Unigas HRX92R-FGR Manual Of Installation - Use - Maintenance Download Page 49

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PART III: OPERATION

FLUIDICS KW3...60°

NOZZLE SUPPLY PRESSURE = 20 bar.

VISCOSITY AT NOZZLE = 5 cSt

Pressure on return (bar)

Flow

rate [

kh/h]

Pressure on return (bar)

low ra

The nominal size of the nozzle is indicated at the ends of the
curve

Summary of Contents for HRX92R-FGR

Page 1: ...BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES MANUAL OF INSTALLATION USE MAINTENANCE HRX92R FGR EA HRX92 FGR EA HRX512R FGR EA HRX512 FGR EA HRX515 FGR EA HRX520 FGR EA LMV 2 3x Microprocessor control...

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: ...f recirculation gas FGR Option 1 Damper with actuator Connect the actuator to the electrical predisposition inside the electrical panel Option 2 Damper manual Damper manual with Opening Closing signal...

Page 6: ...main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which...

Page 7: ...ed in the burner data plate BURNER TYPE MG HRX92R FGR HRX92 FGR Output min max kW 350 2 295 670 2 790 Fuel Natural gas Light oil Natural gas Light oil Category see next paragraph see next paragraph Ga...

Page 8: ...lute pressure 15 C temperature and are valid for G20 gas net calorific value Hi 34 02 MJ Stm3 Note2 Maximum gas pressure 500mbar with Siemens VGD or Dungs MultiBloc MBE Minimum gas pressure see gas cu...

Page 9: ...12 424 280 310 300 790 148 642 942 353 709 228 185 HRX92 FGR EA 50 1376 1486 135 831 35 550 100 420 530 493 955 506 1160 725 435 284 450 360 524 M12 424 280 310 300 532 148 384 624 190 709 228 185 65...

Page 10: ...390 390 390 791 149 642 942 353 830 330 270 524 62 554 195 225 603 9 151 HRX515 FGR EA 50 1685 222 928 371 35 333 595 100 530 522 1155 532 1549 946 515 360 400 494 540 560 M14 552 390 390 390 763 149...

Page 11: ...AIN 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 16 One way...

Page 12: ...stributor 11 Flexible hose 12 Pressure gauge 13 Pressure governor 14 Electrical motor 15 Pressure switch 16 One way valve 17 Flexible hose 18 Flexible hose 19 Manual valve 19 1 Manual valve 20 Pressur...

Page 13: ...mance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests but does not represent the regulation range of the machine On this diagram the max...

Page 14: ...cessary to get the requested furnace input This value must be lower or equal to the pgas value calcula ted before GAS PRESSURE mbar HRX92R MG Stm3 h HRX92 MG Stm3 h GAS PRESSURE mbar HRX512R MG Stm3 h...

Page 15: ...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 16: ...s are referred to pressure 0 mbar in the combustion chamber Gas pressure in combustion head HRX92R FGR MG Stm3 h HRX92 FGR MG Stm3 h Gas pressure in combustion head HRX512R FGR MG Stm3 h HRX512 FGR MG...

Page 17: ...y regulations Do not stand under lifted loads Packing The burners are despatched in wooden crates whose dimensions are 9xA series 1672mm x 1072mm x 1016mm L x P x H Packing cases of this type are affe...

Page 18: ...he diagram In case the burner must be coupled with boilers with a combustion chamber smaller in dia meter or shorter than those described in the diagram please contact the supplier to verify that a co...

Page 19: ...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 20: ...ositioned between the flanges fasten all the components with screws according to the following diagrams make sure bolts on the flanges are properly tightened MBEGas train with valves group VGD and MBE...

Page 21: ...leakage 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 9 Fig 10 2 unscrew screws C and D Fig 9 Fig 10 3 Remove...

Page 22: ...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 23: ...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 24: ...becoming rapidly blocked The filter is normally installed upstream from all the control and on off devices Caution the SKP2 diaphragm D must be vertical see Fig 1 WARNING removing the four screws BS...

Page 25: ...the test space to ambient pressure Test 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...

Page 26: ...e suited for single pipe system recommended in the case of gravity feed as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rota tion referring to...

Page 27: ...e nozzle reducing efficiency Always use O Rings or mechanical seal copper or aluminium gaskets jun ctions if possible An external filter should always be installed in the suction line upstream the fue...

Page 28: ...uts A and R on the inlet and return connections of the pump 2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the lines see the arrows marked on the pump...

Page 29: ...ssary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay WARNING Respect the basic safety rules make sure of the connection to the...

Page 30: ...EPT 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 LOCATED ON THE B...

Page 31: ...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 pre purge time the actuator is in the light oil ignition p...

Page 32: ...equal to the pressure required by the pressure curves burnt gas flow Adjustments brief description The air and fuel rates adjustments must be performed at the maximum ouptput first high flame see the...

Page 33: ...e of the recirculation fumes Check that the combustion parameters are within the recommended limits Check the flow rate by measuring it at the meter or if this is not possible by checking the pressure...

Page 34: ...ator position Fuel While pressing the F key the fuel actuator position can be changed by means of the and keys Key A Used to adjust the air actuator position Air While pressing the A key the air actua...

Page 35: ...torico errori Error history OEM Service Info 900 Dati di processo Process data OEM Service Info Fase Phase Funzione Function Ph00 Fase blocco Lockout phase Ph01 Fase di sicurezza Safety phase Ph10 t10...

Page 36: ...ento 1 stazionario Operation 1 stationary Ph62 t62 massimo tempo bassa fiamma funzionamento 2 in preparazione per spegnimento verso bassa fiamma t62 max time low fire operation 2 prepa ring for shutdo...

Page 37: ...evel 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 _ _ on the right 6 press InFo for 1 3 seconds th...

Page 38: ...and find out the fault in the Error table To perform the reset press InFo for one second The unit displays an event which does not lead to shutdown The display shows current error code c alternating...

Page 39: ...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 flue gas analisys to avoid combustion with air...

Page 40: ...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 41: ...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 42: ...off valve 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...

Page 43: ...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 44: ...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 45: ...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 46: ...PART III OPERATION 46 Fig 25...

Page 47: ...PART III OPERATION 47...

Page 48: ...PART III OPERATION 48 FLUIDICS KW3 60 NOZZLE SUPPLY PRESSURE 20 bar VISCOSITY AT NOZZLE 5 cSt Pressure on return bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve...

Page 49: ...ESSURE 20 bar VISCOSITY AT NOZZLE 5 cSt Pressure on return bar Flow rate kh h Pressure on return bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve The nominal siz...

Page 50: ...eturn bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve Pressure on return bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve...

Page 51: ...o curve see the LMV related manual 5 Only if necessary adjust the supply pressure as follows see related paragraph insert a pressure gauge into the port shown on Fig 27 and act on on the pump adjustin...

Page 52: ...ustion parameters for this reason the pressure switch must be set say at 20 over the pressure recorded during the combustion adjustment The factory setting is 4 bar It is recommended to verify that th...

Page 53: ...nce operations refit the burner turn it on and check the combustion If in doubt replace the defec tive nozzle s In case of intensive use of the burner the nozzles must be replaced at the end of the wo...

Page 54: ...n 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 betwee...

Page 55: ...ombustion head by means of a vacuum cleaner scrape off the scale by means of a metallic brush Note to replace the combustion head reverse the operations described above position to push 1 Position VD...

Page 56: ...detection electrodes after removing adjusting the combustion head Adjust the electrodes position according to the quotes shown othe next picture Checking the detection current To check the detection s...

Page 57: ...sing it due to non compliance with safety requirements or a decrease in performance The owner makes the decision whether to finish using the burner or replacing and disposing of it based on the actual...

Page 58: ...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 WITHOUT ANY GAS...

Page 59: ...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 60: ...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 61: ...Service manual AZL2x LMV2x 3x Burner Management System M12916CD Rev 3 4 03 2023...

Page 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...8 Parameters level heating engineer...

Page 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...50 ERROR CODE TABLE...

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Page 125: ...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 126: ...66 Wiring variants for LMV27 2 Fuel meter input 1 Supply fuel meter ConnectorX75 ConnectorX5 02 ConnectionsPmax...

Page 127: ...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 128: ...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 132: ...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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Summary of Contents for HRX92R-FGR

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Unigas HRX92R-FGR, Manual Of Installation - Use - Maintenance, Page: 49 / 132

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Summary of Contents for HRX92R-FGR

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