Vgd20
CIB UNIGAS - M039180CC NOTE: the bellow joint, the manual valve and the gaskets are not part of the standard supply. 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. - Page 17 CIB UNIGAS - M039180CC DUNGS MBC..SE Siemens SKP actuator Keys 1 spring 2 cap DUNGS MBC valves: Performance range (mbar) 4 - 20 20 - 40 40 - 80 80 - 150 Spring colour black green Siemens VGD valves with SKP actuator:...
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Page 18: Hydraulic Diagrams For Light Oil Supplying Circuits
CIB UNIGAS - M039180CC Hydraulic diagrams for light oil supplying circuits Fig. 11 - Gravity circuit Fig. 12 - Ring circuit Fig. 13 - Suction circuit Manual valve Light oil filter Light oil feeding pump One way valve Flexible hoses Relief valve NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n. -
Page 19: Light Oil Piping Installation Diagram
CIB UNIGAS - M039180CC Light oil piping installation diagram From tank To tank Fig. 14 (*) Only for installations with gravity, siphon or for- ced circulation feed systems. If the device installed Burner is a solenoid valve, a timer must be installed to Flexible hoses (fitted) delay the valve closing. -
Page 20: Suntec Tv Pressure Governor
CIB UNIGAS - M039180CC Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could depo- sit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) jun- ctions if possible. -
Page 21: Connecting The Burner To The Light Oil Pumping Unit
CIB UNIGAS - M039180CC Connecting the burner to the light oil pumping unit Follow the scheme in the picture below to connect the burner to the oil pumping unit. The pump sends the oil coming from the tank to the burner. The pressure governor makes the oil reach the nozzle at the required pressure, while the excess of oil goes back to the tank. -
Page 22: Adjustments
CIB UNIGAS - M039180CC ADJUSTMENTS ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed. -
Page 23: Pressure - Rate In Combustion Head Curves
CIB UNIGAS - M039180CC Pressure - rate in combustion head curves HTP1030 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Gas rate Stm HTP1050 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700... -
Page 24: Gas Filter
CIB UNIGAS - M039180CC Keys Gas filter Gas proving system Gas valves Adjusting cam Actuator Fig. 17 Gas Filter The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burner valves, counters and regulators) from becoming rapidly blocked. -
Page 25: Adjustments - Brief Description
CIB UNIGAS - M039180CC Adjustments - brief description Adjust the air and gas flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respec- tively. Check that the combustion parameters are in the suggested limits. - Page 26 CIB UNIGAS - M039180CC Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner ope- rates at the lowest output) to safely achieve the high flame stage. Start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and that the burner starts drive the burner to high flame stage, by means fo the thermostat TAB.
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Page 27: Calibration Of Air Pressure Switch
CIB UNIGAS - M039180CC head position “MAX” head position Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above. 11 the air and gas rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV1 (gas side) adjusting cam as to reach the minimum output point. -
Page 28: Adjusting The High Gas Pressure Switch (When Provided)
CIB UNIGAS - M039180CC Adjusting the high gas pressure switch (when provided) To calibrate the high pressure switch, proceed as follows according to its mounting position: remove the pressure switch plastic cover; if the maximum pressure switch is mounted upstreaam the gas valves: measure the gas pressure in the network, when flame is off;... -
Page 29: Adjustment For Light Oil Operation
CIB UNIGAS - M039180CC Adjustment for light oil operation The light oil flow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the chart below and the diagram on Fig. 20 (as far as reading the pressure values, see next paragraphs). - Page 30 CIB UNIGAS - M039180CC Pump flow rate Nozzle flow rate Fig. 21 - Bergonzo nozzle - example with 850kg/h nozzle Once the air and gas flow rates are 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).
- Page 31 CIB UNIGAS - M039180CC motor rotation and keep pressing for some seconds until the oil circuit is charged; bleed the air from the M pressure gauge port (Fig. 22) by loosing the cap without removing it, then release the contactor.
- Page 32 CIB UNIGAS - M039180CC Pressure gauge port Fig. 23 Fig. 24 10 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge) without changing the air flow rate set during the gas operation adjustments (see previous paragraph): checking always the combustion parameters, the adjustment is to be performed by means of the SV2 adjusting cam screw (see picture) when the cam has reached the high flame position.
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Page 33: Oil Circuit
CIB UNIGAS - M039180CC As far as fully-modulating burners, see paragraph “Fully modulating burners” on page 28. Light oil circuitOil circuit The fuel is pushed into the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor. The solenoid valve 2 stops the fuel immission into the combustion chamber. -
Page 34: Part Ii: Operation
CIB UNIGAS - M039180CC 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 - M039180CC OPERATION ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Choose the typer of fuel by turning the burner switch, on the burner control panel. -
Page 36: Part Iii: Maintenance
CIB UNIGAS - M039180CC 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: Replacing The Spring In The Gas Valve Group
CIB UNIGAS - M039180CC Replacing the spring in the gas valve group To replace the spring in the gas valve group,proceed as follows: Carefully twist the protection cap 1 and the O-ring 2. remove the “set value” spring 3 from housing 4. -
Page 38: Adjusting The Ignition Electrode
CIB UNIGAS - M039180CC Adjusting the ignition electrode Important Note: check the ignition electrode after each removing of the combustion head. 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 39: Replacing The Ignition Electrode
CIB UNIGAS - M039180CC Replacing the ignition electrode 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. To replace the ignition electrode, proceed as follows: remove the burner cover disconnect the electrode (E) cable (CE);... -
Page 40: Cleaning And Replacing The Detection Photocell
CIB UNIGAS - M039180CC Cleaning and replacing the detection photocell The photocell working life is about 10000 working hours (about 1 year), at max 50°C after which it must be replaced. To clean/replace the detection photocell, proceed as follows: Disconnect the system from the electrical power supply. -
Page 41: Troubleshooting
CIB UNIGAS - M039180CC TROUBLESHOOTING CAUSE / TROUBLE MAIN SWITCH OPEN LACK OF GAS HIGH GAS PRESSURE SWITCH DEFECTIVE DEFECTIVE THERMOSTAT OVERLOAD TRIPPED INTERVENTION AUXILIARIES FUSES INTERRUPTED DEFECTIVE AIR PRESSURE SWITCH DEFECTIVE CONTROL BOX DEFECTIVE ACTUATOR AIR PRESSURE SWITCH FAULT OR... -
Page 42: Spare Parts
CIB UNIGAS - M039180CC SPARE PARTS Desription Code HTP1030 HTP1050 HTP1080 SIEMENS LDU GAS PROVING SYSTEM 2020413 2020413 2020413 SIEMENS LFL CONTROL BOX 2020448 2020448 2020448 IGNITION ELECTRODE 2080257 2080257 2080257 OIL FILTER 2090018 2090018 2090018 GAS FILTER DN80 2090112... -
Page 43: Appendix
APPENDIX SIEMENS LFL 1.3.. CONTROL BOX consent to start-up by means of the thermostat or pressostat "R" start-up program Automatic programme in the event of interruption and indication of posi- tion when interrupted normal burner operation By default, in the event of any kind of interruption, the flow of fuel is imme- regulation stop caused by "R"... - Page 44 Ionisation monitor Twin-tube burners (**) voltage in detector electrode Preignition time until the all clear to the pilot burner valve at normal working 330V ±10% terminal 17. test 380V ±10% First safety time (pilot flame strenght); at the end of the safety time short circuit current max.
- Page 45 Programmer diagram pre-ventilation time limit contact switch for damper OPEN position safety time block remote signal '1st safety time main relay (working network) with contacts "ar" pre-ignition time Monitor fuse 'pre-ignition time block relay with "br" contacts interval for creating current between terminals 18 and 19 fuel valve 'interval for creating current between terminals 17 and 19 reset button...
- Page 46 Gas valve proving is initiated automatically with every burner startup using one or two standard pressure monitors, either VALVE PROVING SYSTEM SIEMENS LDU11 prior to burner startup, The LDU11... gas valve proving system is designed for use in gas-fired during the pre-purge time, if it lasts at least 60 s, plant equipped with two safety shutoff valves.
- Page 47 first test phase (Test 1), or decreases excessively during the second test Specifications phase (Test 2), the control unit inhibits burner startup and goes to lockout. Mains voltage AC 220 V -15 %...240 V +10 % AC 100 V In that case, the lockout reset button lights up to indicate the fault. -15 %...110 V +10 % Mains frequency 50 Remote indication of the fault is also possible.
- Page 48 forming any work on it! The LDU11... is a safety device. It is therefore not permitted to open, Alarm signal "Leaking valve" interfere with or modify the unit! Main relay with contacts "ar..." Check wiring carefully before putting the unit into operation! Built-in fuse Check all safety functions when putting the unit into operation or after Lockout relay with contacts "br..."...
- Page 52 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 Note: specifications and data subject to change. Errors and omissions exceptd.