Unigas LMV5 Series Manual Of Installation - Use - Maintenance Download

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M039487C

0.1 10/2020

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Microprocessor controlled

MANUAL OF INSTALLATION - USE - MAINTENANCE

LMV5x

Gas - Light oil burners

HRX512-FGR
HRX515-FGR
HRX520-FGR

HRX92R-FGR

HRX92-FGR

Summary of Contents for LMV5 Series

Page 1: ...CC 0 1 10 2020 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Microprocessor controlled MANUAL OF INSTALLATION USE MAINTENANCE LMV5x Gas Light oil burners HRX512 FGR HRX515 FGR HRX520 FGR HRX92R FGR HR...

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: ...proving system 8 2 gas valves gas proving system maximum gas pressure switch 8 GAS CONNECTION 50 Rp2 65 DN65 80 DN80 100 DN100 9 Low NOx EF Medium large burners complete with electronic cam and temper...

Page 6: ...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 curves Note3 Burners are suitable only for indoor oper...

Page 7: ...40 560 M14 552 390 390 390 791 149 642 942 353 830 330 270 524 62 554 195 225 603 9 151 HRX515 FGR 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...

Page 8: ...424 280 310 300 790 148 642 942 353 649 228 185 478 55 481 170 200 549 9 131 HRX92 FGR 50 1410 1520 135 831 35 550 100 420 530 493 978 506 1274 725 439 286 316 228 450 360 464 M12 424 280 310 300 532...

Page 9: ...ing to the installed gas train DN65 in the example From the interception point draw an horizontal line as far as matching on the y axis the value of pressure necessary to get the requested furnace inp...

Page 10: ...um output point is usually reached by adjsuting the combustion head to its MAX position see paragraph Adjusting the combustion head the minimum output point is reached setting the combustion head to i...

Page 11: ...R MG Stm3 h GAS PRESSURE mbar RX520 FGR MG Stm3 h ATTENTION the gas rate value is quoted on the x axis the related network pressure is quoted on the y axis pressure value in the combustion chamber is...

Page 12: ...from the boiler s Technical specifications Measuring gas pressure in the combustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one into the combusti...

Page 13: ...on head curves natural gas Curves are referred to pressure 0 mbar in the combustion chamber GAS PRESSURE mbar HRX92R FGR MG Stm3 h HRX92 FGR MG Stm3 h GAS PRESSURE mbar HRX512 FGR MG Stm3 h HRX515 FGR...

Page 14: ...ube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cement Packing The burners are despatched in wooden crates whose dimensions are HRX5xx ser...

Page 15: ...the 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 co...

Page 16: ...lant 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 Flue gas temperatur...

Page 17: ...y tightened To mount 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...

Page 18: ...gas proving test mus be performed according to the procedure set by the laws in force ATTENTION it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the val...

Page 19: ...8xM8x30 in accordance with section 8 4 Screws 4xM5x25 for VD assembly are supplied 5 After installation perform leakage and functional test 6 Disassembly in reverse order 1 Insert studs A 2 Insert se...

Page 20: ...er according to UL 353 and ANSI Z21 18 CSA 6 3 No venting required in loca tions where vent limiters are accepted by the jurisdiction 4 Only PS pressure sensors specified by DUNGS are authorised to be...

Page 21: ...alled 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 be vertical WARNING removi...

Page 22: ...r a preset time test time 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 Te...

Page 23: ...IRCUIT From tank To tank The burner is supplied with filter and flexible hoses all the parts upstream the filter and downstream the return flexible hose must be installed by the customer As far as the...

Page 24: ...es time to deposit on the bottom of the tank thus avoiding the possibility that they might be sucked into the pump On initial commissioning a dry operation is foreseen for a considerable length of tim...

Page 25: ...provided 1 remove the closing nuts 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 se...

Page 26: ...lock nut 4 To increase pressure twist adjusting screw 3 clockwise To decrease the pressure twist screw counterclockwise Tight the lock nut 4 refit the gasket 2 and the cap nut 1 Key 1 Cap nut 2 Gaske...

Page 27: ...the connection functionality and compliance with the health and safety principles of the earth cable If in doubt ask for an accurate inspection by qualified technical engineers Check the connection to...

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: ...maximum air rate the 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...

Page 30: ...ater or other fluids in the generator 4 Check that the ventilation gates dampers in the plant are open and the stack is free 5 Connect the gauges used to adjust and check pressures on the incoming lin...

Page 31: ...the LMV control box starts the system test cycle the AZL display shows the System Test message at the end of the test it shows the main page and the system stops the safety chain is open waiting for t...

Page 32: ...lts occuring it represents the lockout reset function Fault History by selecting this item and pressing the ENTER key the Lockout History will be showed about the last 21 faults occured Lockout Histor...

Page 33: ...rrow keys select Params Display press ENTER the system will ask you to enter the proper password by means of the arrow keys select Access w out pass access without password user level confirm by press...

Page 34: ...the 2 position controller To set these values select the item SD_ModOn SDOn by scrolling down the Load controller menu with the arrow keys and press ENTER the display will show The deafult value for...

Page 35: ...ime Wintertime mode desired and cofirm by pressing ENTER press ESC to exit Set the time zone Time EU US in the same way Languages it allows setting the current language choose the desired language and...

Page 36: ...rner starts upthe Thermal shock protection activated message will be showed If this function is not enabled after startup the burner will rapidly increase the load according to the requested value and...

Page 37: ...en the burner does not follow the modulator and probe settings but operates at the set load For further details see the LMV5x annexed manuals SetLoad Autom Manual Off Autom Manual Off Curr Automatic N...

Page 38: ...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 39: ...ed To calibrate the maximum pressure switch proceed as follows according to its mounting position remove the pressure switch plastic cover if the maximum pressure switch is mounted upstreaam the gas v...

Page 40: ...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 41: ...PART III OPERATION 41 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 42: ...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 43: ...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 44: ...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 17 and act on on the pump adjustin...

Page 45: ...ded to verify that the combustion parameters are within the range of acceptable values even against a pressure varia tion that gets close to the limit of the pressure switch This check should be carri...

Page 46: ...e knob VRT Fasten VB screw when the adjustment is accomplished The diffuser position must be set during the commissioning according to the regulation needs The diffuser position is factory set as show...

Page 47: ...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 48: ...he top H 2 Remove the UV detector out of its housing disconnect electrode cables and the light oil flexible hoses 3 Loosen the screws V holding the gas manifold G loosen the connectors E 4 Some models...

Page 49: ...unscrew the VE fixing screws and remove them place the new electrodes being careful to observe the measures showed on pag reassemlbe following the reversed procedure Caution adjust the nozzle position...

Page 50: ...etector QRI Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner main switch to 0 Off position 2 disconnect the power mains 3 close the fuel valve of the supply l...

Page 51: ...ssure switch damaged or bad links Check air pressure switch functions and links Burner control damaged Replace burner control BURNER LOCKS OUT WITHOUT ANY GAS FLOW Gas valves don t open Check voltage...

Page 52: ...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...

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Page 56: ...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 57: ...Siemens LMV5x Service Manual M12920CC rev 2 1 08 2017...

Page 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...8...

Page 65: ...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 66: ...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 67: ...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 68: ...12 2 2 LMV5x program structure...

Page 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...39...

Page 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 104: ...Note Specifications and data subject to change Errors and omissions excepted...

Page 105: ...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 106: ...Annex1 Example for motor cable...

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Page 108: ...Annex 2 Example for sensor cable...

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Page 111: ...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 112: ...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 113: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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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