Unigas HRX2060 Manual Of Installation - Use - Maintenance Download

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

Summary of Contents for HRX2060

Page 1: ...M039669CB 0 0 05 2022 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES MANUAL OF INSTALLATION USE MAINTENANCE HRX2060 HRX2080 LMV5x Microprocessor controlled Gas light oil burners...

Page 2: ...non original components whether spare parts kits accessories and optionals Force majeure Furthermore the manufacturer declines all responsibility for non compliance with this manual Personnel training...

Page 3: ...rner shut down reser the control box by means of the RESET pushbutton If a second shut down takes place call the Tech nical Service without trying to RESET further The unit shall be operated and servi...

Page 4: ...y El Supply El Consump Fan Motor Protection Drwaing n P I N Do not touch any mechanical moving parts with your hands or any other part of your body Injury hazard Do not touch any parts containing fuel...

Page 5: ...e is provided Other pumps are provided with two pressure regulators one for the high and one for low pressure in double stage systems with one nozzle The adjustable combustion head can improve the bur...

Page 6: ...0 HRX2080 Output min max kW 2500 16000 2500 19000 Fuel MG Natural gas Light oil Category see next paragraph Gas rate min max min max Stm3 h 265 1693 265 2011 Pressure mbar see Note 2 Light oil rate mi...

Page 7: ...04 968 174 P119 430 1200 640 339 555 Boiler recommended drilling template Burner flange Overall dimensions mm HRX2060 HRX2080 The burner is equipped with a height adjustable wheeled trolley B SPECIAL...

Page 8: ...MD S RU A 8 125 EI 1398 2297 659 657 220 751 479 249 612 861 1699 555 2254 732 175 720 1 1 1 7 395 395 790 395 395 790 860 860 35 16 M 395 395 860 395 395 640 924 1190 1347 950 767 711 430 968 907 85...

Page 9: ...PART I SPECIFICATIONS 9 Support frame for burner size 2080 968 1255 1690 1150 1028 164 1370 50 1773 1200 684...

Page 10: ...Pressure governor 14 Actuator 15 Pressure switch 16 One way valve 18 Flexible hose 19 Manual valve 20 Pressure gauge MAIN GAS TRAIN 40 Manual valve 41 Bellows unit 42 Filter 43 Pressure switch PGMIN 4...

Page 11: ...re governor 14 Actuator 15 Pressure switch 16 One way valve 18 Flexible hose 19 Manual valve 20 Pressure gauge MAIN GAS TRAIN 40 Manual valve 41 Bellows unit 42 Filter 43 Pressure switch PGMIN 44 Safe...

Page 12: ...s 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 the x axi...

Page 13: ...he combustion head to its MIN position During the first ignition the combustion head is set in order to find a compromise between the burner output and the generator specifications that is why the min...

Page 14: ...the combustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one into the combustion chamber s pres sure outlet to get the pressure in the combustion ch...

Page 15: ...CIFICATIONS 15 Gas pressure burner head vs natural gas flow rate Curves are referred to pressure 0 mbar in the combustion chamber Gas pressure in combustion head HRX2060 Stm3 h GAS PRESSURE mbar HRX20...

Page 16: ...once the burner is installed to the boiler Packing The burners are despatched in wooden crates whose dimensions are HRX2060 HRX2080 2685 mm x 1900 mm x 2050 mm L x P x H Packing cases of this type are...

Page 17: ...espect of the application involved To correctly match the burner to the boiler verify the type of the blast tube Verify the necessary input and the pressure in combustion chamber are included in the b...

Page 18: ...nt 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 b...

Page 19: ...min and max pressure switches set to 20 of the setpoint 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 pres...

Page 20: ...a suitable replacement Siemens VGD VRD SKPx5 Auxiliary optional micro switch Gas valve Caution the SKP2 diaphragm D must be vertical WARNING removing the four screws BS causes the device to be unserv...

Page 21: ...in in installed execute the electrical connections for all its items gas valves group gas proving system pressure switches Gas Filter if provided The gas filters remove the dust particles that are pre...

Page 22: ...lug must be installed to avoid air and fuel passing through the pump please read carefully the warnings chapter at the beginning of this manual 1 3 2 Key 1 Manual valve 2 Light oil filter 3 Light oil...

Page 23: ...hould therefore be avoided 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...

Page 24: ...1 4 3 Vacuum gauge port to measure the inlet vacuum G1 4 4 To pressure adjusting valve G3 4 Key 1 Pressure regulator 2 Pressure gauge port 3 Vacuum gauge port 4 Solenoid valve 5 Delivery to nozzle 7 I...

Page 25: ...trol box please refer to the clabeling recommendations avaible on the Siemens CD attached to the burner WARNING Respect the basic safety rules make sure of the connection to the earthing system do not...

Page 26: ...NG 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 MACHINE EXCEPT FOR ITS MA...

Page 27: ...lame operation LED B3 Lo flame operation LED B4 Ignition transformer operation LED B5 Fan motor overload tripped LED B6 Stand by signalling lamp G1 Gas valves EV2 operation signalling lamp G2 Gas valv...

Page 28: ...hile the actuator goes to the high flame position after some seconds the two stage operation begins the burner is driven automatically to high flame or low flame according to the plant requirements Op...

Page 29: ...ey previous level it goes back to the prevoius level menu or exits the programming mode without changing data 3 ENTER key next level it confirms the data changing and jumps to the next menu parameter...

Page 30: ...ad load percentage burner output Flame percentage of flame detection current By pressing the ENTER key the display shows the second page Second page Fuel it shows in degrees the fuel actuator position...

Page 31: ...by an error message as To see the other Fault History pages press the arrow keys To exit the Fault History pages press ESC Lockout History To visualise the Lockout History choose the related item and...

Page 32: ...he unit measure of the detected value and its limits are bound up with parameters set at the Service level Once the new set point is set confirm by pressing ENTER otherwise exit without changings by p...

Page 33: ...turn off at a temperature 1 higher than the set point Change value if needed by means of the arrow keys press ENTER to confirm and the press ESC to exit Press only ESC to exit without changing Press t...

Page 34: ...xit choose the temperature and pressure unit and cofirm by pressing ENTER press ESC to exit System lockout If the system locks out the following message will appear call the Technical Service and tell...

Page 35: ...Autom Manual Off three modes are provided Automatic automatic operation Burner on manual operation Burner off burner in stand by If the BurnerOn mode is choosen the burner does not follow the modulato...

Page 36: ...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 37: ...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 38: ...ustion 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 improve the...

Page 39: ...PART III OPERATION 39 Pump flow rate Nozzle flow rate...

Page 40: ...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 41: ...e whole range of the burner output In case of inacceptable values reduce from 20 to 15 the overpressure later on repeat the adjustments described above Pressure governor on return line Pressure govern...

Page 42: ...ng the reverse order operations 8 Make sure there is no leakage and give the power to any electrical equipmente on the filter WARNING ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DI...

Page 43: ...e assembly as shown Note to replace the combustion head reverse the operations described above 4 Clean the combustion head by means of a vacuum cleaner scrape off the scale by means of a metallic brus...

Page 44: ...ead ATTENTION avoid the electrode to get in touch with metallic parts blast tube head etc otherwise the boiler operation would be compromised Check the electrode position after any intervention on the...

Page 45: ...decrease in performance The owner makes the decision whether to finish using the burner or replacing and disposing of it based on the actual state of the appliance and any repair costs The use of the...

Page 46: ...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...

Page 47: ...into the electrodes Improve the installation Ignition transformer damaged Replace the transformer PUMP TOO NOISY Suction too high over 0 35 bar dirty filters check valve in the tank locked and so on...

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...

Page 56: ...8...

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...

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