Unigas H365X, Manual Of Installation - Use - Maintenance

Page 1: ...9552CB 0 0 04 2022 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Microprocessor controlled MANUAL OF INSTALLATION USE MAINTENANCE H365X H440X H500X LMV5x Gas burners Also with flue gas recirculation F...

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: ...by controlling the flame geometry and combustion efficiency Fuel and air are routed through separated channels inside the combustion head then mixed to ignite the flame inside the combustion chamber T...

Page 6: ...ure switch 8 GAS CONNECTION 50 Rp2 65 DN65 80 DN80 100 DN100 9 MICRO PROCESSOR CONTROL ES with no O2 trim control with no VSD control EO with O2 trim control with no VSD control EI with no O2 trim con...

Page 7: ...0 DN80 80 DN80 Gas train 100 100 DN100 100 DN100 Operating temperature C 10 50 10 50 Storage Temperature C 20 60 20 60 Working service Continuous Continuous Note1 All gas flow rates are referred to St...

Page 8: ...552 390 390 390 764 150 613 845 190 856 270 65 1450 1550 295 35 611 117 430 530 488 1020 511 1584 969 615 328 370 494 480 586 M14 552 390 390 390 634 150 484 845 294 856 270 80 1450 1550 295 35 626 13...

Page 9: ...13 845 190 856 270 496 2 618 260 300 577 9 200 65 1463 1563 295 35 611 117 430 530 471 1033 511 1546 969 410 309 350 494 480 586 M14 552 390 390 390 634 150 484 845 294 856 270 496 2 618 260 300 577 9...

Page 10: ...ner 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 intercepitng the netw...

Page 11: ...usually reached by adjsuting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is reached setting the combustion head to its MIN position Du...

Page 12: ...grams refer to natural gas with a calorific value of 8125 kcal Stm3 15 C 1013 mbar and a density of 0 714 kg Stm3 The values in the diagrams refer to GPL with a calorific value of 22300 kcal Stm3 15 C...

Page 13: ...to get the pressure in the combustion chamber and the other one into the butterfly valve s pressure outlet of the burner On the basis of the measured differential pressure it is possible to get the ma...

Page 14: ...at load of the boiler for that burner multiply the required burned power by the depowering factor expressed as follows multiply the back pressure in the combustion chamber by the depressurisation fact...

Page 15: ...PART I SPECIFICATIONS 15 Burner power reduction H440X Thermic Load MW m3 Burner power reduction H500X Thermic Load MW m3...

Page 16: ...All handling operations must be carried out with appropriate resources and qualified personnel ATTENTION Use intact and correctly dimensioned hoisting equipment conforms to the local regulations and...

Page 17: ...agram In case the burner must be coupled with boilers with a combustion chamber smaller in diame ter or shorter than those described in the diagram please contact the supplier to verify that a correct...

Page 18: ...lant designed according to the following guidelines size the FGR pipe as per the example below ATTENTION Pipe elbows increase pressure losses so limit their use as much as possible Flue gas temperatur...

Page 19: ...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 20: ...gas proving test mus be performed according to the procedure set by the laws in force ATTENTION it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the val...

Page 21: ...nly PS cables specified by DUNGS are authorised to be used to connect the PS to the VD R Max cable length 3 m A A C B B C 1 Mount flange into pipe systems Use appropriate sealing agent 2 Insert VB tog...

Page 22: ...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 T VR Performance range mbar neutral yello...

Page 23: ...the beginning both the valves EV1 and EV2 must be closed Test space evacuating EV2 valve burner side opens and keep this position for a preset time td4 in order the bring the test space to ambient pre...

Page 24: ...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 25: ...rols the fan motor revolutions 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 improvi...

Page 26: ...able connection or hook up to the grid must be carried out by qualified informed and trained personnel directly coordinated and authorized by Technical Service Always check in advance that the system...

Page 27: ...Check the connection to the grounding system Do not use any extraneous conductive parts i e fuel feeding pipes metal structures to connect the burner to ground In connecting the supply wires to the bu...

Page 28: ...E MACHINE EXCEPT FOR ITS MAINTENANCE TO SECURE THE MACHINE ACT ON THE ISOLATOR SWITCH IN CASE OF ANOMALIES THAT REQUIRED A SHUT DOWN OF THE BURNER IT S POSSIBLE TO ACT ON THE AUXILIARY LINE SWITCH LOC...

Page 29: ...lator fully modulating burners AIR FLOW AND FUEL ADJUSTMENT First Start up preliminary operations gas supply Recommended actions to be carried out in sequence 1 Check the burner and all its components...

Page 30: ...ain page and the system stops the safety chain is open waiting for the startup enabling signal standby Program phase no 12 Main page 3 check the fan motor rotation see related paragraph 4 make the saf...

Page 31: ...lts occuring it represents the lockout reset function Fault History by selecting this item and pressing the ENTER key the Lockout History will be showed about the last 21 faults occured Lockout Histor...

Page 32: ...rrow keys select Params Display press ENTER the system will ask you to enter the proper password by means of the arrow keys select Access w out pass access without password user level confirm by press...

Page 33: ...the 2 position controller To set these values select the item SD_ModOn SDOn by scrolling down the Load controller menu with the arrow keys and press ENTER the display will show The deafult value for...

Page 34: ...ime Wintertime mode desired and cofirm by pressing ENTER press ESC to exit Set the time zone Time EU US in the same way Languages it allows setting the current language choose the desired language and...

Page 35: ...rner starts upthe Thermal shock protection activated message will be showed If this function is not enabled after startup the burner will rapidly increase the load according to the requested value and...

Page 36: ...en the burner does not follow the modulator and probe settings but operates at the set load For further details see the LMV5x annexed manuals SetLoad Autom Manual Off Autom Manual Off Curr Automatic N...

Page 37: ...nts do not exceed a value that creates a hazardous condition to the burner Adjusting output pressure for positive pressure systems requires PS 10 40 or PS 50 200 Outlet pressure MIN 10 25 50 75 MAX PS...

Page 38: ...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 39: ...n the adjustment is accomplished The diffuser position must be set during the commissioning according to the regulation needs The diffuser position is factory set as shown in figure A x 10 mm Dependin...

Page 40: ...if necesssary Remove and clean the combustion head Examine and clean the ignition electrodes adjust and replace them if necessary Examine and clean the detection electrode photoelement according to t...

Page 41: ...sh Note to replace the combustion head reverse the procedure described above having care to place correctly the O ring OR between burner and gas manifold Attention before adjusting the combustion head...

Page 42: ...lectrodes to contact metallic parts blast tube head etc other wise the boiler operation would be compromised Check the electrodes position after any intervention on the combustion head 3 6 60 60 6 6 6...

Page 43: ...semble the burner by fllowing the procedure in the reversed order A B C D E F To replace the electrodes proceed as follows 1 remove the burner cover C 2 disconnect the electrodes cables 3 emove the co...

Page 44: ...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 ca...

Page 45: ...itch 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 cont...

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Page 48: ...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 49: ...Siemens LMV5x Service Manual M12920CC rev 2 1 08 2017...

Page 50: ...harmful Before any cleaning or servicing operation disconnect the unit from the mains by turning the master switch OFF and or through the cut out devices that are provided Make sure that inlet or exh...

Page 51: ...2 Configuration of a pressure or a temperature probe type at X61 door 20 6 2 1 Configuration of a pressure or a temperature probe signal at X61 door 20 6 3 Configuration of the X62 door input signal...

Page 52: ...must be connected to earth PE Volt must be 0 V between N PE NOTE PE protection earth it is not FE FE functional earth 1 1 2 Protective Earth PE and Functional Earth FE Protective Earth PE Known as an...

Page 53: ...les and to the burner housing e g use a electrical insulating conduit or distance parts e g plastic material see also Appendix Example for wiring earthing and shielding the LMV5 System Prefer a double...

Page 54: ...lso Appendix Example for wiring earthing and shielding the LMV5 System 1 3 2 Shielding The LMV5 FE terminals for the shields are LMV5 internally connected with X52 4 this terminal must be connect exte...

Page 55: ...ables for the Load controller Temperature or Pressure sensor set point load output at the LMV5 X60 X61 X62 X63 Together in cable duct 2 for Line voltage e g Cable for Ignition transformer Cables for o...

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Page 57: ...9 1 4 1 Servomotor wiring example 1 4 2 Bus cable wiring on LMV5x and AZL doors 1 4 3 EARTH connection example...

Page 58: ...urner will immediately turns off keys socket The user interface is made of display it shows menus and parameters ESC key previous level it goes back to the previous level menu or exits the programming...

Page 59: ...ition position phase 38 The burner remains in that position because this is the only one work point in memory The fuel air ratio curve must be set until the maximum load limit 100 output During the se...

Page 60: ...12 2 2 LMV5x program structure...

Page 61: ...ED TO NOT USE O2 MONITORING IF FGR IS INSTALLED AND ACTIVE 2 3 Burner ID number The burner ID number corresponds to the burner serial number NOTE in case of call to the Service Center always tell the...

Page 62: ...rmed by pressing Enter Display before the first password character is entered Enter Password The example displays when entering the third password character Enter Password S If the check of the passwo...

Page 63: ...nals 318 and 319 of the burner supply terminal block see below the system will lead to an immediate burner lockout In case of burner designed with automatic pull out system from the generator the burn...

Page 64: ...address an actuator choose the corresponding actuator and follow the instructions on display When the actuator green LED flashes it means that one of the following function is set according to the nu...

Page 65: ...o according to the next procedure By following the next table set both parameter OperatRampMod and TimeNoFlame to set the ramp up stop times for the VSD and the actuator opening speed from 0 to 90 Fol...

Page 66: ...al output from the LMV to the client DCS or PLC Output Value Selection are Load Load 0 O2 Pos Air Pos Fuel Pos Aux1 Pos Aux2 Pos Aux3 Speed VSD Flame Temp Pt1000 TempNi1000 Temp Pt100 Temp X61 Press X...

Page 67: ...level 5th level 6th level Description Params Display Menu level for making the parameter set tings LoadController Settings for the internal load controller Configuration General configuration of the l...

Page 68: ...ens End of pressure measuring range for input X61 0 99 9 bar 0 2000 C 0 99 9 bar 0 2000 C Set the probe value Example if a max 10bar Siemens sensor is used the voltage output signal will be 0 V at 0 b...

Page 69: ...6th level Description Params Display Menu level for making the t Params Display SD ModOn General configuration of the load SD ModOn SD ModOff General configuration of SD ModOff the display will show T...

Page 70: ...for internal load controller StandardParam Adaption very fast fast normal slow very slow It is possible to manually set the PID parameters to any value in the setting range shown below to activate a...

Page 71: ...100 Ni1000 or Pt 1000 temperature sensor is connected to X60 3 and X60 4 terminals ATTENTION basically these parameters provide a function similar to the safety thermostat one but can not replace it T...

Page 72: ...of the menu by means the Esc 1st level 2nd level 3rd level 4th level 5th level Range Description Params Display Menu level for making the parameter settings VSD Module Settings for the VSD module Conf...

Page 73: ...ogramming levels of the menu by means the Esc 1st level 2nd level 3rd level 4th level 5th level 6th level Description Params Display Menu level for making the para meter set tings RatioControl GasSett...

Page 74: ...corresponding to a hypothetic low flame stage Note points P1 and P2 are temporally mentioned 10 and 100 load independently from the actual load The operator can name the load on each point without re...

Page 75: ...of oil ATTENTION as for increasing by few degrees it means that the increasing must be performed in order to avoid great excess of air or defect of air Therefore the increasing operation must be perfo...

Page 76: ...ir actuator Do not exit by pressing Esc from the values column because data will not be stored Press arrows to select another actuator to be set for example press to choose Fuel Press keys to change t...

Page 77: ...the other points So it is necessary to check the adjustment of the points already set ATTENTION for proper operation it is necessary that the curve of each actuator does not reverse its slope ATTENTI...

Page 78: ...cts are the following 1 Pressures have reciprocal effects 2 The reduction of O2 can lead to a significant increase of NOx levels As a result of these reciprocal effects it is difficult if not impossib...

Page 79: ...ngs for firing on Gas or on Oil AirActuator GasActuat OilActuat AuxActuator AuxActuator 2 AuxActuator 3 AuxActuator 3 AuxActuator 3 MUST be chosen After the addressing activate the FGR servomotor 1st...

Page 80: ...Open 10 4 Setting the load controller mode see the previous chapter regolazione senza FGR WARNING If one of the intLC internal Load Controller option must be choice a temperature sensor cannot be con...

Page 81: ...ulation temperature Auxiliary actuator 3 maintains the ignition position until an adjustable temperature is reached parameter FRG On Temp During the operation the burner regulate its load as per the s...

Page 82: ...inimum amount of flue gas The position is also used to ensure a defined damper position for emergency operation or automatically deactivated flue gas recirculation FGR FGR MaxPos Fact Maximum limitati...

Page 83: ...on FGR factor of 50 leads to a 50 reduction of the damper positions If the temperature value of the smoke during the operation of the burner is higher than the temperature value during the commissioni...

Page 84: ...StageLoad 0 100 15 StageSetp_M od 1 100 Wcurrent 5 Stage Setp_Stage 1 100 Wcurrent 5 MaxTme Mod 1 63 min 3 min MaxTmeStage 1 63 min 3 min Cold start thermal shock protection maximum time per step mult...

Page 85: ...tion this function can be set at user level also see chapter manual operation the CSTP function is momentary excluded when enabling the automatic operation again the CSTP function previously set at Se...

Page 86: ...assword Description ManualOpe ration Menu level for activating manual operation with the preselected load Au tom Manual Off Selection of manual or automatic operation Automatic Burner on Burner off Us...

Page 87: ...39...

Page 88: ...V 10 15 50 60 Hz Imax 5 A PIN3 x Protective earth PE PIN4 x Supply voltage neutral conductor N PIN5 x Supply voltage live conductor L AC 230 V 10 15 50 60 Hz fuse 6 3 AT DIN EN 60 127 2 5 X4 01 Fuel s...

Page 89: ...5 mA PIN2 x Controller closes stage 3 AC 230 V 10 15 50 60 Hz Imax 1 5 mA PIN3 x Controller opens stage 2 AC 230 V 10 15 50 60 Hz Imax 1 5 mA PIN4 x Power signal for control of con troller AC 230 V 10...

Page 90: ...ductor N PIN3 Fuel valve 2 oil AC 230 V 10 15 50 60 Hz 1 A cos 0 4 X7 02 PIN1 x Protective earth PE PIN2 x Neutral conductor N PIN3 Fuel valve 3 oil AC 230 V 10 15 50 60 Hz 1 A cos 0 4 X7 03 PIN1 x Pr...

Page 91: ...oil AC 230 V 10 15 50 60 Hz 1 A cos 0 4 X9 01 PIN4 x Fuel valve 1 gas AC 230 V 10 15 50 60 Hz 2 A cos 0 4 PIN3 x Fuel valve 2 gas AC 230 V 10 15 50 60 Hz 2 A cos 0 4 PIN2 x Fuel valve gas AC 230 V 10...

Page 92: ...vely QRA2 QRA4 U QRA10 refer to section Description of inputs and out puts Umax X3 04 PINS Imax 0 5 mA X50 PIN6 x Reference ground PELV PIN5 x Communication signal CANL DC U 5 V Rw 120 level to ISO D...

Page 93: ...mperature sensor input PT100 X61 PIN5 x Functional earth for shield connec tion PIN4 x Reference ground PIN3 x Current input for temperature pressure signal 0 4 20 mA DC 0 4 20 mA PIN2 x Voltage input...

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Page 96: ...Note Specifications and data subject to change Errors and omissions excepted...

Page 97: ...d an earth external wire for the motor ground The cable for the 4 20mA signal that controls the VSD must be shielded only LMV5x side ends connected to the equipotential terminal If the VSD is not insi...

Page 98: ...Annex1 Example for motor cable...

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Page 100: ...Annex 2 Example for sensor cable...

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Page 103: ...E Power supply Line voltage Gas L1 High Voltage Transformer N M Power supply Line voltage FE X73 Speed sensor VSD Fan Motor Separate conduit shielded line voltage cable X70 X10 02 X9 01 X4 02 Separate...

Page 104: ...ion and current fuel throughput The LMV52 system uses an O2 sensor QGO20 an external O2 module and the standard components of the LMV51 sys tem The PLL O2 module is a detached measuring module for the...

Page 105: ...defined system cables AGG5 641 and AGG5 631 result from the points of intersection in the graph 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 0 5 1 25 2 3 5 7 8 AGG5 631 AG...

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Page 107: ...CAN bus cable 100 m Whenever the distance between the LMV5 and the last actuator exceeds 20 m or if more than one SQM48 is used on the burner refer to sizing chart Determination of maximum cable leng...

Page 108: ...N F T4 AC2 12 V 5 5 3 Not used M L Power trafo 2 AGG5 2 No bus termination No bus termination Bus termination 5 5 5 5 No bus termination No bus termination Installation in the control panel actuator...

Page 109: ...owered by a sec ond transformer to be located near the actuators and the O2 module Connect the power supply line from that transformer to the O2 module PLL52 in ex ample 3a SA6 in example 3b Auxiliary...

Page 110: ...n facility 18 8 1 Inputs and outputs Mounting panel shielding connection Communication and power supply for LMV52 Mounting panel shielding connection Communication and power supply Temperature sensor...

Page 111: ...l o w e d t o j o i n t h e f l u e g a s e s o n t h e i r w a y f r o m t h e b u r n e r t o t h e d e t e c t o r D F l o w v e l o c i t y 1 1 0 m s F l u e g a s t e m p e r a t u r e a t t h e...

Page 112: ...e p o u r B 1 B 2 B 2 T e n s i o n d e t h e r m o c o u p l e M U 3 S i g n a l d e l l m e n t d e c p m p e n s a t i o n d e t e m p r a t u r e G 2 A l i m e n t a t i o n d e l l m e n t d e c...

Page 113: ...k s i t i s r e c o m m e n d e d t o l e a v e t h e m e a s u r i n g s y s t e m Q G O a n d R P O s w i t c h e d o n D u r i n g t h e h e a t i n g u p p h a s e t h e d e t e c t o r c o u l d...

Page 114: ...A G O 2 0 0 0 2 A A R a u c h g a s e i n t r i t t B R a u c h g a s a u s t r i t t C K e r b e D F l a c h d i c h t u n g b e i l i e g e n d L 1 8 0 m m f o r A G O 2 0 0 0 1 A L 2 6 0 m m f o r...

Page 115: ...r h Transport DIN EN 60 721 3 2 Climatic conditions class 2K2 Mechanical conditions class 2M2 Temperature range 30 70 C Humidity 95 r h Operation DIN EN 60 721 3 3 Climatic conditions class 3K5 Mecha...

Page 116: ...GND SHIELD 12VAC1 12VAC2 CANH CANL GND SHIELD AZL5 x FE FE SQM4 LMV52 Brown brn White wh Yellow yl Green grn Black blk Brown brn White wh Yellow yl Green grn Black blk Flue gas temperature PLL52 PLL5...