Unigas R75A Installation, Use & Maintenance Manual
Lmv2x microprocessor controlled gas burners
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- Manual of installation - use - maintenance (76 pages) ,
- Manual of installation - use - maintenance (135 pages)
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Summary of Contents for Unigas R75A
- Page 1 R75A - RX75 - RX75R LMV2x Microprocessor controlled gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039318CD Rel 0.3 02/2015...
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Page 2: General Introduction
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. -
Page 3: Directives And Standards
DIRECTIVES AND STANDARDS do not leave the equipment exposed to weather (rain, sun, etc.) unless expressly required to do so; Gas burners European directives: do not allow children or inexperienced persons to use equipment; - Directive 2009/142/EC - Gas Appliances; The unit input cable shall not be replaced by the user. -
Page 4: Symbols Used
-EN 55014-1Electromagnetic compatibility - Requirements for household appliances, electric tools and similar apparatus. -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 appliances for household and similar purposes. - Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS 1.0 BURNERS FEATURES Note: the figure is indicative only Control panel with startup switch Gas valve group Cover Flange Blast tube-Combustion head group Head adjusting ring nut Air tank Electrical panel Gas operation: the gas coming from the supply line, passes through the valves group provided with filter and governor. This one for- ces the pressure in the utilisation limits.
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Page 6: Gas Connection
Burners are identified by burner type and model. Burner model identification is described as follows. Type Model RX75R MD. S. BURNER TYPE RX75 - RX75R - R75A FUEL M - Natural gas L - LPG OPERATION (Available versions) PR - Progressive... - Page 7 PART I: SPECIFICATIONS BURNER TYPE R75A M-.. R75A L-.. 320 - 2050 Output min. - max. kW Natural gas Fuel Category see next paragraph 3B/P 34 - 217 12 - 77 Gas flow rate min.-max. Stm (see Note 2) Gas pressure min.-max.
- Page 8 1.6 Overall dimensions (mm) Burner: RX75 Reccomended counterflange Burner flange Boiler recommended drilling template A COUNTERFLANGE IS MANDATORY DN = gas valves size A (A A (A ) AA AD B (B ) B (BL) BB Omin Omax 1.50 1162 1287 374 770 352 618 361 270 290 235 330 453 M10...
- Page 9 RX75R, R75A O min. O max. Boiler recommended drilling template and burner flange DN A (A ) A (A ) AA AD B (B ) B (B ) BB Omin Omax 1.40 1162 1287 69 374 750 352 618 361 250 270 235 300 453 M10 233 452 127 325 525 608 210 155 1.50 1162 1287 69...
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Page 10: Performance Curves
1000 1400 1800 R75A To get the input in kcal/h, multiply value in kW by 860. Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine. - Page 11 1.10 Pressure in the Network / gas flow rate curves(natural gas) RX75 RX75R Gas rate Stm Gas rate Stm R75A M-.. Gas rate Stm WARNING: the diagrams refers to natural gas. For different type of fuel please refer to the paragraph “Fuel” at the beginning of this chapter.
- Page 12 PART I: SPECIFICATIONS 1.11 Pressure in the Network / gas flow rate curves(LPG) R75A L-.. Gas rate Stm 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 on the y-axis.
- Page 13 ATTENTION: THE BURNED GAS RATE MUST BE READ AT THE GAS FLOW METER. WHEN IT IS NOT POSSIBLE, THE USER CAN REFERS TO THE PRESSURE-RATE CURVES AS GENERAL INFORMATION ONLY. 1.14 Pressure - rate in combustion head curves Curves are referred to pressure = 0mbar in the combustion chamber! RX75 RX75R R75A M-..
- Page 14 PART I: SPECIFICATIONS 1.15 Pressure - rate in combustion head curves (LPG) Curves are referred to pressure = 0mbar in the combustion chamber! R75A L-..
- Page 15 PART II: INSTALLATION PART II: INSTALLATION 2.0 MOUNTING AND CONNECTING THE BURNER 2.1 Packing The burners are despatched in wooden crates whose dimensions are: 1636mm x 1036mm x 1016mm (L x P x H). Packing cases of this type are affected by humidity and are not suitable for stacking. The following are placed in each packing case: burner with gas train;...
- Page 16 PART II: INSTALLATION 2.3 Fitting the burner to the boiler To install the burner into the boiler, proceed as follows: make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; place the 4 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;...
- Page 17 PART II: INSTALLATION 2.4 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 respect of the application involved.
- Page 18 PART II: INSTALLATION 3.0 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 CUTOFF VALVES ARE CLOSED.
- Page 19 PART II: INSTALLATION 3.1 Assembling the gas grain gas supply network ”direction” arrows for installation Keys 1A..1E Gasket Gas filter Gas valves group Bellows unit Manual valve Fig. 6 - 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;...
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Page 20: Mounting Positions
PART II: INSTALLATION 3.2 MULTIBLOC DUNGS MB-DLE 405..412 Mounting 1. Mount flange onto tube lines: use appropriate sealing agent (see Fig. 9); 2. insert MB-DLE: note position of O rings (see Fig. 9); 3. tighten screws A, B, C and D (Fig. 7 - Fig. 8), accordind to the mounting positions (Fig. 10); 4. - Page 21 PART II: INSTALLATION 3.4 Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) 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; install the valve;...
- Page 22 PART II: INSTALLATION 3.5 Gas Filter (if provided) 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. The filter is normally installed upstream from all the control and on-off devices. ATTENTION: it is reccomended to install the filter with gas flow parallel to the floor in order to prevent dust fall on the safety valve during maintenance operation.
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Page 23: Electrical Connections
PART II: INSTALLATION 4.0 ELECTRICAL CONNECTIONS 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 differential thermal magnet switch adequate for connection to the mains. - Page 24 PART III: OPERATION PART III: OPERATION WARNING: 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.
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Page 25: Gas Operation
PART III: OPERATION Fig. 19 - Burner front panel RWF50.X h min s Keys Lock-out LED Hi-flame operation LED Lo-flame operation LED “Ignition transformer operation” LED “Fan motor overload tripped” LED “EV2 opening” LED “EV1 opening” LED “Gas pressure switch signal ” LED Main switch Operation selector MAN - AUTO (operation in manual or automatic mode): MIN = operation with minimum output... -
Page 26: User Interface
PART III: OPERATION 5.0 ADJUSTING AIR AND GAS FLOW RATES WARNING! 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 fuel decrease slowly until the normal combustion values are achieved. - Page 27 PART III: OPERATION Key F + A While pressing the two keys 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...
- Page 28 PART III: OPERATION User level (info): no password needed Service level (Service) Manifacturer level (OEM) PHASES LIST During operation, the following program phases are shown. The meaning for each phase is quoted in the table below Fase /Phase Funzione Function Ph00 Fase blocco Lockout phase...
- Page 29 PART III: OPERATION The burner and consequently the LMV2x.. are factory set; the air and fuel curves as set as well. Info level To enter the Info level, proceed as follows: in any menu position, press keys + and - at the same time, then the program will start again: the display will show OFF. until the display will show InFo, Press the enter (InFo) key then il will show the first code (167) flashing, on the right side it will show the data entered.
- Page 30 PART III: OPERATION The Info level shows some basic parameters as: Parameter Description Cubic meters of fule (resettable) Operating hours (resettable) Device operating hours Burners start-ups (resettable) Total number of start-ups Burner number (i.e. serial number) Software version Software date Device serial number Customer code Version...
- Page 31 PART III: OPERATION 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 another message Diagnostic code (in the example “diagnostic code:3”).
- Page 32 PART III: OPERATION Parameter Description Flame intensity % output, if set = automatic operation Actuators position, 00=combustibile; 01= aria Lock-outs number 701..725 Lock-outs History (see chapter 23 in the LMV2x manual) the first parameter will be “954”: the percentage of flame is shown on the right. By pressinf + or - it is possible to scroll up/down the parameter list.
- Page 33 PART III: OPERATION 5.3 Adjusting the gas valves group 5.4 Multibloc MB-DLE VS T(VR) The multibloc unit is a compact unit consisting of two valves, gas pressure switch, pres- sure stabilizer and gas filter. The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns.
- Page 34 Adjusting the combustion head CAUTION: perform these adjustments once the burner is turned off and cooled. R75A The burner is factory-adjusted with the combustion head in the "MAX" position, accordingly to the maximum power. To operate the bur- ner at a lower power, progressively shift back the combustion head, towards the "MIN" position, screwing the screw VRT. The ID index shows how much the combustion head moved.
- Page 35 PART III: OPERATION 5.7 (R75A M-..) Center head holes gas flow regulation To adjust the gas flow, partially close the holes, as follows: loosen the three V screws that fix the adjusting plate D; insert a screwdriver on the adjusting plate notches and let it move CW/CCW as to open/close the holes;...
- Page 36 PART III: OPERATION 5.10 Adjusting the maximum gas pressure switch (when provided) To calibrate the maximum 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; by means of the adjusting ring nut VR, set the value read, increased by the 30%.
- Page 37 PART III: OPERATION 5.13 Adjusting the maximum gas pressure switch (when provided) To calibrate the maximum 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; by means of the adjusting ring nut VR, set the value read, increased by the 30%.
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Page 38: Routine Maintenance
PART IV: MAINTENANCE PART IV: 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 39 PART IV: MAINTENANCE Fig. 26 6.2 Removing the filter in the MULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2” Check the filter at least once a year! Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 28-Fig. 29) Δp> 10 mbar. Change the filter if the pressure difference between pressure connection 1 and 2 (Fig.
- Page 40 PART IV: MAINTENANCE 6.3 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. Replace spring 3.
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Page 41: Replacing The Electrodes
EA - Ignition electrode The detection electrode must be aligned to the centre, as shown in the figure. Electrodes position settings R75A 6.7 Replacing the electrodes ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), other- wise the boiler’s operation would be compromised. - Page 42 PART IV: MAINTENANCE RX75, RX75R Detection electrode Fig. 32 R75A Fig. 33...
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Page 43: Seasonal Stop
PART IV: MAINTENANCE 6.8 Checking the detection current (natural gas) To check the detection signal follow the scheme in the picture below. 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. Device Flame detector Minimum detection signal... -
Page 44: Wiring Diagrams
PART IV: MAINTENANCE 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... -
Page 45: Troubleshooting
8.0 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 48 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.