1. Manuals
  2. Brands
  3. Unigas Manuals
  4. Burner
  5. KTP1030
  6. Manual of installation - use - maintenance

Unigas KTP1030 Manual Of Installation - Use - Maintenance

Progressive and fully-modulating gas - heavy oil dual fuel burners
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
KTP1030
KTP1050
KTP1080
Progressive
and fully-modulating
gas - heavy oil dual fuel burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039207CB Rev. 1 05/2008

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the KTP1030 and is the answer not in the manual?

Questions and answers

Related Manuals for Unigas KTP1030

Summary of Contents for Unigas KTP1030

  • Page 1 KTP1030 KTP1050 KTP1080 Progressive and fully-modulating gas - heavy oil dual fuel burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039207CB Rev. 1 05/2008...

  • 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

    the power-driven components in the system (i.e. pumps, burner, etc.) DIRECTIVES AND STANDARDS should be switched off. Gas burners European directives: 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS - Directive 90/396/CEE - Gas Appliances; Directive 2006/95/EC on low voltage;...

  • Page 4: General Features

    C.I.B. UNIGAS - M039207CB 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 separately-mounted control panel (console or wall- mounted).
  • Page 5 C.I.B. UNIGAS - M039207CB 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 6 C.I.B. UNIGAS - M039207CB 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 7: Gas Connection

    Type KTP1030 Model (1) BURNER TYPE KTP1030 - KTP1050 - TP1080 (2) FUEL MN - Dual fuel gas-heavy oil Heavy oil, standard viscosity <= 7° E @ 50° C MD - Dual fuel gas-heavy oil <= 50° E @ 50° C ME - Natural gas - ecological heavy oil between 7°...
  • Page 8 KTP1030 1864 544 1320 348 1898 1301 1000 460 936 200 587 1092 322 1175 372 KTP1030 100 1864 544 1320 348 1914 1317 1000 460 842 200 587 1092 382 1175 372 KTP1050 1864 544 1320 348 1898 1301...
  • Page 9 C.I.B. UNIGAS - M039207CB Performance curves KTP1030 2000 4000 6000 8000 10000 12000 14000 KTP1050 2000 4000 6000 8000 10000 12000 14000 16000 KTP1080 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 10 C.I.B. UNIGAS - M039207CB Pressure in the network / gas rate curves KTP1030 DN80 DN100 1 50 1 00 DN125 1 000 1 1 00 1 200 1 300 1 400 Gas rate Stm KTP1050 DN80 DN100 1 00 DN125...
  • Page 11 Packing The burners are despatched in wodden crates whose dimensions are: KTP1030 - KTP1050: 2180mm x 1180mm x 1210mm (L x P x H) KTP1080: 2180mm x 1580mm x 1560mm (L x P x H) Packing cases of this type are affected by humidity and are not suitable for stacking.

  • Page 12: Fan Installation

    C.I.B. UNIGAS - M039207CB Fitting the burner to the boiler To perform the installation, it is necessary to drill the boiler door as described on paragraph “Overall dimensions”; screw the studbolts (5) on the boiler door, according to the drilling plate (see paragraph “Overall dimensions”);...
  • Page 13 C.I.B. UNIGAS - M039207CB 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 14: Assembling The Gas Train

    C.I.B. UNIGAS - M039207CB Connecting the pilot gas train 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 15: Mounting Positions

    C.I.B. UNIGAS - M039207CB fasten all the items by means of screws, according to the shcemes shown before, obesrving the mounting direction for each item. NOTE: the bellow joint, the manual valve and the gaskets are not part of the standard supply.
  • Page 16 C.I.B. UNIGAS - M039207CB Pressure adjusting range The pressure adjusting range, upstream 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 17: Hydraulic System

    C.I.B. UNIGAS - M039207CB Hydraulic system 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 18 C.I.B. UNIGAS - M039207CB Suntec TV Pressure governor Pressure adjustment Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase pressure, twist adjusting screw 3 clockwise. To decrease the pressure, twist screw counterclockwise. Tight the lock nut 4, refit the gasket 2 and the cap nut 1.
  • Page 19 Connecting the burner to the 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 20 C.I.B. UNIGAS - M039207CB Guidelines for the appropriate use of heavy oil For a correct operation of heavy oil or dual fuel burners (gas - heavy oil), the supply plant must be correctly build and it must ensure two fundamental conditions:...
  • Page 21 C.I.B. UNIGAS - M039207CB VISCOSITY UNITS CONVERSION TABLE Saybolt Saybolt Cinematics Cinematics Cinematics Redwood n. 1 Redwood n. 2 Universal Furol Engler (Centistokes) (Centipoises) (Seconds) (Seconds) (Seconds) (Seconds) (Degrees) °E R.S.I R.S.II S.S.U. S.S.F. 2.95 20.60 20.60 88.4 3.21 23.00 23.00...
  • Page 22 C.I.B. UNIGAS - M039207CB VISCOSITY vs TEMPERATURE DIAGRAM FOR COMBUSTIBLE OILS 1000 PUMPING LIMIT TEMPERATURE (°C) LIGHT OIL 1,3°E AT 20°C HEAVY OIL 2,4°E AT 50°C HEAVY OIL 4°E AT 50°C HEAVY OIL 7,5°E AT 50°C HEAVY OIL 10°E AT 50°C HEAVY OIL 13°E AT 50°C...
  • Page 23 C.I.B. UNIGAS - M039207CB Minimum feeding temperature vs. oil viscosity OIL TEMPERATURE FOR PUMP FEEDING TEMPERATURE (°C) Fig. 13 Pumps operating range PUMP FEEDING PRESSURE Max. for T and TA pumps Max. for E ..1069 pimps TEMPERATURE (°C) Fig. 14 The use of heavy oil forces to feed the burner to a pressure strictly related to the oil temperature.

  • Page 24: Hydraulic Diagrams

    C.I.B. UNIGAS - M039207CB HYDRAULIC DIAGRAMS Fig. 16 - Hydraulic diagram 3ID0023 - Single burner configuration...
  • Page 25 C.I.B. UNIGAS - M039207CB Fig. 17 - Hydraulic diagram 3ID0014 - Two or more burners configuration...
  • Page 26 C.I.B. UNIGAS - M039207CB Hydraulic Diagram 3ID0014 Hydraulic Diagram 3ID0023 1 Main tank 1 Main tank 2 Bottom valve 2 Bottom valve 3 Main tank pre-heating pipe 3 Main tank pre-heating pipe 4 Oil filter (filtration, 1mm) 4 Oil filter...

  • Page 27: Electrical Connections

    C.I.B. UNIGAS - M039207CB 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 28 C.I.B. UNIGAS - M039207CB ADJUSTMENT 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 29 C.I.B. UNIGAS - M039207CB Measuring the gas pressure in the combustion head In order to measure the pressure in the combustion head, insert the pressure gauge probes: one into the combustion chamber’s pres- sure outlet (Fig. 19-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig.
  • Page 30 C.I.B. UNIGAS - M039207CB ADJUSTING AIR AND GAS FLOW RATES Keys Gas filter Gas proving system Gas valves Adjusting cam Actuator Fig. 20 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 31: Adjustment Procedure

    C.I.B. UNIGAS - M039207CB 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 32 C.I.B. UNIGAS - M039207CB according to the gas flow rate change following the steps quoted below; acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values...
  • Page 33 C.I.B. UNIGAS - M039207CB butterfly valve close butterfly valve open Calibration of air pressure switch To calibrate the air pressure switch, proceed as follows: Remove the transparent plastic cap. Once air and fuel setting have been accomplished, startup the burner.
  • Page 34 C.I.B. UNIGAS - M039207CB 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. Go on adjusting the burner as described before, paying attention to use the CMF switch intead of TAB.
  • Page 35 C.I.B. UNIGAS - M039207CB Pump flow rate Nozzle flow rate Fig. 23 - 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 heavy oil operation (OIL, on the burner control panel (see page 28).
  • Page 36 C.I.B. UNIGAS - M039207CB motor rotation and keep pressing for some seconds until the oil circuit is charged; bleed the air from the M pressure gauge port (Fig. 24) by loosing the cap without removing it, then release the contactor.
  • Page 37 C.I.B. UNIGAS - M039207CB 14 Move again cam V towards the minimum to meet the next screw on the adjusting cam and repeat the previous step; go on this way as to reach the desired low flame point. 15 The low flame position must never match the ignition position that is why cam IV must be set 20°- 30° more than the ignition posi- tion.
  • Page 38 C.I.B. UNIGAS - M039207CB 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 39: Gas Operation

    C.I.B. UNIGAS - M039207CB 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 type of fuel by turning the burner switch, on the burner control panel.

  • Page 40: Routine Maintenance

    C.I.B. UNIGAS - M039207CB 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 41 C.I.B. UNIGAS - M039207CB 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 42: Adjusting The Ignition Electrode

    C.I.B. UNIGAS - M039207CB 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 43: Seasonal Stop

    C.I.B. UNIGAS - M039207CB 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 44: Troubleshooting

    C.I.B. UNIGAS - M039207CB 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 45: Electrical Wiring Diagrams

    C.I.B. UNIGAS - M039207CB ELECTRICAL WIRING DIAGRAMS WARNING 1 - Electrical supply 400V 50Hz 3N a.c. 2 - Do not reverse phase with neutral 3 - Ensure burner is properly earthed Wiring diagram 12-143...
  • Page 46 C.I.B. UNIGAS - M039207CB...
  • Page 47 C.I.B. UNIGAS - M039207CB...
  • Page 48 C.I.B. UNIGAS - M039207CB...
  • Page 49 C.I.B. UNIGAS - M039207CB...
  • Page 50 C.I.B. UNIGAS - M039207CB Pumping Unit Electric Wiring Diagrams...
  • Page 51 C.I.B. UNIGAS - M039207CB...
  • Page 52 C.I.B. UNIGAS - M039207CB...

  • Page 53: Spare Parts

    C.I.B. UNIGAS - M039207CB SPARE PARTS Desription Code KTP1030 KTP1050 KTP1080 SIEMENS LDU GAS PROVING SYSTEM 2020413 2020413 2020413 SIEMENS LFL CONTROL BOX 2020448 2020448 2020448 DETECTION ELECTRODE 2080258 2080258 2080258 OIL FILTER 2090018 2090018 2090018 GAS FILTER DN80 2090112...
  • Page 54 C.I.B. UNIGAS - M039207CB BURNERS EXPLODED VIEW AIR INLET BURNER BODY REMOVABLE COVER FIBRE GLASS PLAIT PLATE INLET PERSPEX PHOTOCELL GLASS FRAME FEMALE EYEBOLT BLAST TUBE AIR PRESSURE SWITCH BLACK CONNECTOR 13.1 GAS FILTER 13.2 FLANGE 13.3 FLANGED REVERSIBLE CURVE 13.4...
  • Page 56 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 57 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 58 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 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 without notice. Errors and omissions excepted.

  • Page 61: Technical Specifications

    CIB UNIGAS 600V CONTROLLER USER’S MANUAL COD. M12925CA Rel 1.2 08/2014 SOFTWARE VERSION 1.0x code 80379 / Edition 01 - 06/2012 1 • INSTALLATION 2 • TECHNICAL SPECIFICATIONS Display 2x4 digit green, high display 10 and 7mm Keys 4 of mechanical type (Man/Aut, INC, DEC, F) •...
  • Page 62 3 • DESCRIPTION OF FACEPLATE Function indicators Indication of output states Indicates modes of operation OUT 1 (AL1); OUT 2 (OPEN); OUT 3 (CLOSED) MAN/AUTO = OFF (automatic control) ON (manual control) PV Display: Indication of process variable Error Indication: LO, HI, Sbr, Err PRE-HEATING = ON (running) LO= the value of process variable is <...

  • Page 63: Programming And Configuration

    5 • “EASY” PROGRAMMING and CONFIGURATION S4 Jumper THE EASY CONFIGURATION (Pro=0...12) IS SUITABLE FOR (CPU) VERSIONS WITH AL1/OPEN/CLOSED LEVEL 1 MENU P.V. / S.V. Process variable P.V. / S.V. (PV display) Work Setpoint (SV display) or control output value with controller in manual Password Local Setpoint...
  • Page 64 • InFo Display Information display Software version 0 No Error Self diagnostic 1 Lo error code 2 Hi 3 ERR 4 SBR OUTPUT 2 OUTPUT 3 SERIAL COMMUNICATION 0 = None 0 = None 0 = None +8 error OUT2 card recognition 1 = Relay 1 = Relay +16 error OUT3 card recognition...
  • Page 65 • InP Input settings S, R range 0...1750°C; error < 0.2% f.s. (t > 300°C) / for other sp. r 0 default (remote setpoint present) Def. remote setpoint range; error < 0.5% f.s. error < 0.2% f.s. (t > -150°C) range 44...1800°C;...
  • Page 66 • Out Output settings Select a1. r reference signal for alarm1 AL.1.r AL.x.r Variable to be compared PV (process variable) AL.1.t AL.x.t Direct (high limit) Absolute or Normal 2/3 for a1. t Inverse (low limit) relative to Symmetrical alarm 1 active setpoint (window) direct...
  • Page 67 • Prot Protection code Prot Display Modification SP, Hy.P, Hy.n, AL.2, AL.3, PoS, OuP, INF SP, Hy.P , Hy.n, AL.2, AL.3, PoS SP, Hy.P, Hy.n, AL.2, AL.3, PoS, OuP, INF SP, OuP, INF + 4 to disable InP, Out + 8 to disable CFG + 16 to disable SW “power-up - power down”...
  • Page 68 ld. 1 Function of LEDs Val. Function none MAN/AUTO controller ld. 2 HOLD Selftuning enabled Autotuning enabled ld. 3 Error present Softstart running Set point gradient running Pre-heating running + 16 LED flashes if active • Lin Custom linearization for main input Step 0 beginning Display limits s.

  • Page 69: Pre-Heating Function

    7 • CONSENT FOR BURNER AL1 Obtain burner consent by configuring alarm 1 as inverse deviation with positive hysteresis Hy.P and negative hysteresis Hy.n 8 • PRE-HEATING FUNCTION Enable the pre-heating function by setting parameters GS.0, Ht.0, GS.1 other than zero. It consists of three phases that are activated sequentially at firing: - Ramp 0 phase Enabled by setting GS.0 >...
  • Page 70 9 • ADJUSTMENT WITH MOTORIZED VALVE In an adjustment process the adjustment valve has the function of varying fuel delivery (frequently corresponding to the thermal energy introduced into the process) in relation to the signal coming from the controller. For this purpose it is provided with an actuator able to modify its opening value, overcoming the resistances produced by the fluid passing inside it.

  • Page 71: Control Actions

    Valve control modes With the controller in manual, the setting of parameter At.y ≥ 8 allows direct control of the valve open and close commands through the keyboard Increments and Decrements on the front seats. V0 - for floating valve without potentiometer Model V0 have similar behaviour: every manoeuvre request greater than the minimum impulse t.Lo is sent to the actuator by means of the OPEN/CLOSE relays;...

  • Page 72: Manual Tuning

    11 • MANUAL TUNING A) Enter the setpoint at its working value. B) Set the proportional band at 0.1% (with on-off type setting). C) Switch to automatic and observe the behavior of the variable. It will be similar to that in the figure: Process D) The PID parameters are calculated s follows: Proportional band Variable...
  • Page 73 15 • ACCESSORIES • Interface for instrument configuration Kit for PC via the USB port (Windows environment) for GEFRAN instruments configuration: KIT PC USB / RS485 o TTL Lets you read or write all of the parameters • A single software for all models •...
  • Page 75 21/06/2012 rev. 0 Set-up for 600V RRR0-1-T73 regulator Set up for temperature probe Pt100 (ex Siemens QAE2120 130°C max.) The regulator comes out of the factory preset with the corresponding values of the Siemens RWF40.000 and RWF50.2x Verify wiring of the sensor Regulation of the set-point = 80 It can be modified by using arrows "up"...

  • Page 76: Manual Operation

    A1.r … A1.t 3 (operating mode AL1 =inverse-relative-normal) … rL.1 2 (AL1) rL.2 18 (open) rL.3 19 (close) A.ty 9 (type of servocontrol command) Ac.t 12 (servocontrol running time: SQN72.4…/STA12..=12; SQM40.265=30) t_Lo t_Hi t.on t.oF dE.b 0,1 (dead zone in % of end scale) 99 then push and keep pushed F until visualization of Hrd …...
  • Page 77 Set up for temperature probe Pt100 for high temperature (350°C max.) Verify wiring of the sensor Regulation of the set-point = 80 It can be modified by using arrows "up" and "down". By pushing F you go to parameters: Hy.P 10 (hysteresis positive for output 1 terminals 21-22 (ex Q13-Q14) Hy.n -5 (hysteresis negative for output 1 terminals 21-22 (ex Q13-Q14)
  • Page 78 A1.r … A1.t 3 (mode AL1 =inverse-relative-normal) … rL.1 2 (AL1) rL.2 18 (open) rL.3 19 (close) A.ty 9 (type of servocontrol command) Ac.t 12 (servocontrol running time: SQN72.4…/STA12..=12; SQM40.265=30) t_Lo t_Hi t.on t.oF dE.b 0,1 (dead zone in % of end scale) 99 then push and keep pushed F until visualization of Hrd …...
  • Page 79 Set up for pressure transmitter 2 wires signal 4÷20mA With pressure transmitters first we need to enable their power supply: remove the part as shown below, then, on the CPU unit, move the bridge from Pt100 to +Vt IN/OUT cards Signal selection on terminal 3 Verify wiring of the sensor...
  • Page 80 …. 44 (4÷20mA) … dP_S 2 (decimals num.) Transmitter 1,6bar 3bar 10bar 16bar 25bar 40bar Lo.S 0,00 0,00 0,00 0,00 0,00 0,00 min. sensor scale Hi.S 1,60 3,00 10,00 16,00 25,00 40,00 max sensor scale offset of input correction Lo.L 0,00 0,00 0,00...
  • Page 81 Set -up for thermocouples type Verify wiring of the sensor Regulation of the set-point = 80 It can be modified by using arrows "up" and "down". By pushing F you go to parameters: Hy.P 10 (hysteresis positive for output 1 terminals 21-22 (ex Q13-Q14) Hy.n -5 (hysteresis negative for output 1 terminals 21-22 (ex Q13-Q14) Keep pushing F until you see PASS, release F and through the arrows set 99, push F and visualize Pro...
  • Page 82 A1.r … A1.t 3 (mode AL1 =inverse-relative-normal) … rL.1 2 (AL1) rL.2 18 (open) rL.3 19 (close) A.ty 9 (type of servocontrol command) Ac.t 12 (servocontrol running time: SQN72.4…/STA12..=12; SQM40.265=30) t_Lo t_Hi t.on t.oF dE.b 0,1 (dead zone in % of end scale) 99 then push and keep pushed F until visualization of Hrd …...
  • Page 85 RWF50.2x & RWF50.3x User manual M12922CB Rel.1.0 07/2012...

  • Page 86: Device Installation

    DEVICE INSTALLATION Install the device using the relevant tools as shown in the figure. To wire the device and sensors, follow the instructions on the burner wiring diagram.

  • Page 87: Front Panel

    FRONT PANEL NAVIGATION MENU Parameter level Basic display User Level - Opr SP1 or SP2 (editable) dSP readable and editable through bin1 = 2 InP1 or y (only display) Parameter Level - PArA HYS1 , HYS2 , HYS3 Pb1, dt, rt, db, tt Next parameter Main navigation...
  • Page 88 RWF5 is preset good for 90% of applications. However, you can set or edit parameters as follow: Set-point: set or modification: When the burner is in stand-by, (safety loop open, that is terminals 3-4/T1-T2 on the 7 pole plug open) push the Enter button: on the lower display (green) Opr appears;...
  • Page 89 Setting the kind of sensor to be connected to the device:  push the Enter button: on the lower display (green) Opr appears. Using the up and down arrows find ConF. Push Enter to confirm.  Now on the green display the group InP appears. Push Enter and InP1 is displaied. Enter to confirm. ...
  • Page 90 ConF > Cntr Parameter Value Description CtYP 1 = 3-position controller (open-stop-close only RWF50.2) controller type 2 = continuative action controller (only RWF50.3) CACt 1 = heating controller control action 0 = cooling controller least value of the set-point limitation prevents entry of values outside the defined set-point range -1999..0..+9999 range...
  • Page 91 ConF > OutP (parameter under group only for RWF50.3) Parameter Value Description FnCt 1 = analog input 1 doubling with possibility to convert tipo di controllo (depending on par SiGn) 4 = modulation controller SiGn physical output signal (terminals A+, A-) type of output signal 0 = 0÷20mA 1 = 4÷20mA...
  • Page 92 Manual control :  in order to manual change the burner load, while firing keep pushing the ESC button for more than 5 s; on the lower green display Hand appears.  using the UP and DOWN arrows, the load varies. ...

  • Page 93: Electric Connection

    Electric connection : With 7 pins connector version With terminals version Matches terminals between RWF50.2 and RWF40.0x0...
  • Page 94 Parameters summarising for RWF50.2x: Conf Conf Navigation menù Inp1 Cntr diSP PArA Types of probe SEn1 OFF1 SCL1 SCH1 Unit dECP Pb. 1 dt HYS1 (*) HYS3 (*) SP1 (*) Siemens QAE2120… needless needless 80 350 (#) 80 °C Siemens QAM2120.. needless needless 80 350 (#)
  • Page 95 APPENDIX: PROBES CONNECTION To assure the utmost comfort, the control system needs reliable information, which can be obtained provided the sensors have been installed correctly. Sensors measure and transmit all variations encountered at their location. Measurement is taken based on design features (time constant) and according to specific operating conditions.With wiring run in raceways, the sheath (or pipe) containing the wires must be plugged at the sensor's terminal board so that currents of air cannot affect the sensor's measurements.
  • Page 96 Duct or pipe sensors Installing pressure sensors A - installation on ducts carrying fluids at max. temperature 80°C Installing temperature sensors For measuring outlet air: B - installation on ducts at temperature over 80°C and for refrigerants  after delivery fan or C - installation on ducts at high temperatures: ...
  • Page 97 Immersion or strap-on sensors Immersion probes installation Sensors must be installed on the stretch of pipe in which fluid circulates all the time. The rigid stem (sensing element doing the measuring) must be inserted by at least 75mm and must face the direction of flow. Recommended locations: on a bend or on a straight stretch of pipe but tilted by 45°...
  • Page 98 Duct pressure switches and sensors Installing differential pressure probes for air Basic principles Measuring static pressure(i.e. pressure exerted by air on pipe walls) A - Control a filter (clogging) Measuring dinamic pressure B - Control a fan (upstream/downstream) Kg/m , specific weight of air m/s, air speed 9.81 m/s gravity acceleration...
  • Page 99 Spare parts Description Code Modulator RWF50.2 (uscita a 3 punti - apri, fermo, chiudi) 2570148 2570149 Modulator RWF50.3 (uscita continua 0÷20mA, 4÷20mA, 0÷10V) Temperature probe Siemens QAE2120.010A (30÷130°C) 2560101 2560135 Temperature probe Siemens QAM2120.040 (-15÷+50°C) 2560188 Thermoresistor Pt1000 ø6mm L100mm (30÷130°C) Thermoresistor Pt1000 ø10mm L200mm (0÷350°C) 2560103 2560145...
  • Page 100 Note: Specifications and data subject to change. Errors and omissions excepted.
  • Page 101 KM3 Modulator USER MANUAL M12927CA Rel.1.0 10/2020...
  • Page 102 M12927CA MOUNTING...

  • Page 103: Outp Ut Leds

    M12927CA DISPLAY Y AND KEY onsent to the burner is rned off OUTP UT LEDs ON (o out1) - Consen nt to the burne ▲ - (o out2) Output i ncrease ▼ - (o out3) Output d decrease ● - (ou ut4) Modulato r is powered o perator Mode...

  • Page 104: Probe Connection

    M12927CA CONNECTIONS DIAGRAM Probe connection: • PT1000/NTC/PTC: between terminal 3 and 2 • PT 100: between terminal 3 and 2 with terminal 1 • Passive pressure probe 0/4-20 mA: between terminal 4 ( + ) e 1 ( - ) Note: out4 must be activated ( IO4F must be setted to ON ) •...

  • Page 105: Operation Example

    M12927CA SETPOINT AND HYSTERESIS CONFIGURATION (SP, AL1, HAL1 parameters) Push the     button to enter into the setpoint configuration:  SP setpoint value change: increase decrease 2480 Confirm / Next AL1 parameter value change: increase decrease Confirm / Next HAL1 HAL1 parameter value change: increase decrease Confirm / Next Back to the first parameter To return to normal mode, press the key for 3 seconds or wait the 10s timeout...
  • Page 106 M12927CA LIMITED ACCESS LEVEL Proceed as follows to change some parameters that are not visible in standard user mode: Press the key for Password = 20 3 seconds Access to parameter: Increase the displayed value Decrease the displayed value Confirm and go to next parameter Param Description...
  • Page 107 M12927CA...

  • Page 108: Configuration Parameters

    M12927CA CONFIGURATION How to access configuration level The configuration parameters are collected in various groups. Every group defines all parameters related with a specific function (e.g.: control, alarms, output functions). Push the button for more than 5 seconds. The upper display will show PASS while the lower display will show 0.
  • Page 109 M12927CA Safety output value -100... 100 io4.F I/O4 function selection on = Out4 will be ever ON (used as a transmitter power supply) ,out4 = Uscita 4 (Used as digital output 4), dG2c = Digital input 2 for contact closure, dG2U = Digital input 2 driven by 12... 24 diF1 Digital input 1 function oFF = Not used,...
  • Page 110 M12927CA windows SE.br = Sensor Break LodE = Deviation low alarm (relative) HidE = Deviation high alarm (relative) LHdo = Relative band alarm in alarm out of the band LHdi = Relative band alarm in alarm inside the band Alarm 1 function 0...
  • Page 111 M12927CA AL3 Group - alarm 3 parameters Param Description Values Liv N° Default AL3t Alarm 3 type nonE = Alarm not used nonE LoAb = Absolute low alarm HiAb = Absolute high alarm LHAo = Windows alarm in alarm outside the windows LHAI = Windows alarm in alarm inside the windows...
  • Page 112 M12927CA SELF Self tuning enabling no = The instrument does not perform the self- tuning YES = The instrument is performing the self- tuning Proportional band 1... 9999 (E.U.) page 7 Integral time 0 (oFF) ... 9999 (s) page 7 Derivative time 0 (oFF) ...
  • Page 113 M12927CA AAc = Alarm reset ASi = Alarm acknowledge chSP = Sequential set point selection St.by = Stand by mode. The first press puts the instrument in stand by mode while a second one puts the instrument in Auto mode. Str.t = Timer run/hold/reset P.run = Program run P.rES = Program reset...
  • Page 114 M12927CA con Group - Consumption parameters Param Description Values N° Default Co.tY Count type oFF = Not used 1 = Instantaneous power (kW) 2 = Power consumption (kW/h) 3 = Energy used during program execution. This measure starts from zero when a program runs end stops at the end of the program.

  • Page 115: Automatic Mode

    M12927CA OPERATIVE MODES When the instrument is powered, it starts immediately to work according to the parameters values loaded in its memory. The instrument behaviour and its performance are governed by the value of the stored parameters. At power ON the instrument can start in one of the following mode depending on its configuration: Automatic Mode In Automatic mode the instrument drives automatically the control output according to the parameter value set and the set point/measured value.

  • Page 116: Manual Mode

    M12927CA Direct set point modification This function allows to modify rapidly the set point value selected by [83] A.SP (selection of the active Set point) or to the set point of the segment group (of the programmer) currently in progress. Push button.

  • Page 117: Under-Range

    M12927CA ERROR MESSAGES The upper display shows the OVER-RANGE and UNDERRANGE conditions with the following indications: Over-range: Under-range The sensor break will be signalled as an out of range: Note: When an over-range or an under-range is detected, the alarms operate as in presence of the maximum or the minimum measurable value respectively.
  • Page 118 RWF55.5X & RWF55.6X User manual M12926CA Rel.0.1 10/2015...
  • Page 119 DEVICE INSTALLATION Fixing system Drilling dimensions:...
  • Page 120 FRONT PANEL Burner release Controlling element CLOSED/stage 1 Controlling element OPEN/stage 2 Operating mode 2-stage Actual value display (red) and parameter value USB led Comunication via interface Operating mode 2-stage Thermal shock protection Alarm function Decrease value Increase value ESC button Enter button...
  • Page 121 NAVIGATION MENU User Level - Opr Parameter level SP1 or SP2 (editable) dSP readable and editable through bin1 = 2 InP1 or y (only display) Basic display Parameter level - PArA Pb1, dt, rt, db, tt Heating controllerHYS1 , HYS2 , HYS3 Cooling controller HYS4 , HYS5 , HYS6...
  • Page 122 PID parameters set and modifications (PArA): Push Enter button, on the green display Opr appears; using the down arrow, scroll until group PArA is reached and push Enter. On the green display Pb1 e appears and on the red one the set parameter. Push is sequence the down or up arrow the menu is scrolled. Push Enter to select and the arrows to choose the desired value.
  • Page 123 Setting the kind of sensor to be connected to the device: Push the Enter button: on the lower display (green) Opr appears. Using the up and down arrows find ConF. Push Enter to confirm. Now on the green display the group InP appears. Push Enter and InP1 is displaied. Enter to confirm.You are inside InP1; the green display shows Sen1 (sensor type), while the red display shows the chosen sensor code Push Enter to enter the Sen1 parameter, then choose the desired sensor using the arrows.
  • Page 124 ConF > InP >InP2 Input 2 : this input can be used to specify an external setpoint or carry out setpoint shifting Parameter Value Description no function FnC2 external setpoint (display SPE) setpoint shifting (display dSP) angular positioning feedback SEn2 0 ÷...
  • Page 125 ConF > Cntr Here, the type of controller, operating action, setpoint limits and presettings for self-optimization are selected Parameter Value Description CtYP 3-position controller (open-stop-close) ontroller type continuative action controller (0 ÷10V 4 ÷ 20mA) heating controller CACt control action cooling controller minimum set-point scale -1999..0..+9999...
  • Page 126 Alarm functionAF The alarm function can be used to monitor the analog inputs. If the limit value is exceeded, multifunctional relay K6 (terminals 6N and 6P) is activated (depending on the switching characteristic) The alarm function can have different switching functions (lk1 to lk8) and can be set to a deviation from the active setpoint or to a fixed limit value Limit value AL relative to setpoint (x) Fixed limit value AL...

  • Page 127: Switched-Off

    ConF > AF Parameter Value Description FnCt Without function type of control monitored input Ik1 = InP1 monitored input Ik2 = InP1 monitored input Ik3 = InP1 monitored input Ik4 = InP1 monitored input Ik5 = InP1 monitored input Ik6 = InP1 monitored input Ik7 =...
  • Page 128 ConF > binF This setting decides on the use of the binary inputsD1, D2, DG Parameter Value Description without function bin1 binary imput terminals set-point changeover (SP1 / SP2) – D1) set-point shift (Opr > dSP parameter = value of set-point modify) 2 = l input alarm changeover of operating mode...
  • Page 129 ConF > IntF The controller can be integrated into a data network using an optional RS-485 (terminals R+ and R-) interface or an optional Profibus DP interface(only modelRWF55.6x terminalsC1-C2-C3-C4) Parameter Value Description bdrt 0 = 4800 baud baudrate 1 = 9600 baud 2 = 19200 baud 3 = 38400 baud Address in the data network...

  • Page 130: Display Of Software Version

    Display of software version : The software version is shown by pushing Enter + UP arrow on the upper display Weather-compensated setpoint shifting(climatic regulation): The RWF55 can be configured so that weather-compensated setpoint shifting is activated when an LG-Ni1000 outside sensor or a Pt1000 is connected (see parameter InP3).
  • Page 131 Modbus interface The tables that follow in this chapter specify the addresses of the readable and writable words that the customer is able to access. The customer may read and/or write the values using SCADA programs, PLCs, or similar. The entries under Access have the following meanings: R/O Read Only, value can only be read R/W Read/Write, value can be read and written The number of characters specified under Data type in the case of character strings includes the final \0.
  • Page 132 Configuration level Address Access Data type Signal reference Parameter 0x3426 Float SCL1 Start of display input 1 0x3428 Float SCH1 End of display input 1 0x3432 Float SCL2 Start value input 2 0x3434 Float SCH2 End value input 2 0x3486 Float Start of setpoint limitation 0x3488...
  • Page 133 Dati dell’apparecchio Address Access Data type Signal reference Parameter 0x8000 Char12 Software version 0x8006 Char14 VdN number Stato dell’apparecchio Address Access Data type Signal reference Parameter 0x0200 Word Outputs and states Bit 0 Output 1 Bit 1 Output 3 Bit 2 Output 2 Bit 3 Output 4...

  • Page 134: Electric Connections

    Electric connections : With 7 pins connector version With terminals version Corrispondences bornes entre RWF55.5x y RWF40.0x0Matches terminals betweenRWF55.5x and RWF40.0x0...
  • Page 135 Parameters summarising for RWF55.xx : ConF ConF Navigation menù Inp1 Cntr diSP PArA Types of probe SEn1 OFF1 Unit dECP Pb. 1 HYS1 (*) HYS3 (*) SP1 (*)                          ...
  • Page 136 APPENDIX: PROBES CONNECTION To assure the utmost comfort, the control system needs reliable information, which can be obtained provided the sensors have been installed correctly. Sensors measure and transmit all variations encountered at their location. Measurement is taken based on design features (time constant) and according to specific operating conditions.With wiring run in raceways, the sheath (or pipe) containing the wires must be plugged at the sensor's terminal board so that currents of air cannot affect the sensor's measurements.
  • Page 137 Duct or pipe sensors Installing pressure sensors Installing temperature sensors A - installation on ducts carrying fluids at max. temperature 80°C For measuring outlet air: B - installation on ducts at temperature over 80°C and for refrigerants "after delivery fan or C - installation on ducts at high temperatures : "after coil to be controlled, at a distance of at least 0,5 m ·"increase length of siphon...
  • Page 138 Immersion or strap-on sensors Immersion probes installation Sensors must be installed on the stretch of pipe in which fluid circula- tes all the time. The rigid stem (sensing element doing the measuring) must be inser- ted by at least 75mm and must face the direction of flow. Recommended locations: on a bend or on a straight stretch of pipe but tilted by 45°...
  • Page 139 Duct pressure switches and sensors Installing differential pressure probes for air Basic principles Measuring static pressure(i.e. pressure exerted by air on pipe walls) A - Control a filter (clogging) Measuring dinamic pressure B - Control a fan (upstream/downstream) Legend Kg/m3, specific weight of air m/s, air speed 9.81 m/s2 gravity acceleration mm C.A., dynamic pressure...
  • Page 141 Note: Specifications and data subject to change. Errors and omissions excepted.
  • Page 142 MANUALE USER SUPPORT MULTI-THERMOSTAT MCX06C MCX06C is a multi-thermostat with four 100k NTC inputs. It can control up to 4 temperatures showing them (not more than 2 at the same time) on a couple of displays. It is used to check and adjust oil heater temperatures. it works as follows: as soon as the burner control gives the GO to the digital 1 input (terminals DI1-COM), the adjustment program runs (the relevant LED is ON).
  • Page 143 Connections from terminal side : 24V AC Probe connection: input AI1 = probe Pb1 = set-point “tr” = oil heater temperature probe; input AI2 = probe Pb2 = set-point “tCI” = plant consent temperature probe (when installed); input AI3 = probe Pb3 = set-point “OIL” = oil heater output temperature probe (PID regulation); input AI4 = probe Pb4 = set-point “tcn”...
  • Page 144 (tCI - Pb2 probe only for mechanical atomizing burners) Menu : To enter the menu below, keep pushing ENTER for more than 3 s. Menu code Sub-menu code Function Notes Probes values You can see in sequence the 4 probe values (UP and DOWN keys): the probe code is on display A (Pb1,..., Pb4) and the probe value is on display B (not fitted or out...
  • Page 145 submenu CnF - configuration parameters group : Visibility Password Modbus Menu Parameter Description Additional description Default U.M. condition level index CONFIGURATION Analog Input 1 This parameter enables or disables the Probe 1 Presence probe Calibration Probe 1 Don't modify it -20,0 20,0 °C...
  • Page 146 Visibility Modbus Menu Parameter Description Additional description Default U.M. condition Level index Autotuning Output temperature hysteresis Don't modify it 50,0 °C Startup number Don't modify it Measurement cycles number Don't modify it Max. differential command Don't modify it exit 0,01 10,00 10,00 Differential reduction exit...
  • Page 147 Submenu REG – regulation parameters group : Visibility Modbus Menu Parameter Description Additional description Default U.M. condition Level index REGULATION Probe 1 Set-point Probe 1 Don't modify it (Tank resistor) -50,0 200,0 °C Probe 1 - Low Temperature Alarm Don't modify it Threshold -50,0 200,0...
  • Page 148 Visibility Modbus Menu Parameter Description Additional description Default U.M. condition Level index Overshooting for Integral action Don't modify it (Oil tank exit) 1000 Derivative action enabling Don't modify it (Oil tank exit) Filtering factor for derivative action Don't modify it (Oil tank exit) Duty cicle PWM for output DO3 Don't modify it...
  • Page 149 Alarms & Warning: When the red triangle on the top left lights, one or more alarms are activated. When the red key on the left lights, the output N05-C5 is active and the relay KTRS switches the resistors OFF. Check the reason, correct the failure and, as soon as the temperature is lower than trS, reset it through ALA/rES . In order to show active alarms and warnings, select the relevant menu through ALA/Act.and, using the UP and DOWN buttons, scroll the lines.

This manual is also suitable for:

Ktp1050Ktp1080

Table of Contents