Related Manuals for Unigas RX1025.1
Summary of Contents for Unigas RX1025.1
- Page 1 RX1025.1 RX1030R RX1030.1 Gas burner Microprocessor controller LMV5x MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039699CA Rev. 0.0 02/2023...
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Page 2: Risk Analysis
DANGERS, WARNINGS AND NOTES OF CAUTION - Faults in the fuel supply system; - Use of the burner even after an error and/or fault has occurred; - Repairs and/or overhauls incorrectly carried out; This manual is supplied as an integral and essential part of - Modification of the combustion chamber with inserts that prevent the the product and must be delivered to the user. - Page 3 GENERAL INSTRUCTIONS DEPENDING ON FUEL USED those parts likely to constitute sources of danger shall be made harm- less. ELECTRICAL CONNECTION In case the equipment is to be sold or transferred to another user, or in For safety reasons the unit must be efficiently earthed and installed as ...
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Page 4: Symbols Used
BURER DATA PLATE .Do not touch any mechanical moving parts with your hands Consump or any other part of your body. Injury hazard Do not touch any parts containing fuel (i.e. tank and pipes). Type For the following information, please refer to Scalding hazard Model the data plate:... - Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS Control panel with startup switch Gas train Electrical panel Cover Blast tube + Combustion head Flange Silencer Actuator Air pressure switch Combustion head adjusting ring nut Gas operation: the gas coming from the supply line passes through filter, gas valves and pressure regulator. This one forces the pres- sure in the utilisation limits.
- Page 6 Burners are identified by burner type and model. Burner model identification is described as follows. Type RX1030.1 Model MD. S. BURNER TYPE RX1025.1, RX1030R, RX1030.1 FUEL M - Natural gas, L - LPG OPERATION (Available versions) MD - Fully modulating S - Standard,...
- Page 7 Overall dimensions (mm) RX1025.1, RX1030R, RX1030.1 boiler recommended drilling template burner flange (BS/BL) (AS/AL) B*: SPECIAL blast tube lengths must be agreed with Cib Unigas TIPO DN A (AS) A(AL) AP B (BS) B (BL) BB 2000 1216 1092 1161...
- Page 8 PART I: SPECIFICATIONS GAS TRAIN CONNECTION ATTENTION: Before executing the connections to the gas pipe network, be sure that the manual cutoff valves are closed. The following diagrams show some examples of possible gas trains with the components supplied with the burner and those fitted by the installer.
- Page 9 PART I: SPECIFICATIONS How to read the burner “Performance curve” To check if the burner is suitable for the boiler to which it must be install- Campo di lavoro bruciatori led, 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);...
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Page 10: Performance Curves
PART I: SPECIFICATIONS Performance Curves RX1025.1 M - ..1.xx RX1030R M - ..1.xx RX1030.1 M - ..1.xx Performance Curves N880A L - ..1.xx N925A L - ..1.xx N1060A L - ..1.xx... - Page 11 PART I: SPECIFICATIONS gas flow rate curves RX1025.1 M- RX1030R M- Gas rate Stm Gas rate Stm RX1030.1 M- Gas rate Stm 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 not included).
- Page 12 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves (L.P.G.) RX1025.1 L-..1.xx RX1030R L-..1.xx Gas rate Stm Gas rate Stm RX1030.1 L-..1.xx Gas rate Stm Gas pressure burner head vs natural gas flow rate Curves are referred to pressure = 0 mbar in the combustion chamber! RX1025.1 M-..
- Page 13 PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Packing The burners are despatched in wooden crates whose dimensions are: 2280 x 1730 x 1360 (L x P x H) Such packages fear moisture and are not suitable for stacking.Packing cases of this type are affected by humidity and are not suitable for stacking.
- Page 14 PART II: INSTALLATION Fitting the burner to the boiler To perform the installation, proceed as follows: drill the furnace plateas decribed in paragraph (“Overall dimensions”); place the burner towards the furnace plate: lift and move the burner by means of its eyebolts placed on the top side (see”Lifting and moving the burner”);...
- Page 15 PART II: INSTALLATION GAS TRAIN CONNECTIONS WARNING: before executing the connections to the gas pipe network, be sure that the manual cutoff valves are closed. 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).
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Page 16: Assembling The Gas Train
PART II: INSTALLATION MultiBloc MB-DLE - Assembling the gas train Mounting Mount flange onto tube lines: use appropriate sealing agent Insert MB-DLE: note position of O rings Remove MultiBloc between the threaded flanges After installation, perform leakage and functional test Disassembly in reverse order MB-DLE 405.. - Page 17 PART II: INSTALLATION DUNGS MBE Components and position of pressure switches PGMIN minimum gas pressure switch VD-V VD-R PGMIN minimum gas pressure switch (alternative VD-V VD-R to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded) Valve body (Flange)
- Page 18 PART II: INSTALLATION Siemens VGD20.. e VGD40.. Components and position of pressure switches PGMIN minimum gas pressure switch SKP25 SKP25 PGMIN minimum gas pressure switch (alternative SKP15 SKP15 to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded)
- Page 19 PART II: INSTALLATION Siemens VGD Pressure taps Strainer (G 1/4") (G 1/8") (G 1/4") (G 3/4") (G 1/8") (G 1/4") (G 1/8") Legend pi Inlet pressure pm Pressure between valves po Outlet pressure...
- Page 20 PART II: INSTALLATION BURNERS WITH INVERTER VARIANT (if provided) DANFOSS FC101 INVEOR M DANFOSS FC102 The manufacturer provides: KOSTAL: on-board or wall-mounted (in the latter case the kit is required) DANFOSS: wall-mounted Both can be equipped with a braking resistor. The burner terminal box is prepared to receive certain signals (for connection to the inverter, see the dedicated connection diagram).
- Page 21 PART II: INSTALLATION 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. WARNING! before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be sure that the burner’s main switch is in 0 position (OFF) too.
- Page 22 PART III: OPERATION PART III: OPERATION IN THE EVENT OF A BLOCKAGE, THE CAUSE MUST BE ASSESSED. IF THE FLAME BACKFIRE WARNING LIGHT IS ON, IT IS IMPERATIVE TO CHECK THE INTEGRITY AND GOOD CONDITION OF THE COMBUSTION HEAD AS DESCRIBED IN THE MAINTENANCE SECTION BEFORE UNLOCKING THE APPLIANCE.
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Page 23: Gas Operation
PART III: OPERATION Fig. 6 - Burner control panel Keys Main switch Reset pushbutton for control box CMF switch (0=stop, 1=low flame, 2=high flame, B2 B3 3=automatic) - fully modulating burners only Lock-out LED Hi-flame operation LED Lo-flame operation LED “Ignition transformer operation”... -
Page 24: Adjusting Procedure
PART III: OPERATION Integrated proving system (burners equipped with LME7x, LMV, LDU) This paragraph describes the integrated proving system operation sequence: At the beginning both the valves (EV1 and EV2) must be closed. Test space evacuating: EV2 valve (burner side) opens and keep this position for a preset time ... -
Page 25: Start-Up Procedure
PART III: OPERATION quoted below. Once the throttle valve is completely opened, acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler/utilisation: Start-up procedure Turn the burner on. -
Page 26: Fault History
PART III: OPERATION Press the ENTER key to go back to the main page. To access the main menu, from the main page, press the ESC key tiwce: OperationalStat Operation ManualOperation Params & Display Main menu By pressing the ESC key once, the Operational Status (first item in the main menu) menu is directly shown: Normal operation Status/Reset Fault History... - Page 27 PART III: OPERATION alternating by an error message as: No flame at end of safety time To see the other Lockout History pages, press the arrow keys. To exit the Lockout History pages, press ESC. Setting the temperature/pressure set-point value To set the temperature/pressure set-point value, that is the generator operating temperature/pressure;...
- Page 28 PART III: OPERATION Curr: it shows the current set-point; use the arrows keys to change. NOTE: the availabel range for this parameter depends on the probe provided; the unit measure of the detected value and its limits are bound up with parameters set at the “Service” level. Once the new set-point is set, confirm by pressing ENTER, otherwise exit without changings by pressing ESC.
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Page 29: System Lockout
PART III: OPERATION LoadController Actuators VSD Module confirm by pressing ENTER: Times Languages DateFormat PhysicalUnits Times: it sets the “Summer (SUM) Time / Winter (WIN) Time” operation and the continent (EU - Europe; US - United States) Sum/Winter Time Time EU/US choose the Summertime/Wintertime mode desired and cofirm by pressing ENTER;... - Page 30 PART III: OPERATION 10.08.07 13.47 C:71 D:00 Start No. Load call the Technical Service and tell the message data. Cold start thermal shock (CSTP) If the generator cannot suffer thermal shocks, the CSTP (Cold Start Thermal Schock) function can be enabled. This function is already set by the Technical service (access by reserved password).
- Page 31 PART III: OPERATION Burner off: burner in stand-by If the BurnerOn mode is choosen,the burner does not follow the modulator and probe settings, but operates at the set load. Caution: if BurnerOff mode is selected, the burner stays in stand-by. Caution: in the BurnerOn mode, the safety thresholds are set by the Technical Service.
- Page 32 PART III: OPERATION ADJUSTING THE GAS VALVES GROUP Multibloc MB-DLE The multibloc unit is a compact unit consisting of two valves, gas pressure switch, pressure stabilizer and gas filter. C VS The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns.
- Page 33 PART III: OPERATION Adjusting the combustion head Attention! if it is necessary to change the head position, repeat the air and fuel adjustments described above. .The combustion head position affects the flame stability.The diffuser position must be set during the commissioning according to the regulation needs.
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Page 34: Routine Maintenance
PART IV: MAINTENANCE PART IV: MAINTENANCE 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; in the case of continuous operation the maintenance is carried out every 6 months. - Page 35 PART IV: MAINTENANCE Gas filter maintenance WARNING: Before opening the filter, close the manual cutoff valve downstream the filter and bleed the gas; check that inside the filter there is no pressurised gas. Per pulire o sostituire il filtro gas procedere nel modo seguente: MB-DLE MB-DLE 415 - 420 B01...
- Page 36 PART IV: MAINTENANCE MultiBloc VD-V VD-R Mounting to push position 1. Position VD on VB, fig. 2+3. 2. Slide VD forward up to the stop, fig. 4. 3. Screw VD on with 2 M5 screws for each, max. 5 Nm/44 in.-lb., fig. 5/6. 4.
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Page 37: Electrodes Adjustment
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. RX1025.1 RX1030R, RX1030.1 ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler... - Page 38 PART IV: MAINTENANCE Replacing the detection electrode (natural gas burners) To replace the detection electrode, proceed as follows: remove the combustion head according to the procedure on paragraph “Removing the combustion head”; by means of an allen key, loose the fixing screws of the detection electrode ER and replace it; replace the combustion head.
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Page 39: Seasonal Stop
PART IV: MAINTENANCE 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 Burner disposal In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”. Burner service term - In optimal operating conditions, and with preventive maintenance, the burner can last up to 20 years. - Page 40 PART IV: MAINTENANCE TROUBLESHOOTING GUIDE Gas operation * No electric power supply * Restore power supply * Main switch open * Close switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Reset or replace the thermostat * No gas pressure * Restore gas pressure...
- Page 44 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 excepted.
- Page 45 Siemens LMV 5x User manual M12914CA Rev.0 03/2008...
- Page 47 SIEMENS LMV CONTROLLED BURNERS Keys Burner Combustion head actuator Gas butterfly valve actuator Oil pressure governor actuator Air damper actuator Siemens LMV burner control Personal Computer Gas train Inverter 10 Siemens AZL User interface The control system is made of the Siemens LMV central unit (6) that performs all the burner control functions and of the Siemens AZL local programming unit (10) that interfaces the system with the user.
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Page 48: User Settings
USER SETTINGS Go on adjusting the burner. Users can set only the LMV parameters that can be accessed without password: (see “Adjusting the temperature set-point”). The Siemens AZL User Interface allows programming the Siemens LMV control box and monitoring the system data. The user interface is made of: 1. - Page 49 Start-up procedure Turn the burner on according to the following: ual fuel burners: choose the requested fuel by means of the related control panel switch one fuel burners: turn the burner on by means of the burner main switch (placed on the burner control panel) the LMV controller starts the system test cycle: the AZL display shows the System Test message;...
- Page 50 Setpoint 80°C value 78°C Load Main page Set point: temperature set-point Act value: actual temperature value Load: load percentage (burner output) Flame: percentage of flame detection current. By pressing the ENTER key the display shows the second page: Fuel VSD 0.0 Ld 0.0 Second page Fuel: it shows (in degrees) the fuel actuator position.
- Page 51 Fault History To visualise the Fault History, select it and press the ENTER key. The message will be as: 1 Class: 05Gas Code BF Phase: 10 Diag.: 00 Lod: Start No. alternating by an error message as: O2 control and limiter automat deactivated To see the other Fault History pages, press the arrow keys.
- Page 52 Access w-out PW Access Serv Access OEM Access LS by means of the arrow keys, select “Access w-out pass” (access without password - user level), confirm by pressing ENTER. The other levels require password reserved to the Technical Service, to the Manifacurer, etc. The menu accessed without password is the following: BurnerControl RatioControl...
- Page 53 SetPointW1 SetPointW2 SD_ModOn SD_ModOff the display will show: SD_ModOn Curr: 1.0% New: 1.0% The deafult value for this parameter is1% that is, the burner will light again at a temperature 1% lower than the set-point. Change value, if needed, by means of the arrow keys; press ENTER to confirm and the press ESC to exit. Press only ESC to exit without changing.
- Page 54 Times Languages DateFormat PhysicalUnits Times: it sets the “Summer (SUM) Time / Winter (WIN) Time” operation and the continent (EU - Europe; US - United States) Sum/Winter Time Time EU/US choose the Summertime/Wintertime mode desired and cofirm by pressing ENTER; press ESC to exit. Set the time zone (Time EU/US) in the same way.
- Page 55 Cold start thermal shock (CSTP) If there is a steam boiler that must start up cold in the plant, the fireman will heat the boiler keeping the burner at the lowest output to prevent thermal shocks. The LMV control box provides the CSTP (Cold Start Thermal Schock) function that is already set by the Technical service (access by reserved password).
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Page 56: Spare Parts
SPARE PARTS Desription Code SIEMENS LMV51.100 - 110V BURNER CONTROL 2020460 SIEMENS LMV51.100 - 230V BURNER CONTROL 2020456 SIEMENS LMV51.200 - 110V BURNER CONTROL 2020463 SIEMENS LMV51.200 - 230V BURNER CONTROL 2020457 SIEMENS LMV52.200 - 110V BURNER CONTROL 2020461 SIEMENS LMV52.200 - 230V BURNER CONTROL 2020459 SIEMENS PLL52.110 O2 PCB FOR LMV52 2022111... - Page 60 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...
- Page 61 COD. M07979CD rel. 3.2 01/13 RECOMMENDATIONS FOR LMV5x CONNECTIONS Connections affected by EMC noises are related to the bus cable (actuator line cable, PLL52), detection probe cable, speed sensor cable, 4-20mA signal cable that controls the VSD. Input and power cables (400V e 230V) must be laid separately from the signal cables. The bus cable between control panel and burner and between burner and PLL52 board (used when O2 trim control must be perfomed) must be laid separately and far from power cables.
- Page 62 Annex1 – Example for motor cable...
- Page 64 Annex 2 – Example for sensor cable...
- Page 67 SIEMENS Appendix: Example for wiring, earthing and shielding the LMV5-System Cabinet Siemens MM440 CAN-Bus shielded cable X52.2 X52.4 "VSD - Fan Motor" Separate conduit & shielded line voltage cable! Separate plastic conduit X51, X50 Metal plate = FE for high voltage ign. cable X9-02 X10-01 Power...
- Page 68 Addendum 4: LMV52... with O trim control and O module General The LMV52... system is an extended LMV51... system. A special feature of the LMV52… is control of the residual oxygen content to increase the boiler’s efficiency. In addition to the features of the LMV51..., the LMV52... provides O trim control, con- trol of a maximum of 6 actuators, control of a VSD, and acquisition of cumulated fuel consumption and current fuel throughput.
- Page 69 The maximum cable length between transformer and CAN bus users is dependent on Determination of the the type of cable (cross-sectional area), the number of actuators and the type of actua- maximum cable length tor used (current). The following graphs can be used to determine the maximum CAN bus cable lengths between the transformer and group of actuators or the AZL5…, depending on the rele- vant influencing factors.
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Page 71: Control Panel
Example 2 LMV5... basic unit in the control panel, actuator on the burner; CAN bus cable «LMV5... → SA» > 20 m Jumper Control panel Burner ACT 1 ACT 2 ACT 3 ACT 4 Fixed internal bus termination SQM4... SQM4... SQM4... - Page 72 Example 3a Installation of all components in the burner; CAN bus cable «LMV52... ↔ SA» > 20 m with 6 actuators and O2 module PLL52... Jumper Fixed internal ACT 1 ACT 2 ACT 3 ACT 4 ACT 5 ACT 6 bus termination SQM45...
- Page 73 Notes on example 3a / 3b CAN bus cable with LMV52... and more than 4 actuators and O2 module PLL52... On LMV52... applications with more than 4 actuators (SQM45...), a second transformer is required for powering the extra actuators. In that case, transformer 1 powers the LMV52... basic unit, the AZL5..., and the first 4 actuators.
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Page 74: Inputs And Outputs
O2 module In comparison with the LMV51... system, the extra components to be connected with the LMV52… system are the O module and the O sensor QGO... and, optionally, the combustion air and flue gas temperature sensors. The O module is to be connected to the basic unit via the CAN bus. - Page 76 8 8 8...
- Page 77 ß ß ß...
- Page 78 ©...
- Page 79 Technical Data PLL52... LMV52... basic unit Refer to chapter Technical Data! Mains voltage «X89-01» AC 120 V AC 230 V PLL52... –15 % / +10 % -15 % / +10 % Safety class I with parts according to II as per DIN EN 60730-1 Mains frequency 50 / 60 Hz ±6 % Power consumption...
- Page 80 PLL52... Flue gas temperature X86.3 Shield connection Temperature sensor X86.1 Pt / LG-Ni1000 PLL52... Pt / LG-Ni1000 X86.2 Signal reference X89-01.4 Protective earth (PE) Supply air temperature X89-01.5 Power supply neutral X87.3 conductor (L) Shield connection F 6.3AT Temperature sensor X87.1 X89-01.6 Power supply live Pt / LG-Ni1000...