Unigas G335A, Installation Manual

Page 1: ...M039530CA 0 1 07 2023 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES MANUAL OF INSTALLATION USE MAINTENANCE G258A G335A G380A G400A Gas Light oil burners LMV 2x 3x Microprocessor controlled...

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: ...tion is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which a separat...

Page 6: ...TRY see data plate 6 BURNER VERSION A Standard Y Special 7 EQUIPMENT 0 2 gas valves 1 2 gas valves gas proving system 7 2 gas valves maximum gas pressure switch 8 2 gas valves gas proving system maxim...

Page 7: ...40 Power supply triphase 220 V 230 V 3 380 V 400 V 3N 50 Hz Auxiliary Power supply 220 V 230 V 2 220 V 230 V 1N 50 Hz Total power consumption kW 5 6 7 1 9 1 Pump motor kW 1 1 1 1 1 1 Electric motor kW...

Page 8: ...210 190 G335A 100 1547 181 850 372 35 271 592 145 460 395 1087 509 1499 1085 414 254 290 447 380 518 M12 453 300 340 320 791 148 642 942 353 708 210 190 G380A 50 1486 181 850 372 35 271 550 100 490 39...

Page 9: ...or 6 Solenoid valve 6 1 Solenoid valve 10 Oil distributor 12 Pressure gauge 13 Pressure governor 15 Pressure switch 16 One way valve 16 1 One way valve 18 Flexible hose 19 Manual valve 20 Pressure gau...

Page 10: ...lue 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 i...

Page 11: ...gas flow rate curvesPerformance Curves GAS PRESSURE mbar G258A MG Stm3 h G335A MG Stm3 h GAS PRESSURE mbar G380A MG Stm3 h G400A MG Stm3 h ATTENTION the gas rate value is quoted on the x axis the rela...

Page 12: ...sure in the combustion head insert the pressure gauge probes one into the combustion chamber s pres sure outlet to get the pressure in the combustion chamber and the other one into the butterfly valve...

Page 13: ...ssure burner head vs natural gas flow rate Curves are referred to pressure 0 mbar in the combustion chamber Gas pressure in combustion head G258A M Stm3 h G335A M Stm3 h Gas pressure in combustion hea...

Page 14: ...se dimensions are 1600mm x 1000mm x 860 mm L x P x H Such packages fear moisture and are not suitable for stacking Packing cases of this type are affected by humidity and are not suitable for stacking...

Page 15: ...supplier to verify that a correct matching is possible with respect of the application involved To correctly match the burner to the boiler verify the type of the blast tube Verify the necessary inpu...

Page 16: ...diagrams are in compliance with the current laws Gas train with valves group VGD and MBE with built in gas pressure governor gas leakage pressure switch PGCP Legend WARNING before executing the conne...

Page 17: ...B DLE 10 Manual valve optional MULTIBLOC DUNGS MB DLE 405 412 MB DLE 415 420 Mounting 1 Mount flange onto tube lines use appropriate sealing agent 2 Insert MB DLE note position of O rings 3 Remove Mul...

Page 18: ...oried by min and max 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...

Page 19: ...ilizer Caution the SKP2 diaphragm D must be vertical WARNING removing the four screws BS causes the device to be unserviceable SA SA TP D BS SKP1 SKP2 SIEMENS VGD Mounting positions TP Siemens VGD con...

Page 20: ...ct the gas valves group and pressure switches plugs Overall dimensions mm BURNERS WITH INVERTER VARIANT if provided ATTENTION it is reccomended to install the filter with gas flow parallel to the floo...

Page 21: ...s and with a signal in 0 10V controls it through the inverter Generally the curve of the inverter goes from 50 to 100 of the engine revolutions This in addition to improving the setting of the burner...

Page 22: ...controls it through the inverter Generally the curve of the inverter goes from 50 to 100 of the engine revolutions This in addition to improving the setting of the burner also allows a saving on the c...

Page 23: ...and keep this position for a preset time td3 in order to fill the test space Test gas pressure EV1 closes and keep this position for a preset time td2 The pressure switch PGCP has not to detect a pre...

Page 24: ...be suited for single pipe system recommended in the case of gravity feed as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rota tion referring t...

Page 25: ...e nozzle reducing efficiency Always use O Rings or mechanical seal copper or aluminium gaskets jun ctions if possible An external filter should always be installed in the suction line upstream the fue...

Page 26: ...e pump being careful to avoid exchanging the lines see the arrows marked on the pump For further information refer to the technical documentation of the pump Diesel filters Suntec TA Oil viscosity 3 7...

Page 27: ...it breaker WARNING It is forbidden to use the fuel pipes for the execution and or completion of the grounding The system must comply with the current regulations Earth the system always check in advan...

Page 28: ...time of the offer contract Provide sufficient protections for cables and connectors taking into consideration positioning spaces and the panel burner tracing sur faces Always consult beforehand the el...

Page 29: ...ING 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 EXCEPT FOR ITS M...

Page 30: ...he control box drives the actuator opening and when the maximum opening position is reached the pre purge time counting starts At the end of the pre purge time the actuator is in the light oil ignitio...

Page 31: ...ratio curvepoints see the LMV related manual Set now the low flame output according to the procedure described on the Siemens LMV manual in order to avoid the low flame output increasing too much or...

Page 32: ...gised 6 Fan motor energised 7 Ignition transformers energised 8 Open valves 9 Flame 10 Lock unlock codes 11 Closing actuator 12 Opening actuator 13 Unit measure 14 Key F A While pressing the two keys...

Page 33: ...curezza trasformatore accensione ON TSA1 1st safety time ignition transformer ON Ph42 TSA1 primo tempo sicurezza trasformatore accensione OFF TSA1 1st safety time ignition transformer OFF t42 preignit...

Page 34: ...omplete visualisation press enter again the data will be completely shown for 1 to 3 seconds By pressing enter or and at the same time the system will exit the parameter visualisation and go back to t...

Page 35: ...s orto return to the normal display If a message like the one below is shown during operation it means that the burner is locked out and the Errore code is shown in the example error code 4 this messa...

Page 36: ...is accessed 143 by pressing the End message will blink 3 PressPress InFo for more than three seconds or for more than three seconds orto return to the normal display For further nformation see tha LM...

Page 37: ...1 NOZZLE SUPPLY PRESSURE 25 bar Atomisation angle according to the return pressure _________ Flow rate ATTENTION To achieve the maximum flow rate close completely the return line FLOW RATE kg h DIMENS...

Page 38: ...PART III OPERATION 38 FLUIDICS KW3 60 NOZZLE SUPPLY PRESSURE 20 bar VISCOSITY AT NOZZLE 5 cSt Pressure on return bar Flow rate kg h The nominal size of the nozzle is indicated at the ends of the curve...

Page 39: ...RESSURE 20 bar VISCOSITY AT NOZZLE 5 cS Pressure on return bar Flow rate kg h Pressure on return bar Flow rate kg h The nominal size of the nozzle is indicated at the ends of the curve The nominal siz...

Page 40: ...eturn bar Flow rate kg h The nominal size of the nozzle is indicated at the ends of the curve Pressure on return bar Flow rate kg h The nominal size of the nozzle is indicated at the ends of the curve...

Page 41: ...wise rotation reduces start flow rate anticlockwise rotation incre ases it Do not use a screwdriver on the screw VR The pressure stabilizer is adjusted by operating the screw VS located under the cove...

Page 42: ...requires PS 10 40 or PS 50 200 Outlet pressure MIN 10 25 50 75 MAX PS 10 40 4 mbar 0 4 kPa 2 w c 10 mbar 1 0 kPa 4 w c 25 mbar 2 5 kPa 10 w c 50 mbar 5 0 kPa 20 w c 75 mbar 7 5 kPa 30 w c 100 mbar 10...

Page 43: ...Refit the transparent plastic cover on the pressure switch Calibration the maximum gas pressure switch when provided To calibrate the maximum pressure switch proceed as follows according to its mounti...

Page 44: ...position must be regulated in the plant during the commissioning The factory setting depends on the type of fuel for which the burner is designed For natural gas burners plate holes are fully opened...

Page 45: ...accepted Examination of ignition electrodes cleaning possible adjustment and if necessary replacement Check the detection electrode photocell depending on burner model clean adjust if necessary and re...

Page 46: ...D E F F E 1 3 4 6 T 2 A r re 5 T 1 3 pe 0 pa 5 pBr 0 3 pe pa 6 5 pBr 1 1 0 5 3 6 2 2 Prese di pressione MB DLE 415 420 B01 MB DLE 405 412 0 1 2 3 4 5 2 pe pBr 2 pe 3 pa pBr 5 0 3 pa 2 3 5 0 Check the...

Page 47: ...he 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 holding the gas manifold G loosen the connectors E 4 Some models...

Page 48: ...ombustion head ATTENTION avoid the electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the electrodes position after any interv...

Page 49: ...it if 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...

Page 50: ...decrease in performance The owner makes the decision whether to finish using the burner or replacing and disposing of it based on the actual state of the appliance and any repair costs The use of the...

Page 51: ...witch functions and links Burner control damaged Replace burner control BURNER LOCKS OUT WITHOUT ANY GAS FLOW Gas valves don t open Check voltage on valves if necessary replace valve or the burner con...

Page 52: ...of cables in the ignition transformer or into the electrodes Improve the installation Ignition transformer damaged Replace the transformer PUMP TOO NOISY Suction too high over 0 35 bar dirty filters...

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Page 56: ...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 57: ...Service manual AZL2x LMV2x 3x Burner Management System M12916CD Rev 3 4 03 2023...

Page 58: ...900 Process data 32 Actuators references 33 Gas proving system 33 Air fuel curve points 33 COMMISSIONING THE BURNER 34 Warm setting 38 Cold setting 39 BURNER STARTUP WITH LMV2x ALREADY PROGRAMMED 40...

Page 59: ...CTIONS 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 b...

Page 60: ...ditions 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 Directi...

Page 61: ...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...

Page 62: ...forms all the burner control functions and of the Siemens AZL local programming unit that interfaces the system with the user Keys 1 Burner 2 AZL2 3 Air actuator 4 Fuel actuator 5 LMV2 User interface...

Page 63: ...ice mode Info and Enter keys Used for Info and Service menues Used as Enter key in the setting modes Used as Reset key in the burner operation mode Used to enter a lower level menu Key Used to decreas...

Page 64: ...8 Parameters level heating engineer...

Page 65: ...ription Password 000 Internal parameters OEM Service 100 Informazioni generali General OEM Service Info 200 Controllo bruciatore Burner control OEM Service 300 Controllo bruciatore solo LMV26 Burner c...

Page 66: ...kup data set Service Info Param Descrizione Description Password LMV20 LMV27 LMV26 LMV37 102 Data produzione in gg mm aa Identification date yy mm dd Service Info x x x 103 Numero identificativ Identi...

Page 67: ...ed OEM Service x x 145 Indirizzo dispositivo per Modbus Device address for Modbus OEM Service x x 146 Velocit di trasmissione per Modbus Baud rate for Modbus OEM Service x x 147 Parit per Modbus Parit...

Page 68: ...erci zio azzerabile da Service Fuel 1 Operation hours resettable Service Info x 174 Fuel 1 secondo combustibile Numero di partenze azzerabile da Service Fuel 1 Number of startups resettable Service In...

Page 69: ...e fuel train modula ting multistage actuators etc __ undefined delete curves 1 gas direct ignition G mod 2 ignition by gas pilot connected between the two gas solenoid valves EV1 EV2 Gp1 mod 3 ignitio...

Page 70: ...x x x 210 Allarme impedimento avviamento 0 non attivo 1 attivo Alarm in the event of start prevention 0 deactivated 1 activated OEM Service x x x 211 Tempo aumento giri ventilatore valore fab brica 2...

Page 71: ...nge impostazione 20s 60min Gas Prepurge time default value 20s range 20s 60min OEM Service x x x 226 Gas tempo di preaccensione valore fab brica 2s range impostazione 0 2s 60min Gas Preignition time d...

Page 72: ...ivo 1 esso modificabile solo su LMV37 Dal punto di vista della sicurezza il funzionamento continuo valido esclusiva mente per bruciatori di gas con elettrodo di rilevazione Gas Forced intermittent ope...

Page 73: ...Postpurge time 3 abortion with load controller LR ON OEM Service x x x 261 Olio sonda rilevazione fiamma attivo valore fabbrica 0 0 QRB QRC 1 ION QRA Oil active detector flame evaluation default value...

Page 74: ...0 inactive 1 active from phase 38 2 active from safety time TSA OEM Service x x 277 Olio Pressostato olio di massima ingresso POC 0 inattivo 1 pressostato olio di massima 2 POC Oil Pressure switch max...

Page 75: ...lvole EV1 EV2 del gas regolazione pneumatica Gp1 mod pneu 9 accensione tramite pilota gas con attacco a monte dell elettrovalvola EV1 del gas regolazione pneumatica Gp2 mod pneu 10 olio modulante con...

Page 76: ...ore fabbrica 1 0 QRB QRC 1 ION QRA Fuel 1 Gas active detector flame evalua tion default value 1 0 QRB QRC 1 ION QRA OEM Service x 322 Combustibile 1 Gas Preventilazione valore fabbrica 1 1 attivo 0 no...

Page 77: ...Intervallo 2 valore fabbrica 2s range impostazione 0 2s 60min Fuel 1 Gas Interval 2 default value 2s range 0 2s 60min OEM Service x 333 Combustibile 1 Gas Tempo postcombu stione valore fabbrica 8s ra...

Page 78: ...t filling time default value 3s range 0 2s 10s OEM x 345 Combustibile 1 Gas tempo test pressione gas valore fabbrica 10s range imposta zione 0 2s 60s Fuel 1 Gas proving test time gas pres sure default...

Page 79: ...mbustibile 1 Olio tempo di risposta a cadute di pressione entro TSA1 e TSA2 valore fabbrica 1 8s range imposta zione 0 2s 14 8s Fuel 1 Oil time to respond to pressure faults in TSA1 and TSA2 default v...

Page 80: ...censione corta Ph38 fase pro gramma 38 1 preaccensione lunga con ventilatore Ph22 fase programma 22 Fuel 1 Oil time oil ignition default value 1 0 short preignition Ph38 progr phase 38 1 long preignit...

Page 81: ...ting the cur ves OEM Service x x x 403 Curve controllo inverter F A si accede alla lista dei punti da impostare da P0 a P9 con sultare paragrafo Impostazione curve Ratio control curves VSD curve setti...

Page 82: ...repurge speed 100 Index 2 postpurge speed 50 OEM Service x x 504 Combustibile 1 Posizione servocomando combustibile in assenza di fiamma no flame Indice 0 posizione di sosta 0 Indice 1 posizione preve...

Page 83: ...di carico per modulazione valore fabbrica n d range imposta zione 20 100 Lower load limit default value n d range 20 100 OEM Service x x x 546 Percentuale massima di carico per modula zione valore fa...

Page 84: ...0 combustibile Indice 1 aria Tolerance limit of position monitoring 0 1 Index 0 fuel Index 1 air OEM Service x x x 608 Combustibile 1 Impostazione punto di riferi mento Indice 0 combustibile Indice 1...

Page 85: ...top SQN1 3 both OEM x 613 Tipo di servocomando Indice 0 combustibile Indice 1 aria 0 5s 90 1Nm 1 2Nm 3Nm 1 10s 90 6Nm 2 17s 90 10Nm Type of actuator Index 0 fuel Index 1 air 0 5 s 90 1Nm 1 2Nm 3Nm 1 1...

Page 86: ...tion of analog output default value 0 0 DC 0 10 V 1 DC 2 10 V 2 DC 0 2 10 V OEM Service LMV27 x x ATTENTION as for SQM3x actuators set the direction according to the acutator function As far as SQN1x...

Page 87: ...ror history 701 725 02 diagnostic code Service Info Storico errori 701 725 03 classe errore Error history 701 725 03 error class Service Info Storico errori 701 725 04 fase Error history 701 725 04 ph...

Page 88: ...Active load source OEM Service 945 Solo con LMV26 Combustibile attuale 0 combustibile 0 1 combustibile 1 Actual fuel 0 fuel 0 1 fuel 1 Service Info 947 Risultato interrogazione contatti codifica bit...

Page 89: ...a leakage test designed to detect leaking gas valves and if necessary to pre vent the valves from opening or ignition from being switched on Lockout is initiated When performing valve proving the gas...

Page 90: ...2x already programmed At the first LMV startup the AZL display will show It means that the unit was never set or that no mode was chisen or that some parameters have to be set furthert Push F fuel and...

Page 91: ...l elettrov EV1 del gas Gp2 mod 4 accensione a gasolio modul Lo mod 5 accens a gasolio bistadio Lo 2 stage 6 accens a gasolio tristadio Lo 3 stage Burner operating mode fuel train mod multi stage actua...

Page 92: ...e fuel actuator 0F until the requested value is reached for example 12 15 see below for the ignition point or press F and to decrease the angle To set the air damper opening angle 0A in the ignition p...

Page 93: ...er is operating warm setting by pressing the ENTER InFo or while the burner is in stand by mode cold setting by pressing ENTER CAUTION at the first burner adjustment it is recommended to set the maxim...

Page 94: ...ugh the flue analyser Keep the air excess inside normal figures from 3 to 7 residual O2 operating by means for the air damper servomotor Keep increasing the air damper opening and then the gas throttl...

Page 95: ...t before end by pressing ESC or for a faulty shutdown the message OFF UPr Start preven tion will be diplayed until all the curvepoints will be set Note2 if the gas flow rate at high flame point maximu...

Page 96: ...e than 5 seconds to process the curve downwards The curve is then a straight line go on checking the combustion values point by point change them if necessary and in case linearise the curve again Bef...

Page 97: ...e burntime Ph72 travelling to postpurging Ph74 postpurge countdown is displayed Press ESC the parameter 546 Setting the maximum load is displayed Then press to exit the programming mode The display wi...

Page 98: ...n Longer or shorter pushes on the button do not produce a reset so that the system maintains the lockout position Timeout for menu operation The time for automatically leaving the parameter setting le...

Page 99: ...levels By means of a proper use of the keys it is possible to enter the various level parameters as shown in the following flow chart The burner and consequently the LMV2x are factory set the air and...

Page 100: ...nd go back to the flashing number The Info level shows some basic parameters as 5 Example choose parameter 102 to show the date the display shows parameter 102 flashing on the left and characters _ _...

Page 101: ...h another message Diagnostic code in the example diagnostic code 3 Record the codes and find out the fault in the Error table To perform the reset press InFo for one second The unit displays an event...

Page 102: ...ht By pressinf or it is possible to scroll up down the parameter list 2 Once the last parameter is accessed 143 by pressing the End message will blink 3 Press InFo for more than three seconds or for m...

Page 103: ...ignition time OFF Ph44 t44 intervallo 1 t44 interval 1 Ph50 TSA2 secondo tempo sicurezza TSA2 2nd safety time Ph52 t52 intervallo 2 t52 interval 2 Ph60 Funzionamento 1 stazionario Operation 1 stationa...

Page 104: ...ess ENTER until the display will show with the button go to the group 000 of the parameters and press with the buttons and go to 050 parameter press the disply show press again with the button select...

Page 105: ...uttons by pressing enter to confirm iWith the buttons go to the group 000 of the parameters press end select the 050 parameter press the disply show with the button the display shows press again with...

Page 106: ...50 ERROR CODE TABLE...

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Page 121: ...L PE QRB C N ION QRB C X75 1 X10 05 1 X10 06 1 X3 02 1 PLUFT FLAMME P L PE N L 2 3 L X5 03 1 X8 04 1 X8 02 1 X5 03 X10 05 X7 01 X8 04 X8 02 X75 X10 06 X3 02 X3 04 N PE L 1 1 1 1 1 1 1 1 1 QRA QRA QRA...

Page 122: ...66 Wiring variants for LMV27 2 Fuel meter input 1 Supply fuel meter ConnectorX75 ConnectorX5 02 ConnectionsPmax...

Page 123: ...tion speed output 2 GND signal reference 1 Controller input 4 20mA 5 Supply 4 Feedback signal 3 PWM Pulse Width Modulation speed output 2 GND signal reference 1 External supply 24V DC ConnectorX75 Con...

Page 124: ...dulation speed output 2 GND signal reference 1 Controller input 4 20mA 5 Supply ConnectorX75 ConnectorX64 ConnectorX74 2 Fuel meter input 1 Supply fuel meter ConnectorX5 02 Connections Pmax 4 Feedback...

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Page 128: ...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...