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CIB UNIGAS R91A M Series Manual Of Installation - Use - Maintenance

Lmv2x/3x microprocessor-controlled gas burners
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R91A - R92A - R93A
R512A -R515A
R520A - R525A
LMV2x/3x
Microprocessor-controlled
gas burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039240CC 2.5 03/2015

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  • Page 1 R91A - R92A - R93A R512A -R515A R520A - R525A LMV2x/3x Microprocessor-controlled gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039240CC 2.5 03/2015...

  • Page 2: General Introduction

    DANGERS, WARNINGS AND NOTES OF CAUTION THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER. INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO- DUCT INSTALLATION AND MAINTENANCE.

  • Page 3: Directives And Standards

    DIRECTIVES AND STANDARDS do not leave the equipment exposed to weather (rain, sun, etc.) unless expressly required to do so; Gas burners European directives: do not allow children or inexperienced persons to use equipment; - Directive 2009/142/EC - Gas Appliances; The unit input cable shall not be replaced by the user.

  • Page 4: Symbols Used

    -EN 55014-1Electromagnetic compatibility - Requirements for household appliances, electric tools and similar apparatus. -UNI EN 676 (Gas Burners; -CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements; - EN 50165 Electrical equipment of non-electric appliances for household and similar purposes.

  • Page 5: General Features

    PART I: SPECIFICATIONS PART I: SPECIFICATIONS 1.0 GENERAL FEATURES Fig. 1 Note: the figure is indicative only Control panel with startup switch Gas train Electrical panel Cover Blast tube + Combustion head Flange Silencer Actuator Air pressure switch 10 Combustion head adjusting ring nut Gas operation: the gas coming from the supply line, passes through the valves group provided with filter and governor.
  • Page 6 PART I: SPECIFICATIONS Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type Model R91A MD. S. BURNER TYPE R91A, R92A, R93A, R512A, R515A, R520A, R525A FUEL M - Natural gas L - LPG OPERATION (Available versions) PR - Progressive...

  • Page 7: Burner Type

    PART I: SPECIFICATIONS BURNER TYPE R91A L-.. R92A L-.. R93A L-.. 480 - 2670 480 - 3050 550 - 4100 Output min. - max. kW Fuel Category 3B/P 17.9 - 100 17.9 - 114 20 - 153 Gas rate- min.- max. (Stm see Note 2 Gas pressure mbar...
  • Page 8 PART I: SPECIFICATIONS BURNER TYPE R512A L-.. R515A L-.. R520A L-.. R525A L-...50 R525A L-...xx 600 - 4500 770 - 5200 1000 - 6400 2000 - 6700 2000 - 8000 Output min. - max. kW Fuel Category 3B/P 22 - 167 28 - 194 37 - 238 74 - 250...
  • Page 9 2.4 Overall dimensions (mm) O min O max Burner flange Boiler recommended drilling tem- plate AA AD AN Omin Omax 1356 242 35 550 100 441 866 421 1160 435 265 295 228 450 360 464 M12 424 300 532 148 384 624 190 649 228 185 R91A R91A 1356...
  • Page 10 Burner flange Boiler recommended drilling template AA AD AN 1499 320 35 595 100 530 517 969 446 1590 644 340 380 494 540 494 M14 552 390 390 763 149 614 845 190 764 311 270 R512A R512A 1499 320 35 611 117 530 517 969 446 1613 644 340 380 494 540 494 M14 552 390 390 636 149 487 845 292 764 311 270 1499 320 35 626 132 530 517 969 446 1646 1002 644 340 380 494 540 494 M14 552 390 390 687 149 538 875 310 764 311 270 R512A...
  • Page 11 PART I: SPECIFICATIONS 2.5 How to read the burner “Performance curve” To check if the burner is suitable for the boiler to which it must be instal- Campo di lavoro bruciatori lled, the following parameters are needed: Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65 furnace input, in kW or kcal/h (kW = kcal/h / 860);...

  • Page 12: Performance Curves

    PART I: SPECIFICATIONS Performance Curves R91A R92A 1200 1600 2000 2400 2800 3200 1200 1600 2000 2400 2800 R93A R512A 500 1000 1500 2000 2500 3000 3500 4000 4500 1500 2500 3500 4500 R515A R520A 1500 2500 3500 4500 5500 6500 7500 1500...
  • Page 13 PART I: SPECIFICATIONS 2.7 Pressure in the Network / gas flow rate curves (natural gas) R91A M-.. R92A M-.. R93A M-.. R512A M-.. R515A M-.. R520A M-.. R525A M-.. Rp2 R525A M-.. DN65-80-100 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 combustion chamber is not included).
  • Page 14 PART I: SPECIFICATIONS 2.8 Pressure in the Network / gas flow rate curves(LPG) R91A L-.. R93A L-.. R512A L-.. R520A L-.. 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 combustion chamber is not included).
  • Page 15 PART I: SPECIFICATIONS 2.9 Combustion head gas pressure curves depending on the flow rate The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner properly adjusted (percentage of residual O in the flues as shown in the “Recommended combustion values”...
  • Page 16 PART I: SPECIFICATIONS 2.11 Pressure - rate in combustion head curves (natural gas) Curves are referred to pressure = 0mbar in the combustion chamber! R91A M-.. R92A M-.. 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 100 120 140 160 180 200 220 240 260 280 300 R93A M-..
  • Page 17 PART I: SPECIFICATIONS 2.12 Pressure - rate in combustion head curves (LPG) Curves are referred to pressure = 0mbar in the combustion chamber! R91A L-.. R93A L-.. 100 110 120 130 140 150 160 R512A L-.. R520A L-.. 1 0 0 1 2 5 1 5 0 1 7 5...
  • Page 18 PART II: INSTALLATION PART II: INSTALLATION 3.0 MOUNTING AND CONNECTING THE BURNER 3.1 Packing The burners are despatched in wooden crates whose dimensions are: 9xA series: 1672mm x 1072mm x 1016mm (L x P x H) 5xxA series: 1886mm x 1456mm x 1120mm (L x P x H) Packing cases of this type are affected by humidity and are not suitable for stacking.
  • Page 19 PART II: INSTALLATION 3.3 Fitting the burner to the boiler To install the burner into the boiler, proceed as follows: make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; place the 4 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;...
  • Page 20 PART II: INSTALLATION spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer). a) Heat output in kW b) Lenght of the flame tube in meters c) Flame tube firing intensity in MW/m d) Combustion chamber diameter (m) Fig.
  • Page 21 PART II: INSTALLATION 4.0 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 compliance with the current laws. ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED.
  • Page 22 PART II: INSTALLATION ATTENTION: it is recommended to mount filter and gas valves to avoid that extraneous 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). The procedures of installation fo the gas valves are showed in the next paragraphs, according to the gas train used: threaded gas trains with Siemens VGD20..
  • Page 23 PART II: INSTALLATION 0 - 22 15 - 120 100 - 250 Performance range (mbar) neutral yellow Spring colour Once the gas train in installed, execute the electrical connections for all its items (gas valves group, gas proving system, pressure switches).

  • Page 24: Electrical Connections

    PART II: INSTALLATION 5.0 ELECTRICAL CONNECTIONS WARNING! Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse the phase and neutral connections. fit a differential thermal magnet switch adequate for connection to the mains.
  • Page 25 PART III: OPERATION PART III: OPERATION WARNING: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed.

  • Page 26: Gas Operation

    PART III: OPERATION Fig. 9 - Burner front panel Keys Lock-out LED Hi-flame operation LED Lo-flame operation LED “Ignition transformer operation” LED “Fan motor overload tripped” LED “EV2 opening” LED “EV1 opening” LED “Gas pressure switch signal ” LED Main switch (only on fully modulating burners) Operation selector MAN - AUTO (operation in manual or automatic mode): MIN = operation with minimum output 0 = Stop...

  • Page 27: User Interface

    PART III: OPERATION 7.0 AIR FLOW AND FUEL ADJUSTMENT WARNING! During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide); if this should happen, make the fuel decrease slowly until the normal combustion values are achieved.
  • Page 28 PART III: OPERATION Key F + A While pressing the two keys contemporarly, the code message will appear: by entering the proper password it is possible to access the Service 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...
  • Page 29 PART III: OPERATION User level (info): no password needed Service level (Service) Manifacturer level (OEM) PHASES LIST During operation, the following program phases are shown. The meaning for each phase is quoted in the table below Fase /Phase Funzione Function Ph00 Fase blocco Lockout phase...
  • Page 30 PART III: OPERATION The burner and consequently the LMV2x.. are factory set; the air and fuel curves as set as well. Info level To enter the Info level, proceed as follows: in any menu position, press keys + and - at the same time, then the program will start again: the display will show OFF. until the display will show InFo, Press the enter (InFo) key then il will show the first code (167) flashing, on the right side it will show the data entered.
  • Page 31 PART III: OPERATION The Info level shows some basic parameters as: Parameter Description Cubic meters of fule (resettable) Operating hours (resettable) Device operating hours Burners start-ups (resettable) Total number of start-ups Burner number (i.e. serial number) Software version Software date Device serial number Customer code Version...
  • Page 32 PART III: OPERATION If a message like the one below is shown during operation, it means that the burner is locked out and the Errore code is shown (in the example “error code:4”); this message is alternating with another message Diagnostic code (in the example “diagnostic code:3”).
  • Page 33 PART III: OPERATION Parameter Description Flame intensity % output, if set = automatic operation Actuators position, 00=combustibile; 01= aria Lock-outs number 701..725 Lock-outs History (see chapter 23 in the LMV2x manual) the first parameter will be “954”: the percentage of flame is shown on the right. By pressinf + or - it is possible to scroll up/down the parameter list.
  • Page 34 PART III: OPERATION 7.4 Gas valves Siemens VGD - Version with SKP2. (provided with pressure stabilizer). To increase or decrease gas pressure, and therefore gas flow rate, remove the cap T and use a screwdriver to adjust the regulating screw VR. Turn clockwise to increase the flow rate, counterclockwise to reduce it.
  • Page 35 PART III: OPERATION sting pressure) until the burner lockout, then read the value on the pressure switch scale and set it to a value reduced by 15%. Repeat the ignition cycle of the burner and check it runs properly. Refit the transparent plastic cover on the pressure switch. 7.9 PGCP Gas leakage pressure switch (witn Siemens LDU/LME7x burner control/Siemens LMV Bur- ner Management System) remove the pressure switch plastic cover;...
  • Page 36 PART III: OPERATION 7.12 Center head holes gas flow regulation (LPG burners) To adjust the gas flow, partially close the holes, as follows: loosen the three V screws that fix the adjusting plate D; insert a screwdriver on the adjusting plate notches and let it move CW/CCW as to open/close the holes; once the adjustmet is performed, fasten the V screws.

  • Page 37: Routine Maintenance

    PART IV: MAINTENANCE PART IV: MAINTENANCE WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED! ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL.. At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry out the maintenance at the end of each heating season;...
  • Page 38 PART IV: MAINTENANCE 8.2 Replacing the spring in the gas valve group To replace the spring in the gas valve group,proceed as follows: Carefully twist the protection cap 1 and the O-ring 2. remove the “set value” spring 3 from housing 4. Replace spring 3.

  • Page 39: Electrodes Adjustment

    PART IV: MAINTENANCE 8.4 Electrodes Adjustment Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion 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. Check the electrodes position after any intervention on the combustion head.
  • Page 40 PART IV: MAINTENANCE 8.6 Replacing the detection electrode ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrode position after any intervention on the combustion head. To replace the detection electrode, proceed as follows: remove the combustion head according to the procedure on paragraph “Removing the combustion head”;...

  • Page 41: Seasonal Stop

    PART IV: MAINTENANCE 8.9 Seasonal stop To stop the burner in the seasonal stop, proceed as follows: turn the burner main switch to 0 (Off position) disconnect the power mains close the fuel valve of the supply line 8.10 Burner disposal In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”.

  • Page 42: Wiring Diagrams

    PART IV: MAINTENANCE 9.0 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 earthed...

  • Page 43: Troubleshooting

    TROUBLESHOOTING TROUBLE CAUSE MAIN SWITCH OPEN LACK OF GAS MAXIMUM GAS PRESSURE SWITCH DEFECTIVE THERMOSTATS/PRESSURE SWITCHES DEFECTIVES OVERLOAD TRIPPED INTERVENTION AUXILIARIES FUSE INTERRUPTED DEFECTIVE CONTROL BOX DEFECTIVE ACTUATOR AIR PRESSURE SWITCH FAULT OR BAD SETTING MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIRTY IGNITION TRANSFORMER FAULT IGNITION ELECTRODES BAD POSITION...
  • Page 44 10.0 BURNER EXPLODED VIEW 11.1 6.1.1 6.13 6.7.2 4.1.3 4.1.2 4.1.1 11.5 11.2 11.4 13.2 13.1 12.1 6.7.1 12.2 10.1 11.3 10.2 14.1 14.2.5 14.2.4 14.2.3 7.3.1 14.2.1 7.3.2 14.2.2 11.6.1 7.3.4 7.3.3 7.3.3...
  • Page 45 ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION AIR INLET CONE 7.3.2 SKP ACTUATOR 14.1 OUTPUT CONTROLLER 7.3.3 GAS PRESSURE 14.2.1 LIGHT STANDARD BLAST TUBE 7.3.4 GAS VALVE HOUSING 14.2.2 LIGHT 4.1.1 BRACKET FAIRLEAD 14.2.3 SWITCH 4.1.2 COUPLING FAIRLEAD 14.2.4 SWITCH 4.1.3 ACTUATOR ACTUATOR 14.2.5...
  • Page 48 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: cibunigas@cibunigas.it Note: specifications and data subject to change. Errors and omissions exceptd.

This manual is also suitable for:

R92a m seriesR93a m seriesR91a l seriesR92a l seriesR93a l seriesR512a m series ... Show all

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