1. Manuals
  2. Brands
  3. Unigas Manuals
  4. Burner
  5. HR75A MG Series
  6. Manual of installation - use - maintenance

Unigas HR75A MG Series Manual Of Installation - Use - Maintenance

Gas - light oil burners
Hide thumbs Also See for HR75A MG Series:
Table of Contents

Advertisement

Quick Links

Download this manual
HR75A
Gas - light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039327CA Rel. 1.0 10/2020

Advertisement

Table of Contents
loading

Related Manuals for Unigas HR75A MG Series

Summary of Contents for Unigas HR75A MG Series

  • Page 1 HR75A Gas - light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039327CA Rel. 1.0 10/2020...

  • 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

    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; -2009/142/EC (Gas Directive) The unit input cable shall not be replaced by the user. -2014/35/UE (Low Tension Directive) In case of damage to the cable, switch off the unit and contact qualified -2014/30/UE (Electromagnetic compatibility Directive)

  • Page 4: Symbols Used

    -EN 60204-1:2006 (Safety of machinery – Electrical equipment of machi- nes.) Failure to observe the warning may -CEI EN 60335-1 (Specification for safety of household and similar electri- result in serious injuries or death. DANGER! cal appliances); -CEI EN 60335-2-102 (Household and similar electrical appliances. Safety.
  • Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS BURNERS FEATURES Note: the figure is indicative only. Control panel with startup switch Gas valves group Electrical panel Blast tube + Combustion head Flange Silencer Air pressure switch Adjusting cam (progressive/fully modulating burners only) Oil pressure switch Pump Fig.

  • Page 6: Burner Model Identification

    PART I: SPECIFICATIONS Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type HR75A Model MD. S. BURNER TYPE HR75A FUEL M - Natural gas L - LPG G - Light oil B - Biogas OPERATION (Available versions) PR - Progressive...

  • Page 7: Burner Type

    PART I: SPECIFICATIONS Technical Specifications BURNER TYPE HR75A MG.. HR75A LG.. 320 - 2050 Output min - max kW Light oil L.P.G. - Light oil Fuel Natural gas - Category (see next paragraph) 3B/P Gas rate min.-max. (Stm 34 - 217 11.9 - 77 Gas pressure (see Note 2)
  • Page 8 Overall dimensions (mm) Boiler recommended drilling tem- O min O max Burner flange A (AS) AC AD AE B (BS) Omin Omax V(**) W 1.50 1336 69 553 435 28 305 352 1061 700 361 254 270 235 300 503 M10 233 465 127 338 525 658 218 155 HR75A AB...
  • Page 9 Progressive/Fully modulating version Fig. 2 - 3I2MG-09 v1 Hydraulic diagram ON BOARD ITEMS SUPPLIED LOOSE ITEMS LEGEND OIL TRAIN Filter Flexible hose Pump and pressure governor oil inlet Electrical motor Flexible hose oil outlet Solenoid valve Solenoid valve Flexible hose Oil distributor Flexible hose Pressure gauge...
  • Page 10 Double stage Version Fig. 3 - Hydraulic diagram BY OTHERS OIL TRAIN BY BURNER CONSTRUCTOR Filter Flexible hose Pump and pressure governor Electrical motor Flexible hose Solenoid valve Solenoid valve oil inlet Flexible hose Oil distributor Flexible hose oil outlet Pressure gauge Pressure governor Pressure switch...

  • Page 11: Performance Curves

    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);...
  • Page 12 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves(natural gas) HR75A M-.. 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 PART I: SPECIFICATIONS Combustion head gas pressure curves depending on the flow rate 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 14 PART I: SPECIFICATIONS Pressure - rate in combustion head curves (natural gas) Curves are referred to pressure = 0 mbar in the combustion chamber! HR75A M-.. Pressure - rate in combustion head curves (LPG) Curves are referred to pressure = 0mbar in the combustion chamber! HR75A L-..
  • Page 15 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 16 PART II: INSTALLATION 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), according to the burner’s drilling plate described on paragraph “Overall dimensions”;...

  • Page 17: Assembling The Gas Train

    PART II: INSTALLATION GAS TRAIN CONNECTIONS Referring to the P&ID of the burner, execute the connection. WARNING: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED. Assembling the gas train gas supply network ”direction”...
  • Page 18 PART II: INSTALLATION 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 19: Mounting Positions

    PART II: INSTALLATION MULTIBLOC DUNGS MB-DLE 415..420 Mounting 1. Loosen screws A and B do not unscrew (Fig. 7 - Fig. 8). 2. unscrew screws C and D (Fig. 7 - Fig. 8). 3. Remove MultiBloc between the threaded flanges (Fig. 8). 4.
  • Page 20 PART II: INSTALLATION OIL TRAIN CONNECTIONS Hydraulic diagrams for light oil supplying circuits Fig. 15 - Gravity circuit Fig. 16 - Ring circuit Fig. 17 - Suction circuit Manual valve Light oil filter Light oil feeding pump One way valve Flexible hoses Relief valve NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device.
  • Page 21 PART II: INSTALLATION Installation diagram of light oil pipes PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL. From tank To tank Fig. 14 - Double-pipe system The burner is supplied with filter and flexible hoses, all the parts upstream the filter and downstream the return flexible hose, must be installed by the customer.
  • Page 22 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 tank, thus avoiding the possibility that they might be sucked into the pump.
  • Page 23 PART II: INSTALLATION Rotation speed 3600 rpm max. 1. Connection for manometer 1 – delivery (M1) – G1/4 2. Connection for manometer 2 – suction (M2) – G1/4 3. Connection for manometer 3 (M3) A. Suction connection– G1/2 D. Direct - clockwise I.

  • Page 24: 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 25 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 pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed.
  • Page 26 PART III: OPERATION Fully modulating / Progressive Burners Fig. 15 - Burner front panel 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 Reset pushbutton for control box Operation selector MAN - AUTO (operation in manual or automatic mode):...
  • Page 27 PART III: OPERATION Double stages burner Fig. 16 - Burner front panel 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 Reset pushbutton for control box Fuel selection...

  • Page 28: Fuel Selection

    PART III: OPERATION Fuel selection: In order to start the burner with gas or light oil, the operator must commute the selector on the burner control panel on (1) = gas, or (2) = light oil. If the selector is set on (1) the gas cock must be open, while the light oil cock must be closed. Viceversa if the selector is set on (2). CAUTION: if the fuel chosen is oil, be sure the cutoff valves on the feed and return pipes are open.
  • 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 (HR75A 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; once the adjustmet is performed, fasten the V screws.

  • Page 31: Adjustments For Gas Operation

    PART III: OPERATION ADJUSTMENTS FOR GAS OPERATION Adjustment procedure Turn the burner on by means of its main switch S1: if the burner locks (LED B1 on in the control panel) press the RESET button (S2) on the control panel. See chapter “Operation” for further details. check the fan motor rotation Start the burner up by means of the thermostat series and wait unitl the pre-purge phase comes to end and that burner starts up;...
  • Page 32 PART III: OPERATION Double-stage burners drive the burner to the low flame stage by means of the TAB thermostat; 10 In order to change the gas flow rate slacken the nuts DB (Fig. 17) and adjust the opening angle of the gas butterfly valve by rotating the rod TG (clockwise rotation increases gas flow, anticlockwise rotation decreases it).
  • Page 33 PART III: OPERATION Progressive burners Once the procedure till step 8 described on paragraph “Adjustment procedure” on page 31, is accomplished, go on as follows: set the low flame cam matching the high flame cam; 10 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position; The manual air damper control is not provided on these actuators.
  • Page 34 PART III: OPERATION 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 35 PART III: OPERATION Setting 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 36 PART III: OPERATION ADJUSTMENT PROCEDURE FOR LIGHT OIL OPERATION The light oil flow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the table below and the diagram on Fig. 21 (as far as reading the pressure values, see next paragraphs).
  • Page 37 PART III: OPERATION Fig. 21 Example (Bergonzo): if a 220kg/h flow rate BERGONZO nozzle is provided, set the return pressure at 11bar, supply at 20bar on the delivery to get a 220kg/h flow rate. If the return pressure needed is 5bar, instead, act on the V adjusting screw on the pressure governor (see chapter on page 36).
  • Page 38 PART III: OPERATION Fig. 22...
  • Page 39 PART III: OPERATION Fig. 23 Example (Bergonzo): if a 140kg/h flow rate BERGONZO 45° nozzle is provided, set the return pressure at 13bar, supply at 20bar on the delivery to get a 110kg/h flow rate. If the return pressure needed is 5bar, instead, act on the adjusting screw on the pressure gover- nor.
  • Page 40 PART III: OPERATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar)
  • Page 41 PART III: OPERATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar)
  • Page 42 PART III: OPERATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the...
  • Page 43 PART III: OPERATION FLUIDICS KW3...45° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) Pressure on return (bar) Pressure on return (bar)
  • Page 44 PART III: OPERATION FLUIDICS KW3...45° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) Pressure on return (bar) Pressure on return (bar)
  • Page 45 PART III: OPERATION Double-stage burners Once the air and gas flow rates are adjusted, turn the burner off, switch the CM switch to the heavy oil operation (OIL, on the bur- ner control panel. with the electrical panel open, prime the oil pump acting on the related CP contactor (see next picture): check the pump motor rota- tion and keep pressing for some seconds until the oil circuit is charged;...
  • Page 46 PART III: OPERATION Pressure gauge port Fig. 25 D Adjusting screw cap Pressure adjusting screw M Pressure gauge port VT Needle screw B Return to tank CReturn from nozzle Fig. 26 - Oil manual governor 11 always checking the combustion values, adjust the low flame air flow rate by means of the actuator ST1 (Berger)/III (Siemens) cam;...
  • Page 47 PART III: OPERATION Progressive burners Oil Flow Rate Settings by means of Siemens SQM40.. actuator Once the air and gas flow rates are adjusted, turn the burner off, switch the CM switch to the heavy oil operation (OIL, on the bur- ner control panel.
  • Page 48 PART III: OPERATION Fig. 27) as to get the nozzle pressure at 20bar (Monarch or Fluidics nozzles - see page 36-34). Pressure gauge port Fig. 28 Fig. 29 10 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge) without changing the air flow rate set during the gas operation adjustments (see previous paragraph): checking always the combustion parameters, the adjustment is to be performed by means of the SV2 adjusting cam screw (see picture) when the cam has reached the high flame position.
  • Page 49 PART III: OPERATION Minimum oil pressure switch (when provided) The minimum oil pressure switch on the inlet line, checks that the pressure does not drop below a default value. The pressure switch must be set, say, at 10% under the pressure at the nozzle. Maximum oil pressure switch The oil pressure switch on the return line, checks that the pressure does not exceed a default value.
  • Page 50 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 51 PART IV: MAINTENANCE Gas filter maintenance ATTENTION: Before opening the filter, close the manual cutoff valve downstream the filter and bleed the gas; check that inside the filter there is no pressurised gas. To clean or remove the filter, proceed as follows: remove the cap unscrewing the fixing screws (A);...
  • Page 52 PART IV: MAINTENANCE 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 53: Electrodes Adjustment

    PART IV: MAINTENANCE 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.), other- wise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head.

  • Page 54: Seasonal Stop

    PART IV: MAINTENANCE Checking the detection current 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. Control box Minimum detection signal Siemens LME21-22...

  • Page 55: Wiring Diagrams

    PART IV: MAINTENANCE WIRING DIAGRAMS Refer to the attached wiring diagrams. WARNING 1 - Electrical supply 230V / 400V 50Hz 3N a.c. 2 - Do not reverse phase with neutral 3 - Ensure burner is properly earthed...
  • Page 56 PART IV: MAINTENANCE...

  • Page 57: Start-Up Program

    APPENDIX SIEMENS LME11/21/22 CONTROL BOX The series of equipment LME.. is used for the starup and supervisione of 1- or 2- stage gas burners. The series LME.. is interchangeable with the series LGB.. and LMG.., all diagrams and accessories are interchangea- START-UP PROGRAM ble.
  • Page 58 LME11 control sequence LME21 control sequence B´ B´ SB / R SB / R W / GP W / GP (LR) BV2 7101d05/0206 Control sequence Waiting time LME22 control sequence Purge time B´ TSA Ignition safety time SB / R Preignition time W / GP Postignition time...
  • Page 59 LME11 connection diagram Connection diagram Error message (alarm) Fuel valve PC control EK2 Remote lockout reset button RESET Flame signal Gas pressure switch Air pressure switch Load controller K2/1 K2/2 Fan motor Control thermostat/pressurestat Safety limit thermostat R / W Limit thermostat /pressure switch Ignition transformer 7101 24 /0606...
  • Page 60 CONTROL PROGRAM IN THE EVENT OF FAULT CONTROL BOX LOCKED If a fault occurs, all outputs will immediately be deactivated (in less In the event of lockout, the LME.. remains locked and the red signal lamp than 1s). (LED) will light up.The burner control can immediately be reset. This state After an interruption of power, a restart will be made with the full pro- is also mantained in the case fo mains failure.
  • Page 64 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.

This manual is also suitable for:

Hr75a lg seriesHr75aHr75a abHr75a prHr75a md

Table of Contents