R91A – R92A – R93A R512A – R515A – R520A R525A
Contents
1. 250 300 ff il N 2 aa 1 ul ul ul NL UN E m 1 1 1 Jequ JYNSSJHd SVD R525A DN65 80 100 R525A 2 aon 700 750 800 850 450 500 550 600 650 250 300 350 400 200 JYNSSJHd SVD 23 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 if this should happen make the fuel decrease slowly until the normal combustion values are achieved WARNING NEVER LOOSE THE SEALED SCREWS OTHERWISE THE DEVICE WARRANTY WILL BE INVALIDATE Adjusting air and gas flow rates Gas filter The gas filters remove the dust particles that are present in the gas and prevent the elements at risk e g burners counters and regulators from becoming rapidly blocked The filter is normally installed upstream from all the control and on off devices VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off2. E zem i Ert Ee EU ER 4 E ro 40 EI LT nso 5 a ET 1 o alti L47 mE eer rt a oleum zm o 50 100 150 200 250 300 350 400 450 500 50 100 150 200 250 300 350 400 450 500 550 x Stm3 h Stm3 h Her 7 50 100 150 200 250 300 350 400 450 500 550 600 650 750 Stm3 h Stm3 h GAS PRESSURE mbar 200 400 300 PEN HT P d 100 0 200 300 400 500 700 800 Stm3 h GAS PRESSURE mbar Stm3 h Caution the gas rate value is quoted on the x axis the related network pressure is quoted on the y axis pressure value in the combustion chamber is not included To know the minimum pressure at the gas train inlet necessary to get the requested gas rate add the pressure value in the combustion chamber to the value read on the y axis 12 MOUNTING AND CONNECTING THE BURNER Packing Burners are despatched in wooden crates whose dimensions are series 9xA 1730 x 1280mm x 1020mm L x P x H series 5xxA 1720mm x 1500mm x 1150mm L x P x H series 525A 1800mm x 1500mm x 1300mm L x P x H Packing cases of this type are affected by humidity and are not suitable for stacking The following are placed in each packin
3. U m A O w IN N ELECTRICAL WIRING DIAGRAMS CAUTION 1 Power supply 400V 50 Hz 3N a c 2 Don t reverse phase with neutral 3 Ensure burner is properly hearteD See tha attached wiring diagrams Burners with printed circuit provided WIRING DIAGRAM SE21 018 Burners with no printed circuit provided WIRING DIAGRAM R525A SE09 313 Progressive burners WIRING DIAGRAM R525A 5 09 315 Fully modulatine burners 40 SIEMENS LFL 1 3 control BOX Automatic programme in the event of interruption and indication of position when interrupted By default in the event of any kind of interruption the flow of fuel is immediately interrupted At the same time the programmer stops and this indicates the position at the time of the interruption A symbol on the indicator disc shows each time the type of stoppage 4 start up for example fault the CLOSED signal for the limit contact Z at terminal 8 or some other contact between the terminals 12 and 4 or 4 and 5 is not closed i suspended because of a fault in the OPEN signal for the limit contact A at terminal 8 P Block due to absence of air pressure signal From this moment onwards any absence of air pressure will cause a block Br Block due to malfunction of the flame detector circuit Y Start up interrupted because there is a fault in the MINMUM signal for the auxiliary contact of
4. Dungs MBC SE valves group act on its pressure governor to increase or decrease the pressure and consequently the gas rate T Innensechskantsohilesel 2 5 oer no 2 5 Dum ei nr 2 Siemens VGD Dungs MBC SE 10 To adjust the air flow rate in the high flame stage loose the RA nut and screw VRA as to get the desired air flow rate moving the rod TR towards the air damper shaft the air damper opens and consequently the air flow rate increases moving it far from the shaft the air damper closes and the air flow rate decreases RA VRA Note once the procedure is perfomed be sure that the blocking nut RA is fasten Do not change the position of the air damper rods 11 adjust only if necessary the position of the combustion head to let the burner operate at a lower output loose the VB screw and move progressively back the combustion head towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment is accomplished 28 13 14 15 16 17 18 19 20 The air and gas rate now adjusted at the maximum output go on with the point to point adjustment on the SV adjusting cam as to reach the minimum output point gradually move the adjusting cam in order to adjust each of the V screws as to set the cam foil shape as described on the next step To change the SV position set the actuator on the manual
5. s sms Min 1 _ Tupwernwmpon w 99 8 re Pe e _ T Wongso nemmen _ Notet all gas flow rates are referred to Stm3 h 1013 mbar absolute pressure 15 C temperature and are valid for G20 natural gas nett PIS calorific value Hi 34 02 MJ Stm3 Note2 Maximum gas pressure 500mbar with Siemens VGD gas valves Dungs MBC gas valves pes Minimum gas pressure see gas curves NOTE ON THE BURNER WORKING SERVICE for safety reasons one controlled shutdown must be performed every 24 hours of continuous operation Output 600 4500 770 5200 1000 6400 2000 6700 2000 8000 8000 Fuel Natural gas Caegoy ee next paragraph 0 0 Gas pressure see Note 2 Powersupply __ 400 3N 80 400V 3N 50 400V 3N 50 400V 3N 50 400V 3N 50 rotalponerconsunoion w or ns ws e w _ Protection IO _ ommo egeshe Fdymoah Gas traines 7 50 Rp2 50 Rp2 50 Rp2 SO Rp2 Gas train 100 7 C valves 80 0 80 80 0 80 80 0 80 80 DN amp O Oreeingtempesue e 1 1007000 1 400 oNtoo Working senicet 20 20 90 20 90 _ Maximum gas pressure 500mbar with Siemens VGD gas valves Dungs MBC gas valves Minimum gas pressure
6. 4 RITA R92A R93A R512A R515A R520A R525A Natural gas burners Progressive Fully modulating MANUAL OF INSTALLATION USE AND MAINTENANCE BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES l OPETIKM 039209 Rel 4 2 07 2011 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 WE HIGHLY RECOMMEND TO READ IT CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE 1 GENERAL INTRODUCTION e The equipment must be installed in compliance with the regulations force following the manufacturer s instructions by qualified personnel Qualified personnel means those having technical knowledge in the field of components for civil or industrial heating systems sanitary hot water generation and particularly service centres authorised the manufacturer Improper installation cause injury to people and animals or damage to property for which the manufacturer cannot be held liable e Remove all packaging material and inspect the equipment for integrity In case of any doubt do not use the unit contact the supplier The packaging materials wooden crate nails fastening device
7. 400 440 494 540 612 M14 552 390 390 633 150 483 843 292 882 328 270 R520A 80 1475 323 35 530 508 945 446 1726 1084 642 400 440 494 540 628 M14 552 390 390 685 150 535 875 322 898 328 270 R520A 100 1475 323 35 530 508 945 446 1809 1167 642 400 440 494 540 641 M14 552 390 390 792 150 642 942 382 911 328 270 R525A 50 1475 145 35 530 650 945 571 1713 1071 642 434 484 494 540 597 M14 552 390 390 755 150 605 843 216 867 328 270 R525A 65 1475 145 35 530 650 945 571 1691 1049 642 434 484 494 540 612 M14 552 390 390 633 150 483 843 292 882 328 270 R525A 80 1475 145 35 530 650 945 571 1726 1084 642 434 484 494 540 628 M14 552 390 390 685 150 535 875 322 898 328 270 R525A 100 1475 145 35 530 650 945 571 1809 1167 642 434 484 494 540 641 M14 552 390 390 792 150 642 942 382 911 328 270 DN gas valves size NOTE the overall dimensions are referred to burners provided with Siemens VGD valves 10 Performance Curves R92A anh Wee UE EMI O
8. placed on the burner control panel The gas pressure switches check the pressure to avoid the burner operate when the pressure value is not in the requested pressure range Calibration of air pressure switch To calibrate the air pressure switch proceed as follows 1 Remove the transparent plastic cap 2 Once air and gas setting have been accomplished startup the burner 3 During the pre purge phase o the operation turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout then read the value on the pressure switch scale and set it to a value reduced by 15 4 Repeat the ignition cycle of the burner and check it runs properly 5 Refit the transparent plastic cover on the pressure switch Calibration of low gas pressure switch As for the gas pressure switch calibration proceed as follows sure that the filter is clean 2 Remove the transparent plastic cap 3 While the burner is operating at the maximum output test the gas pressure on the pressure port of the minimum gas pressure switch 4 Slowly close the manual cutoff valve placed upstream the pressure switch see gas train installation diagram until the detected pressure is reduced by 50 Pay attention that the CO value in the flue gas does not increase if the CO values are higher than the limits laid down by law slowly open the cutoff valve as to get values lower than these limits Check that the burner is operating correctly Cl
9. 494 540 597 M14 552 390 390 755 150 605 843 216 867 328 270 R512A 65 1475 323 35 530 508 945 446 1691 1049 642 340 380 494 540 612 M14 552 390 390 633 150 483 843 292 882 328 270 R512A 80 1475 323 35 530 508 945 446 1726 1084 642 340 380 494 540 628 M14 552 390 390 685 150 535 875 322 898 328 270 R512A 100 1475 323 35 530 508 945 446 1809 1167 642 340 380 494 540 641 M14 552 390 390 792 150 642 942 382 911 328 270 R515A 50 1475 323 35 530 508 945 446 1713 1071 642 380 420 494 540 597 M14 552 390 390 755 150 605 843 216 867 328 270 R515A 65 1475 323 35 530 508 945 446 1691 1049 642 380 420 494 540 612 M14 552 390 390 633 150 483 843 292 882 328 270 R515A 80 1475 323 35 530 508 945 446 1726 1084 642 380 420 494 540 628 M14 552 390 390 685 150 535 875 322 898 328 270 R515A 100 1475 323 35 530 508 945 446 1809 1167 642 380 420 494 540 641 M14 552 390 390 792 150 642 942 382 911 328 270 R520A 50 1475 323 35 530 508 945 446 1713 1071 642 400 440 494 540 597 M14 552 390 390 755 150 605 843 216 867 328 270 R520A 65 1475 323 35 530 508 945 446 1691 1049 642
10. DEPENDING ON FUEL USED 3a ELECTRICAL CONNECTION For safety reasons unit must be efficiently earthed and installed as required by current safety regulations It is vital that all saftey requirements met In case of any doubt ask for an accurate inspection of electrics by qualified personnel since the manufacturer cannot be held liable for damages that may be caused by failure to correctly earth the equipment e Qualified personnel must inspect the system to make sure that it is adequate to take the maximum power used by the equipment shown on the equipment rating plate In particular make sure that the system cable cross section is adequate for the power absorbed by the unit e No adaptors multiple outlet sockets and or extension cables are permitted to connect the unit to the electric mains e An omnipolar switch shall be provided for connection to mains as required by the current safety regulations e The use of any power operated component implies observance of a few basic rules for example do not touch the unit with wet or damp parts of the body and or with bare feet do not pull electric cables do not leave the equipment exposed to weather rain sun etc unless expressly required to do so do not allow children or inexperienced persons to use equipment unit input cable shall not be replaced by user In case of damage to the cable switch off the unit and contact qualifie
11. Have qualified personnel inspect the installation to ensure that a the gas delivery line and train are in compliance with the regulations and provisions in force b all gas connections are tight c the boiler room ventilation openings are such that they ensure the air supply flow required by the current regulations and in any case are sufficient for proper combustion Do not use gas pipes to earth electrical equipment e Never leave the burner connected when not in use Always shut the gas valve off In case of prolonged absence of user the main gas delivery valve to the burner should be shut off Precautions if you can smell gas a do not operate electric switches the telephone or any other item likely to generate sparks b immediately open doors and windows to create an air flow to purge the room c close the gas valves d contact qualified personnel Do not obstruct the ventilation openings of the room where gas appliances are installed to avoid dangerous conditions such as the development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 2009 142 Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment
12. OR BAD SETTING MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIRTY IGNITION TRANSFORMER FAULT IGNITION ELECTRODES BAD POSITION BUTTERFLY VALVE BAD SETTING DEFECTIVE GAS GOVERNOR GAS VALVE DEFECTIVE BAD CONNECTION OR DEFECTIVE HIGH LOW FLAME HERMOSTAT OR PRESSURE SWITCH RONG SETTING OF ACTUATOR CAM UV PROBE DIRTY OR DEFECTIVE 37 DOESEN T RETURN IN LOW CYCLE DURING OPERATION DOESN T SWITCH TO HIGH FLAME FLAME TURNS OFF AND REPEAT THE FLAME MONITOR DEVICE DOESN T GIVE CONSENT TO START LOCK OUT DURING OPERATION BURNER EXPLODED VIEW 1 72 73 74 7 5 76 7 72 7 8 7 10 7 1 712 ROD 7 13 716 N N ITEM DESCRIPTION 124 1252 E 12 10 1 AIRDAMPERSILENCER 12402 AIRINTAKE DAMPER SPACER 12 11 2 SILENCER 12 11 3 SILENCER GAS FILTER REVERSIBLE PIPE FLANGED REVERSIBLE CURVE A GAS PRESSURE 38 NO O NO oo N IN JO a la ages N IN ININ IN IO E NO N N gt OO 2 U gt Im A BEY ex a W W N lt 1342 4 4 13 4 5 5 15 52 5 A oa 5 WO Ww O IA O IN gt nN gt lt gt A BIO r 2 O
13. and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Heavy oil burners European directives Directive 2009 142 Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods PART I INSTALLATION GENERAL FEATURES This series represents monoblock gas burners made in die cast aluminium housing that can produce output values from 2670 to 8000kW according to the burner type They can be provided in progressive or fully modulating version Fig 1 Keys 1 Control panel with startup switch 2 Gas filter 3 Gas proving system 4 Gas valves group 5 Electrical panel 6 Cover 7 Blast tube Combustion head 8 Flange 9 Adjusting cam 10 Actuator 11 Silencer 12 Air damper index 13 Air pressure switch 14 Combustion head adjusting ring nut The gas coming from the supply line passes through the valves group provided with filter and governor This one forces the pressure in the utili
14. of non electric appliances for household and similar purposes Safety requirements Light oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Heavy oil burners European directives Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards CEI EN 60335 1 Household and similar electrical appliances SafetyPart 1 General requirements EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements National standards UNI 7824 Monobloc nebulizer burners for liquid fuels Characteristics and test methods Gas Light oil burners European directives Directive 2009 142 Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 EC on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric appliances for household
15. pressostat contacts GP and the safety thermostat and pressostat contacts W must also be closed Start up program A Start up R closes the start up control ring between terminals 4 and 5 The programmer starts up At the same time the ventilator motor is fed through terminal 6 only for pre ventilation and after 17 the ventilator motor or the combustion gas exhaust fan is fed through terminal 7 pre ventilation and post ventilation At the end of 16 the command opening the damper passes through terminal 9 during the damper opening time the programmer does not move since terminal 8 through which the programmer is fed is dead Only once the damper is fully open and the limit contact switch A has switched on feeding terminal 8 does the programme proceed t1 flow Shortly after the beginning of the pre ventilation time the air pressostat should switch off the current between terminals 4 and 13 otherwisethe apparatus would block air pressure monitor At the same time the terminal 14 should be live since current feeding the ignition transformer and the fuel valves passes through this circuit During pre ventilation time the flame detector circuit is checked and in the event of an operational defect the monitor brings about a block At the end of the pre ventilation time the monitor automatically moves the damper servo motor through terminal 10 to the flame ignition position which is governed by the auxiliary contact M Duri
16. see gas curves all gas flow rates are referred to Stm3 h 1013 mbar absolute pressure 15 C temperature and are valid for G20 natural gas nett calorific value Hi 34 02 MJ Stm3 NOTE ON THE BURNER WORKING SERVICE for safety reasons one controlled shutdown must be performed every 24 hours of continuous operation Country and usefulness gas categories GAS CATEGORY COUNTRY 2 FI IS NO CZ DK IT PT EE MT SK LT TR sw Sef A e CERES lea ee e kae ekka ea Se A Overall dimensions _Omin max Burner flange Boiler recommended drilling template A 333 cc o gt 4 242 R92A R92A R92A R92A R93A 1 DN gas valves size NOTE the overall dimensions are referred to burners provided with Siemens VGD valves 00 299 100 O1 O1 1483 1 1393 483 a E Boiler recommended drilling template DN A AD B BB D E R512A 50 1475 323 35 530 508 945 446 1713 1071 642 340 380
17. the damper servo motor at terminal 8 1 Block due to absence of flame signal at the end of the 1st safety period From this moment onwards any absence of a flame signal will cause a block 2 Block due to absence of flame signal at the end of the 2nd safety period flame signal of main burner Block due to absence of flame signal or air pressure during operation Where a block stoppage occurs at any moment between switch on and pre ignition without registering any symbol the cause is normally an unscheduled flame signal Startup program For time variants move the programmer on to the automatic stop after the burner starts up b position of the programmer during normal burner operation a b b b b b a Post ventilation programme after a regulation stop At the start up position a the programmer stops automatically Safety time duration for mono tube burners Safety time duration for twin tube burners The apparatus can be reset immediately after a block After resetting and after the elimination of any problem causing the stoppage or after a power failure the programmer returns to its start up position In this event only the terminals 7 9 10 and 11 are live in accordance with the monitoring programme Only after this the device programs a new startup Operation The wiring system and also the control system of the programmer P have already been given in this manual The response signals required for t
18. the end of the second safety time the main burner should be lit by means of the pilot At the end of this period terminal 17 is dead and therefore the pilot burner will be out t5 Interval at the end of t5 terminal 20 is live At the same time the monitor outlets from 9 to 11 and the terminal 8at the input of the active part of the apparatus are galvanically separated so as to protect the apparatus itself from recovery voltage through the strenght regulator circuit When the strenght regulator LR at terminal 20 gives the consent the start up programme for the apparatus comes to an end Depending on time variants the programmer stops either immediately or at the end of a set time without effecting the position of the contacts B Operational position of the burner B C Burner operation production of heat While the burner is working the strnght regulator controls the damper according to the demand for heat by means of the positioning at nominal load of the auxiliary contact V of the damper servocontrol C Regulation stop for operation of R When there is a regulation stop the fuel valves immediately close At the same time the programmer starts to programme t6 Post ventilation time post ventilation with the ventilator G at terminal 7 Shortly after beginning of the post ventilation time terminal 10 becomes live and moves the damper to the MIN position The full closure of the damper only happens towards the end of the post v
19. valves This check is carried out as soon as the boiler thermostat gives a start signal to the burner creating by means of the diaphragm pump inside it a pressure in the test space of 20 mbar higher than the supply pressure When wishing to monitor the test install a pressure gauge ranged to that of the pressure supply point PA If the test cycle is satisfactory after a few seconds the consent light LC yellow comes on In the opposite case the lockout light LB red comes on To restart it is necessary to reset the appliance by pressing the illuminated pushbutton LB Actuator The actuator provided can be either Berger STM30 Siemens SQMAO see page 27 or Siemens SQL33 see page 29 IMPORTANT the combustion air excess must be adjusted according to the in the following chart Recommended combustion parameters Fe o CO2 recommended O2 recommended 9 5 Natural gas Adjustments brief description e Adjust the air and gas flow rates at the maximum output high flame first by means of the air damper and the adjusting cam respectively e Check that the combustion parameters in the suggested limits Check the flow rate measuring it on the counter or if it was not possible verifying the combustion head pressure by means of a differential pressure gauge as described on par Measuring the gas pressure in the combustion head on page 25 e Then adjust the combustion values corresponding to the points be
20. AUTION avoid the ignition and detection electrodes to contact metallic parts blast tube head otherwise the boilers operation would be compromised Check the electrodes position after intervention on the combustion head To replace the ignition electrodes proceed as follows 1 remove the burner cover loose the nuts that fasten the electrodes group to the combustion head A disconnect the electrodes cables B loose the security dowes of the adjusting ring nut shift the electrodes group back to the outside and remove the combustion head D loose the screw of th eignition electrodes support E remove the electrodes and replace them paying attention to the measures shown in figure F G reassemble the burner by fllowing the procedure in the reversed order ae ee IS 35 Replacing the detection electrode otherwise the boilers operation would be compromised Check the electrodes position after any intervention on the combustion head f CAUTION avoid the ignition and detection electrodes to contact metallic parts blast tube head To replace the detection electrode proceed as follows e remove the combustion head as described on par Removing the combustion head bymeasn of an allen key loose the fixing screws of the detection electrode ER and replace it e replace the combustion head Checking the detection electrode To check the detection signal follow the scheme in picture be
21. ERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH AND ON THE RESET BUTTON IN CASE OF A BURNER SHUT DOWN RESET THE CONTROL BOX BY MEANS OF THE RESET PUSHBUTTON IF A SECOND SHUT DOWN TAKES PLACE CALL THE TECHNICAL SERVICE WITHOUT TRYING TO RESET FURTHER WARNING DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR COUPLING FLANGE CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT OPERATION WARNING BEFORE STARTING UP THE BURNER BE SURE THAT THE MAIN SWITCH IS ON AND THE MANUAL SHUTOFF VALVES ARE OPEN CHECK THAT THE GAS PRESSURE VALUE UPSTREAM THE GAS TRAIN IS IN ACCORDANCE WITH DATA QUOTED ON PARAGRPAH SPECIFICATIONS READ WARNINGS CHAPTER CAREFULLY Turn to the ON position the main switch A on the burner s control panel see next picture Check the flame control device is not locked light B on and eventually release it by means of the pushbutton C reset for more information about the device please refer to the manual s Appendix Check the series of thermostats or pressure switches gives the burner the start signal for operating Check that the gas pressure in the gas network is sufficient if the pressure is normal the lamp E lights The gas proving system test begins when the test is performed the proving system LED turns on At the end of the test the burner staring cycle begins in case of leakage in a valve the gas proving system stops the burner and the lamp E turns
22. L mo BS cS eRe See AGL TT PNT IL 400 800 1200 1600 20001 2400 2800 3200 qr PRESSURE IN COMBUSTION CHAMBER mbar kW PTT EE NT AL BN a i i N E 0 EE PRESSURE IN COMBUSTION CHAMBER mbar PRESSURE IN COMBUSTION CHAMBER mbar 5500 PETAL LEAN EEE PI TT 1500 2500 3500 4500 5500 6500 7500 8500 kW PRESSURE IN COMBUSTION CHAMBER mbar 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 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 On this diagram the maximum output point is usually reached by adjsuting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is reached setting the combustion head to its MIN position During the first ignition the combustion head is set in order to find a compromise between the burner output and the generator specifications that is why the minimum output may be different from the Performance curve minimum 11 Pressure the Network gas flow rate curves GAS PRESSURE mbar Sic
23. NG OF THIS MANUAL Gas train with valves group VGD 20 40 with built in gas pressure governor VPS504 gas proving system manufacturer installer installer Gas train with valves group MBC 1900 3100 50005 2 valves gas filter pressure governor VPS504 gas proving system manufacturer installer Legenda Note the maximum gas pressure switch can be Burner mounted either upstream or downstream the gas valve but upstream the butterfly gas valve see item no 4 in the scheme above Butterfly valve Gas proving system Maximum gas pressure switch option Minimum gas pressure switch Gas filter Bellows unit Manual cutoff valve VGD Valves group MBC Valves group 2 with filter provided MBC Valves group DN65 80 100 16 Assembling the gas train Per assemblare la rampa principale del gas procedere nel modo seguente direction arrows for installation gas supply network Keys 1A 1E Gasket 2 Gas filter 3 Gas valves group 4 Bellows unit 5 Cutoff manual valve Fig 5 Example of gas train To mount the gas train proceed as follows 1 a in case of threaded joints use proper seals according to the gas used 1 b in case of flanged joints place a gasket no 1A 1E Fig 5 between the elements 2 fasten all the items by means of screws according to the diagrams shown observing the mounting direction for each item NOTE the bellow joint the manual cutoff valve and the gaskets ar
24. PECIAL WARNINGS Make sure that the burner has on installation been firmly secured to the appliance so that the flame is generated inside the appliance firebox Before the burner is started and thereafter at least once a year have qualified personnel perform the following operations a set the burner fuel flow rate depending on the heat input of the appliance b set the flow rate of the combustion supporting air to obtain a combustion efficiency level at least equal to the lower level required by the regulations in force c check the unit operation for proper combustion to avoid any harmful or polluting unburnt gases in excess of the limits permitted by the regulations in force d make sure that control and safety devices are operating properly e make sure that exhaust ducts intended to discharge the products of combustion are operating properly f on completion of setting and adjustment operations make sure that all mechanical locking devices of controls have been duly tightened g make sure that a copy of the burner use and maintenance instructions is available in the boiler room In case of a burner shut down reser the control box means of the RESET pushbutton If a second shut down takes place call the Technical Service without trying to RESET further unit shall be operated and serviced by qualified personnel only in compliance with the regulations in force 3 GENERAL INSTRUCTIONS
25. al between end of t4 and response at terminal 20 10 t20 interval before programmer cuts out after start up duration of start up 60 t6 post ventilation time G2 only 12 t13 permitted post ignition time 12 t16 initial delay from opening consent of the air damper t20 interval until the automatic shut off of the programming mechanism after the burner start Key A limit contact switch for damper OPEN position Al block remote signal AR main relay working network with contacts ar AS Monitor fuse BR block relay with br contacts BV fuel valve EK reset button FE detector electrode of ionisation circuit FR flame relay with fr contacts G ventilator motor or burner motor GP gas pressure switch H main interruptor switch L block stoppage LED LK air damper LP air pressostat LR safety regulator M auxiliary contact switch for damper MIN position QRA UV detector QRE ignition spark detector R thermostat or pressostat 5 fuse SA damper servo motor SM synchronous programmer motor V flame signal amplifier V in case of servo motor auxiliary contact for response to fuel valve with regard of damper position W safety pressostat or thermostat 2 ignition transformer Z in case of servomotor end of limit contact switch for damper CLOSED position ZBV pilot burner fuel valve for mono tube burners for twin tube burners 1 input for raising QRA detector voltage to test level 2 input for excitation of flame
26. ame operation light Ignition transformer operation light EV2 opening light EV1 opening light Fan motor overload tripped light Burner in stand by light Burner Modulator only on fully modulating burners UOZzr gt 22 PART Ill 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 WARNING ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED ATTENTION READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNIG OF THIS MANUAL ROUTINE MAINTENANCE Cleaning and examining the gas filter cartridge if necessary replace it see next paragraphs Removal examination and cleaning of the combustion head see page 34 Check ignition electrode cleaning adjustment and if necessary replacement see page 35 Check detection electrode cleaning adjustment and if necessary replacement in case of doubt check the detection circuit following the diagram on page 36 after turning the burner back into operation 5 Cleaning and greasing of leverages and rotating parts pue CAUTION when servicing if it was necessary to disassemble the gas train parts remember to execute the gas proving test once the gas train is reassembled ac
27. and neutral ones Electrical connections for burners provided with printed circuit standard configuration Progressive burners Electric motor connection Probes connection HHHH H D m DAEZ P0 AC OAM A 1000 1835 OHA M M Gl m wo k 520 UHR FEN TC t ST TAB SD 0 6 20mA Fully modulating burners BHBH HHEHHHBHH ST gt gt gt Power supply terminal block Terminal block for connections on printed circuit board qwe m Auxiliary relais power supply Alimentazione ausiliari 1 1 M6 3 T MAX 10A T 400V a c 144 i 1111141 arrrrrr Connections diagrams for burners with printed circuit board Progressive burners Motor connection Probe connection 01 sp rEME j9t sn TFHP SIFMFNS DAE2 UAM 1000 O T ST TAB LB 400V ac Fully modulating burners olo e o o olo c Em F Se inn Auxiliary relais power supply e 2 pu et MIN 3 T MAX 10A T IG ST LB LSPG 400V a c Probes connections by means of 7 pole connector see wiring diagrmas Rotation of fan motor Once the electrical connection of the burner is executed remember to check the rotat
28. astiron boilers three pass flue boilers with the first pass in the rear part the blast tube must protrude no more than 100 mm into the combustion chamber Pressurised boilers with flame reversal in this case the blast tube must penetrate at least 50 100 mm into combustion chamber in respect to the tube bundle plate The length of the blast tubes does not always allow this requirement to be met and thus it may be necessary to use a suitably sized spacer to move the burner backwards or to design a blast tube tha suites the utilisation please contact the manifacturer 14 8 te Ex We m e 0 E Md 0 6 too ert tr 5 4 3 2 0 1 42 26 40 70100 190 480 1200 2450 al Fig 4 Legenda a Heat output in kW b Length of the flame tube in meters c Flame tube firing intensity in MW m3 d Combustion chamber diameter m Fig 4 Firing intensity diameter and length of the test flame tube as a function of the heat input in kW 15 Gas train connections The diagrams show the components of the gas train included the delivery and which must be fitted by the installer The diagrams are in compliance with the current laws ATTENTION BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED READ CAREFULLY THE WARNINGS CHAPTER AT THE BEGINNI
29. ating stages to drive the burner to the high flame stage set 1 to drive it to the low flame stage set CMF 2 To move the adjusting cam set CMF 1 or 2 and then CMF 0 o stop at the current position high flame operation low flame operation automatic operation 30 PART 11 OPERATION LIMITATION 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 THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE ENTRUSTING THE INSTALLATION OF IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR S CONTROL AND SAFETY UNITS CONTROL THERMOSTAT SAFETY ETC WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE E G DISCONNECTION EVEN PARTIAL OF THE ELECTRICAL LEADS OPENING THE GENERATOR DOOR DISMANTLING OF PART OF THE BURNER NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE OPERATE ONLY THE MAIN SWITCH WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OP
30. bustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one into the combustion chamber s pressure outlet Fig 8 2 to get the pressure in the combustion chamber and the other one into the butterfly valve s pressure outlet of the burner Fig 8 3 On the basis of the measured differential pressure it is possible to get the maximum flow rate in the pressure rate curves showed on the next paragraph it is easy to find out the burner s output in Stm3 h quoted on the x axis from the pressure measured in the combustion head quoted on the y axis The data obtained must be considered when adjusting the gas flow rate NOTE THE PRESSURE RATE CURVES ARE GIVEN AS INFORMATION ONLY FOR A PROPER SETTING OF THE GAS RATE PLEASE REFER TO THE GAS METER READING Pressure in combustion head gas flow rate curves 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 40 60 80 100 120 140 160 180 200 220 240 260 280 300 Stm3 h Stm3 h 7 U 0 lt 22 E Lll tl tll EISE I x m E E LH X B BE BN HE EN efit BS EE EN ER RR EE E E 2 8 5 2 lt E e tn Jequ JYNSSJHd f
31. cording to the procedure imposed by the law in force CAUTION Before opening the filter close the manual cutoff valve downstream the filter and bleed the gas check that inside the filter there is no pressurised gas To clean or remove the filter proceed as follows 1 remove the cap unscrewing the fixing screws A 2 remove the filtering cartridge B clean it using water and soap blow it with compressed air or replace it if necessary 3 replace the cartridge in its proper position taking care to place it inbetween the guides as not to hamper the cap replacement 4 sure to replace the ring into its place and replace the cover fastening by the proper screws Inspection and replacement of the MBC SE 500 Inspect the filter at least once a year Change the filter if pressure value between pressure connections 1 and 2 is greather than 10 mbar Change the filter if pressure value between pressure connections 1 and 2 is twice as high compared to the last inspection 1 Interrupt gas supply close ball valve 2 Remove screws 1 2 3 Replace the filter insert 3 4 Screw in screws 1 2 without use force to fasten 5 Perform leakage and funcion test 6 Pay attention that dirt does not fall inside the valve Space requirements for fitting filter A from 150 to 230 mm 33 Replacing the spring in the gas valve group To replace the spring in the gas valve group proceed as follows 1 Carefully t
32. d personnel to replace When the unit is out of use for some time the electric switch supplying all the power driven components in the system i e pumps burner etc should be switched off 3b FIRING WITH GAS LIGHT OIL OR OTHER FUELS GENERAL e The burner shall be installed by qualified personnel and in compliance with regulations and provisions in force wrong installation can cause injuries to people and animals or damage to property for which the manufacturer cannot be held liable e Before installation it is recommended that all the fuel supply system pipes be carefully cleaned inside to remove foreign matter that might impair the burner operation e Before the burner is commissioned qualified personnel should inspect the following a the fuel supply system for proper sealing b the fuel flow rate to make sure that it has been set based on the firing rate required of the burner c the burner firing system to make sure that it is supplied for the designed fuel type d the fuel supply pressure to make sure that it is included in the range shown on the rating plate e the fuel supply system to make sure that the system dimensions are adequate to the burner firing rate and that the system is equipped with all the safety and control devices required by the regulations in force e When the burner is to remain idle for some time the fuel supply tap or taps should be closed SPECIAL INSTRUCTIONS FOR USING GAS
33. e values requested by the boiler utilisation Siemens VGD valves group remove cap T and act on the VR adjusting screw to increase or decrease the pressure and consequently the gas rate screwind VR the rate increases unscrewing it decreases see next figure Dungs MBC SE valves group act on its pressure governor to increase or decrease the pressure and consequently the gas rate lnneneeohekanmteohl sesl No 2 5 Allen key no 2 5 de aix pane male no 2 5 Chiave eamgonale nr 2 5 Siemens VGD Dungs MBC SE 9 To adjust the air flow rate in the high flame stage loose the RA nut and screw VRA as to get the desired air flow rate moving the rod TR towards the air damper shaft the air damper opens and consequently the air flow rate increases moving it far from the shaft the air damper closes and the air flow rate decreases 26 Note once the procedure is perfomed be sure that the blocking nut RA is fasten Do not change the position of the air damper rods 10 adjust only if necessary the position of the combustion head to let the burner operate at a lower output loose the VB screw and move progressively back the combustion head towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment is accomplished 11 12 13 14 15 16 Dopo avere regolato le portate di aria e gas alla potenza massima procedere alla regolazione punto per punt
34. e not part of the standard supply ATTENTION once the gas train is mounted according to the diagram on Fig 5 the gas proving test mus be performed according to the procedure set by the laws in force The procedures of installation fo the gas valves are shown in the next paragraphs according to the gas train used threaded gas trains with Multibloc Dungs MBC SE 1200 or Siemens VGD20 flanged gas trains with Multibloc Dungs MBC SE 1900 3100 5000 or Siemens VGD40 ATTENTION it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the valves during maintenance and cleaning operation of the filters both the filters outside the valves group and the ones built in the gas valves Siemens VGD20 and VGD40 gas valves with SKP2 pressure governor Mounting When mounting the VGD double gas valve two flanges are required as for VGD20 model the flanges are threaded to prevent cuttings from falling inside the valve first fit the flanges to the piping and then clean the associated parts install the valve the direction of gas flow must be in accordance with the direction of the arrow on the valve body ensure that the bolts on the flanges are properly tightened ensure that the connections with all components are tight make certain that the O rings and gaskets between the flanges and the double gas valve are fitted Connect the reference gas pipe TP in figure 8mm external s
35. entilation time and is prompted by an automatic signal from terminal 11 t13 Admissible post ignition time During this time the flame monitor circuit may still receive a flame signal without the apparatus blocking D A End of automatic programme At the end of t6 at the point where the programmer and the automatic contacts have reverted to the starter position the detection probe test restarts During an operational stop even an unscheduled flame signal lasting a few seconds can cause a block because during this period an NTC in the circuit acts as retarder This means that brief unscheduled influences cannot cause a block Times t3 t2 and t4 only apply only to safety devices in the series 01 Specifications Mains voltage 220V 15 240V 10 Frequency 50Hz 696 60Hz 6 Absorbed capacity 3 5 VA Built in fuse T6 3 250E slow action DIN41571 451915070 External fuse max 16A Interference N VDE0875 Flow permitted at terminal 1 5A DIN 0660 AC3 Flow permitted at control terminals 4A DIN 0660 AC3 Flow at monitor contacts input at terminals 4 amp 5 input at terminals 4 amp 11 input at terminals 4 amp 14 and 19 min 1A 250V Emplacement Any Protection IP40 Permitted ambient temp Min temperature trans storage Weight apparatus base 1A 250V 1A 250V function of the load at terminals 16 20 60 C 50 C approx 1 000g approx 165g lonisation monitor voltage in detector electrode n
36. er gas train size it is necessary to know the available gas pressure value upstream the burner s gas valve Then subtract the backpressure The result is called pgas Draw a vertical line matching the furnace input value of the heat generator 600kW in the example quoted on the x axis as far as intercepitng the network pressure curve according to the installed gas train DN65 in the example From the interception point draw an horizontal line as far as matching on the y axis the value of pressure necessary to get the requested furnace input This value must be lower or equal to the pgas value calculated before SS pp ot ft ttt er tt rete Minimum biet qas pressum pessimae qas im Paterza cutpusti ikWw Fig 3 Identificazione bruciatorildentification des bruleurs bruciatori vengono identificati con tipi e modelli L identificazione dei modelli descritta di seguito Type R91A Model PR S 1 80 1 2 8 4 5 6 7 8 1 BURNER 2 FUEL M Natural gas 3 OPERATION PR Progressive MD Fully modulating 4 BLAST TUBE S Standard 5 DESTINATION COUNTRY see ID plate 6 VERSION A Standard 1 2 valves gas proving system UL EON 8 2 valves gas proving system maximum gas pressure switch 65 DN65 80 100 DN100 480 2670 480 3050 550 4100 Natural gas 7 eemmpregaph Gene
37. g case burner with detached gas train e gasket or ceramic fibre plait according to burner type to be inserted between the burner and the boiler e envelope containing this manual and other documents To get rid of the burner s packing follow the procedures laid down by current laws on disposal of materials Handling the burner ATTENTION The Ihandling operations must be carried out by specialised and trained personnel If these operations are not carried out correctly the residual risk for the burner to overturn and fall down still persists To move the burner use means suitable to support its weight see paragraph Technical specifications The unpacked burner must be lifted and moved only by means of a fork lift truck The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck the forks must be inserted into the A anb B ways Remove the stirrup only once the burner is installed to the boiler The burner is designed to work positioned according to the picture below For different installations please contact the Technical Department 13 UP BOTTOM 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
38. he active parts and the flame monitor circuit are shown by a hatching In the absence of these response signals the mechanism interrupts the start up programme the exact time of the interruption can be identified from the visual indicator and will cause a block if the safety code requires it A consent to start up by means of the thermostat or pressostat R A B start up program B C normal burner operation 41 regulation stop caused by R C D programmer returns to start up position A During the regulation stop only terminals 11 and 12 are live and the damper through the limit contact Z of its servo motor is in the CLOSED position The flame detector circuit F is activated terminals 22 and 23 or 23 4 for the detector test and the paracitic light test Where the burners do not have dampers or have an independent 00 damper control mechanism there must be a bridge between terminals 6 8 otherwise the mechanism will not start up the burner For a burner to start up the following conditions must be met Mechanism not blocked reset Damper closed Limit contact switchZ must be in the CLOSED position and allow current to flow between terminals 11 and 8 Any contacts checking that the fuel valve bv is closed or other contacts with similar functions must be closed between terminal 12 and the air pressostat LP The contact for the air pressostat LP must be in the off position LP test so as to feed terminal 4 The gas
39. ion of the fan motor The motor should rotate according to the indication on the body In the event of wrong rotation reverse the three phase supply and check again the rotation of the motor NOTE burners are supplied for three phase 400V supply and in the case of three phase 230V supply it is necessary to change the electrical connections into the terminal box of the electric motor and replace the overload tripped relay WARNING set the thermal relay to the motor rated current As far as electrical connection see attached wiring diagrams 24 Combustion head gas pressure curves depending on the flow rate Curves are referred to pressure Ombar in the combustion head The curves referred to the gas pressure in the combustion head depending on the gas flow rate are referred to the burner properly adjusted percentage of residual O2 in the flues as shown in the Recommended combustion values table and CO in the standard limits During this stage the combustion head the gas butterfly valve and the actuator are at the maximum opening Refer to Fig 1 showing the correct way to measure the gas pressure considering the values of pressure in combustion chamber surveyed by means of the pressure gauge or taken from the boiler s Technical specifications Keys 1 Generator Pressure outlet on the combustion chamber Gas pressure outlet on the butterfly valve Differential pressure gauge pe Measuring the gas pressure in the com
40. ize 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 Leave the blowhole free SA in figure Should the spring fitted not permit satisfactory regulation ask one of our service centres for a suitable replacement Caution the SKP2 diaphragm D must be vertical see pictures WARNING removing the four screws BS causes the device to be unserviceable 17 MOUNTING POSITIONS MULTIBLOC DUNGS MBC300 700 1200SE Threaded valves group Mounting 1 Mount flange onto tube lines Use appropriate sealing agent see Fig 6 2 Insert MBC SE Note position of O rings see Fig 6 3 Tighten screws A H 4 After installation perform leakage and functional test 5 Disassembly in reverse order MOUNTING POSITIONS OPTION 2 Pulse lines 18 MULTIBLOC DUNGS MBC1900 3100 5000SE Flanged valves group Mounting 1 Insert setscrews A 2 Insert seals 3 Insert setscrews B 4 Tighten setscrews A B Ensure correct seating of the seal 6 After installation perform leakage and functional test 7 Disassembly in reverse order MOUNTING 10 Pulse lines POSITIONS Pressure adjusting range The pressure adjusting range downstream the gas valves group changes according to the spring provided with the valve group Keys 1 spring 2 cap DUNGS MBC valves Sieme
41. low If the signal is less than the value indicated check the position of the detection electrode or UV probe the electrical contacts and if necessary replace the electrode or the UV probe Control box Minimum detection signal Siemens LFL1 3 6 pA with electrode Siemens LFL1 3 uA with UV probe Checking the detection electrode with printed circuit To check the detection current follow the diagram on picture below If the signal is lower than the value indicated check the position of the detection electrode or detector the electrical contacts and if necessary replace the electrode or the detector Seasonal stop To stop the burner in the seasonal stop proceed as follows turn the burner main switch to O 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 36 TROUBLESHOOTING CAUSE TROUBLE THE BURNER DOESN T START AND LOCK CONTINUE WITH PRE OUT DOESN TSTART PURGE DOESN T START AND REPEATS THE CYCLE STARTS AND REPEATS THE CYCLE STARTS AND LOCKS OUT MAIN SWITCH OPEN LACK OF GAS MAXIMUM GAS PRESSURE SWITCH DEFECTIVE HERMOSTATS PRESSURE SWITCHES DEFECTIVES OVERLOAD TRIPPED AUXILIARIES FUSE INTERRUPTED CONTROL BOX DEFECTIVE ACTUATOR AIR PRESSURE SWITCH FAULT
42. mode MAN turn the adjusting cam SV and set again the actuator to the AUTO mode to lock the adjusting cam act on the V screw that mathces the bearings referring to the adjusting cam position to adjust the next screw set again the actuator mode to MAN turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw adjust it and go on this way to adjust all the screws in order to set the cam foil shape according to the combustion values read Once the cam foil shape is defined reconnect the TAB thermostat reconnecting the wire to the terminal no 6 or setting the RWF40 burner modulator to AUTO or the CMF switch to 3 only for fully modulating burner Butterfly valve closed Turn the burner off then start it up again Once the pre purge time comes to end drive the burner to the high flame stage by the TAB thermostat and check the combustion values drive the burner to low flame if necessary adjust the low flame size ouput by inserting a screwdriver on the slot FA to move the BF cam The low flame position must never match the ignition position that is why cam BF must be set 20 30 more than the ignition position Now adjust the pressure switches see next paragraph 29 Calibration of air 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
43. ner according to the actuator model provided 25 Settings by means of Berger STM30 Siemens SQM40 actuator 1 Startup the burner by turning its main switch A to on if the burner locks LED B on in the control panel press the RESET button C on the control panel Berger STM30 Cam description High flame Stand by and Ignition Low flame MAN AUTO 2 check the fan motor rotation 21 3 Before starting the burner up drive the high flame actuator microswitch matching the low flame one in order to let the burner operates at the lowest output to safely achieve the high flame stage 4 Start the burner up by means of the thermostat series and wait until the pre purge time comes to an end and that the burner starts up 5 drive the burner to high flame stage by means fo the thermostat TAB high low flame thermostat see Wiring diagrams as far as fully modulating burners see related paragraph 6 Then move progressively the microswitch to higher values until it reaches the high flame position always check the combustion values and eventually adjusting the gas by means of the valves group stabiliser 7 Goon adjusting air and gas flow rates check continuosly the flue gas analisys as to avoid combustion with little air dose the air according to the gas flow rate change following the steps quoted below 8 acting on the pressure stabiliser of the valves group adjust the gas flow rate in the high flame stage as to meet th
44. ng this period the programmer stops until terminal 8 is again activatedthrough contact M After a few seconds the little programmer motor is directly fed by the active part of the apparatus After this point terminal 8 plays no further part in the burner ignition process Pre ventilation time with damper fully open nominal air Mono tube burner 3 Pre ignition time waiting valve at terminal 18 t2 Safety time start up flame strenght at the end of the safety time a flame signal should appear at terminal 22 of the amplifier and it should stay on until a regulation stop if this does not happen the mechanism will block t4 Interval at the end of t4 terminal 19 is live t5 Interval At the end of t5 terminal 20 is live At the same time the monitor outlets from 9 and 11 and terminal 8 into the active part of the apparatus are kept galvanically separatedso as to protect the monitor itself from recovery voltage through the capacity regulator circuit the response from the fuel Twin tube burners t3 Preignition time until the all clear to the pilot burner valve at terminal 17 t2 First safety time pilot flame strenght at the end of the safety time a flame signal should appear at terminal 22 of the amplifier and it should stay on until a regulation stop if it does not the apparatus will block t4 Interval until the consent to the fuel valve at terminal 19 for the first flame of the main burner 9 2nd safety time at
45. nly shall be used e This unit shall be employed exclusively for the use for which it is meant Any other use shall be considered as improper and therefore dangerous The manufacturer shall not be held liable by agreement or otherwise for damages resulting from improper installation use and failure to comply with the instructions supplied by the manufacturer 2 SPECIAL INSTRUCTIONS FOR BURNERS e The burner should be installed in a suitable room with ventilation openings complying with the requirements of the regulations in force and sufficient for good combustion Only burners designed according to the regulations force should be used This burner should be employed exclusively for the use for which it was designed Before connecting burner make sure that the unit rating is the same as delivery mains electricity gas oil or other fuel e Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stopped When the decision is made to discontinue the use of the burner the user shall have qualified personnel carry out the following operations a Remove the power supply by disconnecting the power cord from the mains b Disconnect the fuel supply by means of the hand operated shut off valve and remove the control handwheels from their spindles S
46. ns VGD with SKP Once the train is installed connect electrically all its elements gas valves group pressure switches gas proving system ATTENTION once the gas train is mounted according to the diagram on Fig 5 the gas proving test must be performed according to the procedure set by the laws in force 19 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 Read carefully the chapter WARNINGS and the Electrical connections section To execute the electrical connections proceed as follows 1 remove the cover from the electrical board unscrewing the fixing screws 2 execute the electrical connections to the supply terminal board as shown in the following diagrams 3 check the direction of the fan motor see next pargraph 4 refit the panel cover WARNING The burner is provided with an electrical bridge between terminals 6 and 7 when connecting the high low flame thermostat remove this bridge before connecting the thermostat IMPORTANT Connecting electrical supply wires to the burner teminal block MA be sure that the ground wire is longer than phase
47. o sul settore variabile SV fino al punto di minima potenza Gas butterlfy valve closed The air and gas rate are now adjusted at the maximum output stage go on with the point to point adjustement on the SV adjusting cam as to reach the minimum output point as for the point to point regulation move the gas low flame cam a little lower than the maximum position 90 Set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position move low flame cam 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 V to increase the rate unscrew to decrease Move again cam 111 towards the minimum to meet the next screw on the adjusting cam and repeat the previous step go on this way as to reach the desired low flame point If it is necessary to change the burner output in the low flame stage move low flame cam the low flame position must never match the ignition position that is why the low flame cam must be set 20 30 more than ignition cam Now adjust the pressure switches see page 30 21 Adjustment by the Siemens SQL33 actuator 1 startup the burner by turning its main switch A to on if the burner locks LED B on in the control panel press the RESET button C on the control panel 2 check the fan motor rotation see page 21 3 Start the burner up by means of the thermostat series and wait un
48. ockwise turn the pressure switch adjusting ring nut as to increase the pressure value until the burner stops Slowly fully open the manual cutoff valve Refit the transparent plastic cover on the pressure switch Adjusting the maximum gas pressure switch when provided To calibrate the maximum pressure switch proceed as follows according to its mounting position 1 remove the pressure switch plastic cover 2 if the maximum pressure switch is mounted upstreaam the gas valves measure the gas pressure in the network when flame is off by means of the adjusting ring nut VR set the value read increased by the 30 3 maximum pressure switch is mounted downstream the gas governor gas valves group and upstream the butterfly valve light the burner adjust it according to the procedure in the previous paragrph Then measure the gas pressure at the operating flow rate downstream the gas governor gas valves group and upstream the butterfly valve by means of the adjusting ring nut VR set the value read on step 2 increased by the 30 4 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 thermostat 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 The CMF position sets the opr
49. on Reset it by means of the reset pushbutton on the device in burners with VPS504 pushbutton LB in picture or by the D pushbutton on the burner panel if this one is fitted with LDU11 proving system VPS504 NOTE if the burner is fitted with Dungs VPS504 the pre purgue phase starts once the gas proving system is successfully performed Since the pre purgue phase must be carried out with the maximum air rate the control box drives the actuator opening and when the maximum opening position is achieved the pre purge time counting starts At the end of the pre purge time the actuator drives the complete closing ignition with gas position and as this is achieved the ignition transformer is energised LED L is on the gas valves open Few seconds after the valves opening the transformer is de energised and lamp L turns off The burner is now operating meanwhile the actuator goes to the high flame position and after some seconds the two stage operation begins the burner is driven automatically to high flame or low flame according to the plant requirements Operation in high or low flame is signalled by lamp N on the frontal panel 3l PGMIN eys Main switch Lock out light Reset pushbutton for control box Reset pushbutton for gas proving system only for burners provided with Siemens LDU11 Gas pressure switch consent Lock out light for gas proving system Hi flame operation light Lo fl
50. ormal working 330V 10 test 380V 10 short circuit current max 0 5 mA lonisation current min request 6 pA max permitted length for connecting cables normal cable laid separately 80m armoured cable high frequency protection at terminal 22 140m UV monitor Voltage in UV detector normal working 330V 10 test 380V 10 Detector current min request Max detector current normal working 630 pA test 1300 pA Max length of connecting cable normal cable laid separately 100m armoured cable high frequency protected at terminal 22 200 Weight QRA2 60g QRA10 4504 up in parallel to the measuring device a condenser 100yF 10 25V The wire connecting up the detector electrode should not be in the same sleeve as the other conductor wires Ignition spark monitor with 1 series 02 detector Minimum detector current Operating times t7 initial delay for ventilator G2 2 116 initial delay of air damper OPEN consent 4 t11 opening time for damper any t10 initial delay for air pressure monitor 8 pre ventilation time with damper open 36 t12 travel time for air damper to MIN position any t3 t3 pre ignition time t3 4 t3 t2 12 safety time 1st safety time for burners with intermittent pilot lighter 02 2 t2 t4 interval between start of 12 and response to valve at terminal 19 t4 10 t4 19 2nd safety time for burners with intermittent pilot lighter 2 t5 interv
51. relay during flame detector test circuit contact XIV and during safety time contact IV 3 Do not press EK for more than 10 seconds Programmer diagram t1 pre ventilation time t2 safety time 2 1st safety time t3 pre ignition time pre ignition time t4 interval for creating current between terminals 18 and 19 t4 interval for creating current between terminals 17 and 19 15 interval for creating current between terminals 19 and 20 t6 post ventilation time t7 interval between startup consent and current created at terminal 7 18 duration of start up 9 2nd safety time t10 interval before air pressure monitoring begins t11 damper opening travel time t12 damper closure travel time t13 permissible post combustion time 16 initial delay of damper OPEN response t20 interval before programmer automatically stops These times are valid with the use of a series 01 safety device for monitoring burners with intermittent pilot lighter LFL er d mum po am immi ee je 43 44 45 46 47 CIB UNIGAS Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201 269 web site www cibunigas it e mail clbunigas cibunigas it Note Specifications and data subject to change Errors and omissions excepted
52. s plastic bags foamed polystyrene etc should not be left within the reach of children as they may prove harmful e Before any cleaning or servicing operation disconnect the unit from the mains by turning the master switch OFF and or through the cut out devices that are provided Make sure that inlet or exhaust grilles are unobstructed e In case of breakdown and or defective unit operation disconnect the unit Make no attempt to repair the unit or take any direct action Contact qualified personnel only Units shall be repaired exclusively by a servicing centre duly authorised by the manufacturer with original spare parts Failure to comply with the above instructions is likely to impair the unit s safety To ensure equipment efficiency and proper operation it is essential that maintenance operations are performed by qualified personnel at regular intervals following the manufacturer s instructions e When a decision is made to discontinue the use of the equipment those parts likely to constitute sources of danger shall be made harmless In case the equipment is to be sold or transferred to another user or in case the original user should move and leave the unit behind make sure that these instructions accompany the equipment at all times so that they can be consulted by the new owner and or the installer For the units been modified or have options fitted then original accessory equipment o
53. sation limits The electric actuator that moves proportionally the air damper and the gas butterfly valve uses an adjusting cam with variable shape This one allows the optimisation of the flue gas values as to get an efficient combustion The combustion head positioning determines the burner s output The combustion head determines the energetic quality and the geometry of the flame Fuel and comburent are routed into separated ways as far as the zone of flame generation combustion chamber The control panel placed on the burner s front side shows each operating stage How to interpret the burner s Performance curve To check if the burner is suitable for the boiler to which it must be installled the following parameters are needed furnace input KW or kcal h kW kcal h 860 backpressure data are available on the boiler s ID plate or in the user s manual Example Furnace input 600kW Backpressure 4mbar In the Performance curve diagram Fig 2 draw a vertical line matching the furnace input value and an horizontal line matching the backpressure value The burner is suitable if the intersection point A is inside the performance curve Contropressione in camera di combustione mbar 100 200 300 400 500 600 720 800 900 Potenza kW Fig 2 Data are referred to standard conditions atmospheric pressure at 1013mbar ambient temperature at 15 C Checking the proper gas train size To check the prop
54. the burner 3 place the 4 stud bolts 5 according to the burner s drilling plate described on paragraph Overall dimensions 4 fasten the 4 stud bolts 5 place the ceramic fibre plait on the burner flange 6 install the burner into the boiler 7 fix the burner to the stud bolts by means of the fixing nuts according to the next picture 8 After fitting the burner to the boiler ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement keys Burner Fixing nut Washer Ceramic fibre plait Stud bolt Blast tube 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 To correctly match the burner to the boiler verify the necessary input and the pressure in combustion chamber are included in the burner performance curve otherwise the choice of the burner must be revised consulting the burner manufacturer To choose the blast tube lenght follow the instructions of the boiler manufacturer In absence of these consider the following e C
55. til the pre purge time comes to an end and that the burner starts up 4 burner starts up with the actuator on the ignition position set it to the MAN manual mode by the MAN AUTO selector ignition position read on the air damper index 5 disconnect the TAB thermostat removing the wire from the terminal no 6 or by setting MAN on the RWF40 modulatore or by setting 0 by means of the CMF switch only for fully modulating burners 6 setthe actuator on the manual mode MAN by means of the MAN AUTO switch see next pictures 7 manually drive the adjusting cam SV to the high flame position and set the actuator to the AUTO mode by the related switch see picture to lock the adjusting cam SQL33 actuator cams red cam locking lever for high flame S green cam locking lever for stand by and ignition BF Low flame cam F plastic cam 8 Goon adjusting air and gas flow rates check continuosly the flue gas analisys as to avoid combustion with little air dose the air according to the gas flow rate change following the steps quoted below 9 acting on the pressure governor of the valves group adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler utilisation Siemens VGD valves group remove cap T and act on the VR adjusting screw to increase or decrease the pressure and consequently the gas rate screwind VR the rate increases unscrewing it decreases see next picture
56. tween maximum and minimum set the shape of the adjusting cam foil The adjusting cam sets the air gas ratio in those points regulating the opening closing of the throttle gas valve Set now the low flame output acting on the low flame microswitch of the actuator in order to avoid the low flame output increasing too much or that the flues temperature gets too low to cause condensation in the chimney change the burner setting during the testing in the plant follows the next procedure according to the actuator model provided mod Berger STM30 Siemens 50 40 or Siemens SQL 24 Adjusting procedure If the burner is provided with the DUNGS MBC SE gas valves group set the pressure regulator to 1 3 of its stroke using a 2 5 allen key Innenaechzkardaschllizzsl Mo 2 5 Cio da sk mala Pressure governor Chlave esagonala cava nr 2 5 CAUTION perform these adjustments once the burner is turned off and cooled The burner is factory set wih the adjusting plate holes fully open and the combustion head at its MAX position so it is fit to work at the maximum output To adjust the gas flow partially close the holes as follows loosen the three V screws that fix the adjusting plate D insert a screwdriver on the adjusting plate notches and let it move CW CCW as to open close the holes once the adjustmet is performed fasten the V screws p peu Open holes Closed holes Now adjust the bur
57. wist the protection cap 1 and the O ring 2 Remove the set value spring 3 from housing 4 2 Replace spring 3 Carefully insert the new set value spring Pay attention to mount properly First insert the spring part with smaller diameter in the housing 3 Place O ring 2 in protective cap 1 Screw in the protective cap with the O ring in it 4 Stick the adhesive label for spring identification on the type plate ie DUNGS MBC SE Siemens SKP actuator Removing the combustion head 1 Remove the cover C 2 remove the electrodes cables 3 unscrew the 3 screws V which hold in position the gas manifold G and pull out the complete group as shown in the picture below 4 Clean the combustion head by a compressed air blow or in case of scale scrape it off by a scratchbrush Note to replace the combustion head reverse the procedure described above having care to place correctly the O ring OR between burner and gas manifold Legenda VRT Head adjusting screw Threaded rod Fixing screw Gas manifold O ring Cover 34 Adjusting the electrodes CAUTION avoid the ignition and detection electrodes to contact metallic parts blast tube head otherwise the boilers operation would be compromised Check the electrodes position after intervention on the combustion head R92A R93A R512A R515A R520A R525A A 534mm 519 515 5 5 Replacing the ignition electrodes C
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