Related Manuals for Unigas HR1025
Summary of Contents for Unigas HR1025
- Page 1 HR1025 HR1030 HR1040 Progressive and fully-modulating gas - light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039115CG 0.0 04/2020...
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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 PRODUCT INSTALLATION AND MAINTENANCE. -
Page 3: Directives And Standards
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS DIRECTIVES AND STANDARDS Gas burners GENERAL European directives The burner shall be installed by qualified personnel and in compliance -Regulation 2016/426/UE (appliances burning gaseous fuels) with regulations and provisions in force; wrong installation can cause -2014/35/UE (Low Tension Directive) injuries to people and animals, or damage to property, for which the -2014/30/UE (Electromagnetic compatibility Directive) -
Page 4: Symbols Used
Burner data plate Type Gas - Light oil burners For the following information, please refer to Model Year European Directives the data plate: S.Number -Regulation 2016/426/UE (appliances burning gaseous fuels) burner type and burner model: must be Output Oil Flow -2014/35/UE (Low Tension Directive) reported in any communication with the Fuel... - Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS GENERAL FEATURES This series represents monobloc gas burners made in die-cast aluminium housing, that can burn either gas or light oil, thanks to the adjustable combustion head which allows a good performance with both fuels.They can be provided in progressive or fully-modulating version.
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Page 6: Burner Type
Burners are identified by burner type and model. Burner model identification is described as follows. Type HR1025 Model MD. S. BURNER TYPE HR1025 - HR1030 - HR1040 FUEL G - Light oil M - Natural gas B - Biogas L - LPG... -
Page 7: Technical Specifications
PART I: SPECIFICATIONS Technical Specifications HR1025 HR1030 HR1030 HR1040 BRUCIATORE TIPO xG..xx xG..65 xG..xx xG..xx 2550 - 8700 2550 - 9500 2550 - 10600 2550 - 13000 Output min. - max. kW Fuel Category (see next paragraph) min.- max. (Stm... - Page 8 Overall dimensions (mm) **Also available with plastic control panel Burner flange Boiler recommended drilling template AA AB AC AD AE AN AP 50 2088 377 1452 651 585 809 100 544 641 1544 680 2142 1320 822 400 450 709 660 816 M16 651 460 460 1036 200 265 836 80 1092 142 216 1146 379 330 65 2088 377 1452 651 585 827 118 544 641 1544 680 2121 1299 822 400 450 709 660 816 M16 651 460 460 914 200 265 714...
- Page 9 Fig. 2 - 3I2MG-17 v1 Hydraulic diagram - nozzle M3 ON BOARD ITEMS SUPPLIED LOOSE ITEMS 3I2MG17 LEGEND OIL TRAIN Filter Flexible hose Pump and pressure governor Electrical motor Solenoid valve oil inlet Flexible hose Oil distributor oil outlet Pressure gauge with manual valve One-way valve Flexible hose Pressure gauge with manual valve...
- Page 10 Fig. 3 - 3I2MG-18 v1 Hydraulic diagram - nozzle type G ON BOARD ITEMS SUPPLIED LOOSE ITEMS 3I2MG18 LEGEND OIL TRAIN Filter Flexible hose Pump and pressure governor Electrical motor Solenoid valve Flexible hose Oil distributor Pressure gauge with manual valve oil inlet One-way valve Flexible hose...
- Page 11 PART I: SPECIFICATIONS How to read the burner “Performance curve” To check if the burner is suitable for the boiler to which it must be instal- Campo di lavoro bruciatori lled, the following parameters are needed: Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65 furnace input, in kW or kcal/h (kW = kcal/h/860);...
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Page 12: Performance Curves
PART I: SPECIFICATIONS Performance Curves HR1025 DN50 HR1025 DN65 - DN80 - DN100 HR1030 DN65 HR1030 DN80 - DN100 HR1040 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 13 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves(natural gas) HR1025 M-..1.50 HR1025 M-..1.xx Gas rate Stm Gas rate Stm HR1030 M-..65 HR1030 M-..1.xx Gas rate Stm Gas rate Stm HR1040 M-. Gas rate Stm ATTENTION: 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).
- Page 14 PART I: SPECIFICATIONS Combustion head gas pressure curves Combustion head gas pressure depends on gas flow and combustion chamber backpressure. When backpressure is subtracted, it depends only on gas flow, provided combustion is properly adjusted, flue gases residual O2 percentage complies with “Recommended combustion values”...
- Page 15 PART I: SPECIFICATIONS Pressure - rate in combustion head curves (natural gas) Curves are referred to pressure = 0 mbar in the combustion chamber! HR1025 Gas rate Stm HR1030 HR1040 Gas rate Stm Gas rate Stm...
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Page 16: Transport And Storage
PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Transport and storage ATTENTION! The equipment must be installed in compliance with the regulations in force, following the manufac- turer’s instructions, by qualified personnel. All handling operations must be carried out with appropriate resources and qualified personnel ATTENTION: Use intact and correctly dimensioned hoisting equipment, conforms to the local regulations and health and safety regulations. - Page 17 PART II: INSTALLATION Fitting the burner to the boiler To perform the installation, proceed as follows: drill the furnace plateas decribed in paragraph (“Overall dimensions”); place the burner towards the furnace plate: lift and move the burner by means of its eyebolts placed on the top side (see”Lifting and moving the burner”);...
- Page 18 PART II: INSTALLATION - first step: install the flanges to prevent the entry of foreign bodies in the gas line; - on the gas pipe, clean the already assembled parts and then install the valve unit; - check gas flow direction: it must follow the arrow on the valve body; - VGD20: make sure the O-rings are correctly positioned between the flanges and the valve;...
- Page 19 PART II: INSTALLATION Siemens VGD20.. e VGD40.. Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) - Connect the reference gas pipe (TP in figure; 8mm-external size pipe supplied loose), to the gas pressure nipples placed on the gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size.
- Page 20 PART II: INSTALLATION MultiBloc MBE Example of gas train MBE ALLA V. FARFALLA 501939 GAS BRUCIATORE ø185 VD-R VD-V VD-R VD-V Gas filter PGMAX PGMAX PGMIN PGMIN PS pressure sensor PGCP PGCP VD-V VD-R Gas filter PGMIN PGCP PGMAX To mount the gas train, proceed as follows: 1) in case of threaded joints: use proper seals according to the gas used;...
- Page 21 PART II: INSTALLATION Threaded train with MultiBloc MBE - Mounting 1. Mount flange into pipe systems. Use appropriate sealing agent. 1. Insert studs A. 2. Insert VB together with supplied O-rings. 2. Insert seals B. Check current position of O-rings. 3.
- Page 22 PART II: INSTALLATION 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 to the gas supply to the burner network gas proving system connection (optional) SIEMENS VGD40..
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Page 23: Gravity Circuit
PART II: INSTALLATION Hydraulic diagrams for light oil supplying circuits GRAVITY CIRCUIT RING CIRCUIT 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve SUCTION CIRCUIT NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device. - Page 24 PART II: INSTALLATION must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer. Double-pipe system: as for the single pipe system, a pipe that connects the tank to the pump’s inlet is used besides another pipe that connects the pump’s return port to the tank, as well.
- Page 25 PART II: INSTALLATION About the use of fuel pumps Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth, thus obstructing them. After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of the ...
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Page 26: Electrical Connections
PART II: INSTALLATION 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. WARNING! 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 27 PART III: OPERATION PART III: OPERATION DANGER! Incorrect motor rotation can seriously damage property and injure people.WARNING: 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”.
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Page 28: Gas Operation
PART III: OPERATION Fig. 7 - Burner control panel Keys Main switch Reset pushbutton for control box CMF switch (0=stop, 1=low flame, 2=high flame, B2 B3 3=automatic) - fully modulating burners only Lock-out LED Hi-flame operation LED Lo-flame operation LED “Ignition transformer operation”... - Page 29 PART III: OPERATION AIR FLOW AND FUEL ADJUSTMENT 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 30 PART III: OPERATION 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.
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Page 31: Pressure Taps
PART III: OPERATION MultiBloc MBE Regulation VD-R whith PS Setting scale is „Not“ linear! Various sensors available. Output pressure according to sensor‘s measuring range. Increasing pressure Adjust the outlet pressure to the value specified by the burner or equipment manufacturer! While making outlet pressure adjustments, do not exceed a value that creates a hazardous condition to the burner! - Page 32 PART III: OPERATION Calibration 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 bur- ner control panel.
- Page 33 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; once the adjustmet is performed, fasten the V screws. HR1025 - HR1030 HR1040 open holes...
- Page 34 Fig. 20 (as far as reading the pressure values, see next paragraphs). NOZZLE NOZZLE SUPPLY PRESSURE FLUIDICS WR2/UNIGAS M3 BERGONZO B FLUIDICS NOZZLE: REFERENCE DIAGRAM (INDICATIVE ONLY) Atomisation angle FLOW RATE kg/h...
- Page 35 PART III: OPERATION Pump flow rate Nozzle flow rate Fig. 11 - Bergonzo B nozzle - example with 850kg/h nozzle...
- Page 36 PART III: OPERATION Oil Flow Rate Settings Once the air and gas flow rates are adjusted, turn the burner off, switch to the oil operation (OIL, on the burner control panel). with the electrical panel open, prime the oil pump acting directly on the related CP contactor (see next picture): check the pump motor rotation and keep pressing for some seconds until the oil circuit is charged;...
- Page 37 PART III: OPERATION tion. Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps. Pressure gauge port Fig. 13 Fig. 14 Fig. 15 Fully-modulating burners .To adjust the fully-modulating burners, use the CMF switch on the burner control panel (see next picture), instead of the TAB thermo- stat as described on the previous paragraphs about the progressive burners.
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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 MultiBloc MBE MultiBloc VD Mounting to push position 1. Position VD on VB, fig. 2+3. 2. Slide VD forward up to the stop, fig. 4. 3. Screw VD on with 2 M5 screws for each, max. 5 Nm/44 in.-lb., fig. 5/6. 4.
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Page 40: Adjusting The Ignition Electrode
PART IV: MAINTENANCE Adjusting the ignition electrode ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrode position after any intervention on the combustion head. Fig. - Page 41 PART IV: MAINTENANCE Replacing the ignition electrode ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler 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);...
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Page 42: Seasonal Stop
PART IV: MAINTENANCE Flame detection probe To clean/replace the detection photocell, proceed as follows: Disconnect the system from the electrical power supply. Shut off the fuel supply; remove the photocell from its slot (see next figure); clean the bulbe if dirty, taking care not to touch it with bare hands; if necessary, replace the bulb;... - Page 43 PART IV: MAINTENANCE TROUBLESHOOTNG GUIDE - Light oil operation * No electric power supply * Wait for electric power supply is back * Main switch open * Close the switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Set or replace the thermostat * No gas pressure...
- Page 44 TROUBLESHOOTNG GUIDE - Gas operation * No electric power supply * Wait until power supply is back * Main switch open * Close the switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Set or replace the thermostat * No gas pressure * Restore gas pressure...
- Page 45 BURNER EXPLODED VIEW ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION AIR INLET CONE 10.5.1 ADJUSTING BUSH 14.1 BRACKET SPACER 10.5.2 STANDARD COMPLETE OIL GUN 14.2 PUMP FLEXIBLE HOSE 10.5.2.1.1 SOLENOID VALVE 14.3 COUPLING FLEXIBLE HOSE 10.6 IGNITION CABLE 14.4 PRESSURE GOVERNOR FLEXIBLE HOSE 10.7 GAS FLEXIBLE HOSE...
- Page 46 10.5.2.1.1...
- 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 excepted.
- Page 49 LME73.000Ax + PME73.831AxBC LME73.831AxBC Service instruction manual M12921CB Rel.1.2 02/2016...
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Page 50: General Features
GENERAL FEATURES LME/ is suitable for gas, light and heavy oil burners LME7 series has two devices: LME73.000 (hardware) and PME73.831AxBC (programmable unit). The LME73.831AxBC is also available: it has a built in software and it isa not programmable. LME7 is inside the control panel. If supplied, PME73.831BC is inside the LME7; The display AZL23.. -
Page 51: User Interface
User interface : Button A - Display preset output - In lockout position: Power value to the time of fault Info and Enter button - Reset in the event of fault, changeover visual diagnostic of the cause of fault (refer to chapter Diagnostics of cause of fault ) - button - Display flame signal current 2 or phases display - In lockout position: MMI phase to the time of fault... - Page 52 List of phase display on board LME : Phase number of Function 7-segment display Standby Standby, waiting for heat demand Mains ON / test phase (e.g. detector test) Startup Yellow Safety valve ON, air pressure switch test / POC test (timeout / locking Yellow Fan motor ON / air pressure switch test / settling time Yellow...
- Page 53 Operation : The lockout reset button (info button) (EK) is the key operating element for resetting the burner control and for activating / deactivating the diagnostics functions. The multicolor signal lamp (LED) is the key indicating element for visual diagnostics. Both lockout reset button (EK) and signal lamp (LED) are located in the control panel.
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Page 54: Program Sequence
Program sequence : Version 1: • Ignition load < low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 > 0 seconds) - Page 55 Program sequence : Version 2: • Ignition load > low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 = 0 seconds)
- Page 56 Phase Function number Lockout phase Standby, waiting for heat demand Operation, modulating operation Interval until release of load controller target (analog or 3-position step input) Under voltage Safety loop open Extraneous light on burner startup (timeout/locking after 30 seconds) Mains ON/test phase (e.g. detector test) Shutdown, actuator opens in CLOSE position (homerun) Safety valve ON, air pressure switch OFF, actuator opens in CLOSE position Part 1: Fan motor ON...
- Page 57 Error code table : Red blink code of fault signal lamp (LED) Possible cause 2 x blinks No establishment of flame at the end of the safety time (TSA) - Faulty or soiled flame detector - Faulty or soiled fuel valves - Poor adjustment of burner, no fuel - Faulty ignition equipment 3 x blinks...
- Page 58 Flame detection – detection electrode : Short-circuit current Max. AC 1 mA Required detector current Min. DC 2 μA, display approx. 45 % Possible detector current Max. DC 3 μA, display approx. 100 % Permissible length of detector cable (laid separately) 30 m (core-earth 100 pF/m) Measuring circuit Keys...
- Page 59 Gas proving system : Valve proving is dependent on input valve proving ON / OFF (X2-02). When a leak is detected, the gas valve proving function ensures that the gas valves will not be opened and that ignition will not be switched on. Lockout will be initiated. Valve proving with separate pressure switch (P LT) Step 1: td4 –...
- Page 60 Instruction, control and modify via AZL2x : The AZL2x.. display/programming unit is shown below: The keys functions are the following: 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...
- Page 61 The display will show these data: Lock+unlock codes Flame Open valves Ignition transformers energised Fan motor energised Oil pre-heater energised Plant heat request Parameter setting mode Info mode Service mode Closing actuator Opening actuator Unit measure While pushing the button together with whatever else button, LME73 locks out; the display shows On stand-by position, appears On operation, all the phases appears with their number.
- Page 62 List of phase with display AZL2x : Phase number Function Standby Standby, waiting for heat request Ph08 Power ON / test phase (e.g. detector test) Startup Ph21 Safety valve ON, air pressure switch test / POC test (timeout / locking after 5 seconds), actuator opens in low-fire position / CLOSE position Ph22 Fan motor ON or air pressure switch test / settling time...
- Page 63 Error code list with operation via internal AZL : Error code Clear text Possible cause Loc 2 No establishment of flame at the - Faulty or soiled fuel valves end of the safety time (TSA) - Faulty or soiled flame detector - Poor adjustment of burner, no fuel - Faulty ignition equipment Loc 3...
- Page 64 Entering the Parameter levels: y means of a proper use of the keys, it is possible to enter the various level parameters, as shown in the following flow chart :...
- Page 65 Info level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
- Page 66 Service level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. . If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
- Page 67 Process data Normalized speed Read only 100% 0.01 % Service Mains voltage Read only LME73.000A1: Service 175 V LME73.000A2: 350 V Flame intensity Read only 100% Service...
- Page 68 Parameter level (Heating engeneering) : This level lets the engineer to modify some burner parameters. It is protect with a 4 digit password (SO level) and a 5 digit password (OEM level) Password input : push F and A buttons together until the display shows "code" and 7 underlines. The left one flashes. By move the flashing underline until it is on the desired position and push "enter".
- Page 69 Repetition in the event of loss of flame during operation Edit 0 SO 0 = None 1 = None 2 = 1 x Repetition 241.00 Valve proving Edit 1 SO 0 = Off 1 = On 241.01 Valve proving Edit 0 SO 0 = During prepurge time (t1) 1 = During postpurge time (t8)
- Page 70 Power setting Analog input (feedback potentiometer ASZxx.3x required) Edit 0 SO 0 = 3-position step input 1 = 0...10 V 2 = 0...135 Ω 3 = 0...20 mA 4 = 4...20 mA with lockout at I <4 mA 5 = 4...20 mA WARNING Parameter Num.
- Page 72 Note: Specifications and data subject to change. Errors and omissions excepted.