CIB UNIGAS PN60 Manual Of Installation - Use - Maintenance

Heavy oil bruners progressive/fully-modulating

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PN60

PN70

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Heavy oil bruners

Progressive/Fully-modulating

MANUAL OF INSTALLATION – USE – MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

M039190CE Rel.4.4 10/20156

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Summary of Contents for CIB UNIGAS PN60

Page 1 PN60 PN70 PN81 Heavy oil bruners Progressive/Fully-modulating MANUAL OF INSTALLATION – USE – MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039190CE Rel.4.4 10/20156...
Page 2 WARNINGS THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER. INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE. THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION OF THIS MANUAL.
Page 3 DIRECTIVES AND STANDARDS 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS Gas burners GENERAL European directives:  - Directive 2009/142/EC - Gas Appliances; The burner shall be installed by qualified personnel and in - Directive 2006/95/EC on low voltage; compliance with regulations and provisions in force;...
Page 4 PART I - INSTALLATION Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type PN60 Model PN60 (1) BURNER TYPE ≤ N – heavy oil, viscosity 50 cSt (7°E) @ 50° C ≤...
Page 5 Overall dimensions (mm) Burner flange Boiler recommeded drilling template Burner flange Boiler recommeded drilling template...
Page 6 A (AL) B (BL) PN60 1051 1186 102 324 274 727 365 496 208 238* 240 344 M10 269 190 92 613 162 120 PN70 1244 1394 138 407 373 837 376 511 220 300 475 M10 330 233 14 630 198 155...
Page 7 Performance curves PN60 PN70 кW кW PN81 кW To get the input in kcal/h, multiply value in kW by 860. Data are referred to the following conditions: 1013mbar atmospheric pressure, 15°C ambient temperature. NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine.
Page 8 Packing The burners are despatched wooden cages whose dimensions are: PN60: 1210 mm x 1020 mm x 790 mm (L x P x H) PN70 - PN81: 1580 mm x 1010 mm x 860 mm (L x P x H) The following are placed in each packing case.
Page 9 Fitting the burner to the boiler To install the burner into the boiler, proceed as follows: 1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) 2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;...
Page 10 Hydraulic circuit 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. In this system, the by- pass pulg, if provided, must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer.
Page 11 Pumps PN60-PN70 Pumps for heavy-oil viscosity ≤ 50 cSt (7° E) @ 50° C Suntec E4 - E6 - E7 1001 Viscosity 2.8 - 450 сSt Oil temperature 0 - 90 °C Min. suction pressure - 0.45 bar to avoid gasing Max.
Page 12 Connections to the oil gun (PN81) Inlet Return Gun opening Heating wire (only for viscosity > 50cSt (7°E) @ 50°C oil burners) Cartdrige-type heater (only for viscosity > 50cSt (7°E) @ 50°C oil burners) Recommendations to design heavy oil feeding plants This paragraph is intended to give some suggestions to make feeding plants for heavy oil burners.
Page 13 Adjusting the supplying oil ring According to the heavy oil viscosity used, in the table below indicative temperature and pressure values to be set are shown. Note: the temperature and pressure range allowed by the supplying ring components must be checked in the specifications table of the components themselves HEAVY OIL VISCOSITY AT PIPELINE...
Page 14 Viscosity units conversion table Saybolt Saybolt Redwood n.1 Saybolt n. 2 Engler degrees Cinematics viscosity Seconds Seconds Seconds Seconds (°E) Centistokes (cSt) Universal (SSU) Furol (SSF) (Standard) (Admiralty) 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 2.17 12.95...
Page 15 Fig. 2...
Page 16 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). Fig. 3 Indicative diagram showing the oil pressure according to its temperature. Fig.
Page 17 Hydraulic schemes Fig. 6 –3ID0023 - Single burner configuration...
Page 18 KEYS OIL TRAIN Main tank OIL PUMPING UNIT Manual valve Filter Pump coupled to electrical motor Safety valve One-way valve Manual valve Pressure gauge Maximum pressure switch Minimum pressure switch PRESSURE GOVERNOR UNIT Manual valve Pressure governor Needle valve Pressure gauge DAILY TANK Daily tank Electrical resistor...
Page 19 Fig. 7 - 3ID0014 - Two or more burners configuration...
Page 20 KEYS OIL TRAIN Filter Pump and pressure governor Electrical motor Pressure gauge with manual valve Electrical preheater tank Electrical preheater tank Thermostat - TR Low thermostat - TCN High thermostat - TRS Thermometer 3-way solenoid valve Flexible hose Flexible hose Flexible hose Oil distributor Low thermostat - TCI...
Page 21 Fig. 8 – P&ID 3I2D-06 – PN81 ATTENTION: connect the oil outlet line to the degassing bottle (standard UNI 9248), as shown in the previous paragraph "RECOMMENDATIONS TO DESIGN HEAVY OIL FEEDING PLANTS"...
Page 22 Fig. 9 – P&ID 3I2D-14 – PN60-70 ATTENTION: connect the oil outlet line to the degassing bottle (standard UNI 9248), as shown in the previous paragraph "RECOMMENDATIONS TO DESIGN HEAVY OIL FEEDING PLANTS"...
Page 23 KEYS 3I2D-06 KEYS 3I2D-14 OIL TRAIN Filter Filter Flexible hose Pump and pressure governor Pump and pressure governor Electrical preheater tank Thermostat - TR Pre-heater tank Thermostat - TR Low thermostat - TCN Low thermostat - TCN High thermostat - TRS High thermostat - TRS Thermometer 3-way solenoid valve...
Page 24 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. ATTENTION: 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 Connecting the oil heating resistors 2.4 - 4.5 kW 8 - 12 kW 18 - 24 kW ELECTRIC MOTOR CONNECTION Oil thermostat adjustment To find the thermostats, remove the cover of the burner switchboard. Adjust them using a screwdriver on the VR screw as shown in the next picture.
Page 26 ADJUSTMENTS ATTENTION: 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. ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide);...
Page 27 Adjusting light oil flow rate The light oil flow rate can be adjusted choosing a nozzle that suits the boiler/utilisation output and setting the delivery and return pres- sure values according to the ones quoted on the following charts. NOZZLE SUPPLY PRESSURE = 20 bar 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.
Page 28 FLUIDICS NOZZLE: REFERENCE DIAGRAM (INDICATIVE ONLY) Atomisation angle FLOW RATE kg/h Indicative DIMENSIONS pessure on return (bar) Pressure on return (bar) Pressure on return (psi) Up to 100kg/h Over 100kg/h Flow rate NOZZLE SUPPLY PRESSURE = 25 bar Tab. 3 - - - - - Atomisation angle according to the return pressure ̶...
Page 29 Adjusting the combustion head PN60 - PN70 The burner is factory-set with the head in its MAX position (maximum output). To let the burner operate at a lower output, turn clockwise the VRT screw and move progressively the combustion head back towards the MIN position.
Page 30 Oil Flow Rate Settings by means of Berger STM30../Siemens SQM40.. actuator Actuator cams High flame Stand-by and Ignition Low flame With the electrical panel open, prime the oil pump acting on the related CV contactor (see next picture): check the pump motor rotation (see “Fan-pump motor direction” on page 24) and keep pressing for some seconds until the oil circuit is charged.
Page 31 Pressure gauge Pressure gauge port PN60-70 PN81 the nozzle supply pressure is already factory-set and must not be changed. Only if necessary, adjust the supply pressure as follows: insert a pressure gauge into the port shown on picture above and act on on the pump adjusting screw VR (see Fig.
Page 32 Adjustment by the Siemens SQL33.. actuator with the electrical panel open, prime the oil pump acting directly on the related CV contactor (see next picture): check the pump motor rotation (see “Fan-pump motor direction” on page 10) and keep pressed for some seconds until the oil circuit is charged.
Page 33 Pressure gauge Pressure gauge port PN60-70 PN81 10. in order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge): always checking the combustion parameters, the adjustment is to be performed by means of the SV adjusting cam screw V (see picture) when the cam has reached the high flame position.
Page 34 CMF = stop at the current position CMF = 1 high flame operation CMF = 2 low flame operation CMF = 3 automatic operation Calibration of air pressure switch (if provided) To calibrate the air pressure switch, proceed as follows: Remove the transparent plastic cap.
Page 35 Oil circuit (PN81) 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.
Page 36 PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.
Page 37 Burner main switch High flame lamp Low flame lamp Ignition transformer operation Manual operation switch: 0= 1= High flame - 2= Low flame - 3= Automatic Fan motor overload tripped intervention Burner lockout Burner in stand-by Auxiliaries heaters switch Heavy solenoid lamp operation...
Page 38 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 39 Removing the combustion head (PN60-PN70) Remove cover C; remove the photoresistor from its housing; unscrew the rotating couplings on the two oil hoses (use two spanners to avoid loosening the couplings fixed to the distributor block); remove the complete assembly L as shown in the figure.
Page 40 To check the flame itensity signal, follow the diagram shown on the next picture. If the measured value is lower than the suggested one, check the photoresistor position, the electrical contacts. Replace the photoresistor if necessary. PN60: LOA24/LMO24 PN70-PN81: LMO44 Minimum current intensity with flame: 70 µA (LOA24) - 45 µA(LMO24-44) Maximum current intensity without flame: 5.5 µA (LOA24/LMO24-44)
Page 41 2 - Do not reverse phase with neutral 3 - Ensure burner is properly earthed See the attached wiring diagrams. Wiring diagram 05-558 - Progressive burners - PN60 Wiring diagram 05-618 - Fully-modulating burners - PN60 Wiring diagram 07-345 / 07-516 - Progressive burners - PN70-PN81...
Page 42 BURNER EXPLODED VIEW– PN60/PN70 POS. DESCRIZIONE POS. DESCRIZIONE POS. DESCRIZIONE 16.5 LONG IGNITION ELECTRODE BOARD 4.11 OIL PRE-HEATER 16.6 LONG IGNITION ELECTRODE 1.2.1 FRONT CONTROL PANEL PRESSURE GOVERNOR 16.7 NOZZLE 1.2.2 LIGHT BRACKET 16.8 O RING 1.2.3 LIGHT AIR INTAKE 1.2.4...
Page 44 BURNER EXPLODED VIEW – PN81 POS. DESCRIPTION POS. DESCRIPTION POS. DESCRIPTION BLAST TUBE BRACKET BODY SOLENOID VALVE 12.1 COVER OIL DISTRIBUTOR RING 12.2 FLANGE CONTROL PANEL RING GASKET CONTROL PANEL COVER HALF JOINT DISC 4.1.1 COMBUSTION HEAD HALF JOINT GLASS 4.1.2 IGNITION ELECTRODE HALF JOINT...
Page 46 Colour code table SIEMENS OIL BURNERS AUTOMATIC CONTROLLER SIEMENS LMO14 - LMO24 - LMO44 Status Colour code Colour The LMO... burner controls are designed for the start-up and supervision of single- or 2-stage forced draught oil burners in intermittent operation. Oil pre-heater heats, lllllllllll Yellow...
Page 47 Connection diagram and internal diagram Flame signal LMO14 Flame signal amplifier K... Contacts of control relay 3-colour signal lamps Burner motor Release contact of oil pre-heater Pre-purge time Pre-ignition time Post-ignition time A´ Beginning of start-up sequence with burners using an oil pre-heater Beginning of start-up sequence with burners using no oil pre-heater...
Page 48 Measurement circuit for detector current µA DC DC microamperometer with an internal resistance of 5 kW max. Blue Black Brown...
Page 52 Note: Specifications and data subject to change. Errors and omissions excepted.
Page 53 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 54 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 55 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 56 • 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 57 • 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 58 • 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 59 • 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 60 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 61 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 62 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 63 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 64 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 65 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 67 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 68 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 69 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 70 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 71 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 72 …. 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 73 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 74 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 77 RWF50.2x & RWF50.3x User manual M12922CB Rel.1.0 07/2012...
Page 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 Electric connection : With 7 pins connector version With terminals version Matches terminals between RWF50.2 and RWF40.0x0...
Page 86 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 87 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 88 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 89 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 90 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 91 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 92 Note: Specifications and data subject to change. Errors and omissions excepted.
Page 93 KM3 Modulator USER MANUAL M12927CA Rel.1.0 10/2020...
Page 94 M12927CA MOUNTING...
Page 95 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 96 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 97 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 98 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 99 M12927CA...
Page 100 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 101 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 102 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 103 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 104 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 105 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 106 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 107 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 108 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 109 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 110 RWF55.5X & RWF55.6X User manual M12926CA Rel.0.1 10/2015...
Page 111 DEVICE INSTALLATION Fixing system Drilling dimensions:...
Page 112 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 113 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 114 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 115 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 116 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 117 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 118 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 119 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 120 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 121 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 122 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 123 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 124 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 125 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 126 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 127 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 128 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 129 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 130 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 131 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 133 Note: Specifications and data subject to change. Errors and omissions excepted.
Page 134 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 135 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 136 (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 137 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 138 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 139 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 140 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 141 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.

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