Unigas URB40 Manual Of Installation - Use - Maintenance
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Unigas URB40 Manual Of Installation - Use - Maintenance

Gas burners microprocessor controlled
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URB40
URB70
Gas burners
Microprocessor controlled
LMV5x
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039646CA 0.0 06/2021

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  • Page 1 URB40 URB70 Gas burners Microprocessor controlled LMV5x MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039646CA 0.0 06/2021...

  • 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 ...

  • 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 Wind box Burner flange Gas lances and nozzles Blast tube Air damper Pilot gas train Butterfly valve Air actuator Flexible hoses 10 Manual valves 11 Junction box 12 Gas servodrive 13 Control panel with separate lectern 14 Main gas train...
  • Page 6 URB burner series is supplied with a refractory blast tube made by a set of preformed and precooked refractory bricks including from average 59% Al The tiles must be mounted at site on the boiler front wall by professional and qualified personnel, according to CIB UNIGAS lay-out dra- wings and recommendations.

  • Page 7: Burner Model Identification

    PART I: SPECIFICATIONS Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type URB40 Model MD. S. 200. BURNER TYPE URB40 FUEL M - Natural gas OPERATION (Available versions) MD - Fully modulating...
  • Page 8 Overall dimensions (mm) 1659 2173 1281 N.16x (M16) 1247 2157 Air inlet flange Natural gas Inlet N.8x N.14-...
  • Page 9 HYDRAULIC DIAGRAMS DISCHARGE TO ATMOS- PHERE COMPRESSED AIR INLET ONBOARD THE BURNER GAS MAIN INLET PREASSEMBLED ON SEPARATE FRAME COMBUSTION AIR INLET N.G./L.P.G.PILOT INLET...

  • Page 10: Combustion Air

    Gas flexible hose (right pilot) Gas flexible hose (left pilot) Gas manual valve Ignition pilot burner NOTES The following POS are supplied loose 11, 12, 20, 33 The following POS are not included in CIB Unigas supply 10, 30, 31, 32...
  • Page 11 2432 SEZ: A-A REV.03 DETT.:C Eyebolts Mount part 9 on the top of the burner, fixing 10,17,15. The handling support 8 must be fixed to the support 9 mounted on the top of the burner. Before inserting the support, remove the eye-bolt shown be- Remove the screws 12, 17 (Dett C) .
  • Page 12 PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Packing The burners are despatched in wooden crates whose dimensions are: BURNER PACKAGING: 2200mm x 2200mm x 2000 mm (L x P x H) The burners are supplied in small wooden boxes: 2234mm x 1650mm x 1250 mm (L x P x H) Packing cases of this type are affected by humidity and are not suitable for stacking.
  • Page 13 PART II: INSTALLATION Matching the burner to the boiler refracory tiles Air winbox to be mounted on the burner flange. Gas ring, register and gas guns group. To be Burner Flange. installed on the air Windbox. If the lifting devices permit, mount the complete burner on the boiler, otherwise divide the burner into the parts shown. Install the complete burner on the boiler if the lifting devices permit, otherwise divide the burner into the parts shown.
  • Page 14 Fill bottom half of space with castable or plastic refractory Fill top half of space with high temperature insulation Fig. 4 Rough dimensions of burner tile in mm Tile size URB5 URB10 URB15 URB20 URB25 URB30 URB32 URB35 URB40 URB45 URB50 URB60 URB70 1016 1067 1118 1168 1219...
  • Page 15 PART II: INSTALLATION Mounting the gas guns 1 2 3 4 5 6 ... Align the reference notch (A) to the “0” mark (B) Align the ring (F) with the edge (C) Once the nozzle “0” position is set, tighten the three grub screws (ref. D) around the removable flange (ref E).
  • Page 16 PART II: INSTALLATION The following pictures show the factory set value of gas lances: During the adjustment operations, a different configuration could be required, depending on the plant and the application involved.
  • Page 17 PART II: INSTALLATION GAS TRAIN CONNECTIONS Referring to the P&ID of the burner, execute the connection. WARNING: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED. burner main gas train connection pilot gas train connection A: ”direction”...

  • Page 18: Pilot Burner

    PART II: INSTALLATION Gas Filter (if provided) The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burner valves, counters and regulators) from becoming rapidly blocked. The filter is normally installed upstream from all the control and on-off devices. ATTENTION: it is reccomended to install the filter with gas flow parallel to the floor in order to prevent dust fall on the safety valve during maintenance operation.

  • Page 19: Electrical Connections

    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 20 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 pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed.

  • Page 21: Adjusting Procedure

    PART III: OPERATION ADJUSTING AIR AND FUEL FLOW RATES Adjusting air and gas flow rates 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 22: Start-Up Procedure

    PART III: OPERATION 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

    PART III: OPERATION 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 PART III: OPERATION 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; proceed as follows. From the main page, enter the main menu by pressing the ESC key twice: OperationalStat Operation...
  • Page 25 PART III: OPERATION Setpoint Actual value SDoff SDon To set these values, select the item SD_ModOn (SDOn), by scrolling down the “Load controller” menu with the arrow keys and press ENTER: SetpointW1 SetpointW2 SD_ModOn SD_ModOff the display will show: SD_ModOn Curr:: 1.0% New:...

  • Page 26: System Lockout

    PART III: OPERATION 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; press ESC to exit. Set the time zone (Time EU/US) in the same way.
  • Page 27 PART III: OPERATION 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). if this function is enabled, when the burner starts upthe “Thermal shock protection activated”...

  • Page 28: Adjustments For Gas Operation

    PART III: OPERATION ADJUSTMENTS FOR GAS OPERATION Adjusting the gas gun The gas lances are already factory-set at standard position. Only when necessary, change the position following the next procedure: to move the lance back or forth, loosen the screws V, on each lance ...
  • Page 29 PART III: OPERATION Setting air pressure switches The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of the control box unlock pushbutton, placed on the burner control panel.
  • Page 30 PART III: OPERATION Gas pressure governor Brahma gas valve EGRx12 Adjusting the air register If necessary, adjust the air register, by moving the R selector: central position: register closed.  counterclockwise rotation (CCW): the flame rotates couterclockwise  clockwise rotation (CW):the flame rotates clockwise ...

  • Page 31: 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 32 PART IV: MAINTENANCE Removing the combustion head Check the gas lances positioning on their reference, in order to re-establish the same positioning later  Close the manual valves (MV) at the gas flexible hoses inlet  Remove the gas pilot (GP) after having disconnected the flexible hoses. ...
  • Page 33 PART IV: MAINTENANCE ATTENTION: to assemble the combustion head, reverse the operation described above. To reassemble the gas lances, pay attention to insert them in the same position as before, checking the referen- ces H on the operator side top plate (P) Replacing the ignition electrode ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised.
  • Page 34 PART IV: MAINTENANCE Cleaning and replacing the flame detector Remove the detector from its seat (see picture);  to clean the detector’s lens, use a soft, clean cloth (free from oil and solvents);  check wiring and all safety functions each time a flame detector has been replaced. ...

  • Page 35: 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”. Wiring diagrams attached 14-0076/2...
  • Page 36 PART IV: MAINTENANCE TROUBLESHOOTNG 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 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.

  • 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.

  • 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...
  • Page 57 ß ß ß...
  • 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...

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