Unigas K590X Manual Of Installation - Use - Maintenance Download

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Summary of Contents for K590X

Page 1: ...84CB 0 1 05 2022 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES MANUAL OF INSTALLATION USE MAINTENANCE Gas burners K590X K660X K750X Microprocessor controlled LMV 2x 3x Also with flue gas recirculation...

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: ...ometry and combustion efficiency Fuel and air are routed through separated channels inside the combustion head then mixed to ignite the flame inside the combustion chamber The ignition spark is provid...

Page 6: ...ut inverter EB micro processor control with inverter BURNER TYPE K590X M K660X M K750X M K590X L K660X L K750X L Output min max kW 670 5900 680 6600 860 7500 670 5900 680 6600 860 7500 Fuel M Natural...

Page 7: ...ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH I2E LU PL I2E R B BE I2EK NL I2ELL DE I2Er FR DANGER The burner must be used only with the fuel specified in the burner data pla...

Page 8: ...1201 524 1695 969 726 383 400 405 494 540 690 M16 651 460 460 460 636 150 487 845 292 960 336 270 80 1631 1731 366 25 626 132 430 530 626 1201 524 1728 1002 726 383 400 405 494 540 690 M16 651 460 460...

Page 9: ...636 150 487 845 292 960 336 270 482 18 712 85 1690 1790 366 25 626 132 430 530 626 1260 524 1864 1002 862 383 400 405 494 540 690 M16 651 460 460 460 687 150 538 875 313 960 336 270 482 18 712 100 169...

Page 10: ...9 150 85 1690 1790 366 1082 670 25 314 626 132 430 530 626 1260 524 1590 1002 504 383 400 405 494 540 690 M16 651 460 460 460 687 150 538 875 313 960 336 270 482 18 712 195 225 588 9 150 100 1690 179...

Page 11: ...rner 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 axis as far as intercepitng the net...

Page 12: ...ting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is reached setting the combustion head to its MIN position During the first ignition t...

Page 13: ...y to find out the burner s output in Stm3 h quoted on the x axis from the pressure measured in the combu stion head quoted on the y axis The data obtained must be considered when adjusting the gas flo...

Page 14: ...of the boiler for that burner multiply the required burned power by the depowering factor expressed as follows multiply the back pressure in the combustion chamber by the depressurisation factor squa...

Page 15: ...PART I SPECIFICATIONS 15 Burner power reduction K590X Thermic Load MW m3 Burner power reduction K660X Thermic Load MW m3 Burner power reduction K750X Thermic Load MW m3...

Page 16: ...sonnel All handling operations must be carried out with appropriate resources and qualified personnel ATTENTION Use intact and correctly dimensioned hoisting equipment conforms to the local regulation...

Page 17: ...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 corr...

Page 18: ...ts are not part of the standard supply GAS TRAIN CONNECTIONS The diagrams show the components of the gas trai included in the delivery and which must be fitted by the installer The diagrams are in com...

Page 19: ...lve optional MULTIBLOC DUNGS MB DLE 405 412 MB DLE 415 420 Mounting 1 Mount flange onto tube lines use appropriate sealing agent 2 Insert MB DLE note position of O rings 3 Remove MultiBloc between the...

Page 20: ...UCIATORE 185 501939 PGMAX PGCP PGMI EV1 EV2 S EV2 EV1 PGMAX PGMIN VD R PGCP VD V VD V VD R PS PS pressure sensor Gas filter Example of gas train MBE A A C B B C 1 Mount flange into pipe systems Use ap...

Page 21: ...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 pressure sensor i...

Page 22: ...mbar neutral yellow red Spring colour SKP 25 0 0 22 15 120 100 250 Spring colour SKP 25 4 7 700 150 1500 Siemens VGD valves with SKP actuator The pressure adjusting range upstream the gas valves group...

Page 23: ...hes plugs Overall dimensions mm BURNERS WITH INVERTER VARIANT if provided ATTENTION it is reccomended to install the filter with gas flow parallel to the floor in order to prevent dust fall on the saf...

Page 24: ...s and with a signal in 0 10V controls it through the inverter Generally the curve of the inverter goes from 50 to 100 of the engine revolutions This in addition to improving the setting of the burner...

Page 25: ...controls it through the inverter Generally the curve of the inverter goes from 50 to 100 of the engine revolutions This in addition to improving the setting of the burner also allows a saving on the c...

Page 26: ...itable to the installed power see electrical diagram enclosed paying attention to the voltage values printed on the burner plate Always check in advance the protection from overcurrents and electromag...

Page 27: ...inal 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 recommendations avaible on the Siemens CD a...

Page 28: ...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 29: ...sure is sufficient signalled by an error code on the AZL display Burners fitted with gas proving system the gas proving system test begins when the test is performed the proving system LED turns on At...

Page 30: ...flame output increasing too much or that the flues temperature gets too low to cause condensation in the chimney User interface The AZL2x display is shown below The keys functions are the following WA...

Page 31: ...Serivce during the curve adjustments Key Used to increase a a value Used to enter Info and Serivce during the curve adjustments Keys ESC By pressing and at the same time the ESCAPE function is perfome...

Page 32: ...rimo tempo sicurezza trasformatore accensione ON TSA1 1st safety time ignition transformer ON Ph42 TSA1 primo tempo sicurezza trasformatore accensione OFF TSA1 1st safety time ignition transformer OFF...

Page 33: ...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 34: ...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 35: ...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 36: ...meet the values requested by the boiler utilisation If necessary change the combusiton head positionl The air and gas flow rate are now adjusted at the maximum power stage go on with the point to poin...

Page 37: ...ection G 1 8 8 Test point connection G 1 8 downstream of valve 1 on both sides 9 Output flange 10 Test point connection M4 downstream of valve 2 11 Gas flow direction 12 Test connection G 1 8 downstre...

Page 38: ...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 10 40...

Page 39: ...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 40: ...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 41: ...if necesssary Remove and clean the combustion head Examine and clean the ignition electrodes adjust and replace them if necessary Examine and clean the detection electrode photoelement according to t...

Page 42: ...filter if the pressure difference between pressure connection 1 and 3 Fig 1 Fig 3 is twice as high compared to the last check You can change the filter without removing the fitting 1 Interrupt the gas...

Page 43: ...ten the V screws The adjusting plate correct position must be regulated in the plant during the commissioning 9xA series 1 5 mm 5xxA series 1 3 mm Flame detection probe To clean replace the detection...

Page 44: ...removing adjusting the combu stion head ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc other wise the boiler s operation would be compromised Chec...

Page 45: ...trodes group back to the outside and remove the combustion head D 6 loose the screw of th eignition electrodes support E 7 remove the electrodes and replace them paying attention to the measures showe...

Page 46: ...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 Seas...

Page 47: ...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 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: ...Service manual AZL2x LMV2x 3x Burner Management System M12916CD Rev 3 4 03 2023...

Page 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...8 Parameters level heating engineer...

Page 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...50 ERROR CODE TABLE...

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Page 113: ...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 114: ...66 Wiring variants for LMV27 2 Fuel meter input 1 Supply fuel meter ConnectorX75 ConnectorX5 02 ConnectionsPmax...

Page 115: ...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 116: ...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 120: ...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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