Related Manuals for Unigas TP1030
Summary of Contents for Unigas TP1030
- Page 1 TP1030 TP1050 TP1080 Gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039168CC Rev. 2 05/2008...
-
Page 2: Table Of Contents
CIB UNIGAS - M039168CB TABLE OF CONTENTS WARNINGS ................................3 PART I: INSTALLATION ............................5 GENERAL FEATURES ................................... 5 How to choose the burner ................................7 Burner model identification ................................8 Country and usefulness gas categories ............................8 Overall dimensions (mm) ................................. 9 Performance curves .................................. -
Page 3: Warnings
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 PRO- DUCT INSTALLATION AND MAINTENANCE. THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION OF THIS MANUAL. - Page 4 the power-driven components in the system (i.e. pumps, burner, etc.) DIRECTIVES AND STANDARDS should be switched off. Gas burners European directives: 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS - Directive 90/396/CEE - Gas Appliances; Directive 2006/95/EC on low voltage;...
-
Page 5: Part I: Installation
CIB UNIGAS - M039168CC PART I: INSTALLATION GENERAL FEATURES This series of industrial burners is designed for all those applications that require big-sized air fans or air-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). - Page 6 CIB UNIGAS - M039168CC Fig. 1 Adjusting cam Actuator Bellows Air inlet flange Junction box Combustion head adjusting screw Gas filter Gas valves group Cover 10 Ignitor gas train 11 Combustion head-blast tube ass.y 12 Burner flange The gas coming from the supply line, passes through the valves group provided with filter and stabiliser. This one forces the pressure in the utilisation limits.
-
Page 7: How To Choose The Burner
CIB UNIGAS - M039168CC How to choose the burner To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed: fuel furnace input, in kW or kcal/h (kW = kcal/h / 860);... -
Page 8: Burner Model Identification
Burners are identified by burner type and model. Burner model identification is described as follows. Type TP1030 Model M-. PR. (1) BURNER TYPE TP1030 - TP1050 - TP1080 (2) FUEL M - Natural gas (3) OPERATION (Available versions) PR - Progressive... -
Page 9: Overall Dimensions (Mm)
Overall dimensions (mm) Air inlet flange Boiler drilling plate Burner flange TP1030 1864 544 1320 348 1898 1301 1000 460 936 200 587 1092 322 1175 372 TP1030 100 1864 544 1320 348 1914 1317 1000 460 842 200 587 1092 382 1175 372... -
Page 10: Performance Curves
CIB UNIGAS - M039168CC Performance curves TP1030 2000 4000 6000 8000 10000 12000 14000 TP1050 2000 4000 6000 8000 10000 12000 14000 16000 TP1080 4000 6000 8000 10000 12000 14000 16000 18000 20000 Performance range To get the input in kcal/h, multiply value in kW by 860. -
Page 11: Pressure In The Network / Gas Rate Curves
C.I.B. UNIGAS - M039168CC Pressure in the network / gas rate curves TP1030 DN80 DN100 1 50 1 00 DN125 1 000 1 1 00 1 200 1 300 1 400 Gas rate Stm TP1050 DN80 DN100 DN125 1 00... -
Page 12: Installation
Packing The burners are despatched in wooden crates whose dimensions are: TP1030 - TP1050: 2180mm x 1580mm x 1210mm (L x P x H) TP1080: 2180mm x 1580mm x 1560mm (L x P x H) Packing cases of this type are affected by humidity and are not suitable for stacking. -
Page 13: Fitting The Burner To The Boiler
CIB UNIGAS - M039168CC Fitting the burner to the boiler To perform the installation, it is necessary to drill the boiler door as described on paragraph “Overall dimensions”; screw the studbolts (5) on the boiler door, according to the drilling plate (see paragraph “Overall dimensions”);... -
Page 14: Gas Train Connections
CIB UNIGAS - M039168CC GAS TRAIN CONNECTIONS The diagrams show the components of the gas trai included in 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. - Page 15 CIB UNIGAS - M039168CC Gas train - 3: Gas train with valves group VGD 20/40 with built-in gas pressure governor + PGCP MANUFACTURER INSTALLER Gas train 4(DN65/80/100): Gas train with valves group MBC 1900/3100/5000SE (2 valves + gas filter + pressure governor +...
-
Page 16: Pilot Burner Mounting
CIB UNIGAS - M039168CC Pilot burner mounting The pilot gas train is already installed to the burner, the following connections must be executed: connection from the filter with stabiliser to the gas supply network connection from the valve to the main gas train, by means of the pipe provided with the burner. -
Page 17: Assembling The Gas Grain
CIB UNIGAS - M039168CC Assembling the gas grain To assemble the main gas train, proceed as follows: gas supply network ”direction” arrows for installation Keys 1A..1E Gasket Gas filter Gas valves group Bellow joint Manual cock Fig. 6 - Example of gas train 1) in case of threaded joints: use proper seals according to the gas used;... -
Page 18: Pressure Adjusting Range
CIB UNIGAS - M039168CC SIEMENS VGD..MOUNTING POSI- TIONS SKP1. SKP2. 7631z05/0101 Fig. 9 Fig. 8 Fig. 7 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. - Page 19 CIB UNIGAS - M039168CC DUNGS MBC valves: Performance range (mbar) 4 - 20 20 - 40 40 - 80 80 - 150 Spring colour black green Siemens VGD valves with SKP actuator: Performance range (mbar) 0 - 22 15 - 120...
-
Page 20: Electrical Connections
CIB UNIGAS - M039168CC 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. -
Page 21: Combustion Head Pressure Curves Depending On The Gas Flow Rate
CIB UNIGAS - M039168CC Combustion head pressure curves depending on the gas flow rate Curves are referred to pressure= 0mbar 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 (3% of residual O in the flues and CO in the standard limits). -
Page 22: Pressure - Rate In Combustion Head Curves
C.I.B. UNIGAS - M039168CC Pressure in combustion head- gas rate curves TP1030 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Gas rate Stm TP1050 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700... -
Page 23: Adjusting Air And Gas Flow Rates
CIB UNIGAS - M039168CC ADJUSTING AIR AND GAS FLOW RATES Keys Gas filter Gas proving system Gas valves Adjusting cam Actuator Fig. 13 Gas Filter (Fig. 13 - 2) The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burner valves, counters and regulators) from becoming rapidly blocked. -
Page 24: Adjusting Air And Gas Flow Rates
CIB UNIGAS - M039168CC Adjusting air and gas flow rates ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed. - Page 25 CIB UNIGAS - M039168CC III IV Servocontrol cams High flame AUTO Stand-by and Ignition Low flame Stroke limitation Turn the burner on by means of its main switch : if the burner locks press the RESET button on the control panel - see chapter “OPERATION”.;...
- Page 26 CIB UNIGAS - M039168CC head position “MAX”head position Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above. 11 the air and gas rate are 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.
-
Page 27: Calibration Of Air Pressure Switch
CIB UNIGAS - M039168CC Calibration of air pressure switch To calibrate the air pressure switch, proceed as follows: Remove the transparent plastic cap. Once air and fuel setting have been accomplished, startup the burner. During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction (to increase the adju- sting pressure) until the burner lockout, then read the value on the pressure switch scale and set it to a value reduced by 15%. -
Page 28: Part Ii: Operation
CIB UNIGAS - M039168CC PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CON- NECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSI- DERED IMPROPER AND THEREFORE DANGEROUS. -
Page 29: Operation
CIB UNIGAS - M039168CC OPERATION ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Turn on the burner main switch. -
Page 30: Part Iii: Maintenance
CIB UNIGAS - M039168CC PART III: 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. -
Page 31: Replacing The Spring In The Gas Valve Group
CIB UNIGAS - M039168CC Replacing the spring in the gas valve group To replace the spring in the gas valve group,proceed as follows: Carefully twist the protection cap 1 and the O-ring 2. remove the “set value” spring 3 from housing 4. -
Page 32: Adjusting The Ignition Electrode
CIB UNIGAS - M039168CC Adjusting the ignition electrode Important Note: check the ignition electrode after each removing of the combustion head. 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 33: Replacing The Ignition Electrode
CIB UNIGAS - M039168CC Replacing the ignition electrode 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. To replace the ignition electrode, proceed as follows: remove the burner cover disconnect the electrode (E) cable (CE);... -
Page 34: Cleaning And Replacing The Detection Photocell
CIB UNIGAS - M039168CC Cleaning and replacing the detection photocell The photocell working life is about 10000 working hours (about 1 year), at max 50°C after which it must be replaced. To clean/replace the detection photocell, proceed as follows: Disconnect the system from the electrical power supply. -
Page 35: Troubleshooting
CIB UNIGAS - M039168CC TROUBLESHOOTING CAUSE / TROUBLE MAIN SWITCH OPEN LACK OF GAS HIGH GAS PRESSURE SWITCH DEFECTIVE DEFECTIVE THERMOSTAT OVERLOAD TRIPPED INTERVENTION AUXILIARIES FUSES INTERRUPTED DEFECTIVE AIR PRESSURE SWITCH DEFECTIVE CONTROL BOX DEFECTIVE SERVOCONTROL AIR PRESSURE SWITCH FAULT OR... -
Page 36: Burners Exploded View
BURNERS EXPLODED VIEW POS. DESCRIPTION POS. DESCRIPTION 1.1.1 BURNER FLANGE 5.2.1 AIR PRESSURE SWITCH 1.1.2 COVER ADJUSTING CAM CERAMIC FIBRE PLAIT 5.3.1 ADJUSTING CAM FOIL AIR INTAKE DAMPER LEVERAGE INSPECTION GLASS GASKET BRACKET REVERSIBLE PIPE INLET 6.3.1 GAS VALVE HOUSING BELLOWS 6.3.2 "SKP"... -
Page 38: Spare Parts
CIB UNIGAS - M039168CC SPARE PARTS Desription Code TP1030 TP1050 TP1080 GAS PROVING SYSTEM SIEMENS LDU 2020413 2020413 2020413 CONTROL BOX SIEMENS LFL 2020448 2020448 2020448 DETECTION ELECTRODE 2080258 2080258 2080258 GAS FILTER DN80 2090112 GAS FILTER DN100 2090113 2090113... -
Page 39: Reference Electrical Wiring Diagrams
CIB UNIGAS - M039168CC REFERENCE ELECTRICAL WIRING DIAGRAMS COMPLETE KEY Fan motor remote contactor coil (line) Fan motor remote contactor coil (star) Fan motor remote contactor coil (triangle) Auxiliary fan motor contactor (star) Auxiliary fan motor contactor (triangle) Fan motor contactor (line) -
Page 52: Appendix
APPENDIX consent to start-up by means of the thermostat or pressostat "R" SIEMENS LFL 1.3.. CONTROL BOX start-up program Automatic programme in the event of interruption and indication of posi- normal burner operation tion when interrupted regulation stop caused by "R" By default, in the event of any kind of interruption, the flow of fuel is imme- programmer returns to start-up position A. - Page 53 Ionisation monitor Twin-tube burners (**) voltage in detector electrode Preignition time until the all clear to the pilot burner valve at normal working 330V ±10% terminal 17. test 380V ±10% First safety time (pilot flame strenght); at the end of the safety time short circuit current max.
- Page 54 Programmer diagram pre-ventilation time limit contact switch for damper OPEN position safety time block remote signal '1st safety time main relay (working network) with contacts "ar" pre-ignition time Monitor fuse 'pre-ignition time block relay with "br" contacts interval for creating current between terminals 18 and 19 fuel valve 'interval for creating current between terminals 17 and 19 reset button...
- Page 55 using one or two standard pressure monitors, either VALVE PROVING SYSTEM SIEMENS LDU11 prior to burner startup, The LDU11... gas valve proving system is designed for use in gas-fired plant equipped with two safety shutoff valves. During each startup cycle, during the pre-purge time, if it lasts at least 60 s, the control unit automatically programs the valve proving test and, in the immediately after the controlled shutdown, or...
- Page 56 phase (Test 2), the control unit inhibits burner startup and goes to lockout. Specifications In that case, the lockout reset button lights up to indicate the fault. Mains voltage AC 220 V -15 %...240 V +10 % AC 100 V Remote indication of the fault is also possible.
- Page 57 forming any work on it! The LDU11... is a safety device. It is therefore not permitted to open, Alarm signal "Leaking valve" interfere with or modify the unit! Main relay with contacts "ar..." Check wiring carefully before putting the unit into operation! Built-in fuse Check all safety functions when putting the unit into operation or after Lockout relay with contacts "br..."...
- Page 60 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 Note: specifications and data are subject to change without notice. Errors and omissions excepted.