Unigas HR92A, Manual Of Installation - Use - Maintenance

Page 1: ...9252CE 0 1 12 2020 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Microprocessor controlled MANUAL OF INSTALLATION USE MAINTENANCE LMV2x Gas light oil burners HR91A HR92A HR93A HR512A HR515A HR520A HR5...

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: ...gaseous fuels 2014 35 UE Low Tension Directive 2014 30 UE Electromagnetic compatibility Directive 2006 42 EC Machinery Directive Harmonized standards UNI EN 676 Automatic forced draught burners for ga...

Page 4: ...s oil and solid fuel burning appliances having electrical connections UNI EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction National Standard UNI 7...

Page 5: ...s far as the zone of flame generation combustion cham ber The control panel placed on the burner front side shows each operating stage Country and usefulness gas categories Fuel GAS CATEGORY COUNTRY I...

Page 6: ...80 2 670 480 3 050 550 4 100 480 2 670 480 3 050 550 4 100 Fuel Natural gas Light oil L LPG Light oil Category see next paragraph I3B P Gas rate Natural gas M min max Stm3 h 51 283 51 323 58 434 51 28...

Page 7: ...A LG HR515A LG HR520A LG HR525A LG 50 HR525A LG xx Output min max kW 600 4 500 770 5 200 1 000 6 400 2 000 6 700 2 000 8 000 Fuel L LPG Light oil Category I3B P LPG rate L min max Stm3 h 22 168 29 194...

Page 8: ...228 185 65 1507 242 831 327 35 300 564 117 490 441 1017 421 1406 971 435 269 299 228 447 360 523 M12 424 280 310 300 632 148 484 846 292 708 228 185 80 1507 242 831 327 35 300 579 132 490 441 1017 42...

Page 9: ...830 310 270 100 1669 320 928 371 35 333 639 145 530 517 1139 446 1726 1082 644 380 420 494 540 560 M14 552 390 390 791 149 642 942 353 830 310 270 HR520A 50 1671 320 928 371 35 333 595 100 530 517 11...

Page 10: ...OS OIL TRAIN 1 Filter 2 Flexible hose 3 Pump and pressure governor 4 Electrical motor 6 Solenoid valve 6 1 Solenoid valve 10 Oil distributor 12 Pressure gauge 13 Pressure governor 15 Pressure switch 1...

Page 11: ...se 6 Solenoid valve 7 Flexible hose 8 3 way solenoid valve 9 Flexible hose 10 Oil distributor 11 Flexible hose 12 Pressure gauge 13 Pressure governor 14 Electrical motor 15 Pressure switch 16 One way...

Page 12: ...ailable 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...

Page 13: ...t 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 Performance curve minimum BACK PRESSURE IN COMBUSTIO...

Page 14: ...R520A MG Stm3 h GAS PRESSURE mbar HR525A MG Rp2 Stm3 h HR525A MG DN65 80 100 Stm3 h ATTENTION the gas rate value is quoted on the x axis the related network pressure is quoted on the y axis pressure v...

Page 15: ...h GAS PRESSURE mbar HR520A LG Stm3 h ATTENTION the gas rate value is quoted on the x axis the related network pressure is quoted on the y axis pressure value in the combustion chamber is not included...

Page 16: ...from the boiler s Technical specifications Measuring gas pressure in the combustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one into the combusti...

Page 17: ...r in the combustion chamber 0 5 10 15 20 25 30 35 40 40 60 80 100 120 140 160 180 200 220 240 260 280 300 0 5 10 15 20 25 30 35 40 45 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 0 5 1...

Page 18: ...12A LG Stm3 h GAS PRESSURE mbar HR520A LG Stm3 h 0 2 4 6 8 10 12 14 16 18 20 22 24 26 10 20 30 40 50 60 70 80 90 100 110 0 10 20 30 40 50 60 70 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 0...

Page 19: ...nd the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement Packing The burners are despatched in wooden crates whose dimensions are 9xA series 1672...

Page 20: ...ions of the boiler manu facturer In absence of these consider the following Cast iron boilers three pass flue boilers with the first pass in the rear part the blast tube must protrude no more than Dis...

Page 21: ...een the flange fasten all the components with screws according to the following diagrams make sure bolts on the flanges are properly tightened 1 Filter 6 Butterfly valve 2 Pressure switch PGMIN 7 Pres...

Page 22: ...eration of the filters both the filters outside the valves group and the ones built in the gas valves WARNING Slowly open the fuel cock to avoid breaking the pressure regulator ALLA V FARFALLA GAS BRU...

Page 23: ...etpoint 2 Mounting on pipe Sensor position 5x DN according to MBE Pipe fitting with female thread size mount sensor with seal observe torque 3 The pressure sensor includes a vent limiter according to...

Page 24: ...reccomended to install the filter with gas flow parallel to the floor in order to prevent dust fall on the safety valve during maintenance operation SA SA TP D BS SKP1 SKP2 SIEMENS VGD Mounting posit...

Page 25: ...train in installed execute the electrical connections for all its items gas valves group pressure switch DANGER Incorrect motor rotation can seriously damage property and injure people ATTENTION once...

Page 26: ...essure Test space filling EV1 opens 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...

Page 27: ...en the gear teeth thus obstructing them After filling the tank wait before starting the burner This will give any suspended impurities time to deposit on the bottom of the tank thus avoiding the possi...

Page 28: ...t is mandatory to fill the adduction pipes with diesel fuel and bleed out residual air bubbles Prior to switching on the burner check direction of rotation of the pump motor by briefly pressing the st...

Page 29: ...o flexible hoses on the 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 Sunte...

Page 30: ...RC circuit Siemens between the terminal 2 terminal X3 04 4 in case of LMV2x LMV3x LMV5x LME7x of the base and the earth terminal RC466890660 For LMV5 control box please refer to the clabeling recomme...

Page 31: ...F THE 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...

Page 32: ...to on Gas operation At the beginning of the start up cycle the actuator drives the air damper to the maximum opening position then the fan motor starts up the pre purge phase begins At the end of the...

Page 33: ...ates adjustments must be performed at the maximum ouptput first high flame see the LMV related manual Check that the combustion parameters are in the suggested limits Check the flow rate measuring it...

Page 34: ...vice 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 decrea...

Page 35: ...t1 tempo preventilazione t1 prepurge time Ph36 Verso posizione accensione Traveling to the ignition position Ph38 t3 tempo preaccensione t3 preignition time Ph40 TSA1 primo tempo sicurezza trasformato...

Page 36: ...ess the enter InFo key 3 then il will show the first code 167 flashing on the right side it will show the data entered By pressing or it is possible to scroll up or down the parameter list 4 If a dot...

Page 37: ...End message will flash 10 Press InFo for more than three seconds or for more than three seconds orto return to the normal display If a message like the one below is shown during operation it means th...

Page 38: ...f phases Example Error code 111 diagnostic code 0 To reset press InFo for a second Record the codes and check the Error List to find the type of faults Service level To enter the Service mode press In...

Page 39: ...ng GAS by means of the switch on the burner control panel Adjust the air and gas flow rates in according to the air gas ratio curvepoints setting procedure on the LMV manual Check con tinuosly the flu...

Page 40: ...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 10 40...

Page 41: ...in the network when flame is off by means of the adjusting ring nut VR set the value read increased by the 30 if the maximum pressure switch is mounted downstream the gas governor gas valves group and...

Page 42: ...ers plate holes are fully opened Center head holes gas flow regulation LPG burners To adjust the gas flow partially close the holes as follows 1 loosen the three V screws that fix the adjusting plate...

Page 43: ...ENSIONS FLOW RATE kg h Indicative pessure on return bar Min Max 40 13 40 19 50 16 50 22 60 20 60 20 70 23 70 23 80 26 80 23 90 30 90 22 100 33 100 22 115 38 115 21 130 43 130 22 145 48 145 21 160 53 1...

Page 44: ...nozzle is provided set the return pressure at 11bar supply at 20bar on the delivery to get a 220kg h flow rate If the return pressure needed is 5bar instead act on the V adjusting screw on the pressu...

Page 45: ...PART III OPERATION 45 Fig 8...

Page 46: ...PART III OPERATION 46...

Page 47: ...ways the combustion parameters Turn the burner off then start it up again If the adjustment is not correct repeat the previous steps Maximum oil pressure switch The oil pressure switch on the return l...

Page 48: ...parts IMPORTANT Remove the combustion head before checking the ignition electrode Remove and clean the compressed air regulator Remove and clean the oil regulator if provided 1 Close the bowl valve be...

Page 49: ...bove WARNING Before opening the filter close the manual cutoff valve downstream the filter and bleed the gas check that inside the filter there is no pressurised gas C B A To clean or remove the filte...

Page 50: ...is fastened Replacing the ignition electrode ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc other wise the boiler s operation would be compromised...

Page 51: ...lace the photocell into its slot 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...

Page 52: ...ssure switch damaged or bad links Check air pressure switch functions and links Burner control damaged Replace burner control BURNER LOCKS OUT WITHOUT ANY GAS FLOW Gas valves don t open Check voltage...

Page 53: ...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...

Page 54: ...2 7 1 6 7 1 1 7 1 2 7 1 3 21 3 2 3 2 1 1 3 2 1 2 18 17 10 1 10 4 10 2 10 3 7 3 14 2 14 14 1 1 12 1 2 1 1 1 1 5 1 1 5 1 9 1 1 24 15 3 3 23 4 2 4 10 4 1 3 4 1 2 4 1 1 4 1 4 3 21 7 4 1 8 1 15 1 15 1 15...

Page 55: ...N CABLE 1 9 FLANGE 6 1 ACTUATOR 16 STANDARD BLAST TUBE 1 12 PRESSURE PLUG 6 2 PRESSURE GAUGE 17 PHOTOCELL 1 15 COUPLING 6 3 PRESSURE GOVERNOR 18 FLEXIBLE HOSE 1 21 1SPACER 7 1 1 GAS VALVE BODY 20 FLEX...

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...

Page 107: ...51...

Page 108: ...52...

Page 109: ...53...

Page 110: ...54...

Page 111: ...55...

Page 112: ...56...

Page 113: ...57...

Page 114: ...58...

Page 115: ...59...

Page 116: ...60...

Page 117: ...61...

Page 118: ...62...

Page 119: ...63...

Page 120: ...64...

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...

Page 125: ......

Page 126: ......

Page 127: ......

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...

Page 129: ......

Page 130: ......

Page 131: ......

Page 132: ......

Page 133: ......

Page 134: ......

Page 135: ......

Page 136: ......

Page 137: ......

Page 138: ......

Page 139: ......

Page 140: ......