Unigas P75R, Manual Of Installation - Use - Maintenance

Page 1: ...M039318CD Rel 0 0 05 2019 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES LMV2x 3x Microprocessor controlled gas burners MANUAL OF INSTALLATION USE MAINTENANCE P75A P75R R75A R75R RX75 RX75S RX75R...

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: ...limits The actuators move proportionally the air damper and the gas butterfly valve in order to achieve the optimisation of the gas flue values as to get an efficient combustion The adjustable combus...

Page 6: ...4 BLAST TUBE S Standard L Extended 5 DESTINATION COUNTRY 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 p...

Page 7: ...0 mg kWh Class 3 EN676 BURNER TYPE R75R M R75A M R75A L Output min max kW 320 1650 320 2050 320 2050 Fuel Natural gas Natural gas LPG Category see next paragraph I3B P Gas flow rate min max Stm3 h 34...

Page 8: ...mbar with Dungs MBDLE 500 mbar with Siemens VGD or Dungs MultiBloc MBE Minimum gas pressure see gas curves Note3 Burners are suitable only for indoor operation with a maximum relative humidity of 80...

Page 9: ...6 608 210 155 RX75S 65 69 1097 1182 372 305 390 758 352 1080 718 362 219 249 233 300 453 M10 330 216 250 233 562 130 432 593 292 608 210 155 RX75S 80 69 1097 1182 372 305 390 758 352 1054 692 362 219...

Page 10: ...5 210 155 P75R 80 69 1157 1267 354 385 495 772 330 964 692 272 234 264 287 300 420 M10 330 216 250 233 558 130 428 565 310 575 210 155 P75A 50 69 1275 374 503 772 374 906 634 272 254 270 233 300 420 M...

Page 11: ...210 155 R75R 80 69 1143 1253 372 385 495 758 350 1054 692 362 234 264 233 300 420 M10 330 216 250 233 558 130 428 565 292 575 210 155 R75A 50 69 1261 403 503 758 350 996 634 362 254 270 233 300 453 M...

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: ...um output point is usually reached by adj suting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is rea ched setting the combustion head to...

Page 14: ...5S Gas rate Stm3 h RX75R Gas rate Stm3 h GAS PRESSURE IN THE NETWORK mbar RX75 Gas rate Stm3 h GAS PRESSURE IN THE NETWORK mbar R75R P75R Gas rate Stm3 h R75A P75A Gas rate Stm3 h WARNING the diagrams...

Page 15: ...enerator 2 Pressure outlet on the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge Measuring gas pressure in the combustion head In order to measure the pr...

Page 16: ...ate in combustion head curves natural gas ATTENTION THE BURNED GAS RATE MUST BE READ AT THE GAS FLOW METER WHEN IT IS NOT POSSIBLE THE USER CAN REFERS TO THE PRESSURE RATE CURVES AS GENERAL INFORMATIO...

Page 17: ...PART I SPECIFICATIONS 17 Pressure rate in combustion head curves LPG Curves are referred to pressure 0mbar in the combustion chamber R75A L P75A L Stm3 h...

Page 18: ...cardboard packages whose dimensions are 1636mm x 1036mm x 1016mm L x P x H Packing cases of this type are affected by humidity and are not suitable for stacking The following are placed in each packin...

Page 19: ...4 stud bolts place the ceramic fibre plait on the burner flange install the burner into the boiler fix the burner to the stud bolts by means of the fixing nuts according to the next picture After fitt...

Page 20: ...tha suites the utilisation please contact the manifacturer RX75 RX75S RX75R Matching the burner to the boiler low NOx burners The burners described in this manual have been tested with combustion cham...

Page 21: ...sure governor pressure switch gas leakage pressure switch PGCP Gas train with valves group VGD with built in gas pressure governor gas leakage pressure switch PGCP 1 Filter 6 Butterfly valve 2 Pressur...

Page 22: ...s are correctly positioned between the flanges and the valve VGD40 and MBE make sure the gaskets are correctly positioned between the flanges fasten all the components with screws according to the fol...

Page 23: ...akage and functional test 5 disassembly in reverse order 2 MULTIBLOC DUNGS MB DLE 415 420 Mounting 1 Loosen screws A and B do not unscrew Fig 10 Fig 11 2 unscrew screws C and D Fig 10 Fig 11 3 Remove...

Page 24: ...aneous material drops inside the valves during maintenance and cleaning operation of the filters both the filters outside the valves group and the ones built in the gas valves WARNING Slowly open the...

Page 25: ...ncludes a vent limiter according to UL 353 and ANSI Z21 18 CSA 6 3 No venting required in locations where vent limiters are accep ted by the jurisdiction 4 Only PS pressure sensors specified by DUNGS...

Page 26: ...gas and prevent the elements at risk e g burner valves counters and regulators from becoming rapidly blocked The filter is normally installed upstream from all the control and on off devices Caution t...

Page 27: ...t atmospheric pressure EV2 closes and keep this position for a preset time test time td1 The pressure switch PGCP has not to detect a rise of pressure Test space filling EV1 opens and keep this positi...

Page 28: ...C 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 recommend...

Page 29: ...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 30: ...begins when the test is performed the proving system LED turns on At the end of the test the burner staring cycle begins in case of leakage in a valve the gas proving system stops the bur ner and the...

Page 31: ...operate with insufficient air flow danger of formation of carbon monoxide if this should happen make the fuel decrease slowly until the normal combustion values are achieved WARNING the combustion air...

Page 32: ...OEM Service 400 Curve rapporto Ratio curves OEM Service 500 Controllo rapporto Ratio control OEM Service 600 Servocomandi Actuators OEM Service 700 Storico errori Error history OEM Service Info 900 Da...

Page 33: ...llo 2 t52 interval 2 Ph60 Funzionamento 1 stazionario Operation 1 stationary Ph62 t62 massimo tempo bassa fiamma funzionamento 2 in preparazione per spegnimento verso bassa fiamma t62 max time low fir...

Page 34: ...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 35: ...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 36: ...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 37: ...y 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 more...

Page 38: ...ckwise 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 co...

Page 39: ...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 40: ...position is factory set as shown in figure A x 10 mm If different settings are required it is possible to change the position loosen the VB screw and slightly move the combustion head backwards turnin...

Page 41: ...which the burner is designed For natural gas burners plate holes are fully opened R75A L Center head holes gas flow regulation To adjust the gas flow partially close the holes as follows 1 loosen the...

Page 42: ...5 Perform leakage and functional test pmax 360 mbar 6 Pay attention that dirt does not fall inside the valve Check the filter at least once a year Change the filter if the pressure difference between...

Page 43: ...MBEMultiBloc VD Mounting position to push 1 Position VD on VB fig 2 3 2 Slide VD forward up to the stop fig 4 3 Screw VD on with 2 M5 screws for each max 5 Nm 44 in lb fig 5 6 4 VD can be mounted rot...

Page 44: ...astic cover on the pressure switch Calibration of low gas pressure switch As for the gas pressure switch calibration proceed as follows Be sure that the filter is clean Remove the transparent plastic...

Page 45: ...condition of the burner boiler gasket Eventually substitute it Check the fan s motor no specific maintenance is needed In case of anomalous noises when running check the condition of the bearings and...

Page 46: ...ted Clean the combustion head by means of compressed air or scrape off the scale using a metallic brush Ignition pilot electrode positions if provided WARNING Before opening the filter close the manua...

Page 47: ...burner pilot P 5 remove the electrode and replace it referring to the values quoted on figure ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc otherw...

Page 48: ...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 ER EA G M the gap between i...

Page 49: ...s and replace them paying attention to the measures showed in previous paragraph Reassemble the burner by fllowing the procedure in the reversed order ATTENTION avoid the ignition and detection electr...

Page 50: ...the detector 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 valve of the supply...

Page 51: ...LL ITS FEA TURES WITHOUT IGNITING THE BURNER Air pressure switch damaged or bad links Check air pressure switch functions and links Burner control damaged Replace burner control BURNER LOCKS OUT WITHO...

Page 52: ...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 53: ...Service manual AZL2x LMV2x 3x Burner Management System M12916CD Rev 3 4 03 2023...

Page 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...8 Parameters level heating engineer...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...50 ERROR CODE TABLE...

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Page 117: ...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 118: ...66 Wiring variants for LMV27 2 Fuel meter input 1 Supply fuel meter ConnectorX75 ConnectorX5 02 ConnectionsPmax...

Page 119: ...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 120: ...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 124: ...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...

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