Unigas E115X-FGR M Series Manual Of Installation - Use - Maintenance Download

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Summary of Contents for E115X-FGR M Series

Page 1: ...M039602CA 0 0 08 2020 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES MANUAL OF INSTALLATION USE MAINTENANCE E115X FGR E140X FGR E190X FGR Microprocessor controlled LMV 5x Gas 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: ...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: ...tion head can improve the burner performance The combustion head determines the energetic quality and the geometry of the flame Fuel and comburent are routed into separated ways as far as the zone of...

Page 6: ...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 maximum gas pressure switch 8 GAS CONNECTION see Specification...

Page 7: ...with Dungs MBDLE Maximum gas pressure 500 mbar with Siemens VGD or Dungs MultiBloc MBE Minimum gas pressure see gas curves Warning Burners are suitable only for indoor operation with a maximum relati...

Page 8: ...30 220 250 233 127 338 529 x 575 210 155 369 30 410 170 200 436 9 131 1 65 1232 1332 129 28 400 500 369 772 481 1438 1002 267 259 280 210 287 300 420 M10 330 220 250 233 275 127 406 565 292 575 210 15...

Page 9: ...ize it is necessary to the available 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 6...

Page 10: ...imum Pressure in the Network gas flow rate curves natural gas GAS PRESSURE IN THE NETWORK mbar E115X FGR Gas rate Stm3 h E140X FGR Gas rate Stm3 h GAS PRESSURE IN THE NETWORK mbar E190X FGR Gas rate S...

Page 11: ...ssure in the combustion head insert the pressure gauge probes one into the combustion chamber s pressure outlet to get the pressure in the combustion chamber and the other one into the butterfly valve...

Page 12: ...r 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 1013 mbar...

Page 13: ...r to the boiler ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insu lating material ceramic fibre cord or refractory cement ATTENTION The equipment mus...

Page 14: ...pressure in combustion chamber are 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 consid...

Page 15: ...is obtained in a plant 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...

Page 16: ...not part of the standard supply Gas train with valves group VGD with built in gas pressure governor gas leakage pressure switch PGMIN LT 1 Filter 8 Main burner 3 Safety valve with built in gas governo...

Page 17: ...Insert MB DLE note position of O rings 3 Remove MultiBloc between the threaded flanges 4 After installation perform leakage and functional test 5 Disassembly in reverse order Keys 1 Gasket 2 Gas filt...

Page 18: ...ce 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 fuel cock to avoid breaking the pressure regulator ALLA...

Page 19: ...observe torque 3 The pressure sensor includes 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...

Page 20: ...he filter is normally installed upstream from all the control and on off devices Once the train is installed connect the gas valves group and pressure switches plugs Caution the SKP2 diaphragm D must...

Page 21: ...e td1 The pressure switch PGCP has not to detect a rise of pressure 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 clos...

Page 22: ...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 23: ...NOMALIES THAT REQUIRED A SHUT DOWN OF THE BURNER IT S POSSIBLE TO ACT ON THE AUXILIARY LINE SWITCH LOCATED ON THE BURNER FRONT PANEL IN CASE OF A BURNER SHUT DOWN RESET THE CONTROL BOX BY MEANS OF THE...

Page 24: ...aring cycle begins in case of leakage in a valve the gas proving system stops the bur ner and the lamp B1 turns on At the beginning of the start up cycle the actuator drives the air damper to the maxi...

Page 25: ...ts brief description The air and fuel rates adjustments must be performed at the maximum ouptput first high flame see the LMV5 related manual Check that the combustion parameters are in the suggested...

Page 26: ...pen Flame the flame lights up Driving to low flame the actuator drives to low flame NOTE the C and A on the Once the ignition cycle ends the main page is shown Main page Set point temperature set poin...

Page 27: ...story will be showed about the last 9 lockouts occured and the related date and hour Alarm act deact enable disable the horn in case of alarm Fault History To visualise the Fault History select it and...

Page 28: ...press ENTER the following menu is shown Choose ControllerParam and press ENTER the following menu is shown Choose SetPointW1 and press ENTER Curr it shows the current set point use the arrows keys to...

Page 29: ...u by menas of the arrow keys and press ENTER the display will show The deafult value for this parameter is10 that is the burner will turn off at a temperature 1 higher than the set point Change value...

Page 30: ...month day year choose the desired format and cofirm by pressing ENTER press ESC to exit PhysicalUnits it allows setting the measuring units for temperature and pressure Settable temperature units C o...

Page 31: ...ion the manual mode is provided To choose the manual mode Manual Operation use the SELECT arrow keys Items to be set are the following SetLoad to set the required load percentage set the required perc...

Page 32: ...uces 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 cover C By screwing d...

Page 33: ...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 34: ...the combustion head backwards turning clockwise the knob VRT Fasten VB screw when the adjustment is accomplished Depending on the boiler application it is possible to act on the holes figure B to imp...

Page 35: ...ced by 15 Repeat the ignition cycle of the burner and check it runs properly Refit the transparent plastic cover on the pressure switch Calibration of low gas pressure switch As for the gas pressure s...

Page 36: ...ary in case of doubt check the detection circuit after the burner start up Clean and grease leverages and rotating parts At least every 2 months or more often if needed clean the room where the burner...

Page 37: ...Fig 10 Fig 11 is twice as high compared to the last check You can change the filter without removing the fitting 1 Interrupt the gas supply closing the on off valve 2 Remove screws 1 4 using the Alle...

Page 38: ...replacement 4 be sure to replace the O ring into its place C and replace the cover fastening by the proper screws A Remove the lid C Unscrew the screws V holding in position the manifold G and pull o...

Page 39: ...asten 5 Perform leakage and functional test pmax 360 mbar 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 betw...

Page 40: ...paragraph Reassemble the burner by fllowing the procedure in the reversed order ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc other wise the boil...

Page 41: ...er or replacing and disposing of it based on the actual state of the appliance and any repair costs The use of the burner for other purposes after the expiry of the terms of use is strictly prohibited...

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Page 44: ...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 45: ...Siemens LMV5x Service Manual M12920CC rev 2 1 08 2017...

Page 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 53: ...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 54: ...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 55: ...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 56: ...12 2 2 LMV5x program structure...

Page 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...39...

Page 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 92: ...Note Specifications and data subject to change Errors and omissions excepted...

Page 93: ...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 94: ...Annex1 Example for motor cable...

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Page 96: ...Annex 2 Example for sensor cable...

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Page 99: ...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 100: ...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 101: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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...

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