Unigas KP91, Manual Of Installation - Use - Maintenance

Page 1: ...M03940CL 0 0 06 2020 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES MANUAL OF INSTALLATION USE MAINTENANCE Gas heavy oil burners KP91 KP92 KP93 KR512 KR515 KR520 KR525...

Page 2: ...e employed exclusively for the use for which it was designed Before connecting the burner make sure that the unit rating is the same as delivery mains electricity gas oil or other fuel Observe caution...

Page 3: ...ixtures DIRECTIVES AND STANDARDS Gas burners European directives Regulation 2016 426 UE appliances burning gaseous fuels 2014 35 UE Low Tension Directive 2014 30 UE Electromagnetic compatibility Direc...

Page 4: ...quipment of machi nes EN 60335 2 Electrical equipment of non electric appliances for house hold and similar purposes Safety requirements Burner data plate For the following information please refer to...

Page 5: ...PR Progressive MD Fully modulating 4 BLAST TUBE S Standard L Extended 5 DESTINATION COUNTRY see data plate 6 BURNER VERSION A Standard 7 EQUIPMENT 1 2 gas valves gas proving system 8 2 gas valves gas...

Page 6: ...BURNERS KR512 KR515 KR520 KR525 Output min max kW 600 4500 770 5200 1000 6400 2000 8000 Fuel Natural gasHeavy oil Category see next paragraph Gas rate min max Stm3 h 63 476 81 550 106 677 212 847 Gas...

Page 7: ...nt BURNERS KR512 L KR515 L KR520 L KR525 L Output min max kW 600 4500 770 5200 1000 6400 2000 8000 Fuel LD L LPG D Heavy oil viscosity 400cSt 50 E 50 C Category see next paragraph Gas rate LPG min max...

Page 8: ...s appliance can moreover be converted and or be calibrated for the appliance category E I2E This therefore implies that the appliance is suitable for G gas and H gas or is demonstrably suitable for G...

Page 9: ...533 1553 464 957 441 596 304 344 228 288 360 466 M12 424 280 310 300 632 148 484 44 750 292 765 240 185 80 1615 152 221 35 473 439 132 560 441 1055 533 1555 464 959 441 596 304 344 228 307 360 466 M1...

Page 10: ...7 967 476 642 380 420 354 540 560 M14 552 390 390 633 150 483 843 292 891 328 270 80 1766 229 35 313 626 132 555 508 1119 598 1644 407 1002 476 642 380 420 354 540 560 M14 552 390 390 685 150 535 875...

Page 11: ...46 598 1727 1085 642 380 420 494 540 492 M14 552 390 390 792 150 642 942 382 759 328 270 KR520 50 1682 144 35 594 100 530 508 1152 598 1585 943 642 434 484 494 540 492 M14 552 390 390 755 150 605 843...

Page 12: ...67 642 454 504 494 540 492 M14 552 390 390 633 150 483 843 292 759 343 270 80 1682 144 35 626 132 530 650 1152 598 1644 1002 642 454 504 494 540 492 M14 552 390 390 685 150 535 875 322 759 343 270 100...

Page 13: ...ter tank 21 Filter Pb4 Temperature probe 22 Pressure switch PGMIN Pb1 Temperature probe 23 Safety valve with built in gas governor Pb3 Temperature probe 24 Proving system 9 3 way solenoid valve 25 Pre...

Page 14: ...1 Electrical preheater tank 14 Low thermostat TCI 22 Pressure switch PGMIN 5 Thermostat TR 15 Pressure governor 23 Safety valve with built in gas governor 6 Low thermostat TCN 16 Flexible hose 24 Cont...

Page 15: ...ding 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 in...

Page 16: ...n 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...

Page 17: ...50 Rp2 50 DN100 DN80 DN65 0 40 80 120 160 200 50 100 150 200 250 300 350 400 450 500 Rp 2 50 DN65 DN80 DN100 0 50 100 150 200 50 100 150 200 250 300 350 400 450 500 550 Rp 2 50 DN65 DN80 DN100 0 50 10...

Page 18: ...nical specifications Measuring 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 pressure o...

Page 19: ...3 h 0 5 10 15 20 25 30 35 40 45 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 0 5 10 15 20 25 30 35 40 45 50 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 0 5 10 15...

Page 20: ...ot suitable for stacking The following are placed in each packing case burner with gas train detached gasket to be inserted between the burner and the boiler envelope containing this manual To get rid...

Page 21: ...ith 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 a...

Page 22: ...unt the gas train proceed as follows NOTE the bellows unit the manual cutoff valve and the gaskets are not part of the standard supply WARNING before executing the connections to the gas pipe network...

Page 23: ...UCIATORE 185 501939 PGMAX PGCP PGMI EV1 EV2 S EV2 EV1 PGMAX PGMIN VD R PGCP VD V VD V VD R PS PS pressure sensor Gas filter Example of gas train MBE A A C B B C 1 Mount flange into pipe systems Use ap...

Page 24: ...pressure switches set to 20 of the setpoint 2 Mounting on pipe Sensor position 5x DN according to MBE Pipe fitting with female thread size mount sensor with seal observe torque 3 The pressure sensor i...

Page 25: ...n SA SA TP D BS SKP1 SKP2 SIEMENS VGD Mounting positions TP Siemens VGD con SKPx Example of gas train Gas filter PGCP PGMIN PGMAX T VR Performance range mbar neutral yellow red Spring colour SKP 25 0...

Page 26: ...d oil is driven to the nozzle a part comes out from the nozzle while the othe part goes back to the pump In this system the by pass plug if provided must be removed and the optional return port on the...

Page 27: ...Connecting the oil flexible hoses to the pump To connect the flexible oil hoses to the pump proceed as follows according to the pump provided 1 remove the closing nuts A and R on the inlet and return...

Page 28: ...PART II INSTALLATION 28 Connecting the burner to the oil pumping unit A G1 2 G1 2 G3 4 G1 Legend A inlet B return B G1 G3 8 KR515 KR520 KR525...

Page 29: ...PART II INSTALLATION 29 PLANT WITH DEGASING BOTTLE A G1 G1 G1 2 G1 2 G1 2 G1 Legend A inlet KP91 KP92 KP93 KR512 A G1 2 G1 2 G3 4 G1 G1 2 G1 2 G1 2 G1 Legend A inlet B return B G1 KR515 KR520 KR525...

Page 30: ...case of three phase 220 V or 230 V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay WARNING Respect the b...

Page 31: ...ig 5 18 24 kW Fig 6 230V 400 V W2 U2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 L1 L2 L3 L1 L2 L3 ELECTRIC MOTOR CONNECTION R1 R1 230V 400 V R2 R2 R3 R3 L3 L3 L2 L2 L1 L1 R1 R1 230V 400 V R2 R2 R3 R3 R4 R4 R5 R5 R...

Page 32: ...be heated at about 80 C Pipe heating system Pipe heating system must be provided that is a system to heat pipes and plant components to mantain the viscosity in the pumping lim its Higher the oil visc...

Page 33: ...4 48 150 19 3 128 14 48 43 2 5 92 200 23 5 170 18 9 54 7 35 250 28 212 23 45 65 8 79 300 32 5 254 28 87 6 11 7 400 41 9 338 37 1 110 14 6 500 51 6 423 46 2 132 17 5 600 61 4 508 55 4 154 20 45 700 71...

Page 34: ...30 40 50 60 70 80 90 100 110 120 130 140 150 160 TEMPERATURE C VISCOSITY E LIGHT OIL 1 3 E AT 20 C HEAVY OIL 2 4 E AT 50 C HEAVY OIL 4 E AT 50 C HEAVY OIL 7 5 E AT 50 C HEAVY OIL 10 E AT 50 C HEAVY OI...

Page 35: ...osity the oil atomising temperature should be between 145 C and 160 C see diagram OIL TEMPERATURE FOR PUMP FEEDING 1 10 100 0 10 20 30 40 50 60 70 80 90 TEMPERATURE C VISCOSITY E a 50 C Fig 8 PUMP FEE...

Page 36: ...valve 15 Daily tank 26 Manual valve 6 One way valve 16 Electrical resistor TO THE BURNER 7 Manual valve 17 Heating device 27 Degassing bottle 8 Pressure gauge 18 Pressure gauge 28 Manual valve 9 Maxim...

Page 37: ...ve 3 Filter 4 Pump coupled to electrical motor 5 Safety valve 6 One way valve 7 Manual valve 8 Pressure gauge 9 Maximum pressure switch 10 Minimum pressure switch PRESSURE GOVERNOR UNIT 11 Manual valv...

Page 38: ...CHNICAL 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 GE...

Page 39: ...indicator lights G1 and G2 on Few seconds after the opening of the gas valves the ignition transformer is de energised and LED B4 is off To move from the low flame position the actuator opening time 1...

Page 40: ...actuator microswitch matching the low flame one in order to let the burner ope rates at the lowest output to safely achieve the high flame stage 3 Start the burner up by means of the thermostat series...

Page 41: ...tput pressure according to sensor s measuring range Adjust the outlet pressure to the value specified by the burner or equipment manufacturer While making outlet pressure adjustments do not exceed a v...

Page 42: ...the gas low flame microswitch towards the minimum to meet the next screw on the adjusting cam and repeat the pre vious step go on this way as to reach the desired low flame point 18 Now adjust the pr...

Page 43: ...ckout then read the value on the pressure switch scale and set it to a value reduced by 15 Repeat the ignition cycle of the burner and check it runs properly Refit the transparent plastic cover on the...

Page 44: ...as soon as the boiler thermostat gives a start signal to the burner creates by means of the diaphragm pump inside it a pressure in the test space of 20 mbar higher than the supply pressure When wishi...

Page 45: ...ocumentation Fig 19 Probe connections Danfoss MCX for burners with 2 tanks Before starting up the burner make sure that the return pipe to the tank is not obstructed Any obstruction would cause the pu...

Page 46: ...t 400 cSt 400 cSt 4000 cSt 12 E 7 E 7 E 15 E 15 E 50 E 50 E 530 E Par rEG Pb1 tr Oil heater temperature probe parameter not visible Pb2 tCI Plant consent temperature probe when installed 20 C 70 C 70...

Page 47: ...eturn line DIMENSIONS FLOW RATE kg h Indicative pessure on return bar Min Max 40 13 40 19 50 16 50 22 60 20 60 20 70 23 70 23 80 26 80 23 90 30 90 22 100 33 100 22 115 38 115 21 130 43 130 22 145 48 1...

Page 48: ...ure gauge without changing the air flow rate set during the gas operation adjustments see previous paragraph checking always the combustion parameters the adjustment is to be performed by means of the...

Page 49: ...PART III OPERATION 49 Pressure gauge port RP Pressure gauge port V2 SV2 PG...

Page 50: ...nd grease joints and rotating parts IMPORTANT Remove the combustion head before checking the ignition electrode Remove and clean the compressed air regulator Remove and clean the oil regulator if prov...

Page 51: ...MBEMultiBloc VD Mounting position to push 1 Position VD on VB fig 2 3 2 Slide VD forward up to the stop fig 4 3 Screw VD on with 2 M5 screws for each max 5 Nm 44 in lb fig 5 6 4 VD can be mounted rot...

Page 52: ...ter Self cleaning filter Removing the combustion head 1 Remove the top H 2 Remove the UV detector out of its housing disconnect electrode cables and the light oil flexible hoses 3 Loosen the screws V...

Page 53: ...the measures in mm shown on the next picture 1 Move the combustion head all ahead by the head stroke limitation cam acting on the ring nut 2 fix it by means of screw 1 2 place the gas plate 6 accordin...

Page 54: ...fuel supply 3 remove the photocell from its slot see next figure 4 clean the bulbe if dirty taking care not to touch it with bare hands 5 if necessary replace the bulb replace the photocell into its s...

Page 55: ...ssure switch damaged or bad links Check air pressure switch functions and links Burner control damaged Replace burner control BURNER LOCKS OUT WITHOUT ANY GAS FLOW Gas valves don t open Check voltage...

Page 56: ...22 1 7 1 7 23 3 15 23 2 23 4 23 1 20 3 6 20 10 25 2 13 20 1 20 2 20 4 20 5 20 7 1 18 2 16 3 4 3 24 1 24 17 3 25 1 18 1 15 20 8 1 20 8 5 11 16 1 9 18 3 27 7 27 5 27 3 27 4 27 5 22 3 27 6 8 19 3 20 6 1...

Page 57: ...22 2 PRESSURE GOVERNOR 30 2 2 3 LIGHT 13 AIR PRESSURE SWITCH 22 3 BRACKET 30 2 2 4 PROTECTION 14 RESISTOR 23 1 MOTOR 30 2 2 5 FLAME UNLOCK BUTTON 15 RESISTOR 23 2 COUPLING 30 2 2 6 SWITCH 16 1 BURNER...

Page 58: ...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 bri...

Page 59: ...because during this period an NTC in the circuit acts as retarder This means that brief unscheduled influences can not cause a block Times t3 t2 and t4 only apply only to safety devices in the series...

Page 60: ...ot 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 relay during flame detector test circuit contact...

Page 61: ......

Page 62: ......

Page 63: ......

Page 64: ...a L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it Note specifications and data subject to change Errors an...

Page 65: ...Pb3 Connections from terminal side Probe connection input AI1 probe Pb1 set point tr oil heater temperature probe input AI2 probe Pb2 set point tCI plant consent temperature probe when installed input...

Page 66: ...InF rEL Software version Installed software version tUN Autotuning Activation On deactivation ESC PID parameter autotuning Alarms Warning When the red triangle on the top left lights one or more alarm...

Page 67: ...letter show n in the burner model P N E D H 89 cSt 50 cSt 50 cSt 110 cSt 110 cSt 400 cSt 400 cSt 4000 cSt 12 E 7 E 7 E 15 E 15 E 50 E 50 E 530 E Par rEG Pb1 tr Oil heater temperature probe parameter...

Page 68: ...4 terminals AI4 COM controls the inner heater temperature As soon the relevant set point is got it drives the output number 4 terminals C4 NO4 linked to the relais KTCN This allows the oil pump to sta...

Page 69: ...r temperature probe input AI2 probe Pb2 set point tCI plant consent temperature probe when installed input AI3 probe Pb3 set point OIL oil heater output temperature probe PID regulation input AI4 prob...

Page 70: ...gin first CnF Configuration menu Parameter configuration rEG Regulation menu Set to set point probe thresholds etc ALA Alarm menu Access to alarm management Act Active alarms Show the active alarms rE...

Page 71: ...9 30 0 A4P 2 3 11 A4C Calibration Probe 4 Don t modify it 20 0 20 0 0 0 C A4P 0 3 12 dI Digital input 1 dI1 Input 1 polarity Pump Change type of digital input NC o NO 0 1 1 3 13 dI2 Alarm polarity fr...

Page 72: ...Startup number Don t modify it 0 5 2 3 36 tU3 Measurement cycles number Don t modify it 1 4 2 3 37 tU4 Max differential command exit Don t modify it 0 01 10 00 10 00 V 3 38 tU5 Differential reduction...

Page 73: ...pe of regulation of probe 3 Oil tank exit Type of regulation 0 thermostat 1 PID don t modify 0 1 1 3 50 OIL Set point Probe 3 Oil tank exit Nozzle oil temperature according to the table Set point adju...

Page 74: ...p24 DerivativeTime Td for PID Probe 1 Tank resistor Derivative time for second PID regulation 0 0 300 0 23 0 s rE3 1 3 66 p25 Overshooting for Integral action Tank resistor Don t modify it 100 1000 2...

Page 75: ...bout 1 5 E which guarantees correct and safe functioning of the burner The temperature values in the table guarantee the respect of that parameter and are valid when the pre heating tank is installed...