Unigas RN510, Manual Of Installation - Use - Maintenance

Page 1: ...MANUAL OF INSTALLATION USE MAINTENANCE RN510 RN515 RN520 RN525 M039215CB REL 1 1 02 2014 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive Fully modulating Heavy oil Burners ...

Page 2: ...UCTIONS FOR BURNERS z 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 z Only burners designed according to the regulations in force should be used z This burner should be employed exclusively for the use for which it was designed z Before connecting the burner make sure that t...

Page 3: ...nditions such as the development 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 EN 55014 1Electromagnetic compatibility Requirements for household appliances electric tools and similar ap...

Page 4: ... apparatus EN 50165 Electrical equipment of non electric appliances for household and similar purposes Safety requirements UNI EN 746 2 Industrial thermoprocessing equipment Burner data plate For the following information please refer to the data plate z burner type and burner model must be reported in any communication with the supplier z burner ID serial number must be repor ted in any communica...

Page 5: ...dulating 4 BLAST TUBE S Standard L Extended 5 DESTINATION COUNTRY see data plate 6 BURNER VERSION A Standard BURNER RN510 RN515 RN520 RN525 Output min max kW 1314 3953 1628 4884 2326 6977 2000 8000 Fuel Heavy oil Viscosity See Burner model identification table Heavy oil rate min max kg h 117 352 145 435 207 622 178 713 Oil train inlet pressure bar 4 max Power supply 400V 3N a c 50Hz Total power co...

Page 6: ...ition see paragraph Adjusting the combustion head the minimum output point is rea ched 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 Per formance curve minimum PRESSURE IN COMBUSTION CHAMBER mbar RN5...

Page 7: ...0 530 468 1152 571 1285 349 643 556 642 345 385 540 496 M14 552 390 390 37 36 897 328 270 RN515 1502 1682 145 217 246 35 350 530 508 1152 598 1285 x 643 x 642 384 424 540 496 M14 552 390 390 37 36 802 328 270 RN520 1502 1682 145 207 250 35 350 530 508 1152 598 1285 x 643 x 642 422 472 540 496 M14 552 390 390 37 36 802 328 270 RN525 1502 1682 145 197 275 35 350 530 650 1152 598 1285 x 643 x 642 434...

Page 8: ...f the combustion chamber as described on paragraph Overall dimensions 2 place the burner to the boiler lift it up and handle it according to the procedure described on paragraph Handling the burner 3 place the stud bolts 5 on boiler s door according to the burner drilling template described on paragraph Overall dimensions 4 fasten the stud bolts 5 place the gasket on the burner flange 6 install th...

Page 9: ... flange in a horizontal position in order to obtain the correct inclination of the pre heating tank For different installations please contact the Technical Department MOUNTING POSITION Key 1 Burner flange upper side indicated 2 Bracket 3 Pre heating tank on the burner SIDE UP SIDE DOWN 1 2 3 ...

Page 10: ...t 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 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 ...

Page 11: ...ipe that connects the pum s return port to the tank as well The excess of oil goes back to the tank this installation can be considered self ble eding If provided the inside by pass plug must be installed to avoid air and fuel passing through the pump Burners come out from the factory provided for double stage systems They can be suited for single pipe system recommended in the case of gravity fee...

Page 12: ...amages inject some lubrication oil into the vacuum inlet z Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the joint noise and overloading the gears z Pipes should not contain air pockets Rapid attachment joint should therefore be avoided and threaded or mechanical seal jun ctions preferred Junction threads elbow joints...

Page 13: ... the burner The pressure governor makes the oil reach the nozzle at the required pressure while the excess of oil goes back to the tank To change the delivery pressure act on the adjusting screw of the delivery pressure governor from pump to the burner inlet air discharge valve from oil governor from burner to oil governor discharge cap from oil governor to degassing bottle inlet ...

Page 14: ... pressurised The pressurisation is also necessary to feed the burner pump avoiding its cavitation because of the high suction at the inlet The supplying system scope is to pump and heat oil The oil viscosity is referred in various unit measures the most common are E cSt Saybolt and Redwood scales Table 3 shows the various unit convertions e g 132 cSt viscosity corresponds to 17 5 E viscosity The d...

Page 15: ...oil temperature Pump operating maximum pressure both for the supplying system and burner Remember that pumps and all the system components through which the oil circulates feature an upper limit Always read the techni cal documentation for each component Schemes on and are taken from UNI 9248 liquid fuel feeding lines from tank to burner stan dard and show how a feeding line should be designed For...

Page 16: ... 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 1 592 64 6 176 23 35 800 81 677 73 8 198 26 3 900 91 762 83 220 29 2 1000 100 7 896 92 1 330 43 8 1500 150 1270 138 2 440 58 4 2000 200 1690 184 2 550 73 2500 250 2120 230 660 87 6 3000 300 2540 276 880 117 4...

Page 17: ...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 OIL 13 E AT 50 C HEAVY OIL 22 E AT 50 C HEAVY OIL 50 C HEAVY OIL 47 E AT 50 C HEAVY OIL 70 E AT 50 C HEAVY OIL 200 E AT 50 C ...

Page 18: ...emperature 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 10 PUMP FEEDING PRESSURE Max for E 1069 pimps Max for T and TA pumps 0 1 2 3 4 5 6 40 60 80 100 120 140 160 TEMPERATURE C PRESSURE bar Fig 11 PRESSION D ALIMENTATION POMPE VISCOSITY vs TEMPERATURE DIAGRAM BEST VISCOSITY RANGE FOR A PRO...

Page 19: ...19 HYDRAULIC DIAGRAMS Fig 13 3ID00014 v2 Hydraulic diagram Two or more burners configuration M M PI PI PSL PSH M M PI PSH PSL PSH PI TI TSH TSL TS ...

Page 20: ...2 Hydraulic diagram Single burner configuration M M PI PI PSL PSH PSL PSH PI TI TSH TSL TS Обратный ход жидкости для подогрева Вход жидкости для подогрева Горелка n 1 См P ID горелки Группа рабочей емкости Насосная группа ...

Page 21: ...UNIT 11 Manual valve 12 Pressure governor 13 Needle valve 14 Pressure gauge DAILY TANK 15 Daily tank 16 Electrical resistor 17 Heating device 18 Pressure gauge 19 Thermometer 20 High pressure switch 21 Low pressure switch 22 Thermostat high 23 Thermostat low 24 Thermostat 25 Manual valve 26 Manual valve TO THE BURNER 27 Degassing bottle 28 Manual valve 29 Filter supplied loose with the burner 30 S...

Page 22: ...ZZLE DELIVERY PRESSURE bar RETURN PRESSURE MAX bar RETURN PRESSURE MIN bar FLUIDICS WR2 UNI GAS M3 25 19 20 7 9 indicative values Tab 3 Fig 15 Atomisation angle according to the return pressure _________ Flow rate FLOW RATE kg h DIMENSIONS Min Max 40 13 40 50 16 50 60 20 60 70 23 70 80 26 80 90 30 90 100 33 100 115 38 115 130 43 130 145 48 145 160 53 160 180 59 180 200 66 200 225 74 225 250 82 250...

Page 23: ...ale up to 200 C Fig 16 Danfoss MCX Fig 17 Probe connections Danfoss MCX Menu path Oil viscosity at 50 C according to the letter shown 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 not visible Pb2 tCI Plant consent temperature probe when installed 20 C 70 C 70 C...

Page 24: ...sistors thermostat TRS it is factory preset and sealed Don not modify it When the set temperature is exceeded check the reason and reset it by means of the push button PR Resistor thermostat TR check the best atomising oil tempe rature and set it on TR Thermostat TCN it gives the enabling signal to the oil N C valve set TCN at about 20 less than TR Fig 18 Probe connections Danfoss MCX PR Pb3 Pb1 T...

Page 25: ... charged 3 bleed the air from the M pressure gauge port Fig 17 by loosing the cap without removing it then release the solenoid starter Fig 19 4 Before starting the burner up drive the high flame 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 5 Turn the burner on by means of its main switch A see next...

Page 26: ...on on the pump adjusting screw VR see Fig 17 as to get the nozzle pressure at 25bar see diagram on page 22 10 in order to get the maximum oil flow rate adjust the pressure reading its value on the PG pressure gauge checking always the combu stion parameters the adjustment is to be performed by means of the SV adjusting cam screw V see picture when the cam has reached the high flame position 11 To ...

Page 27: ...he TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position as for fully modulating burners refer to the related paragraph 15 move cam III towards the minimum to make the actuator move towards the low flame until the two bearings find the adjusting screw that refers to a lower position screw V to increase the rate unscrew to decrease in order to g...

Page 28: ...it the transparent plastic cover on the pressure switch Fully modulating burners To adjust the fully modulating burners use the CMF switch on the burner control panel see next picture instead of the TAB thermo stat as described on the previous paragraphs about the progressive burners Go on adjusting the burner as described before paying attention to use the CMF switch intead of TAB The CMF positio...

Page 29: ... is feeded at constant pressure while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see prevoius paragraph Fig 23 Stand by Fig 24 Prepurge Fig 25 Low flame Fig 26 High flame Key 1 Oil pump 2 Oil solenoid valve 3 Nozz...

Page 30: ...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 THR...

Page 31: ... light F on the front panel z At the end of the pre purge the ignition transformer is energised signalled by the indicator light C on the panel Two seconds later the oil valve opens and the ignition transformer is de energized light C off The burner is now into operation the servocontrol begins the opening after few seconds the burner goes to two stages operation and eventually switches to the hig...

Page 32: ...lame 3 Automatic D Fan motor thermal cutout intervention E Burner lockout F Burner in stand by IRA Auxiliary resistors wsitch L Heavy oil solenoid lamp operation N Contrlol box reset pushbutton P Heating resistors safety thermostat Q Pre heating tank R Modulator T Main switch RN515 RN520 RN525 A B C D E L P Q N R F T R A B C D E F L N P P Q Q T ...

Page 33: ... Remove and clean the combustion head page 35 z Examine and clean the ignition electrodes adjust and replace if necessary see page 35 z Examine and clean the detection probe adjust and replace if necessary see page 36 z Examine the detection current see page 36 z Remove and clean page 36 the heavy oil nozzle Important use solvents for cleaning not metallic tools and at the end of the maintenance p...

Page 34: ...VL screw and remove the oil gun and the electrodes check the oil gun replace it fi necessary 3 after removing the oil gun unscrew the nozzle and replace it if necessary 4 in order to replace the electrodes unscrew the VE fixing screws and remove them place the new electrodes being careful to observe the measures showed on pag reassemlbe following the reversed procedure Fig 29 Fig 27 Key 1 Inlet 2 ...

Page 35: ...stor To clean replace the photoresistive detector remove it from its slot To clean the photoresistor use a clean cloth not cleaning sprays Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner main switch to 0 Off position 2 disconnect the power mains 3 close the fuel valve of the supply line Burner disposal In case of disposal follow the instructions according...

Page 36: ...OSTAT MALFUNCTION z FAN THERMAL CUTOUT TRIPPED z AUXILIARY FUSE BLOWN z OIL RESISTOR FAULTY z z OIL ENABLING THERMOSTAT TRIPPED z z CONTROL UNIT MALFUNCTION z z z z z z AIR SERVOCONTROL MALFUNCTION z CIRCUIT ENABLING THERMOSTAT z z SMOKY FLAME z z IGNITION TRANSFORMER FAULTY z IGNITION ELECTRODES WRONGLY POSITIONED z DIRTY NOZZLE z z FAULTY OIL VALVE z z FAULTY OR DIRTY PHOTORESISTOR z FAULTY RESI...

Page 37: ...N 9 5 1 ADJUSTING CAM FOIL 13 2 OIL MANIFOLD 18 3 6 PROTECTION 9 6 ACTUATOR 13 3 CONNECTOR 18 3 7 SWITCH 9 7 LEVERAGE 14 1 PLUG 18 3 8 SWITCH 9 8 CAM 14 2 PLUG 19 1 CONTROL BOX 9 9 JOINT 14 3 OIL PRE HEATER 19 2 IGNITION TRANSFORMER 9 10 BRACKET 14 4 SHEATH 9 11 BRACKET 14 5 RESISTOR 9 12 BRACKET 14 6 1 OIL FILTER 9 13 1 PRESSURE GOVERNOR 14 6 2 GASKET 9 13 2 BRACKET 14 6 3 GAS BLEEDING VALVE 10 E...

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Page 39: ...39 WIRING DIAGRAMS Refer to the attached wiring diagrams WARNING 1 Electrical supply 230V 50Hz 1 a c 400V 50Hz 3N a c 2 Do not reverse phase with neutral 3 Ensure burner is properly earthed ...

Page 40: ...liary switch v in the actuator t5 Interval On completion of t5 terminal 20 receives power At the same time control outputs 9 to 11 and input 8 are galvanically separated from the LAL s control section LAL is now protected against reverse voltages from the load control circuit With the release of LR at terminal 20 the startup sequence of the LAL ends After a few idle steps steps with no contact pos...

Page 41: ...4 A max 20 A peak Internal fuse T6 3H250V according to IEC 127 External fuse max 10 A Weight Device 1000 g Plug in base 165 g Sequence diagram Key t1 Prepurge time with air damper fully open t2 Safety time t3 Preignition time short Z connected to terminal 16 T3 Preignition time long Z connected to terminal 15 t3n Postignition time Z connected to terminal 15 t4 Interval between voltage at terminals...

Page 42: ... sequence excluding t11 and t12 t10 Interval from startup to the beginning of the air pressure check t11 Air damper running time to the OPEN position t12 Air damper running time to the low fire position MIN t13 Permissible afterburn time t16 Interval to the OPEN command for the air damper t20 For self shutdown of the sequence switch ...

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Page 44: ...Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it Note specifications and data subject to change Errors and omissions exceptd ...