Unigas RG2050, Manual Of Installation - Use - Maintenance

Page 1: ...M039414CA Rel 0 1 05 2017 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES MANUAL OF INSTALLATION USE MAINTENANCE RG2050 RG2060 RG2080 LMV5x Microprocessor controlled light oil burners...

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: ...egulator except for some models for which a separate regulating valve is provided Other pumps are provided with two pressure regulators one for the high and one for low pressure in double stage system...

Page 6: ...ol EI with no O2 trim control with VSD control EK with O2 trim control with VSD control RG2050 RG2060 RG2080 Output min max kW 2500 15200 2500 16000 2500 19000 Fuel Light oil Light oil rate min max kg...

Page 7: ...1117 239 215 1375 425 542 768 1363 1660 RG2060 2377 741 831 868 7 645 321 650 885 728 850 650 710 850 950 M16 1117 239 215 1375 425 542 872 1365 1910 RG2080 2377 741 831 868 7 645 321 527 885 728 850...

Page 8: ...otor 6 Solenoid valve 7 Flexible hose 9 Flexible hose 10 Oil distributor 12 Pressure gauge 13 Pressure governor 14 Actuator 15 Pressure switch 16 One way valve 18 Flexible hose 19 Manual valve 20 Pres...

Page 9: ...otor 6 Solenoid valve 7 Flexible hose 10 Oil distributor 11 Flexible hose 12 Pressure gauge 13 Pressure governor 14 Actuator 15 Pressure switch 16 One way valve 18 Flexible hose 19 Manual valve 20 Pre...

Page 10: ...is diagram the maximum output point is 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...

Page 11: ...l 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 hea...

Page 12: ...lange 5 install the burner into the boiler 6 fix the burner to the stud bolts by means of the fixing nuts according to the picture below 7 After fitting the burner to the boiler ensure that the gap be...

Page 13: ...included in the burner performance curve otherwise the choice of the burner must be revised consulting the burner manufacturer To choose the blast tube lenght follow the instructions of the boiler man...

Page 14: ...ngs chapter at the beginning of this manual 1 3 2 Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve NOTE in plants where gravity or ring fe...

Page 15: ...and threaded or mechanical seal jun ctions preferred Junction threads elbow joints and couplings should be sealed with removable sg component The number of jun ctions should be kept to a minimum as th...

Page 16: ...or LMV5 control box please refer to the clabeling recommendations avaible on the Siemens CD attached to the burner Pressure adjustment Remove cap nut 1 and the gasket 2 unscrew the lock nut 4 To incre...

Page 17: ...OR PARTIAL TAMPERING 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 MACHIN...

Page 18: ...urge phase must be carried out at the maximum air rate the 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...

Page 19: ...stem to start up 5 the combustion cycle starts the system will show the operating stages Prepurging program phase no 30 Driving to ignition position program phase no 36 Ignition position program phase...

Page 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...ic cover on the pressure switch Adjusting the combustion head Only if necessary change the combusiton head position to let the burner operate at a lower output loose the VB screw and move pro gressive...

Page 26: ...PART III OPERATION 26 Pump flow rate Nozzle flow rate...

Page 27: ...g 8 4 As for setting the fuel air ratio curve see the LMV related manual 5 Only if necessary adjust the supply pressure as follows insert a pressure gauge into the port shown on figure and act on on t...

Page 28: ...table values reduce from 20 to 15 the overpressure later on repeat the adjustments described above Pressure governor on return line Pressure governor works between two different pressure values The mi...

Page 29: ...tive nozzle s In case of intensive use of the burner the nozzles must be replaced at the end of the working season check and carefully clean the flame detection photoresistor if necessary replace it...

Page 30: ...burner status is considered to be at its limit if it is technically impossible to continue using it due to non compliance with safety requirements or a decrease in performance The owner makes the deci...

Page 31: ...s according to the laws in force in your country about the Disposal of materials WIRING DIAGRAMS Refer to the attached wiring diagrams WARNING 1 Electrical supply 400V 50Hz 3N a c 2 Do not reverse pha...

Page 32: ...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 36: ...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 37: ...Siemens LMV5x Service Manual M12920CC rev 2 1 08 2017...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 45: ...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 46: ...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 47: ...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 48: ...12 2 2 LMV5x program structure...

Page 49: ...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 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...39...

Page 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 84: ...Note Specifications and data subject to change Errors and omissions excepted...

Page 85: ...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 86: ...Annex1 Example for motor cable...

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Page 88: ...Annex 2 Example for sensor cable...

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Page 91: ...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 92: ...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 93: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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...