Unigas PBY93 Manual For Use, Installation And Maintenance Download

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MANUAL OF INSTALLATION - USE - MAINTENANCE

PBY90 - PBY91
PBY92 - PBY93

PBY510 - PBY515
PBY520 - PBY525

M039397CA Rel.

/20

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Progressive, Fully-modulating

Heavy oil Burners

with pneumatic atomization

(LMV2x/3x micro-processor control)

Summary of Contents for PBY93

Page 1: ...NCE PBY90 PBY91 PBY92 PBY93 PBY510 PBY515 PBY520 PBY525 M039397CA Rel 1 0 04 2020 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Progressive Fully modulating Heavy oil Burners with pneumatic atomizatio...

Page 2: ...y 2 SPECIAL INSTRUCTIONS 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 c...

Page 3: ...irectives 2009 142 EC Gas Directive 2014 35 UE Low Tension Directive 2014 30 UE Electromagnetic compatibility Directive 2006 42 EC Machinery Directive Harmonized standards UNI EN 676 Automatic forced...

Page 4: ...ype Characteristics and test methods Industrial burners European directives 2009 142 EC Gas Directive 2014 35 UE Low Tension Directive 2014 30 UE Electromagnetic compatibility Directive 2006 42 EC Mac...

Page 5: ...d on the site All burners are ignited by means of a pilot flame burning LPG or Natural gas The standard ver sion of the burner uses compressed air to atomize oil fuel If compressed air is not availabl...

Page 6: ...UBE S Standard L Extended 5 DESTINATION COUNTRY see data plate 6 BURNER VERSION A Standard 6 MICRO PROCESSOR CONTROL EA micro processor control without inverter EB micro processor control with inverte...

Page 7: ...y oil Oil viscosity See Burner model identification table Heavy oil rate min max kg h 98 446 107 535 107 579 160 651 Gas pressure max mbar 500 Gas pressure after gas governor mbar 100 Compressed air p...

Page 8: ...237 35 266 497 321 455 964 525 1158 647 510 324 364 360 468 M12 280 310 110 60 41 495 53 707 228 185 PBY92 1291 237 35 266 497 327 455 964 525 1158 647 510 365 405 360 468 M12 280 310 110 60 41 495 5...

Page 9: ...9 PBY510 475 535 570 454 584 35 43 76 265 374 953 466 204 492 270 761 605 644 1249 114 387 311 1326 M14 540 390 540 390 427 390 390 5 5 2 Burner flange boiler recommended drilling template...

Page 10: ...331 1511 204 76 35 584 265 454 466 378 558 517 953 570 1249 605 644 474 540 492 M16 390 114 93 43 535 329 761 270 PBY520 1331 1511 204 76 35 584 265 454 466 378 558 517 953 570 1249 605 644 474 540 49...

Page 11: ...M M M PI PI PI PS PS PSL M PI PI PI TI TC TC TC TSH TS TSL ON BOARD ITEMS SUPPLIED LOOSE ITEMS compressed air oil inlet to the tank natural gas LPG combustion air LPG gas out of Cib Unigas scope of s...

Page 12: ...re governor for L P G tank 12 Temperature probe 77 Manual valve 13 Temperature probe 78 Pressure gauge 14 Temperature probe 79 L P G tank 15 Temperature gauge COMBUSTION AIR TRAIN 16 Pneumatic valve 8...

Page 13: ...ts but does not represent the regulation range of the machine On this diagram the maximum output point is usually reached by adj suting the combustion head to its MAX position see paragraph Adjusting...

Page 14: ...output point is rea ched setting the combustion head to its MIN position During the first ignition the combustion head is set in order to find a compromise between the burner output and the generator...

Page 15: ...king follow the procedures laid down by current laws on disposal of materials Handling the burner The burner is mounted on a stirrup provided for handling the burner by means of a fork lift truck the...

Page 16: ...se 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 correct matching i...

Page 17: ...to find the correct inclination of the pre heater tank For different installations please contact the Technical Department Key 1 Burner flange upper side indicated 2 Bracket 3 Pre heating tank on the...

Page 18: ...t should therefore be avoided and threaded or mechanical seal jun ctions preferred Junction threads elbow joints and couplings should be sealed with removable sg component The number of jun ctions sho...

Page 19: ...rows marked that show the inlet and the return Pumps capacity l h power kW speed rpm connection max outlet pressure bar max inlet pressure bar Kral KF 10 BCB 500 0 37 1500 DN25 10 2 Kral KF 15 BCB 800...

Page 20: ...20 Connecting the compressed air hoses To connect the compressed air supply refer to the following pictures Flow governor with filter...

Page 21: ...network must be carried out Once the gas train in installed execute the electrical connections for all its items gas valves group pressure switch ATTENTION once the gas train is mounted according to t...

Page 22: ...ot reverse the phase and neutral connections fit a differential thermal magnet switch adequate for connection to the mains ATTENTION before executing the electrical connections pay attention to turn t...

Page 23: ...the case of three phase 230V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay Connecting the oil heating r...

Page 24: ...at is a system to heat pipes and plant components to mantain the viscosity in the pumping lim its Higher the oil viscosity and lower the ambient temperature more necessary the pipe heating system Inle...

Page 25: ...19 3 128 14 48 43 2 5 92 200 23 5 170 18 9 54 7 35 250 28 212 23 45 65 8 79 300 32 5 254 28 87 6 11 7 400 41 9 338 37 1 110 14 6 500 51 6 423 46 2 132 17 5 600 61 4 508 55 4 154 20 45 700 71 1 592 64...

Page 26: ...0 70 80 90 100 110 120 130 140 150 160 TEMPERATURE C VISCOSITY E LIGHT OIL 1 3 E AT 20 C HEAVY OIL 2 4 E AT 50 C HEAVY OIL 4 E AT 50 C HEAVY OIL 7 5 E AT 50 C HEAVY OIL 10 E AT 50 C HEAVY OIL 13 E AT...

Page 27: ...pump inlet should be 80 C see diagram Indicative diagram showing the oil pressure according to its temperature OIL TEMPERATURE FOR PUMP FEEDING 1 10 100 0 10 20 30 40 50 60 70 80 90 TEMPERATURE C VISC...

Page 28: ...k 10 Daily tank OIL PUMPING UNIT 11 Heating device 2 Manual valve 12 Electrical resistor 3 Filter 13 Pressure gauge 4 Pump coupled to electrical motor 14 High pressure switch PO MAX 5 Safety valve 15...

Page 29: ...ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE E G DISCONNECTION EVEN PARTIAL OF THE ELEC...

Page 30: ...esistors safety thermostat lamp M Plant enabling thermostat lamp AZL Siemens output controller N Oil pump in operation O Pilot solenoid valve lamp PH Heavy oil operation lamp Q Pilot gas pressure swit...

Page 31: ...e following table Tab 3 The pressure values shown in the table are intended as working range In order to obtain a more accurate indication please refer to the nozzle pressure flow diagrams Before star...

Page 32: ...sed air to clean the gun With this operation the oil between the valves and the nozzle is drained The air pressure value for the gun cleaning must be setted to the pressure value of the atomization me...

Page 33: ...curve see the LMV2x 3x related manual 5 The nozzle supply pressure is already factory set and must not be changed Only if necessary adjust the supply pressure as fol lows see related paragraph read th...

Page 34: ...adjustment is not correct repeat the previous steps Calibration of air pressure switch To calibrate the air pressure switch proceed as follows z Remove the transparent plastic cap z Once air and heav...

Page 35: ...ion sets the oprating stages to drive the burner to the high flame stage set CMF 1 to drive it to the low flame stage set CMF 2 Oil thermostat adjustment Progressive and fully modulanting oil burners...

Page 36: ...T to increase the gas pressure at the outlet use a screwdriver on the screw TR as shown in the next picture Screw to increase the pressure unscrew to decrease once the regulation is performed replace...

Page 37: ...ondensation in the chimney User interface The AZL2x display is shown below The keys functions are the following ATTENTION During commissioning operations do not let the burner operate with insufficien...

Page 38: ...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 menu Bloc De...

Page 39: ...ansformer 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 TSA2 secondo...

Page 40: ...l 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 parameter li...

Page 41: ...essing 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 more than th...

Page 42: ...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 display of p...

Page 43: ...ssing the End message will blink 3 Press InFo for more than three seconds or for more than three seconds orto return to the normal display For further nformation see tha LMV2 related manual Parameter...

Page 44: ...sively it is recommended to replace the nozzle as a preventive measure at the begin of the operating season z Clean and grease joints and rotating parts IMPORTANT Remove the combustion head before che...

Page 45: ...body CU replace the nozzle if necessary 4 in order to replace the electrode unscrew the fixing screw and remove it place the new electrode being careful to observe the measures in mm shown on next pic...

Page 46: ...46 Fig 25 To change the nozzle position please contact the Technical Dpt V C CU VE 2 1 3 50 xBY5xx A 0 A A 0 50 PBY9x 3...

Page 47: ...n is permitted This means that if the error occurs again the next time the system is shut down the unit initiates lockout Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 tur...

Page 48: ...48 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 earthed...

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Page 51: ...N MAIN SWITCH OPEN z LINE FUSE INTERVENTION z MAX PRESSURE SWITCH FAULT z z FAN THERMAL CUTOUT INTERVENTION z AUXILIARY RELAIS FUSES INTERVENTION z CONTROL BOX FAULT z z z z z SERVOCONTROL FAULT z SMO...

Page 52: ...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 53: ...Service manual AZL2x LMV2x 3x Burner Management System M12916CD Rev 3 4 03 2023...

Page 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...8 Parameters level heating engineer...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...50 ERROR CODE TABLE...

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Page 117: ...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 118: ...66 Wiring variants for LMV27 2 Fuel meter input 1 Supply fuel meter ConnectorX75 ConnectorX5 02 ConnectionsPmax...

Page 119: ...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 120: ...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 124: ...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 PBY93, Manual For Use, Installation And Maintenance

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