Unigas TP1030, Installation, User'S, And Maintenance Manual

Page 1: ...M039168CC Rev 2 05 2008 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Gas burners MANUAL OF INSTALLATION USE MAINTENANCE TP1030 TP1050 TP1080 ...

Page 2: ...22 ADJUSTING AIR AND GAS FLOW RATES 23 Gas Filter 23 VPS504 Gas proving system 23 Adjusting the pilot gas flow rate Brahma EG12 R valve and pressure governor 23 Adjusting air and gas flow rates 24 Adjustments brief description 24 Adjustment procedure 24 Calibration of air pressure switch 27 Calibration of minimum gas pressure switch 27 Adjusting the high gas pressure switch when provided 27 PGCP G...

Page 3: ...urner make sure that the unit rating is the same as delivery mains 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 hav...

Page 4: ...ngerous conditions such as the development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE 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 ...

Page 5: ...r flue heat exchangers to be installed in sound proof areas to reduce noise They can be provided with built in or separate mounted control panel console or wall mounted Note the picture shows one of the possible installations Fan and electrical panel can be placed according to the customer needs PART I INSTALLATION Burner Fan Gas train Electric panel ...

Page 6: ...sation limits The electric actuator 2 that moves proportionally the air damper and the gas butterfly valve uses an adjusting cam 1 with variable shape This one allows the optimisation of the gas flue values as to get an efficient combustion The combustion head positioning determines the burner s output The combustion head 11 determines the energetic quality and the geometry of the flame Fuel and c...

Page 7: ...ps less consumption fewer swigings in the generator temperature and pressure values Checking the proper gas train size To check the proper gas train size it is necessary to 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 600kW in the example quoted on the x axis as far as...

Page 8: ...ecifications 50 Rp2 65 DN65 80 DN80 100 DN100 BURNER TYPE TP1030 TP1050 TP1080 Output min max kW 2550 13000 3500 15500 4500 19000 Fuel Natural gas Category see next paragraph Gas rate min max Stm3 h 270 1376 370 1641 476 2010 Power supply 400V 3N 50Hz Total power consumption kW 0 5 Protection IP40 Operation Progressive Fully modulating Pressure see Note 2 Gas train 80 ØValves Connection 80 DN80 Ga...

Page 9: ...0 80 1864 544 1320 348 1898 1301 597 489 539 710 185 660 660 845 M16 651 460 1000 460 936 200 265 736 80 587 1092 322 1175 408 330 TP1050 100 1864 544 1320 348 1914 1317 597 489 539 710 185 660 660 845 M16 651 460 1000 460 842 200 265 642 80 587 1092 382 1175 408 330 TP1080 100 1864 544 1320 348 1914 1317 597 514 564 710 185 660 660 845 M16 651 460 1000 460 842 200 265 642 80 587 1092 382 1175 408...

Page 10: ... get the input in kcal h multiply value in kW by 860 Data are referred to standard conditions 1013mbar 15 C Performance range 2000 4000 6000 8000 10000 12000 14000 kW 2000 4000 6000 8000 10000 12000 14000 16000 kW 4000 6000 8000 10000 12000 14000 16000 18000 20000 kW ...

Page 11: ...bar TP1080 Gas rate Stm3 h 0 50 1 00 1 50 200 250 300 350 400 450 200 300 400 500 600 700 800 900 1 000 1 1 00 1 200 1 300 1 400 DN80 DN100 DN125 0 1 00 200 300 400 500 300 400 500 600 700 800 900 1 000 1 1 00 1 200 1 300 1 400 1 500 1 600 1 700 DN80 DN100 DN125 0 50 1 00 1 50 200 250 300 350 400 450 400 500 600 700 800 900 1 000 1 1 00 1 200 1 300 1 400 1 500 1 600 1 700 1 800 1 900 2000 21 00 DN...

Page 12: ...ing cases of this type are affected by humidity and are not suitable for stacking The following are placed in each packing case 1 burner with gas train detached 1 gasket to be inserted between the burner and the boiler 1 envelope containing this manual ATTENTION Handling operations must be performed by trained personnel specialised on handling loads If these operations are not carried out correctl...

Page 13: ... the burner and according to the fan features as well Matching the burner to the boiler To correctly match the burner to the boiler verify the necessary input and the pressure in combustion chamber are included in the bur ner 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 ...

Page 14: ...uilt in gas pressure governor VPS504 gas proving system Gas train 2 DN65 80 100 Gas train with valves group MBC 1900 3100 5000SE 2 valves gas filter pressure governor pressure switch VPS504 gas proving system 1 Burner 2 Butterfly valve 3 Gas proving system 4 Maximum gas pressure switch optional 5 Minimum gas pressure switch 6 Gas filter 7 Bellow joint 8 Manual cutoff valve 11 VGD Valves group 14 P...

Page 15: ...r pressure switch PGCP 1 Burner 2 Butterfly valve 4 Maximum gas pressure switch optional 5 Minimum gas pressure switch 6 Gas filter 7 Bellow joint 8 Manual cutoff valve 11 VGD Valves group 14 Pressure governor with filter 15 Pilot gas valve 16 PGCP leakage control pressure switch 19 MBC Valves group DN65 80 100 1 2 4 5 6 7 8 11 16 15 15 4 7 8 14 MANUFACTURER INSTALLER 1 2 3 4 5 7 8 15 15 4 7 8 14 ...

Page 16: ...stabiliser to the gas supply network z connection from the valve to the main gas train by means of the pipe provided with the burner Fig 5 pipe port 3 for connecting the pilot gas train to the valves group of the main gas train connection to the gas supply network connection from the pilot gas train to the gas valves group of the main train 3 SIEMENS VGD40 DUNGS MBC3100 5000SE ...

Page 17: ...the associated parts z install the valve z the direction of gas flow must be in accordance with the direction of the arrow on the valve body z ensure that the bolts on the flanges are properly tightened z ensure that the connections with all components 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 i...

Page 18: ...s 1 spring 2 cap Fig 7 Fig 8 SIEMENS VGD MOUNTING POSI TIONS Fig 9 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 Fig 10 DUNGS MBC SE Siemens SKP actuator BS BS SKP1 SKP2 BS BS SA TP 7631z05 0101 Mounting positions OPTION 10 pulse lin...

Page 19: ...roup pressure switches gas proving system Performance range mbar 4 20 20 40 40 80 80 150 Spring colour ed 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 6 the gas proving test mus be performed according to the procedure set by the laws in force ...

Page 20: ...check again the rotation of the motor 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 p...

Page 21: ...t on the boiler 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 boiler s pressure outlet Fig 12 2 to get the pressure in the combustion chamber and the other one into the butterfly valve s pressure outlet of the burner Fi...

Page 22: ...3 h Gas pressure in combustion head TP1080 Gas rate Stm3 h 0 20 40 60 80 100 120 140 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 0 10 20 30 40 50 60 70 80 90 100 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 0 20 40 60 80 1 00 1 20 1 40 1 60 400 500 600 700 800 900 1 000 1 1 00 1 200 1 300 1 400 1 500 1 600 1 700 1 800 1 900 2000 21 00 2200 ...

Page 23: ...utlet gas pressure use a screwdriver on the screw TR as shown in the picture below Screw to increase the pressure unscrew to decrease once the regulation is performed replace cap T Fig 13 Keys 1 Gas filter 2 Gas proving system 3 Gas valves 4 Adjusting cam 5 Actuator 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 ...

Page 24: ...rocedure On the DUNGS MBC SE gas valves group set the pressure regulator to 1 3 of its stroke using a 2 5 allen key 1 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 2 cam IV stroke limitation cam must be set a little higher than the cam III to limit t...

Page 25: ...e or decrease the pressure and conse quently 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 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 th...

Page 26: ...thermostat to the minimum in order that the actuator moves progressively towards the low flame position 14 move cam III 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 15 Move again cam III towards the minimum to meet the next screw on the adjusting cam and r...

Page 27: ...f 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 z Check that the burner is operating correctly z Clockwise turn the pressure sw...

Page 28: ...ANTEES 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 T...

Page 29: ...mper ot the maximum opening position the pre purge time counting starts 8 At the end of the pre purge time the air damper moves to the ignition position the ignition transformer is energised the solenoid gas valves EVP1 and EVP2 are energised as well and consequently EV1 and EV2 9 Few seconds after the gas valves opening the transformer is de energised the pilot gas valves are disconnected later 1...

Page 30: ...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 be sure to replace the Or ring into its place C and replace the cover faste...

Page 31: ...crew in the protective cap with the O ring in it 6 Stick the adhesive label for spring identification on the type plate Removing the combustion head z Remove the cover C z remove the electrodes cables z unscrew the 3 screws V which hold in position the gas manifold G and pull out the complete group as shown in figure Note to replace the combustion head reverse the procedure described above having ...

Page 32: ...P and ignition elecctrode E Fig 17 Detailed view of the combustion head with pilot P and ignition elecctrode E Observe the values quoted on the next picture Fig 18 ATTENTION avoid the ignition electrode to contact metallic parts blast tube head etc otherwise the boiler s operation would be compromised Check the electrode position after any intervention on the combustion head E P E P 5mm P E ...

Page 33: ...par Removing the combustion head 4 loose screw B that fasten the ignition electrode E to the burner pilot P 5 remove the electrode and replace it referring to the values quoted on Fig 18 ATTENTION avoid the ignition electrode to contact metallic parts blast tube head etc otherwise the boiler s operation would be compromised Check the electrode position after any intervention on the combustion head...

Page 34: ...its slot Checking the detection current To check the detection signal follow the scheme in Fig 19 If the signal is lower than the value quoted check the position of the UV detector photocell the electrical contacts and if necessary replace the UV detector Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner s main switch to 0 Off position 2 disconnect the powe...

Page 35: ...SSURE SWITCH DEFECTIVE z DEFECTIVE THERMOSTAT z OVERLOAD TRIPPED INTERVENTION z AUXILIARIES FUSES INTERRUPTED z DEFECTIVE AIR PRESSURE SWITCH z DEFECTIVE CONTROL BOX z z z DEFECTIVE SERVOCONTROL z z z z AIR PRESSURE SWITCH FAULT OR BAD SETTING z GAS PRESSURE SWITCH BAD SETTING z IGNITION TRANSFORMER FAULT z z z z DETECTION ELECTRODE BAD POSITION z BUTTERFLY VALVE BAD SETTING z DEFECTIVE GAS GOVERN...

Page 36: ...OUSING 1 7 BELLOWS 6 3 2 SKP ACTUATOR 1 8 LEVERAGE 6 3 3 SKP ACTUATOR 1 9 BRACKET 6 3 4 GAS PROVING SYSTEM 2 STANDARD BLAST TUBE 6 3 5 GAS PRESSURE 3 1 BUTTERFLY GAS VALVE 6 4 GAS FILTER 4 1 GAS MANIFOLD 6 5 FLANGED REVERSIBLE CURVE 4 2 IGNITION ELECTRODE 7 1 JUNCTION BOX 4 3 FALSE LANCE 7 2 IGNITION TRANSFORMER 4 4 RING NUT 8 IGNITION CABLE 4 5 STANDARD COMBUSTION HEAD 9 PHOTOCELL 4 6 O RING 10 1...

Page 37: ...C I B UNIGAS M039168C 37 ...

Page 38: ...VGD DN100 2190174 2190174 2190174 GAS VALVE ACTUATOR SKP15 2190181 2190181 2190181 GAS VALVE ACTUATOR SKP25 2190183 2190183 2190183 GAS VALVE GROUP SIEMENS VGD DN125 2190184 2190184 2190184 GAS VALVE GROUP DUNGS MBC3100SE DN80 21903M7 21903M7 21903M7 GAS VALVE GROUP DUNGS MBC5000SE DN100 21903M8 21903M8 21903M8 PILOT GAS ELECTROVALVE 2190502 2190502 2190502 GAS PROVING SYSTEM VPS504 2191604 219160...

Page 39: ...pply terminal block plate 1 MA2 Supply terminal block plate 2 MC1 Terminal block for connection of burner components plate 1 MC2 Terminal block for connection of burner components plate 2 MV Fan motor N Neutral PA Combustion air pressure switch PGMAX High gas pressure switch where supplied remove the bridge between terminal 156 and 158 in terminal block MC PGMIN Low gas pressure switch PGP Pilot g...

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Page 52: ...ctivated 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 and 8 otherwise the mechanism will not start up the burner For a burner to start up the following conditions must be met z Mechanism not blocked reset z Damper closed Limit contact...

Page 53: ... 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 01 Specifications Mains voltage 220V 15 240V 10 Frequency 50Hz 6 60Hz 6 Absorbed capacity 3 5 VA Built in fuse T6 3 250E slow action DIN41571 No 451915070 External fuse max 16A Interference N VDE0875...

Page 54: ...lot 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 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 t2 1st safety time t3 pre ignition time t3 pre ignition tim...

Page 55: ...h vent pipe to the atmosphere Gas valve proving is initiated automatically with every burner startup using one or two standard pressure monitors either z prior to burner startup z during the pre purge time if it lasts at least 60 s z immediately after the controlled shutdown or z on completion of the burner control s control program e g on comple tion of the post purge time The valve proving test ...

Page 56: ...urns to its start position where it switches itself off During these idle steps the position of the control contacts of the pro gramming mechanism remains unchanged Program and lockout indicator When the unit goes to lockout the programming mechanism stops and also the position indicator fitted to the spindle of the mechanism The symbol that stops above the reading mark not only indicates during w...

Page 57: ...terfere with or modify the unit z Check wiring carefully before putting the unit into operation z Check all safety functions when putting the unit into operation or after replacing a fuse z Ensure protection against electric shock hazard on the unit and at all electrical connections through appropriate mounting z Electromagnetic emissions must be checked from an application point of view z The reg...

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Page 60: ...are subject to change without notice 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 ...