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CIB UNIGAS Unigas RX90 Manual Of Installation - Use - Maintenance

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RX90
RX91
Gas burners
Low NOx series
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039175CD Rel. 3.0 07/2010

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  • Page 1 RX90 RX91 Gas burners Low NOx series MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039175CD Rel. 3.0 07/2010...

  • Page 3: 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 4: Directives And Standards

    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 2009/142/EC - Gas Appliances; pliance with regulations and provisions in force; wrong installation Directive 2006/95/EC on low voltage;...

  • Page 5: General Features

    C.I.B. UNIGAS - M039175CD PART I: INSTALLATION MANUAL GENERAL FEATURES The gas coming from the supply line, passes through the valves group provided with filter and stabiliser. This one forces the pressure in the utilisation limits. The electric actuator (14), that moves proportionally the air damper and the gas butterfly valve, uses an adjusting cam (13) with variable shape.

  • Page 6: Burner Type

    C.I.B. UNIGAS - M039175CD BURNERS FEATURES Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type RX90 Model M-. PR. S. *. (4) (5) (1) BURNER TYPE RX90 - RX91 (2) FUEL M - Natural gas (3) OPERATION (Available versions) PR - Progressive...
  • Page 7 C.I.B. UNIGAS - M039175CD Country and usefulness gas categories COUNTRY CATEGORY ES GR SE NO CZ DK GB CY EE MT SK BG RO TR CH 2E( R ) B 2ELL...
  • Page 8 Overall dimensions (mm) boiler recommended drilling template and burner flange Omin Oma AD AN RX90 1168 35 429 100 290 843 422 1294 RX90 1168 35 406 118 290 843 422 1391 RX90 1168 35 439 132 290 843 422 1393 RX90 1168 35 592 145 290...

  • Page 9: Performance Curves

    C.I.B. UNIGAS - M039175CD Performance Curves RX90 RX91 1000 1400 1800 1200 1600 2000 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 10 C.I.B. UNIGAS - M039175CD MOUNTING AND CONNECTING THE BURNER Packing The burners are despatched in wooden crates whose dimensions are: 1730mm x 1280mm x 1020mm (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 11 C.I.B. UNIGAS - M039175CD 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’s drilling template described on paragraph “Overall dimensions”;...
  • Page 12 C.I.B. UNIGAS - M039175CD 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 13: Assembling The Gas Train

    C.I.B. UNIGAS - M039175CD Assembling the gas train To assemble the main gas train, proceed as follows: gas supply network ”direction” arrows for installation Keys 1A..1E Gasket Gas filter Gas valves group Bellows unit Manual valve Fig. 8 - Example for gas train 1-a) in case of threaded joints: use proper seals according to the gas used;...
  • Page 14 C.I.B. UNIGAS - M039175CD 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 15 C.I.B. UNIGAS - M039175CD MULTIBLOC DUNGS MBC300-700-1200SE (Threaded valves group) Mounting 1. Mount flange onto tube lines. Use appropriate sealing agent (see Fig. 14) 2. Insert MBC...SE. Note position of O rings (see Fig. 15). 3. Tighten screws A – H Fig.
  • Page 16 C.I.B. UNIGAS - M039175CD DUNGS MBC valves: Performance range (mbar) 4 - 20 20 - 40 40 - 80 80 - 150 Spring colour black green Siemens VGD valves with SKP actuator : Performance range (mbar) 0 - 22 15 - 120 100 - 250 Spring colour neutral...

  • Page 17: Electrical Connections

    C.I.B. UNIGAS - M039175CD 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. ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be sure that the burner’s main switch is in 0 position (OFF) too.
  • Page 18 C.I.B. UNIGAS - M039175CD Electrical wiring diagram for burners provided with printed circuit (standard configuration). .As far as connections, refer to the terminal block shown on Fig. 19. Fig. 19: Terminal board for connections on printed circuit Connect the signal conductors from the boiler to the burner, as for the next elements (Fig. 20 - Fig. 22): ST: thermostat/pressure switch series TAB: High/low flame thermostat Connect the signal conductors from the burner to the boiler, as for the next elements (Fig.

  • Page 19: Rotation Of Fan Motor

    C.I.B. UNIGAS - M039175CD Electrical wiring diagram for burners with no printed circuit provided If the burner is ordered without printed circuit, follow the next connections diagrams. Fig. 24 - Progressive burners Fig. 26 - Fully modulating burners Fig. 25 - Probes connection (**) Probes connection Probes connection by means of the 7-pins plug (Fig.
  • Page 20 C.I.B. UNIGAS - M039175CD ADJUSTING AIR AND GAS 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 21 C.I.B. UNIGAS - M039175CD Pressure in combustion head - gas flow rate curves RX90 RX91 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 reque- sted gas rate, add the pressure value in the combustion chamber to the value read on the y-axis.
  • Page 22 C.I.B. UNIGAS - M039175CD Adjusting air and gas flow rates 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. The filter is normally installed upstream from all the control and on-off devices. VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off valves.

  • Page 23: Adjustment Procedure

    C.I.B. UNIGAS - M039175CD Adjusting air and gas flow rates 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 24 C.I.B. UNIGAS - M039175CD Air and Gas Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator mensions Dimensions in SQM4... Actuator cams High flame Stand-by and Ignition Low flame MAN-AUTO MAN-AUTO Berger STM30 Siemens SQM40 Check the fan motor rotation and act directly on the related contactor (see next picture). 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.
  • Page 25 C.I.B. UNIGAS - M039175CD Dungs MBC..SE Siemens VGD.. 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 26 C.I.B. UNIGAS - M039175CD Gas throttle valve open Gas throttle valve closed 17 If it is necessary to change the burner output in the low flame stage, move cam III: the low flame position must never match the ignition position, that is why cam III must be set 20°- 30° more than cam II. 18 Turn the burner off;...
  • Page 27 C.I.B. UNIGAS - M039175CD - Siemens VGD valves group: remove cap T and act on the VR adjusting screw to increase or decrease the pressure and conse- quently the gas rate; screwind VR the rate increases, unscrewing it decreases (see next figure). - Dungs MBC..SE valves group: act on its pressure governor to increase or decrease the pressure and consequently the gas rate.
  • Page 28 C.I.B. UNIGAS - M039175CD Gas throttle valve open Gas throttle valve closed 16 Turn the burner off, then start it up again. 17 Once the pre-purge time comes to end, drive the burner to the high flame stage by the TAB thermosta and check the combustion values;...
  • Page 29 C.I.B. UNIGAS - M039175CD Calibration of low gas pressure switch As for the gas pressure switch calibration, proceed as follows: Be sure that the filter is clean. Remove the transparent plastic cap. While the burner is operating at the maximum output, test the gas pressure on the pressure port of the minimum gas pressure switch.

  • Page 30: Limitations Of Use

    C.I.B. UNIGAS - M039175CD 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 31 C.I.B. UNIGAS - M039175CD the gas valves opening, the transformer is de-energised and the LED I turns off.The burner is now operating and at the same time the servocontrol moves to the hi-flame position (90° - see page 21). Some seconds after the gas valves opening, the burner starts the automatic operation: it automatically switches to low or high flame stage (progressive PR- burners) or to the operation requested by the burner modulator (Fully modulating - MD buners) according to the requirements of the plant.

  • Page 32: Routine Maintenance

    C.I.B. UNIGAS - M039175CD 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 33 C.I.B. UNIGAS - M039175CD 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.
  • Page 34 C.I.B. UNIGAS - M039175CD 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 picture. 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.

  • Page 35: Electrodes Adjustment

    C.I.B. UNIGAS - M039175CD Electrodes Adjustment 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. The gap between ignition electrode E and grounded electrode M must be 4mm.
  • Page 36 C.I.B. UNIGAS - M039175CD Checking the detection current (for models without printed circuti board) Control box Minimum detection signal To check the detection signal follow the scheme in Fig. 32 or 6µA (with electrode) Siemens LFL1.3.. Fig. 33. If the signal is less than the value indicated, check the 70µA with UV detector) Siemens LFL1.3..

  • Page 37: 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 38: Spare Parts

    C.I.B. UNIGAS - M039175CD SPARE PARTS Code Desription RX90 RX91 2020448 2020448 CONTROL BOX DETECTION ELECTRODE 2080106 2080107 IGNITION ELECTRODE 2080269 2080266 2090119 2090119 GAS FILTER - Rp 2” 2090117 2090117 GAS FILTER - DN65 2090112 2090112 GAS FILTER - DN80 2090113 2090113 GAS FILTER - DN100...

  • Page 39: Wiring Diagrams

    C.I.B. UNIGAS - M039175CD WIRING DIAGRAMS Complete key 21-018 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 LINE FUSE UV FLAME DETECTOR MAINS SWITCH AUXILIARY LINE SWITCH...
  • Page 43 APPENDIX SIEMENS LFL 1.3.. CONTROL BOX tion.The flame detector circuit F is activated (terminals 22 and 23 or 23/4) for the detector test and the paracitic light test. Automatic programme in the event of interruption and indication of posi- Where the burners do not have dampers (or have an independent 00 tion when interrupted damper control mechanism) there must be a bridge between terminals 6 By default, in the event of any kind of interruption, the flow of fuel is imme-...
  • Page 44 ratus itself from recovery voltage through the strenght regulator circuit. Weight QRA2 60 g When the strenght regulator LR at terminal 20 gives the consent, the start-up programme for the apparatus comes to an end. Depending on QRA10 450 g. time variants, the programmer stops either immediately or at the end of a *Connect up in parallel to the measuring device a condenser 100µF, set time, without effecting the position of the contacts.
  • Page 45 circuit (contact XIV) and during safety time (contact IV) interval between startup consent and current created at terminal 7 Do not press EK for more than 10 seconds duration of start-up 2nd safety time Programmer diagram interval before air pressure monitoring begins pre-ventilation time damper opening travel time safety time...
  • 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 and data subject to change. Errors and omissions excepted.

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