CIB UNIGAS Unigas RX90, Manual Of Installation - Use - Maintenance

Page 1: ...M039175CD Rel 3 0 07 2010 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Gas burners Low NOx series MANUAL OF INSTALLATION USE MAINTENANCE RX90 RX91 ...

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Page 3: ...ains electricity gas oil or other fuel z 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 Rem...

Page 4: ... of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 2009 142 EC 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...

Page 5: ...hing 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 Fig 4 The values are referred to standard environmental conditions 1013mbar 15 C Checking the proper gas train size To check the proper gas train size it is necessary to know the available gas pressure value upstream the burner s gas...

Page 6: ...ions 50 Rp2 65 DN65 80 DN80 100 DN100 BURNER TYPE RX90 RX91 Output min max kW 288 1480 674 2008 Fuel Natural gas Category see next paragraph Gas rate min max Stm3 h 30 5 157 71 213 Gas pressure see Note 2 Power supply 400V 3N 50Hz Total power consumption kW 3 5 4 5 Electric motor kW 3 4 Approximate weight kg 250 Protection IP40 Operation Progressive Fully modulating Gas train 50 Connection ØValves...

Page 7: ... B UNIGAS M039175CD 7 Country and usefulness gas categories GAS CATEGORY COUNTRY I2H AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH I2E LU PL I2E R B BE I2L NL I2ELL DE I2Er FR ...

Page 8: ...5 439 132 290 419 843 422 1393 959 434 228 258 307 360 464 M12 417 280 310 295 592 148 444 750 322 649 228 185 RX90 100 1168 242 35 592 145 290 419 843 422 1483 1049 434 228 258 447 360 464 M12 417 280 310 295 672 148 524 824 382 649 228 185 RX91 50 1168 242 35 429 100 290 419 843 422 1294 860 434 273 303 329 360 464 M12 417 280 310 295 522 148 374 624 216 649 228 185 RX91 65 1168 242 35 406 118 2...

Page 9: ...ion 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 Per formance curve minimum Pressure in the Network gas flow rate curves PRESSURE IN COMBUSTION CHAMBER mbar RX90 kW RX91 kW GAS PRESSURE mbar RX90 Stm3 h RX91 Stm3 h Caution the gas rate value is quoted on the x axis the related network p...

Page 10: ... The following are placed in each packing case z burner with gas train z gasket to be inserted between the burner and the boiler z envelope containing this manual To get rid of the burner s packing follow the procedures laid down by current laws on disposal of materials Fig 6 ATTENTION The lhandling operations must be carried out by specialised and trained personnel If these opera tions are not ca...

Page 11: ...d in the diagram please contact the supplier to verify that a correct matching is possible with res pect 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 manu facturer To choose the blast tube ...

Page 12: ... 40 with built in gas pressure governor VPS504 gas proving system Gas train 2 Rp2 Gas train with valves group MBC 1200SE 2 valves gas filter pressure governor VPS504 gas proving system Gas train 3 DN65 80 100 Gas train with valves group MBC 1900 3100 5000SE 2 valves gas filter pressure governor VPS504 gas proving system 1 Burner 2 Butterfly valve 3 Gas proving system 4 Maximum gas pressure switch ...

Page 13: ...ext paragraphs according to the gas train used z threaded gas trains with Multibloc Dungs MBC SE 1200 or Siemens VGD20 z flanged gas trains with Multibloc Dungs MBC SE 1900 3100 5000 or Siemens VGD40 ATTENTION once the gas train is mounted according to the diagram on Fig 8 the gas proving test mus be performed according to the procedure set by the laws in force ATTENTION it is recommended to mount...

Page 14: ...ents are tight z make certain that the O rings and gaskets between the flanges and the double gas valve are fitted z Connect the reference gas pipe TP in figure 8mm external size pipe supplied loose to the gas pressure nipples placed on the gas pipe downstream the gas valves gas pressure must be measured at a distance that must be at least 5 times the pipe size Leave the blowhole free SA in figure...

Page 15: ...agent see Fig 14 2 Insert MBC SE Note position of O rings see Fig 15 3 Tighten screws A H 4 After installation perform leakage and functional test 5 Disassembly in reverse order Fig 15 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 Fi...

Page 16: ...s valves group gas proving system pressure switches Performance range mbar 4 20 20 40 40 80 80 150 Spring colour red black green Performance range mbar 0 22 15 120 100 250 Spring colour neutral yellow red ATTENTION once the gas train is mounted according to the diagram on Fig 8 the gas proving test mus be performed according to the procedure set by the laws in force ...

Page 17: ...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 Ele...

Page 18: ...Burner s lockout signalling LED LSPG Gas proving system lockout signalling LED 3 In case of modulating burners the 5 6 and 7 terminals on the MA teminal block are already connected to the output controller mod RWF40 A 4 pole plug coming out from the electrical panel is provided for the temperature and pressure probes connec tions see Fig 21 Note the output controller modulator is provided accordin...

Page 19: ... the event of wrong rotation reverse the three phase supply and check again the rota tion of the motor NOTE the burners are supplied for three phase 400V supply and in the case of three phase 230V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay Fig 24 Progressive burners Fig 25 Probes connection Fig 26 F...

Page 20: ... Generator 2 Pressure outlet on the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge Measuring the gas pressure in the combustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one into the combustion chamber s pres sure outlet Fig 28 2 to get the pressure in the combustion chamber and the other one into th...

Page 21: ...xis 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 reque sted gas rate add the pressure value in the combustion chamber to the value read on the y axis 0 5 10 15 20 25 30 20 40 60 80 100 120 140 160 5 15 25 35 45 55 60 80 100 120 140 160 180 200 220 ...

Page 22: ...7 VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off valves This check is carried out as soon as the boiler thermostat TAB 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 into the pressure supply...

Page 23: ...procedure To change the burner setting during the testing in the plant follow the next procedure On the DUNGS MBC SE gas valves group set the pressure regulator to 1 3 of its stroke using a 2 5 allen key Now adjust the burner according to the actuator model provided ATTENTION before starting the burner up be sure that the manual cutoff valves are open and check that the pres sure upstream the gas ...

Page 24: ... 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 go on 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 qu...

Page 25: ...re now adjusted at the maximum power stage go on with the point to point adjustement on the SV adjusting cam as to reach the minimum output point 12 as for the point to point regulation move the gas low flame microswitch cam III a little lower than the maximum position 90 13 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position 14 move ...

Page 26: ...sition set it to the MAN manual mode by the MAN AUTO selector ignition position read on the air damper index ID1 see picture on pag 31 5 disconnect the TAB thermostat removing the wire from the terminal no 6 or by setting MAN on the RWF40 modulatore or by set ting 0 by means of the CMF switch only for fully modulating burners 6 manually drive the adjusting cam SV to the high flame position and set...

Page 27: ...djustment is accomplished 11 the air and gas rate are now adjusted at the maximum output go on with the point to point adjustment on the SV1 adjusting cam as to reach the minimum output point gradually move the adjusting cam in order to adjust each of the V1 screws as to set the cam foil shape as described on the next steps 12 to change the SV position set the actuator on the manual mode MAN turn ...

Page 28: ...CMF 2 To move the adjusting cam set CMF 1 or 2 and then CMF 0 Calibration of air and gas pressure switches Fig 29 2 5 The air pressure switch locks the control box if the air pressure is not the one requested If it happens unlock the burner by means of the control box unlock pushbutton placed on the burner control panel The gas pressure switches check the pressure to avoid the burner operate when ...

Page 29: ...crease the pressure value until the burner stops z Slowly fully open the manual cutoff valve z Refit the transparent plastic cover on the pressure switch Adjusting the high gas pressure switch when provided To calibrate the high 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 ...

Page 30: ...YING 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 1 Turn to the ON position the main switch A on the burner s control panel see Fig 29 2 Check the control box is not locked LED B on and eventually release it by means of the pushbutton C reset for more inform...

Page 31: ...odulating MD buners according to the requirements of the plant As far as the modulator is concerned refere to the related manual Fig 29 Burner front panel Key A Main switch B Lock out LED C Reset pushbutton for control box D Reset pushbutton for gas proving system only for burners provided with Siemens LDU11 E Gas pressure switch signal LED F Lock out LED for gas proving system G Hi flame operatio...

Page 32: ...eplacement 4 be sure to replace the O ring into its place C and replace the cover fastening by the proper screws A Inspection and replacement of the MULTIBLOC DUNGS MBC SE filter Threaded valves group 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 MAN...

Page 33: ... set value spring 3 from housing 4 3 Replace spring 3 4 Carefully insert the new set value spring Pay attention to mount properly First insert the spring part with smaller diameter in the housing 5 Place O ring 2 in protective cap 1 Screw in the protective cap with the O ring in it 6 Stick the adhesive label for spring identification on the type plate DUNGS MBC SE SKP Siemens actuator 3 1 2 4 4 1 ...

Page 34: ... position the gas manifold G and pull out the complete group as shown in picture 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 Key VRT Head adjusting screw AR Threaded rod V Fixing screw G Gas manifold OR O ring C Cover V C G AR OR VRT C AR G ...

Page 35: ...rodes see picture 5 remove the electrodes and replace them referring to the quotes in the previous paragraph 6 reconnect the electrodes calbes 7 replace the combustion head 8 replace the burner cover ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc otherwise the boi ler s operation would be compromised Check the electrodes position after any inter...

Page 36: ...etection signal remove the bridge on TEST ER or TEST UV and connect a micro ammeter when Fig 34 If the signal is less than the value indicated check the position of the detection electrode or detector the electrical contacts one ER terminal for the electrode two FC terminals for the UV probe see pictureon the side and if necessary replace the electrode or the UV detector Fig 34 Control box Minimum...

Page 37: ... TO START DOESEN T SWITCH TO HIGH FLAME DOESEN T RETURN IN LOW FLAME LOCK OUT DURING OPERATION TTURNS OF AND REPEATS CYCLE DURING OPERATION MAIN SWITCH OPEN z LACK OF GAS z z MAXIMUM GAS PRESSURE SWITCH DEFECTIVE z z THERMOSTATS PRESSURE SWITCHES DEFECTIVES z z z OVERLOAD TRIPPED INTERVENTION z AUXILIARIES FUSE INTERRUPTED z DEFECTIVE CONTROL BOX z z z z z DEFECTIVE ACTUATOR z z z AIR PRESSURE SWI...

Page 38: ... MOTOR 2180276 2180277 GAS VALVE GROUP SIEMENS VGD Rp2 2190171 2190171 GAS VALVE GROUP SIEMENS VGD DN65 2190172 2190172 GAS VALVE GROUP SIEMENS VGD DN80 2190169 2190169 GAS VALVE GROUP SIEMENS VGD DN100 2190174 2190174 GAS VALVE ACTUATOR SKP15 2190181 2190181 GAS VALVE ACTUATOR SKP25 2190183 2190183 GAS VALVE GROUP DUNGS MBC SE Rp2 21903M5 21903M5 GAS VALVE GROUP DUNGS MBC SE DN65 21903M6 21903M6 ...

Page 39: ...VALVE EV2 LPGMIN INDICATOR LIGHT FOR PRESENCE OF GAS IN THE NETWORK LS INDICATOR LIGHT FOR BURNER STAND BY LSPG INDICATOR LIGHT FOR LEAKAGE OF VALVES LT INDICATOR LIGHT FOR FAN OVERLOAD TRIPPED LTA IGNITION TRANSFORMER INDICATOR LIGHT MV FAN MOTOR PA COMBUSTION AIR PRESSURE SWITCH PGMAX MAXIMUM PRESSURE GAS SWITCH OPTIONAL PGMIN MINIMUM GAS PRESSURE SWITCH PS LOCK OUT RESET BUTTON PT100 TEMPERATUR...

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Page 43: ... the CLOSED position and allow current to flow between terminals 11 and 8 z Any contacts checking that the fuel valve bv is closed or other con tacts with similar functions must be closed between terminal 12 and the air pressostat LP z The contact for the air pressostat LP must be in the off position LP test so as to feed terminal 4 z The gas pressostat contacts GP and the safety thermostat and pr...

Page 44: ...equest 6 µA 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 70µA Max detector current normal working 630 µA test 1300 µA Max length of connecting cable normal cable laid separately 100m armoured cable high freque...

Page 45: ... for creating current between terminals 19 and 20 t6 post ventilation time t7 interval between startup consent and current created at terminal 7 t8 duration of start up t9 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 t16 initial delay of damper OPEN response t20 interval before ...

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Page 48: ...d and data subject to change Errors and omissions excepted C I B UNIGAS S p A Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it ...