Related Manuals for Unigas PBY1025
Summary of Contents for Unigas PBY1025
- Page 1 PBY1025 PBY1030 PBY1040 Progressive, Fully-modulating Heavy oil Burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039126CE Rel. 4.3 04/2017...
-
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: General Features
C.I.B. UNIGAS - M039126CE PART I: INSTALLATION GENERAL FEATURES This particular burner series has been studied to use compressed air or alternatively steam, to atomize heavy oil. In this way we have achieved higher efficiency compared to mechanical atomization. These burners are equipped with a low pressure nozzle which permits to save fuel and, above all, to preserve the whole system. -
Page 6: Burner Model Identification
Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type PBY1025 Model (1) BURNER TYPE PBY1025 - PBY1030 - PBY1040 ≤ (2) FUEL H - heavy oil, viscosity 4000cSt (530°E) @ 50°C... - Page 7 C.I.B. UNIGAS - M039126CE Performance Curves PBY1025 PBY1030 2500 3500 4500 5500 6500 7500 8500 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 PBY1040 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 To get the input in kcal/h, multiply value in kW by 860.
- Page 8 (PBY1025) A(*S) A(*L) AA AM B(*S) B(*L) BB PP QQ PBY1025 1784 1980 377 641 1408 680 1312 680 632 472 522 660 815 M16 651 460 460 49 1145 379 330 PBY1030 1761 2006 377 657 1408 680 1312 680 632 633 524 660 815 M16...
- Page 9 81 Actuator 82 Remote draught fan with electromotor LPG gas - out of Cib Unigas scope of supply 83 Pressure switch - PA 86 Burner The following items are out of CIB UNIGAS scope of supply: 77 - 78 - 79...
- Page 10 LPG gas - out of Cib Unigas scope of supply 81 Actuator 82 Remote draught fan with electromotor 83 Pressure switch - PA 86 Burner The following items are out of CIB UNIGAS scope of supply: 77 - 78 - 79...
-
Page 11: Installing The Burner
C.I.B. UNIGAS - M039126CE INSTALLING THE BURNER Packing Burners are despatched in wooden crates whose dimensions are: 2280 mm x 1730 mm x 1360 mm(L x P x H) Packing cases of this kind are affected by humidity and are not suitable for stacking. The fol- lowing are placed in each packing case: burner;... - Page 12 C.I.B. UNIGAS - M039126CE 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 13 C.I.B. UNIGAS - M039126CE Fan motor and pump motor direction Once the electrical connection of the burner is performed, remember to check the rotation of the motor. The motor should rotate accor- ding to the arrow shown on the next picture. In the event of incorrect rotation reverse the three-phase supply and check again the rota- tion of the motor.
- Page 14 C.I.B. UNIGAS - M039126CE RECOMMENDATIONS TO DESIGN HEAVY OIL FEEDING PLANTS This paragraph is intended to give some suggestions to make feeding plants for heavy oil burners. To get a regular burner operation, it is very important to design the supplying system properly. Here some suggestions will be mentioned to give a brief description.
- Page 15 C.I.B. UNIGAS - M039126CE Viscosity units conversion table Saybolt Cinematics Saybolt Redwood Engler Degrees Seconds Redwood Seconds viscosity Seconds Seconds no.1 (°E) Universal no..2 (Admiralty) Centistokes (cSt) Furol (SSF) (Standard) (SSU) 2.56 1.16 32.1 1.31 36.2 1.58 44.3 5.83 10.3 1.88...
- Page 16 C.I.B. UNIGAS - M039126CE 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 17 C.I.B. UNIGAS - M039126CE Indicative diagram showing the oil temperature at burner pump inlet vs. oil viscosity Example: if the oil has a 50°E @ 50°C viscosity, the oil temperature at the pump inlet should be 80°C (see diagram). OIL TEMPERATURE FOR PUMP FEEDING TEMPERATURE (°C)
- Page 18 C.I.B. UNIGAS - M039126CE...
- Page 19 C.I.B. UNIGAS - M039126CE Pilot gas train The connection to the pilot gas train must be done according to the following scheme, valid for LPG. In case of natural gas, connect the pressure goveror (pos. 3) to the natural gas line (maximum input pressure = 1 bar).
- Page 20 C.I.B. UNIGAS - M039126CE Light oil pilot The burner can be provided with light oil pilot, instead of gas pilot. light oil pilot nozzle light oil pilot pump Fig. 17 EVG Light oil solenoid valve Manometer Pump Heavy oil pumps The pump provided with the burner must be installed according to the hydraulic diagram.
- Page 21 C.I.B. UNIGAS - M039126CE Light oil pilot pump Suntec AS47-57-67 B Oil viscosity 2 - 12 cSt Oil temperature 0 - 60 °C Max. suction pressure 2 bar max. Max. return pressure 2 bar max. Min. suction pressure - 0.45 barto avoid gasing Rotation speed 3600 rpm max.
-
Page 22: Connecting The Pump
C.I.B. UNIGAS - M039126CE Connecting the pump According to the pump provided, proceed as follows: emove the closing nuts A and B on the inlet and return connections of the pump; connect the pump being careful to avoid exchanging the lines: see the arrows marked on the pump. -
Page 23: Hydraulic Connections
C.I.B. UNIGAS - M039126CE Hydraulic connections Compressed Air Fig. 21... - Page 24 C.I.B. UNIGAS - M039126CE ADJUSTING AIR AND FUEL RATE ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open. Be sure that the mains switch is closed. .ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide);...
- Page 25 C.I.B. UNIGAS - M039126CE Fluidics noozles The oil flow rate can be adjusted choosing nozzles that suit the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted in the diagram below (as far as reading the pressure values, see next paragraphs).
- Page 26 C.I.B. UNIGAS - M039126CE Oil thermostat adjustment Progressive and fully modulanting oil burners are equipped with electronic multi-thermostat Danfoss MCX, whose operation is con- trolled by thyristor. (for details refer to the attached technical documentation) Fig. 23 - Danfoss MCX Fig.
- Page 27 C.I.B. UNIGAS - M039126CE Adjust this thermostat to the correct value according to the visco- sity-temperature diagram and check the temperature by using a thermometer with a scale of up to 200° C mounted on the pre-hea- ting tank. Safety resistors thermostat TRS: it is factory preset and sealed.
- Page 28 C.I.B. UNIGAS - M039126CE Adjustments - brief description Adjust the air and oil flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respectively. Check that the combustion parameters are in the suggested limits.
- Page 29 C.I.B. UNIGAS - M039126CE During high fire operation, oil pressure is about 2 bar (read on oil pressure gauge - see picture below). compressed air pressure gauge oil pressure gauge Fig. 25 Set the atomising air pressure switch PA (Fig. 26) at 0.5 bar Set the pilot gas pressure switch PG (Fig.
- Page 30 C.I.B. UNIGAS - M039126CE 11 in order to get the maximum oil flow rate, adjust the pressure (reading its value on the oil pressure gauge (Fig. 31): checking always the combustion parameters, the adjustment is to be performed by means of the SV adjusting cam screw V (Fig. 33) when the cam has rea- ched the high flame position.
- Page 31 C.I.B. UNIGAS - M039126CE 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 32: Limitations Of Use
C.I.B. UNIGAS - M039126CE PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNEC- TED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDE- RED IMPROPER AND THEREFORE DANGEROUS. - Page 33 C.I.B. UNIGAS - M039126CE Control panel High flame lamp Low flame lamp Ignition transformer lamp Fan motor thermal cutout lamp Burner lockout lamp Burner stand-by lamp Solenoid valve lamp Atomisation air pressure switch lamp Compressed air solenoid valve lamp Heating resistors safety thermostat lamp...
-
Page 34: Routine Maintenance
C.I.B. UNIGAS - M039126CE 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 35 C.I.B. UNIGAS - M039126CE Maintenance of the gas governor with filter (pilot gas train) Before disassmbling the device, be sure that there is no pressurised gas inside it. To check the filtering part (1) on threaded bodies (see Fig. 36): remove the bottom cover, unscrewing the fixing screws;...
- Page 36 C.I.B. UNIGAS - M039126CE Removing the oil gun, replacing/adjusting the nozzle and 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.
- Page 37 C.I.B. UNIGAS - M039126CE Checking the detection current To measure the detection signal follow the diagram in Fig. 40. If the signal is not in the advised range, check the electrical contacts, the cleaning of the combustion head, the position of the photore- sistor and if necessary replace it.
-
Page 38: Troubleshooting
C.I.B. UNIGAS - M039126CE TROUBLESHOOTING Heavy oil operation MAIN SWITCH OPEN LINE FUSE INTERVENTION MAX. PRESSURE SWITCH FAULT FAN THERMAL CUTOUT INTERVENTION AUXILIARY RELAIS FUSES INTERVENTION CONTROL BOX FAULT SERVOCONTROL FAULT SMOKEY FLAME IGNITION TRANSFORMER FAULT IGNITION ELECTRODE DIRTY OR WRONG POSI-... - Page 39 BURNER EXPLODED VIEW ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION AIR INLET CONE 20.1 AIR PRESSURE SWITCH 23.4 NOZZLE HOLDER BURNER HOUSING 20.2 COMPRESSED AIR SOLENOID VALVE 23.5 COMBUSTION HEAD COVER 20.3 ONE-WAY VALVE 23.6 IGNITION CABLE CERAMIC FIBRE PLAIT 20.4 COMPRESSED ARI GOVERNOR WITH FILTER 23.7.1 IGNITION ELECTRODE...
- Page 41 APPENDIX t3’ Long preignition time: «Z» connected to terminal 15. Postignition time: SIEMENS LAL.. CONTROL BOX - «Z» must be connected to terminal 15 - With short preignition, «Z» remains on until «TSA» has elapsed connec- Control and supervision of oil atomization burners tion to terminal 16.
- Page 42 During burner off times, the flame supervision circuit is live. Lockout indication Startup sequence b-b’ Idle step (with no contact confirmation) b(b’)-a Postpurge program Burner control can immediately be reset after lockout: Do not press the lockout reset button for more than 10 seconds The sequence switch always travels to the start position first After resetting After rectification of a fault that led to shutdown...
- Page 43 Sequence diagram Control output at terminal t3" t3 n t1 6 V II V III X II t10* X III X IV Lockout position indication Prepurge time with air damper fully open Safety time Preignition time, short («Z» connected to terminal 16) T3’...
- Page 44 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 45 WIRING DIAGRAMS / SCHEMI ELETTRICI SE12-088: PBY1025 - progressive burners/bruciatori progressivi SE12-090: PBY1025 - fully-modulating burners/bruciatori modulanti SE12-087: PBY1030 - progressive burners/bruciatori progressivi SE12-089: PBY1030 - fully-modulating burners/bruciatori modulanti E039126MA Rev. 0 06/2009...
- Page 46 ELECTRICAL WIRING DIAGRAMS / SCHEMI ELETTRICI Electric supply connections must be arranged in order to ensure the burner stops if IRxx switcesh are open. When the three phase power supply is interrupted, the auxiliary (single phase) power supply must be interrupted as well.
- Page 81 RWF55.5X & RWF55.6X User manual M12926CA Rel.0.2 11/2023...
-
Page 82: Device Installation
DEVICE INSTALLATION Fixing system Drilling dimensions:... -
Page 83: Front Panel
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 84: Navigation Menu
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 85 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 86 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 87 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 88 ConF > Cntr Here, the type of controller, operating action, setpoint limits and presettings for self-optimization are selected Parameter Value Description 3-position controller (open-stop-close) CtYP ontroller type continuative action controller (0 ÷10V 4 ÷ 20mA) heating controller CACt control action cooling controller minimum set-point scale -1999..0..+9999...
- Page 89 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 90: Switched-Off
ConF > AF Parameter Value Description Without function FnCt type of control InP1 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... - Page 91 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 92 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 0 = 4800 baud bdrt baudrate 1 = 9600 baud 2 = 19200 baud 3 = 38400 baud Address in the data network...
-
Page 93: 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 94 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 95 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 96 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 97: 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 98 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 (*) Siemens QAE2120… needless needless 80 °C Siemens QAM2120.. needless needless -2,5 40°C Pt1000 (130°C max.) needless needless...
- Page 99 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 100 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 101 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 102 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 104 Note: Specifications and data subject to change. Errors and omissions excepted.
- Page 105 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 106 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 107 (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 108 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 109 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 110 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 111 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 112 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.