Unigas R91 Installation Manual Download Page 43

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IV
: MAIN

TENANCE

DESCRIPTION

DETECTION ELECTRODE

IGNITION ELECTRODE

GROUND ELECTRODE

GASKET

PLUG

GAS MANIFOLD

COMBUSTION HEAD

BLAST TUBE

BURNER STAND

PLATE

GAS MANIFOLD BRACKET

WINDBOX

IGNITION CABLE

DETECTION CABLE

Summary of Contents for R91

Page 1: ...M039267CA 0 1 07 2015 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES LMV2x 3x Microprocessor controlled Multihead gas burners MANUAL OF INSTALLATION USE MAINTENANCE R91 R92 R93 R512 R515 R520 R525...

Page 2: ...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 3: ...evelopment of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives 2009 142 EC Gas Directive 2006 95 CEC Low Tension Directive 2004 108 EC Electromagnetic compatibility...

Page 4: ...ments for house hold appliances electric tools and similar apparatus EN 746 2 Industrial thermoprocessing equipment Part 2 Safety requi rements for combustion and fuel handling systems EN 50165 Electr...

Page 5: ...ities of these boilers the need to operate in slight depression and to heat the boiler in low flame for a long time before exploiting the highest performance The flame is divided into smaller flames p...

Page 6: ...ol with inverter BURNER TYPE R91 M R92 M R93 M Output min max kW 480 2670 480 3050 550 4100 Fuel M Natural gas Category see next paragraph Gas rate Natural gas min max Stm3 h 51 283 51 323 58 434 Gas...

Page 7: ...tural gas min max Stm3 h 63 476 81 550 106 677 212 709 212 847 PressureGas pressure mbar see Note 2 Power supply 230V 3 400V 3N 50Hz Total power consumption kW 9 7 11 5 16 5 19 19 Electric motor kW 9...

Page 8: ...8 532 1370 934 436 255 386 255 442 221 447 550 464 M12 510 510 887 404 483 843 290 739 185 R92 VS 1 80 80 1464 411 20 579 132 326 419 1138 532 1405 969 436 255 386 255 442 221 447 550 464 M12 510 510...

Page 9: ...565 1692 1049 643 275 483 275 516 258 494 750 612 700 M16 700 350 550 550 887 404 483 843 290 987 270 R520 VS 1 80 80 1560 474 324 508 1236 565 1727 1084 643 275 483 275 516 258 494 750 626 700 M16 7...

Page 10: ...o 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 600kW in the example q...

Page 11: ...head is set in order to find a compromise between the burner output and the generator specifications that is why the minimum output may be different from the Per formance curve minimum BACK PRESSURE...

Page 12: ...520 M Stm3 h GAS PRESSURE mbar R525 M Rp2 Stm3 h R525 M DN65 80 100 Stm3 h Caution the gas rate value is quoted on the x axis the related network pressure is quoted on the y axis pressure value in the...

Page 13: ...the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge 1 10 Measuring the gas pressure in the combustion head In order to measure the pressure in the combust...

Page 14: ...00 120 140 160 180 200 220 240 260 280 300 0 5 10 15 20 25 30 35 40 45 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 0 5 10 15 20 25 30 35 40 45 50 50 75 100 125 150 175 200 225 250 275...

Page 15: ...acking The burners are despatched in wooden crates whose dimensions are z 9x series 1720mm x 1420mm x 1130mm L x P x H z 5xx series 1960mm x 1360mm x 1310mm L x P x H z 525 1960mm x 1460mm x 1310mm L...

Page 16: ...PART II INSTALLATION 16 Fig 5 H a 0 50 mm...

Page 17: ...kets are not part of the standard supply WARNING BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED Gas train with valves group VGD with built in...

Page 18: ...ted z Connect the reference gas pipe TP in figure 8mm external size pipe supplied loose to the gas pressure nipples placed on the gas pipe downstream the gas valves gas pressure must be measured at a...

Page 19: ...pressure Test atmospheric pressure EV1 closes and keep this position for a preset time test time td1 The pressure switch PGCP has not to detect a rise of pressure z Test space filling EV2 opens and k...

Page 20: ...terminal X3 04 4 in case of LMV2x LMV3x LMV5x LME7x on the board and the earth terminal an RC Siemens RC466890660 filter must be inserted For LMV5 control box please refer to the clabeling recommenda...

Page 21: ...ER OPEN OR DISMANTLE ANY COMPONENT OF THE 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...

Page 22: ...s pressure is sufficient signalled by an error code on the AZL display z At the beginning of the start up cycle the actuator drives the air damper to the maximum opening position then the fan motor st...

Page 23: ...o low to cause condensation in the chimney 4 6 User interface The AZL2x display is shown below The keys functions are the following WARNING During commissioning operations do not let the burner operat...

Page 24: ...justments 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 perfomed to enter a lower level me...

Page 25: ...gnition transformer ON Ph42 TSA1 primo tempo sicurezza trasformatore accen sione OFF TSA1 1st safety time ignition transformer OFF t42 preignition time OFF Ph44 t44 intervallo 1 t44 interval 1 Ph50 TS...

Page 26: ...splay will show InFo Press 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 par...

Page 27: ...or by pressing ESC or InFo for more seconds the display will show 9 Once the last parameter is accessed 143 by pressing the End message will flash 10 Press InFo for more than three seconds or for mor...

Page 28: ...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 with diagnostic code d Press InFo to return to the dis...

Page 29: ...ner control panel see next picture instead of the TAB thermo stat as described on the previous paragraphs about the progressive burners Go on adjusting the burner as described before paying attention...

Page 30: ...Slowly fully open the manual cutoff valve z Refit the transparent plastic cover on the pressure switch 4 11 Adjusting the maximum gas pressure switch when provided To calibrate the maximum pressure sw...

Page 31: ...burner operate at a lower output loose the VB screw and move pro gressively back the combustion head towards the MIN position by turning clockwise the VRT ring nut Fasten VB screw when the adjustment...

Page 32: ...the high flame stage to the complete opening 90 Example Actuator On time 1 second Set the 0 1 1 seconds scale and the cursor to 10 for the KT1 timer Actuator Off time 3 minutes Set the 1 10 minutes s...

Page 33: ...ollows 1 remove the cap unscrewing the fixing screws A 2 remove the filtering cartridge B clean it using water and soap blow it with compressed air or replace it if necessary 3 replace the cartridge i...

Page 34: ...e manifold CO 6 remove the manifold CO 7 find the electrode cable that is broken and remove it To replace the spring in the gas valve group proceed as follows 1 Carefully twist the protection cap 1 an...

Page 35: ...air box CA 11 opne the air box CA remove the combustion head ass y as shown on the next picture ATTENTION do not remove the the burner flange securing screws VB 12 replace the cables if damaged obser...

Page 36: ...5 4 Electrodes Adjustment Important Note Check the ignition and detection electrodes after removing adjusting the combustion head Adjust the electrodes position according to the quotes shown othe nex...

Page 37: ...tural gas To check the detection signal follow the scheme in the picture below If the signal is less than the value indicated check the position of the detection electrode or detector the electrical c...

Page 38: ...switch to 0 Off position 2 disconnect the power mains 3 close the fuel valve of the supply line 5 8 Burner disposal In case of disposal follow the instructions according to the laws in force in your...

Page 39: ...MAINTENANCE 39 6 0 WIRING DIAGRAMS Refer to the attached wiring diagrams WARNING 1 Electrical supply 230V 50Hz 1 a c 400V 50Hz 3N a c 2 Do not reverse phase with neutral 3 Ensure burner is properly e...

Page 40: ...AS z z MAXIMUM GAS PRESSURE SWITCH DEFECTIVE z z THERMOSTATS PRESSURE SWITCHES DEFECTIVES z z z OVERLOAD TRIPPED INTERVENTION z AUXILIARIES FUSE INTERRUPTED z DEFECTIVE CONTROL BOX z z z z z DEFECTIVE...

Page 41: ...1 2 13 1 1 13 3 11 3 12 1 12 2 3 12 2 2 12 2 1 18 2 14 3 4 14 3 3 14 3 1 14 3 2 14 3 1 14 1 14 2 17 1 17 3 17 2 19 7 19 8 18 1 19 3 19 4 19 1 19 6 19 5 19 2 16 2 6 7 4 13 1 10 5 8 16 1 1 13 6 13 7 3...

Page 42: ...ION HEAD ASS Y 15 2 COUPLING 12 1 BUTTERFLY GAS VALVE 15 3 BRACKET 12 2 1 ACTUATOR 16 1 FAN WHEEL 12 2 2 COUPLING 16 2 MOTOR 12 2 3 BRACKET 17 1 FLAME DETECTOR RELAY 13 1 BURNER HOUSING 17 2 CONTROL B...

Page 43: ...RODE 2 IGNITION ELECTRODE 3 GROUND ELECTRODE 4 GASKET 5 GASKET 6 PLUG 7 GAS MANIFOLD 8 COMBUSTION HEAD 9 BLAST TUBE 10 BURNER STAND 11 PLATE 12 GAS MANIFOLD BRACKET 13 WINDBOX 14 IGNITION CABLE 15 DET...

Page 44: ...units IFS 110 IM IFS 111 IM IFS 410 or IFS 414 It can also be used where there is no fully automatic control required FEATURES Flame control with ionisation electrode or UV probe For intermittent oper...

Page 45: ...rol unit s safety period 3 s 5 s or 10 s Very long gas pipes may possibly lead to delayed ignition of a burner and to switchoff of the entire system This is why the pilot gas valves should be installe...

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Page 48: ...ia 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 a...

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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Unigas R91, Installation Manual

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