Unigas HTP90A Installation, User's, And Maintenance Manual
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Unigas HTP90A Installation, User's, And Maintenance Manual

Progressive and fully-modulating gas - light oil burners
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HTP90A - HTP91A
HTP92A - HTP93A
HTP512A - HTP515A
HTP520A - HTP525A
and fully-modulating
gas - light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
Progressive
M039219CA Rev. 0 08/2008

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  • Page 1 HTP90A - HTP91A HTP92A - HTP93A HTP512A - HTP515A HTP520A - HTP525A Progressive and fully-modulating gas - light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039219CA Rev. 0 08/2008...

  • Page 2: General Introduction

    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 3: Directives And Standards

    should be switched off. DIRECTIVES AND STANDARDS Gas burners European directives: 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS - Directive 90/396/CEE - Gas Appliances; GENERAL Directive 2006/95/EC on low voltage; The burner shall be installed by qualified personnel and in com- Directive 2004/108/CEE on electromagnetic compatibility...

  • Page 4: General Features

    C.I.B. UNIGAS - M039219CA 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 separate-mounted control panel (console or wall- mounted).
  • Page 5 C.I.B. UNIGAS - M039219CA Data requested: Power output diagram at 15àC air temperature furnace input; air temperature altitude TP1050 Example: TP1030 furnace input: 9600kW TP525A air temperature: 15°C TP520A altitude: 0m TP515A TP512A TP93A TP92A Fig. 1 TP91A TP90A 2000...

  • Page 6: Burner Specifications

    C.I.B. UNIGAS - M039219CA BURNER SPECIFICATIONS Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type HTP91A Model (1) BURNER TYPE HTP91A (2) FUEL M - Natural gas G - Light oil...
  • Page 7 C.I.B. UNIGAS - M039219CA BURNER TYPE HTP512A HTP515A HTP520A HTP525A 1000 - 6400 2000 - 9750 Output min - max kW 600-4500 770 - 5200 Natural gas - Light oil Fuel Gas category (see next paragraph) 63 - 476 81 - 550...
  • Page 8 Overall dimensions (mm) Boiler drilling plate Air inlet flange and burner flange HTP90A 1356 1342 HTP90A 1356 1447 HTP90A 1356 1449 HTP90A 100 1356 1539 1049 HTP91A 1356 1342 HTP91A 1356 1447 HTP91A 1356 1449 HTP91A 100 1356 1539 1049...
  • Page 9 Air inlet flange Burner flange Recommended burner counterflange Recommended boiler drilling plate HTP512A 50 1475 1570 1071 160 605 HTP512A 65 1475 1548 1049 160 483 HTP512A 80 1475 1583 1084 160 535 HTP512A 100 1475 1666 1167 160 642 HTP515A 50 1491 1570 1071...
  • Page 10 C.I.B. UNIGAS - M039219CA Performance Curves Output diagram (air temperature = 15°C) HTP525A HTP520A HTP515A HTP512A HTP93A HTP92A HTP91A HTP90A 2000 4000 6000 8000 10000 12000 14000 16000 Campo di scelta bruciatore Burner performance range To get the input in kcal/h, multiply value in kW by 860.
  • Page 11 C.I.B. UNIGAS - M039219CA Pressure in the Network / gas flow rate curves HTP90A HTP91A Rp 2" (50) DN65 Rp 2" (50) DN65 DN80 DN80 DN100 DN100 90 110 130 150 170 190 210 230 250 HTP92A HTP93A Rp 2" (50) Rp 2"...
  • Page 12 C.I.B. UNIGAS - M039219CA MOUNTING AND CONNECTING THE BURNER Packing The burners are despatched in wooden crates. Their dimensions are: 9xA series: 1740mm x 1270mm x 1010mm (LW x PH x HD) 5xxA series: 1740mm x 1420mm x 110mm (LW x PH x HD) burner with gas train detached;...
  • Page 13 C.I.B. UNIGAS - M039219CA 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 14 C.I.B. UNIGAS - M039219CA Gas train 3(DN65/80/100) - Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor + pressure switch) + VPS504 gas proving system MANUFACTURER INSTALLER Gas train - 4 - Gas train with valves group VGD 20/40.. with built-in gas pressure governor + PGCP gas leakage pressure switch...
  • Page 15 C.I.B. UNIGAS - M039219CA 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. 4 - 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 16 C.I.B. UNIGAS - M039219CA WARNING: removing the four screws BS causes the device to be unserviceable! SIEMENS VGD..MOUNTING POSITIONS SKP1. SKP2. 7631z05/0101 Fig. 7 Fig. 6 Fig. 5 MULTIBLOC DUNGS MBC300-700-1200SE (Threaded valves group) Mounting 1. Mount flange onto tube lines. Use appropriate sealing agent (see Fig. 8) 2.
  • Page 17 C.I.B. UNIGAS - M039219CA Pressure adjusting range The pressure adjusting range, downstream the gas valves group, changes according to the spring provided with the valve group. DUNGS MBC..SE Siemens SKP actuator Keys 1 spring 2 cap DUNGS MBC valves: Performance range (mbar)
  • Page 18 C.I.B. UNIGAS - M039219CA 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. 4).
  • Page 19 C.I.B. UNIGAS - M039219CA The pumps that are used can be installed both into single-pipe and double-pipe systems. Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is driven to the nozzle: a part comes out from the nozzle while the othe part goes back to the pump.
  • Page 20 C.I.B. UNIGAS - M039219CA Danfoss KSM.. Oil viscosity 2.5 ÷ 450 cSt Oil temperature -10 ÷ 160 °C Max. suction pressure 4 bar Min. suction pressure -0.45 bar to avoid gasing Max. return pressure 4 bar Rotation speed 3450 rpm max...
  • Page 21 C.I.B. UNIGAS - M039219CA 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 22 C.I.B. UNIGAS - M039219CA Electrical wiring diagram for burners provided with printed circuit (standard configuration). As far as connections, refer to the terminal block shown on Fig. 18. Fig. 18: Terminal board for connections on printed circuit Connect the signal conductors from the boiler to the burner, as for the next elements (Fig. 19 - Fig. 21):...
  • Page 23 C.I.B. UNIGAS - M039219CA Electrical wiring diagram for burners with no printed circuit provided If the burner is ordered without printed circuit, follow the next connections diagrams. Fig. 22 - Progressive burners Fig. 24 - Fully modulating burners Probes connection by means of the 7-pins plug (Fig. 25) - see Fig.
  • Page 24 C.I.B. UNIGAS - M039219CA Combustion head gas pressure curves depending on the 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 properly adjusted (percentage of residual O in the flues as shown in the “Recommended combustion values”...
  • Page 25 C.I.B. UNIGAS - M039219CA Pressure in combustion head - gas flow rate curves HTP90A HTP91A 100 120 140 160 180 200 220 240 260 280 300 Stm3/h Stm3/h HTP92A HTP93A 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340...
  • Page 26 C.I.B. UNIGAS - M039219CA ADJUSTING AIR AND GAS FLOW RATES Keys Gas filter Gas proving system Gas valves Adjusting cam Actuator Fig. 27 Gas Filter 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 27 C.I.B. UNIGAS - M039219CA Air and gas flow rate adjustements ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed.
  • Page 28 C.I.B. UNIGAS - M039219CA HTP91A - HTP92A - HTP93A open holes closed holes HTP512A - HTP515A - HTP520A - HTP525A open holes closed holes Now, adjust the burner according to the actuator model provided. Settings by means of Berger STM30.. actuator set GAS fuel by means of the burner CM switch (it is placed on the burner control panel) STM30..
  • Page 29 C.I.B. UNIGAS - M039219CA Note: once the procedure is perfomed, be sure that the blocking nut RA is fasten. Do not change the position of the air damper rods. 10 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 output point.
  • Page 30 C.I.B. UNIGAS - M039219CA - Dungs MBC..SE valves group: act on its pressure governor to increase or decrease the pressure and consequently the gas rate.: 10 To adjust the air flow rate in the high flame stage, loose the RA nut and screw VRA as to get the desired air flow rate: moving the rod TR towards the air damper shaft, the air damper opens and consequently the air flow rate increases, moving it far from the shaft the air damper closes and the air flow rate decreases.
  • Page 31 C.I.B. UNIGAS - M039219CA Calibration of air and gas pressure switches 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 32 C.I.B. UNIGAS - M039219CA Adjusting light oil flow rate 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. 29-Fig. 30 (as far as reading the pres- sure values, see next paragraphs).
  • Page 33 C.I.B. UNIGAS - M039219CA FLOW RATE kg/h DIMENSIONS Fig. 30 Example (Fluidics): as for over 100kg/h nozzles, the 80% of the nozzle flow rate can be obtained with a return pressure at about 18bar (see Fig. 30). Oil Flow Rate Settings by means of Berger STM30.. actuator Once the air and gas flow rates are adjusted, turn the burner off, switch it on again by turning the CM switch to the oil operation (OIL, on the burner control panel).
  • Page 34 C.I.B. UNIGAS - M039219CA record the high flame value set during the gas operation adjustments (see previous paragraphs); start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and that the bruner starts drive the burner to high flame stage, by means fo the thermostat TAB.
  • Page 35 C.I.B. UNIGAS - M039219CA manually drive the adjusting cam SV2 to the high flame position and set the actuator to the AUTO mode (by the related switch - see picture) to lock the adjusting cam. SQL33.. actuator cams AUTO AB = High flame...
  • Page 36 C.I.B. UNIGAS - M039219CA 18 The low flame position must never match the ignition position that is why cam BF2 must be set 20°- 30° more than the ignition position. 19 Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps.

  • Page 37: Limitations Of Use

    C.I.B. UNIGAS - M039219CA 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 38 C.I.B. UNIGAS - M039219CA 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.

  • Page 39: Routine Maintenance

    C.I.B. UNIGAS - M039219CA 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 40 C.I.B. UNIGAS - M039219CA Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group) Inspect the filter at least once a year. Change the filter, if pressure value between pressure connections 1 and 2 is grea- ther than 10 mbar.
  • Page 41 C.I.B. UNIGAS - M039219CA Adjusting the electrodes position Adjust the electrodes position, according to the quotes shown on the next picture. Keys electrodes air pipe ignition gas pipe nozzle Fig. 41 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.
  • Page 42 C.I.B. UNIGAS - M039219CA Checking the detection current To check the detection signal follow the scheme in Fig. 42 or Fig. 43. If the signal is less than the value indicated, check the position of the detection electrode or detector, the electrical contacts and, if necessary, replace the electrode or the detector.

  • Page 43: Troubleshooting

    TROUBLESHOOTING TROUBLE CAUSE MAIN SWITCH OPEN LACK OF GAS MAXIMUM GAS PRESSURE SWITCH DEFECTIVE THERMOSTATS/PRESSURE SWITCHES DEFECTIVES OVERLOAD TRIPPED INTERVENTION AUXILIARIES FUSE INTERRUPTED DEFECTIVE CONTROL BOX DEFECTIVE ACTUATOR AIR PRESSURE SWITCH FAULT OR BAD SETTING MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIRTY IGNITION TRANSFORMER FAULT IGNITION ELECTRODES BAD POSITION...

  • Page 44: Spare Parts

    C.I.B. UNIGAS - M039219CA SPARE PARTS Desription Code HTP90A HTP91A HTP92A HTP93A 2020448 2020448 2020448 2020448 CONTROL BOX IGNITION ELECTRODE 2080292 2080292 2080292 2080292 OIL FILTER 2090018 2090018 2090018 2090018 GAS FILTER - Rp 2 2090019 2090019 2090119 2090119 GAS FILTER - DN65...
  • Page 45 C.I.B. UNIGAS - M039219CA Desription Code HTP512A HTP515A HTP520A HTP525A CONTROL BOX 2020448 2020448 2020448 2020448 IGNITION ELECTRODE 2080292 2080292 2080292 2080292 OIL FILTER 2090018 2090018 2090018 2090018 GAS FILTER - Rp 2 2090119 2090119 2090119 2090119 GAS FILTER - DN65...

  • Page 46: Wiring Diagrams

    C.I.B. UNIGAS - M039219CA WIRING DIAGRAMS Wiring diagram Cod. 05-680 - Progressive burners Wiring diagram Cod. 05-681 - Fully modulating burners Wiring diagram HTP525 Cod. 11-336/1 - Progressive burners Wiring diagram HTP525 Cod. 11-339/1- Fully modulating burners Wiring diagram 21-002/3 - Burners fitted with printed circuit - Complete key BERGERSTM30..
  • Page 47 Wiring diagram 21-002/3...
  • Page 50 C.I.B. UNIGAS - M039219CA WIRING DIAGRAM - Cod. 11-336/2...
  • Page 51 C.I.B. UNIGAS - M039219CA...
  • Page 52 C.I.B. UNIGAS - M039219CA...
  • Page 53 C.I.B. UNIGAS - M039219CA WIRING DIAGRAM - Cod. 11-339/2...
  • Page 54 C.I.B. UNIGAS - M039219CA...
  • Page 55 C.I.B. UNIGAS - M039219CA...
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  • Page 57 APPENDIX consent to start-up by means of the thermostat or pressostat "R" SIEMENS LFL 1.3.. CONTROL BOX start-up program Automatic programme in the event of interruption and indication of posi- normal burner operation tion when interrupted regulation stop caused by "R" By default, in the event of any kind of interruption, the flow of fuel is imme- diately interrupted.
  • Page 58 2nd safety time; at the end of the second safety time the main bur- test 1300 µA ner should be lit by means of the pilot. At the end of this period, terminal Max.length of connecting cable 17 is dead and therefore the pilot burner will be out. normal cable (laid separately**) 100m Interval;...
  • Page 59 interval for creating current between terminals 19 and 20 input for raising QRA detector voltage to test level post-ventilation time input for excitation of flame relay during flame detector test interval between startup consent and current created at circuit (contact XIV) and during safety time (contact IV) terminal 7 Do not press EK for more than 10 seconds duration of start-up...
  • Page 60 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.

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