Table of Contents
Related Manuals for Unigas R91 VS Series
Summary of Contents for Unigas R91 VS Series
- Page 1 R91..VS R92..VS R93..VS R515..VS R520..VS R525..VS Gas - light oil burners LMV5x Microprocessor-controlled MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039228CB Rel 1.2 04/2011...
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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 BURNERS FEATURES These burners are designed to be installed into boilers provided with very big combustion chamber but the tube nest very close to the burner stokhole. The flame produced by this burner series is very short, but has the energy necessary to take up all the combustion chamber and then exchange this energy to the water, as to get very high efficiency.
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Page 6: Burner Model Identification
Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type R91 Model (1)BURNER TYPE R91 - R92 - R93 - R515 - R520 - R525 (2)FUEL MG - Natural gas-Light oil (3)OPERATION PR - Progressive MD - Fully modulating... - Page 7 BURNER TYPE R515..VS R520..VS R525..VS 770 - 5200 1000 - 6400 2000 - 8000 Output min. - max. kW Fuel MG - Natural gas-Light oil see next paragraph ”Gas category” Category 81.5 - 550 106 - 677 212 - 847 Gas rate min - max (Stm min.- max.
- Page 8 Overall dimensions (mm) Recommended boiler drilling AA AD AN AP G GG H HH R91 VS - 1.50 1464 411 20 549 100 326 419 1138 532 1173 737 436 255 386 255 442 221 449 550 464 M12 510 510 778 404 374 624 216 739 185 R91 VS - 1.65 1464 411...
- Page 9 Recommended boiler drilling R515 VS - 1.50 50 1560 474 508 1236 565 1714 1071 643 700 M16 700 1009 404 605 970 270 R515 VS - 1.65 65 1560 474 508 1236 565 1692 1049 643 700 M16 700 404 483 987 270 R515 VS - 1.80...
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Page 10: Performance Curves
Performance curves R91 M-..VS.1.65/80/100 R92 M-..VS.1.50/65/80/100 1000 1400 1800 2200 2600 3000 1200 1600 2000 2400 2800 3200 3600 R93 M-..VS.1.50/65/80/100 R515 M-..VS.1.50/65/80/100/ 1500 2500 3500 4500 1500 2500 3500 4500 5500 R520 M-..VS.x.50/65/80/100 R525 M-..VS.1.50/65/80/100 1500 2500 3500 4500 5500 6500 7500 8500 1500 2500 3500... - Page 11 Pressure in the network - gas rate curves R91..VS R92..VS Rp 2" (50) Rp 2" DN65 DN65 DN80 DN100 DN80 DN10 Gas rate Stm Gas rate Stm R93..VS R515..VS Rp 2" (50) Rp 2" (50) DN65 DN65 DN80 DN80 DN100 DN100 50 100 150 200 250 300 350 400 450 500 550 600 650 Gas rate Stm...
- Page 12 MOUNTINGS AND CONNECTIONS Packing The burners are despatched wooden cages whose dimensions: R91/92/93..VS: 1720mm x 1420mm x 1130mm (L x P x H) R515/R520..VS: 1690mm x 1360mm x 1310mm (L x P x H) R525..VS: 1960mm x 1460mm x 1310mm (L x P x H) Packing cases of this kind are affected by humidity and are not sui- table for stacking.
- Page 13 ATTENTION: Pay special attention to the burner mounting: all nozzles must go inside the combustion chamber, must extend beyond the inside of the boiler front wall. The burner is opened by means of a special hinge right/left joint: leave the space required for opening the air duct.
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Page 14: Electrical Wiring
Electrical wiring Remove the cover of the burner electrical board. Effect the electrical connections to the supply terminal board as shown in the following diagrams, check the direction of the fan motor (see note at end of page) and refit the panel cover.Remove the cover of the burner elec- trical board. - Page 15 GAS TRAIN CONNECTIONS The diagrams show the components of the gas train 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 16 Assembling the gas grain To assemble the gas train, proceed as follows: ”direction” arrows for installation Keys 1A..1E Gasket Gas filter Gas valves group Bellow joint Manual cock Fig. 2 - Example of gas train To mount the gas train, proceed as follows: 1-a) in case of threaded joints: use proper seals according to the gas used;...
- Page 17 Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) Mounting When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded); to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts; ...
- Page 18 Pressure adjusting range The pressure adjusting range, upstream the gas valves group, changes according to the spring provided with the valve group.Keys 1 spring 2 cap Performance range (mbar) 0 - 22 15 - 120 100 - 250 Spring colour neutral yellow Siemens SKP actuator...
- Page 19 Combustion head gas pressure curves depending on the flow rate Curves are referred to pressure = 0mbar in the combustion head! 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 20 Pressure - rate in combustion head curves R91..VS R92..VS 100 125 150 175 200 225 250 275 300 325 350 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 Gas rate Stm Gas rate Stm R93..VS R515..VS 100 150 200 250 300 350 400 450 500 550 600...
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Page 21: Gas Filter
Gas Filter The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burners, counters and regu- lators) from becoming rapidly blocked. The filter is normally installed upstream from all the control and on-off devices. Adjustments - brief description Adjust the air and gas flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respec- tively. -
Page 22: Start-Up Procedure
Start-up procedure Turn the burner on. 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 the startup enabling signal (standby - Program phase no. Setpoint 80°C Act.value... -
Page 23: Fault History
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 Lockout History the Operational Status menu provides the following items: Normal operation: by selecting this item and pressing the ENTER key, the main page is showed;... - Page 24 10.08.07 13.47 C:71 D:00 Start No. Load alternating by an error message as:к 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 set-point value To set the temperature set-point value, that is the generator operating temperature;...
- Page 25 SetPointW1 Choose “SetPointW1” and press ENTER: SetpointW1 Curr: 90° New: 90° 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”...
- Page 26 BurnerControl RatioControl O2Contr./Guard. LoadController scroll this menu down until the tiem “AZL” is reached 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;...
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Page 27: Manual Mode
Settable temperature units: °C or °F Settable pressure units: bar or psi. choose the desired unit and cofirm by pressing ENTER; press ESC to exit. choose the temperature and pressure unit and cofirm by pressing ENTER; press ESC to exit. ... - Page 28 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. For further details, see the LMV5x annexed manuals.
- Page 29 Calibration of air pressure switch To calibrate the air pressure switch, proceed as follows: Remove the transparent plastic cap. Once air and fuel setting have been accomplished, startup the burner. During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction (to increase the adju- ...
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Page 30: Limitations Of Use
PART II: OPERATION PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNEC- TED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDE- RED IMPROPER AND THEREFORE DANGEROUS. - Page 31 PART III: MAINTENANCE PART III: 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 32 PART III: MAINTENANCE Removing the combustion head To dismantle the combustion head assembly, proceed as follows: unscrew the four fixing screws securing the cap C from the rest of the burner: remove the cap AR. Threaded rod B. Hinge holder CA.
- Page 33 PART III: MAINTENANCE If it is necessary to service the combustion head, after removing the CO manifold, carry out the following operations: 10 unscrew the eight VA screws that fasten the CA air box; 11 open the CA air box; 12 remove the group of heads as indicated in the following figure;...
- Page 34 PART III: MAINTENANCE ATTENTION: while replacing the manifold, remember to insert the “OR”. While centering the heads, do not completely fasten the manifold screws at its base. Fasten the screws after centering. Do not act on the burner hinge and flange screws. Electrodes position adjustments Detection electrode Grounded electrode...
- Page 35 PART III: MAINTENANCE Matching the combustion heads and the control boxes The combustion head is modae of four heads: one is provided with Siemens QRA detection probe connected to the Siemens LFL control box (Fig. 57-Fig. 59-A); the other three heads are provided with Krom-Schroeder UVS5 probes, connected to the Krom- Schroeder IFW15 flame detectors (Fig.
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Page 36: Seasonal Stop
PART III: MAINTENANCE Seasonal stop To stop the burner in the seasonal stop, proceed as follows: turn the burner’s main switch to 0 (Off position) disconnect the power mains close the fuel valve in 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”. - Page 37 ДЕТАЛИРОВОЧНЫЙ ЧЕРТЕЖ ГОРЕЛКИ...
- Page 38 PART III: MAINTENANCE DESCRIPTION REFERENCE ELECTRODE IGNITION ELECTRODE EARTH ELECTRODE SUPPLY SUPPLY PROBE GAS MANIFOLD BURNER COMBUSTION HEAD NOZZLE HINGED BURNER SUPPORT PLATE GAS MANIFOLD SUPPORT AIR BOX IGNITION ELECTRODE CABLE CONTROL ELECTRODE CABLE...
- Page 40 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 41 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 42 Annex1 – Example for motor cable...
- Page 44 Annex 2 – Example for sensor cable...
- Page 47 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 48 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 49 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 51: 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 52 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 53 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 54: 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 56 8 8 8...
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- Page 58 ©...
- Page 59 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 60 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...