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CIB UNIGAS KR1030 Manual Of Installation - Use - Maintenance

Progressive and fully-modulating gas - heavy oil burners
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KR1025
KR1030
KR1040
Progressive
and fully-modulating
gas - heavy oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039123CD 3.3 04/2021

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Summary of Contents for CIB UNIGAS KR1030

  • Page 1 KR1025 KR1030 KR1040 Progressive and fully-modulating gas - heavy oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039123CD 3.3 04/2021...

  • 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 KR1025 Model PR. S. Burners are identified by burner type and model. Burner model identification is described as follows. BURNER TYPE KR1025 - KR1030 - KR1040 FUEL  N - Heavy oil, viscosity 50cSt (7° E) @ 50° C ...
  • Page 6 PART I: SPECIFICATIONS Country and usefulness gas categories GAS CATEGORY COUNTRY AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH LU PL 2E( R ) B 2ELL Fuel Type...
  • Page 7 65 2088 377 657 1544 680 2121 1299 822 815 M16 651 714 80 1092 142 292 1145 372 330 KR1030 80 2088 377 657 1544 680 2123 1301 822 815 M16 651 736 80 1092 142 322 1145 372 330...
  • Page 8 PART I: SPECIFICATIONS Performance curves Performance Curves KR1025 ..1.xx KR1030 ...1.65 KR1030 ..1.xx KR1040 ...1.xx 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.
  • Page 9 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves (natural gas) R1025 M-..1.xx Gas rate Stm R1030 M-..65 R1030 M-..1.xx Gas rate Stm Gas rate Stm R1040 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 (pres- sure value in the combustion chamber is not included).
  • Page 10 PART I: SPECIFICATIONS Pressure - rate in combustion head curves (natural gas) Curves are referred to pressure = 0 mbar in the combustion chamber! R1025 M-.. Gas rate Stm R1030 M-.. R1040 M-.. Gas rate Stm Gas rate Stm...
  • Page 11 PART I: SPECIFICATIONS Combustion head gas pressure curves Combustion head gas pressure depends on gas flow and combustion chamber backpressure. When backpressure is subtracted, i depends only on gas flow, provided combustion is properly adjusted, flue gases residual O2 percentage complies with “Recommended combustion values”...

  • Page 12: 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 13 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 14 PART II: INSTALLATION Matching the burner to the boiler The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in diameter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with respect of the application involved.
  • Page 15 PART II: INSTALLATION MultiBloc MBE ALLA V. FARFALLA Example of gas train MBE 501939 GAS BRUCIATORE ø185 VD-R VD-V VD-R VD-V Gas filter PGMAX PGMAX PGMI PGMIN PS pressure sensor PGCP PGCP ATTENTION: once the gas train is mounted according, the gas proving test mus be performed, according to the procedure set by the laws in force.
  • Page 16 PART II: INSTALLATION Mounting VD-R & PS-... ActuatorVD-V ActuatorVD-R M12 x 5 Pin The actuator VD-V does not need any adjustment (funzione ON-OFF)  The actuator VD-R It must be combined with the PS sensor (include  regolatore di pressione) VD-R + PS 1.

  • Page 17: Mounting Positions

    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 18 PART II: INSTALLATION 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. The term “heavy oil”...
  • Page 19 PART II: INSTALLATION 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 52.3 6.77 13.1...
  • Page 20 PART II: INSTALLATION 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 HEAVY OIL 22°E AT 50°C HEAVY OIL 50°C...
  • Page 21 PART II: INSTALLATION 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) Fig.
  • Page 22 Fig. 5 3ID00014 v2 Hydraulic diagram - Two or more burners configuration BURNER 2 SEE THE BURNER 1 SEE THE BURNER P&ID BURNER P&ID HEATING MEDIUM INLET HEATING MEDIUM OUTLET PRESSURE GOVERNOR UNIT OIL PUMPING UNIT DAILY TANK UNIT OIL PUMPING UNIT PIPE HEATING SYSTEM: SEE THE SPECIFIC HEATING MEDIUM INLET MAIN TANK INLET...
  • Page 23 Fig. 6 - 3ID0023 v2 - Hydraulic diagram - Single burner configuration BURNER 1 SEE THE BURNER P&ID OIL TRAIN Main tank OIL PUMPING UNIT Manual valve Filter Pump coupled to electrical motor Safety valve HEATING MEDIUM INLET One-way valve Manual valve HEATING MEDIUM OUTLET Pressure gauge...

  • Page 24: Hydraulic System

    PART II: INSTALLATION 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 25: Oil Pumps

    PART II: INSTALLATION Oil pumps Suntec T.. Viscosity 3 - 75 cSt Oil temperature 0 - 150 °C Minimum suction pressure - 0.45 bar to prevent gasing Maximum suction pressure 5 bar Rated speed 3600 rpm max. Inlet G3/4 Pressure gauge port G1/4 Vacuum gauge port to measure the inlet vacuum G1/4 To pressure adjusting valve G3/4 "Note: pump with “C”...
  • Page 26 PART II: INSTALLATION 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 27: Electrical Connections

    PART II: INSTALLATION ELECTRICAL CONNECTIONS Any cable connection or hook-up to the grid must be carried out by qualified, informed and trained personnel, directly coordinated and authorized by Technical Service. Always check in advance that the system electrical interlock is fitted with a safety circuit breaker. WARNING! It is forbidden to use the fuel pipes for the execution and/or completion of the grounding The system must comply with the current regulations.
  • Page 28 PART III: OPERATION PART III: 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 29 PART III: OPERATION remove the pressure switch plastic cover;  adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch;  replace the plastic cover.;  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.
  • Page 30 PART III: OPERATION WARNING:It is recommended to install a shunt trip disconnect switch that acts on the preheater unit supply line and avoids the oil overheating / resistance damage in case of a malfunction of the resistance contactor. Inside the electric board a free contact is provided (terminals 507 - 508) for this purpose. Connecting the oil heating resistors ELECTRIC MOTOR CONNECTION 18 - 24 kW...
  • Page 31 PART III: OPERATION 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. Don not modify it! When the set temperature is exceeded, check the reason and reset it by means of the push button PR...
  • Page 32 PART III: OPERATION value lower than the one set for TR. Adjusting air and gas flow rates ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed.
  • Page 33 PART III: OPERATION rates at the lowest output) to safely achieve the high flame stage. Start the burner up by means of the thermostat series, closing terminals 3 and 4; wait until the pre-purge time comes to an end and that the burner starts up;...
  • Page 34 PART III: OPERATION Gas throttle valve open Gas throttle valve closed 12 as for the point-to-point regulation, move the gas low flame microswitch (cam III) a little lower than the maximum position (90°); 13 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position; 14 move cam III to the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw that refers to the lower position: screw V1 to increase the rate, unscrew to decrease.

  • Page 35: 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 36 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 37 PART III: OPERATION Adjusting heavy oil flow rate The oil flow rate can be adjusted choosing a nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the following charts. FLUIDICS NOZZLE: REFERENCE DIAGRAM (INDICATIVE ONLY) Atomisation angle FLOW RATE kg/h...
  • Page 38 PART III: OPERATION Pump flow rate Nozzle flow rate Fig. 13 - Bergonzo nozzle - example with 850kg/h nozzle...
  • Page 39 PART III: OPERATION 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 42). 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 40 PART III: OPERATION 10 as for the point-to-point regulation in order to set the cam foil shape, move the oil low flame microswitch (cam IV) a little lower than the maximum position (90°); 11 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position; 12 move cam IV (oil low flame) towards the minimum to move the actuator towards the low flame until the two bearings find the adju- sting screw that refers to a lower position: screw V2 to increase the rate, unscrew to decrease, in order to get the pressure as shown on chart/diagram on “Adjusting heavy oil flow rate”...

  • Page 41: Oil Circuit

    PART III: OPERATION Oil circuit The fuel is pushed into the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor. The solenoid valve 2 stops the fuel immission into the combustion chamber. The fuel flow rate that is not burnt goes back to the tank through the return circuit. The spill-back nozzle is feeded at constant pressure, while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam.

  • Page 42: Limitations Of Use

    PART II: OPERATION 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 43 PART II: OPERATION Burner front panel Fig. 21 - Burner control panel Burner in stand-by signalling lamp Modulator (only fully modulating burners) ON-OFF mains switch Lockout signalling lamp Pilot pressure switch enabling signalling lamp Reset button for burner control device Valve EVP operation signalling lamp Reset button for burner gas proving system (only for bur- ners fitted with Siemens LDU)
  • Page 44 PART III: MAINTENANCE 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 45 PART III: MAINTENANCE Thecnical procedure of self cleaning filters substitution (valid for all models) Close the bowl valve before the self cleaning filter 2 Switch off any electrical equipment on board on the filter (example motorization or heaters) WARNING! Drain the system by unscrewing the drain screw on the bottom of the self cleaning filter Disconnect the outlet pipe from the cover of the self cleaning filter 4 Remove the cover with all the filter pack, leaving only the bowl on the line 5 Clean any residue on the bottom of the bowl and clean the seat of the O-ring seal...
  • Page 46 PART III: MAINTENANCE Replacing the ignition electrode 1 To replace the ignition electrode, proceed as follows:remove the burner cover 2 disconnect the electrode (E) cable (CE); 3 remove the combustion head (see par. “Removing the combustion head”); 4 loose screw (B) that fasten the ignition electrode (E) to the burner pilot (P); 5 remove the electrode and replace it, referring to the values quoted on figure.
  • Page 47 PART III: MAINTENANCE TERMINAL BOARD Control box Minimum detection signal 70µA with UV detector) Siemens LFL1.3.. Fig. 22: Detection by photocell QRA.. Adjusting the electrodes and nozzle position Adjust the electrodes position, according to the measures (in mm) shown on the next picture. generator gasket inspection glass head stroke limitation slot...
  • Page 48 PART III: MAINTENANCE Removing the oil gun, replacing the nozzle and the electrodes ATTENTION: avoid the electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrodes position after any intervention on the combustion head. To remove the oil gun, proceed as follows: remove the combustion head as described on the prevoius paragraph;...

  • Page 49: Seasonal Stop

    PART III: MAINTENANCE Seasonal stop To stop the burner in the seasonal stop, proceed as follows: turn the burner main switch to 0 (Off position) disconnect the power mains close the fuel valve of the supply line Burner disposal In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”. WIRING DIAGRAMS WIRING DIAGRAM SE12-072 - Progressive burners WIRING DIAGRAM SE12-097 - Fully-modulating burners...

  • Page 50: Troubleshooting

    PART III: MAINTENANCE 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 ...
  • Page 51 PART III: MAINTENANCE TROUBLESHOOTNG GUIDE Gas operation * No electric power supply * Restore power supply * Main switch open * Close switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Reset or replace the thermostat * No gas pressure * Restore gas pressure...

  • Page 52: Burner Exploded View

    BURNER EXPLODED VIEW ITEM DESCRIPTION ITEM DESCRIPTION AIR INLET CONE 11.4 AIR DAMPER SPACER 11.5.1 SILENCER FLEXIBLE HOSE 11.5.2 AIR DAMPER SILENCER FLEXIBLE HOSE 11.6 NAME PLATE FLEXIBLE HOSE 11.7 INDEX LABEL BUTTERFLY GAS VALVE 11.8 AIR DAMPER INDEX PHOTOCELL 12.1 GAS PRESSURE LEVERAGE...
  • Page 54 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 55 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 56 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 57 Gas valve proving is initiated automatically with every burner startup using one or two standard pressure monitors, either VALVE PROVING SYSTEM SIEMENS LDU11  prior to burner startup, The LDU11... gas valve proving system is designed for use in gas-fired ...
  • Page 58 first test phase (Test 1), or decreases excessively during the second test Specifications phase (Test 2), the control unit inhibits burner startup and goes to lockout. Mains voltage AC 220 V -15 %...240 V +10 % AC 100 V In that case, the lockout reset button lights up to indicate the fault. -15 %...110 V +10 % Mains frequency 50 Remote indication of the fault is also possible.
  • Page 59 forming any work on it!  The LDU11... is a safety device. It is therefore not permitted to open, Alarm signal "Leaking valve" interfere with or modify the unit! Main relay with contacts "ar..."  Check wiring carefully before putting the unit into operation! Built-in fuse ...
  • 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. Errors and omissions excepted.
  • Page 61 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 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 : 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 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: List Of Possible Errors

    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 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 : 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:

Kr1025Kr1040