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Unigas LMV5 Series Manual Of Installation - Use - Maintenance

Microprocessor controlled gas - light oil burners
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HRX92R-FGR
HRX92-FGR
HRX512-FGR
HRX515-FGR
HRX520-FGR
LMV5x
Microprocessor controlled
Gas - Light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039487CC 0.1 10/2020

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  • Page 1 HRX92R-FGR HRX92-FGR HRX512-FGR HRX515-FGR HRX520-FGR LMV5x Microprocessor controlled Gas - Light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039487CC 0.1 10/2020...

  • 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 PRODUCT INSTALLATION AND MAINTENANCE.

  • Page 3: Directives And Standards

    3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS DIRECTIVES AND STANDARDS Gas burners GENERAL European directives  The burner shall be installed by qualified personnel and in compliance -Regulation 2016/426/UE (appliances burning gaseous fuels) with regulations and provisions in force; wrong installation can cause -2014/35/UE (Low Tension Directive) injuries to people and animals, or damage to property, for which the -2014/30/UE (Electromagnetic compatibility Directive)

  • Page 4: Symbols Used

    Burner data plate Type Gas - Light oil burners For the following information, please refer to Model Year European Directives the data plate: S.Number -Regulation 2016/426/UE (appliances burning gaseous fuels) burner type and burner model: must be Output  Oil Flow -2014/35/UE (Low Tension Directive) reported in any communication with the Fuel...
  • Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS BURNERS FEATURES Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type HRX515-FGR Model MD. S. BURNER TYPE HRX92R-FGR, HRX92-FGR, HRX512-FGR, HRX515-FGR, HRX520-FGR FUEL MG - Natural gas-Light oil OPERATION (Available versions) PR - Progressive MD - Fully modulating...

  • Page 6: Technical Specifications

    PART I: SPECIFICATIONS Technical Specifications BURNER TYPE HRX92R-FGR HRX92-FGR HRX512-FGR HRX515-FGR HRX520-FGR 320 - 1870 680 - 2504 1280 - 3600 1.065 - 4160 1600 - 4816 Output min. - max. kW Natural gas / light oil Fuel see next paragraph Category 55 - 198 72 - 265...
  • Page 7 Overall dimensions (mm) BOILER RECOMMENDED DRILLING TEMPLATE FGR FLANGE VISTA A BURNER FLANGE TIPO DN A(AS) AA AC AD AE AP B(BS) BB Omin Omax XA XB XC XF XG XH 1685 222 924 364 35 326 595 100 522 1155 532 1549 946 515 309 349 494 540 560 M14 552 390 763 149 614 845 190 830 305 270 524 62 554 195 225 603 1685 222 924 364 35 326 611 117 522 1155 532 1572 969 515 309 349 494 540 560 M14 552...
  • Page 8 Overall dimensions (mm) (AS-AL) (BS-BL) boiler recommended drilling template O max O min ØXG FGR Flange burner flange VISTA A Ø Ø Ø Ø AA AB AD AN AP XA XB XC XD XE XF (AS) (AL) (BS) (BL) 50 1380 1480 135 831 35 550 100 390 490 493 978 506 1274 725 439 261 291 228 450 360 464 M12 424 280 310 300 532 148 384 624 190 649 228 185 478 55 481 170 200 549 65 1380 1480 135 831 35 564 117 390 490 493 978 506 1520 971 439 261 291 228 447 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 478 55 481 170 200 549 80 1380 1480 135 831 35 579 132 390 490 493 978 506 1551 1002 439 261 291 228 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185 478 55 481 170 200 549 100 1380 1480 135 831 35 592 145 390 490 493 978 506 1634 1085 439 261 291 228 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 185 478 55 481 170 200 549...
  • 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 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 10: Performance Curves

    PART I: SPECIFICATIONS Performance Curves HRX92R-FGR HRX92-FGR HRX512-FGR HRX515-FGR HRX520-FGR To get the input in kcal/h, multiply value in kW by 860. Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15° C NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine.
  • Page 11 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves (natural gas) RX92R-FGR MG.. RX92-FGR MG.. RX512-FGR MG.. RX515-FGR MG.. RX520-FGR MG.. 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 Combustion head gas pressure curves Combustion head gas pressure depends on gas flow and combustion chamber backpressure. When backpressure is subtracted, i depends only on gas flow, provided combustion is properly adjusted, flue gases residual O2 percentage complies with “Recommended combustion values”...
  • Page 13 PART I: SPECIFICATIONS Pressure - rate in combustion head curves (natural gas) Curves are referred to pressure = 0 mbar in the combustion chamber! HRX92R-FGR MG.. HRX92-FGR MG.. HRX512-FGR MG.. HRX515-FGR MG.. HRX520-FGR MG..
  • Page 14 PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Packing The burners are despatched in wooden crates whose dimensions are: HRX5xx series: 1820 mm x 1390 mm x 960 mm (L x P x H)  HRX9x series: 1600 mm x 1180 mm x 860 mm (L x P x H) ...
  • Page 15 PART II: INSTALLATION Matching the burner to the boiler low NOx burners) The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose dimensions are described in the diagram . In case 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 is possible, with respect of the application involved.
  • Page 16 PART II: INSTALLATION Sizing of the FGR pipe (FGR burners only) ATTENTION! Performance curve is obtained in a plant designed according to the following guidelines, size the FGR pipe as per the example below. 1111 Keys 4 Bellow unit (a counter-flange supplied 7 Stack 1 Stainless steel FGR pipe, insulated loose is to be welded to the FGR duct)
  • Page 17 PART II: INSTALLATION 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. ”direction” arrows for installation gas supply network Keys 1A..1EGasket 2 Gas filter...
  • Page 18 PART II: INSTALLATION Gas train with valves group VGD and MBE with built-in gas pressure governor + gas leakage pressure switch (PGCP) BY OTHERS SUPPLIED BY BURNER CONSTRUCTOR GAS INLET GAS INLET Legend 1 Filter 6 Butterfly valve 2 Pressure switch - PGMIN 7 Pressure transducer 3 Safety valve with built in gas governor 8 Main burner...
  • Page 19 PART II: INSTALLATION Threaded train with MultiBloc MBE - Mounting 1. Insert studs A. 2. Insert seals B. 3. Insert studs C. 4. Tighten studs in accordance with section 8. Ensure correct position of the seal! 5. Perform leak and functional tests after mounting. 6.
  • Page 20 PART II: INSTALLATION Mounting VD-R & PS-... ActuatorVD-R ActuatorVD-V The actuator VD-V does not need any adjustment (funzione M12 x 5 Pin  ON-OFF) The actuator VD-R It must be combined with the PS sensor  (include regolatore di pressione) The PS sensor chosen based on the necessary pressure ...

  • Page 21: Mounting Positions

    PART II: INSTALLATION Siemens VGD20.. e VGD40.. Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) - Connect the reference gas pipe (TP in figure; 8mm-external size pipe supplied loose), to the gas pressure nipples placed on the gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size.
  • Page 22 PART II: INSTALLATION 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 23: Gravity Circuit

    PART II: INSTALLATION OIL TRAIN CONNECTIONS OIL TRAIN CONNECTIONS Hydraulic diagrams for light oil supplying circuits GRAVITY CIRCUIT RING CIRCUIT 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve SUCTION CIRCUIT NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device.
  • Page 24 PART II: INSTALLATION Depending on the installed pump, it is possible to design the plant for single or double pipe feeding line Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is driven to the nozzle: a part comes out from the nozzle while the othe part goes back to the pump.
  • Page 25 PART II: INSTALLATION 1. Connection for manometer 1 – delivery (M1) – G1/4 2. Connection for manometer 2 – suction (M2) – G1/4 3. Connection for manometer 3 (M3) A. Suction connection– G1/2 D. Direct - clockwise I. Indirect – counter clockwise R.
  • Page 26 PART II: INSTALLATION Suntec T+TV HP Technik UHE-A Suntec TA Suntec TV Pressure governor Pressure adjustment Vite di regolazione Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase della pressione pressure, twist adjusting screw 3 clockwise. To decrease the pressure, twist screw counterclockwise.

  • Page 27: Electrical Connections

    PART II: INSTALLATION ELECTRICAL CONNECTIONS Any cable connection or hook-up to the grid must be carried out by qualified, informed and trained personnel, directly coordinated and authorized by Technical Service. Always check in advance that the system electrical interlock is fitted with a safety circuit breaker. WARNING! It is forbidden to use the fuel pipes for the execution and/or completion of the grounding The system must comply with the current regulations.
  • Page 28 PART III: OPERATION PART III: 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 29: Gas Operation

    PART III: OPERATION Fig. 6 - Burner front panel Main switch (0=Off, 1=GAS, 2=OIL) CMF switch (0=stop, 1=low flame, 2=high flame, 3=auto- matic) - fully modulating burners only Gas valves EV2 operation signalling lamp Gas valves EV1 operation signalling lamp Gas pressure switch signalling lamp Oil pump in operation lamp Oil valve EVG operation signalling lamp...
  • Page 30 PART III: OPERATION 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 31: Start-Up Procedure

    PART III: OPERATION 14 Bleed the line, getting rid of all the air in the pipe. Adjust the pump plug during priming and on the pre-heating tank (if any), so that the resistors are not damaged. For any advice, see the pump chapter. DANGER! Venting the air from the oil line can also be accompanied by oil leakage, with the consequent risks for the operator and the surrounding devices.

  • Page 32: Fault History

    PART III: OPERATION Fuel Second page Fuel: it shows (in degrees) the fuel actuator position. Air: it shows (in degrees) the air actuator position. Ax1..3: auxiliaries. VSD: % value on the inverter maximum frequency O2: oxygen percentage Ld: load percentage (burner output). Press the ENTER key to go back to the main page.
  • Page 33 PART III: OPERATION Lockout History To visualise the Lockout History, choose the related item and press ENTER. The message will be: 10.08.07 13.47 C:71 D:00 Start No. Load alternating by an error message as: No flame at end of safety time To see the other Lockout History pages, press the arrow keys.
  • Page 34 PART III: OPERATION Choose “ControllerParam” and press ENTER: the following menu is shown: ContrlParamList MinActuatorStep SW_FilterTmeCon 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 35 PART III: OPERATION The deafult value for this parameter is10% that is, the burner will turn off at a temperature 1% higher 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 36: System Lockout

    PART III: OPERATION UnitTemperature UnitPressure 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 37 PART III: OPERATION SetLoad Autom/Manual/Off Autom/Manual/Off Curr:: Automatic New: Burner On three modes are provided: Automatic: automatic operation Burner on: manual 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.

  • Page 38: Pressure Taps

    PART III: OPERATION MultiBloc MBE Regulation VD-R whith PS Setting scale is „Not“ linear! Various sensors available. Output pressure according to sensor‘s measuring range. Increasing pressure Adjust the outlet pressure to the value specified by the burner or equipment manufacturer! While making outlet pressure adjustments, do not exceed a value that creates a hazardous condition to the burner!
  • Page 39 PART III: OPERATION Calibration air and gas 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 bur- ner control panel.
  • Page 40 PART III: OPERATION Adjustment procedure for light oil operation The light oil flow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the below diagrams. FLUIDICS NOZZLE: REFERENCE DIAGRAM (INDICATIVE ONLY) Atomisation angle FLOW RATE kg/h...
  • Page 41 PART III: OPERATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar)
  • Page 42 PART III: OPERATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar)
  • Page 43 PART III: OPERATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the...
  • Page 44 PART III: OPERATION Oil Flow Rate Settings Once the air and gas flow rates are adjusted, turn the burner off, switch to the oil operation (OIL, on the burner control panel). with the electrical panel open, prime the oil pump acting directly on the related CP contactor (see next picture): check the pump motor rotation and keep pressing for some seconds until the oil circuit is charged;...
  • Page 45 PART III: OPERATION Maximum oil pressure switch The oil pressure switch on the return line, checks that the pressure does not exceed a default value. This value must not be higher than the maximum acceptable pressure on the return line (this value is reported on the specification table). A pressure change on the return line could affect the combustion parameters: for this reason, the pressure switch must be set, say, at 20% over the pressure recorded during the combustion adjustment.
  • Page 46 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.

  • Page 47: 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 48 PART IV: MAINTENANCE Thecnical procedure of self cleaning filters substitution (valid for all models) 1 Close the bowl valve before the self cleaning filter 2 Switch off any electrical equipment on board on the filter (example motorization or heaters) WARNING! Drain the system by unscrewing the drain screw on the bottom of the self cleaning filter 3 Disconnect the outlet pipe from the cover of the self cleaning filter 4 Remove the cover with all the filter pack, leaving only the bowl on the line 5 Clean any residue on the bottom of the bowl and clean the seat of the O-ring seal...

  • Page 49: Electrodes Adjustment

    PART IV: MAINTENANCE 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 50: Seasonal Stop

    PART IV: MAINTENANCE Checking the detection current with electrode (natural gas) To check the detection signal follow the scheme in the picture below. If the signal is less than the value indicated, check the position of the detection electrode or detector, the electrical contacts and, if necessary, replace the electrode or the detector. Minimum detection signal: 3.5Vdc Fig.
  • Page 51 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 52 PART IV: MAINTENANCE TROUBLESHOOTNG GUIDE - Light oil operation * No electric power supply * Wait for electric power supply is back * Main switch open * Close the switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Set or replace the thermostat * No gas pressure...
  • Page 56 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 57 Siemens LMV5x Service Manual M12920CC rev 2.1 08/2017...
  • Page 58 Warnings: To avoid injury to persons, damage to property or the environment, the following warning notes must be observed Qualified personal In the sense of this documentation, qualified personal are those who are knowledgeable and qualified to install, mount, commission, operate and service / maintain LMV5 system together with burner &...
  • Page 59     WIRING RECOMMENDATIONS ....................................... 4     Earthing ......................................4     1.1.1 TN earthing system ................................4     1.1.2 Protective Earth (PE) and Functional Earth (FE) ........................4     .Frequency inverter / Variable Speed Drive (VSD) ......................... 5  ...

  • Page 60: Wiring Recommendations

    1 WIRING RECOMMENDATIONS Earthing 1.1.1 TN earthing system For the LMV5x-System it is preconditioned that a TN earthing system is used. In a TN earthing system, one of the points in the generator or transformer is connected with earth, usually the star point in a three-phase system. TN−S: PE and N are separate conductors that are connected together only near the power source.
  • Page 61 .Frequency inverter / Variable Speed Drive (VSD) A VSD is one of the strongest EMC sources in a boiler house, so the following is recommended: LMV5 hi ld Earth Note: If the LMV5 is mounted in a cabinet, alternative to (X73.6 / FE), also a connection with the PE- rail in the cabinet is possible Use only VSD with EMC- filter!
  • Page 62 1.3.1 Recommendations It is recommended to use a metal "mounting plate" for the LMV5 Base Unit and the Transformer AGG5.220. Use this plate to provide the Functional Earth (FE), see also /EARTH connection example The connection of the FE to the LMV5 has to be made by connecting the X52.4 terminal with FE! Follow exactly the shield and earth connection in the wiring diagram In some cases connecting the terminal X52.2 with FE results in an improved EMC- immunity of the LMV5.
  • Page 63 Wireway and electrical conduit The following cables are recommended for separate wiring; Complete separate from all other cables: • Cable for "VSD to Fan motor" Line voltage, see also "1. Frequency inverter / Variable Speed Drive (VSD)" • Cable for ignition high voltage, see also "2. Ignition" •...
  • Page 65 1.4.1 Servomotor wiring example 1.4.2 Bus cable wiring on LMV5x and AZL doors. 1.4.3 EARTH connection example...
  • Page 66 2 AZL display/programming unit 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: display: it shows menus and parameters key (previous level): it goes back to the previous level menu or exits the programming mode without changing...
  • Page 67 LMV5x program operating phases Phase number Description Sequence Home run Stand by 20,21 Waiting to start realase Startup Start fan on Startup Driving to pre-purge Startup 30..34 Pre purging Startup Driving to ignition pos Startup Ingnition pos Startup 40,42,44 Fuel release 1 Startup 50,52 Fuel release 2...
  • Page 68 LMV5x program structure...
  • Page 69 NOTE: (1) only for LMV52.400, LMV51.300 without temperature compensation (2) only for LMV5.200 (controlling the oxygen level in the exhaust gas flue) and LMV52.400 (monitoring the oxygen level in the exhaust gas flue, a lock out occur if a limit value is overcoming) (3) Only for LMV51.300 (in this case VSD cannot be used), LMV52.xxx ATTENTION: LMV51.300: HAS ONE AUX.
  • Page 70 Password 2.4.1 Access to service levels by password Depending on password (service or OEM), different parameters are visible. "Service" parameters, as per the actuator curves and the set-point values, are password protected. The operator must logon using the "9876" password. "User"...
  • Page 71 3 Thermostatic series and safety loop The burner shuts down properly when the thermostatic series (X5-03.1 and X5-03.4 - terminals 3 and 4 of the burner terminal block) opens. In this way, before shut-down, the burner drives to the minimum load, then the fuel valve will close. The post-purging phase will be performed if set. By re-closing the thermostatic series, the burner will start-up again.
  • Page 72 4 Actuators Addressing the actuators The addressing assigns to each actuator its proper function. The addressing is factory set by the burner manufacturer. If an actuator must be replaced, it is necessary to address it, otherwise the system will not work. The parameter that sets the actuator function is protected by the Service level password.
  • Page 73 Actuator doors configuration After the adressing of the actuators, it is necessary to activate and to configure the operation way for each servomotor. ATTENTION: Activate only the actuators that are really present, otherwise an error will occur. 1st level 2nd level 3rd level 4th level Possible choices...
  • Page 74 5 Setting the load controller Door X60 is used for IntLC... choice and a temperature modulationg probe is used. ATTENTION: in case of FGR, it is not possible to connect a modulating temperature probe at the X60 door of the LMX5...
  • Page 75 ExtLC X5-03 = three-point external controller (X5-03 terminals) Int LC = internal controller (LMV5x) (it switches between 2 set points, W1,W2 set thought AZL. the switch from W1 and W2 is realized opening/closing the LMV5x... terminals X62.1, X62.2). Int LC Bus = internal controller and set point setting via bus connection Int LC X62 = internal controller (LMV), but set point is externally controlled by means of a voltage/current signal on X62 terminals Ext LC X62 = external controller, the burner output is controlled by means of a voltage/current signal on X62 terminals Ext LC Bus = external controller, the burner output is controlled via bus...
  • Page 76 Configuration of a pressure or a temperature probe type at X61 door ATTENTION: If the external load controller is set do not connected to terminals X60 or X61. If a modulation probe is connected to the X61 terminal, proceeding as follows: 1st level 2nd level 3rd level...
  • Page 77 Setting the setpoint and the burner and the PID operative band. 6.4.1 Set-point To set the temperature set-point value, that is the generator operating temperature; proceed as follows. 1st level 2nd level 3rd level 4th level 5th level 6th level Description Params &...
  • Page 78 The default value for this parameter is10% that is, the burner will turn off at a temperature 1% higher than the set-point. Press the ENTER to confirm, the press ESC to exit. Otherwise press ESC to exit without changing data. Press the ESC to exit 6.4.3 PID control parameters The controller’s memory contains 5 standard parameter sets.
  • Page 79 Setting functions “TL_ThreshOff” and “TL_SD_On” These functions enable the settable threshold for the immediate shutdown, if value set on TL_ThreshOff is exceeded. The automatic restart is performed for values lower than the one set on TL_SD_On. On display, values detected by temperature/pressure probe are shown at the same time. TL_ThreshOff turns the burner off if temperature exceeds the set value.
  • Page 80 7 VSD Standardization Motor standardization (speed acquisition) allows the LMV unit to control the motor rounds at the maximum frequency signal coming from the VSD. A temporary standardization is factory set only for test purpose. The definite standardization must be performed on site by the Service Center (only if the fan is supplied), before the plant test.
  • Page 81 8 SPECIAL POSITIONS Ignition position The ignition point is independent from the other curve points of the air/fuel ratio curve. As far as dual fuel burners, the ignition point set for the gas operation does not depend on the one set for the oil operation. LMV5x allow two different ignition position for gas mode and oil mode.
  • Page 82 9 ADJUSTING THE AIR/FUEL RATIO CURVES ATTENTION: when burners are provided with VSD, before setting the air/fuel ratio curves, the Standardization of the motor speed must be performed (see chapter “Standardization”). 1st level 2nd level 3rd level 4th level 5th level 6th level Description Params &...
  • Page 83 Setting the load points output (burners with no FGR) Following the below route access to the programming levels of the menu 1st level 2nd level 3rd level 4th level 5th level 6th level Description Params & Display RatioControl Parameter settings for fuel/ air ratio control GasSettings Parameter settings for firing...
  • Page 84 Point Load To choose the actuator to set, press the “left arrow” and choose Air or VSD Fuel Point Load Press "Enter" to access the Air actuator value to be set. Fuel Point Load Press keys to change value. Fuel Point Load Press Enter...
  • Page 85 Caution! In case it is necessary to immediately shut the burner down while working at high flame and the maximum load point is not already set observing the combustion parameters, decrease gas by means of the pressure governor as to drive the burner to a sufficient excess of air, then shut the burner down by the main switch.
  • Page 86 10 Configurations for burner with FGR 10.1 Recommendations Note! Reduction of maximum burner output Use of the flue gas recirculation (FGR) function or the flue gas mass introduced to the supply air duct might lower the burner’s maximum output. This means that the maximum amount of combustion air that can be introduced will be reduced. It is recommended to consider a proper air excess during the regulation of the burner in order to have to the right O2 content in the smoke, after the flue gas recirculation.
  • Page 87 10.2 Address and activate the AUX3 servomotor. Usually these operations are already set in the manufacturer factory. They would be necessary in same cases as: the substitution of the servomotor, in case the FGR mode were not activated yet or the LMV5x were be supplied loose…...
  • Page 88 10.3 Setting the special positions 1st level 2nd level 3rd level 4th level 5th level 6th level Description Param & Display RatioControl GasSettings OilSettings SpecialPosition Suggested positions are below. They can be modify during the commissioning according to right needs. Special Position: AUX3 POS •...
  • Page 89 10.5 FGR mode choice 1st level 2nd level 3rd level 4th level 5th level 6th level Description Param & Display Flue Gas Recirc According to the preference and FGR-Mode AUX3onCurve instruction in the table below. time temperature temp. contr. TCautoDeact deactMinpos auto deact Description of the FGR mode.
  • Page 90 10.6 Main parameter of the FGR function LMV50 LMV52.4.. Parameter Description LMV51.3 LMV52.2 DelaytimeFGR Gas Setting of delay time for auxiliary actuator 3 to be kept in the ignition position after entering phase ● ● OPERATION DelaytimeFGR Oil ThresholdFGR Gas Setting of temperature that must not be exceeded so that auxiliary actuator 3 can be kept in the ●...
  • Page 91 10.7 Example of FGR factor and FGR Maps Factor on the burner regulation. We consider to set the AUX3 for FGR with the “temp.contr.” Mode The curve is as per the below table. Point Note Load % 37,5 % 62,5 % 75 % 100 % AUX3 FGR Curve...
  • Page 92 11 Cold start thermal shock (CSTP) If there is a steam boiler or a boiler that must start up cold in the plant and to avoid thermal shocks a slow heating is required for the boiler by maintaining the burner at the minimum output, the automatic function “Cold start thermal shock” can be performed instead of the manual operation at minimum load. The CSTP (Cold Start Thermal Schock) function can be enabled by the Technical service only (access by reserved password).
  • Page 93 Note: by enabling the manual operation (this function can be set at user level also -see chapter “manual operation”) the CSTP function is momentary excluded, when enabling the automatic operation again, the CSTP function (previously set at Service level) will be enabled as well.
  • Page 94 12 BURNER MANUAL OPERATION The operator can decide if choosing burner manual operation at a settable fixed load or modulating operation through the automatic load controller, then can also set the burner shutdown by means of the “burner off” function. Choose the type of operation (Au-tom / Manual / Off).
  • Page 96 Terminal Description of connection termi- nals group Connection symbol Electrical rating PIN1 Fan motor contactor AC 230 V +10 % / -15 %, 50...60 Hz, 1 A, cos.0.4 PIN2 Alarm AC 230 V +10 % / -15 %, 50...60 X3-01 Hz, 1 A, cos.0.4 PIN1 Air pressure switch (LP)
  • Page 97 Terminal Connection symbol Description of connection terminals Electrical rating group PIN1 Protective earth (PE) Pressure switch min-oil (DWmin-oil) AC 230 V +10 % / -15 %, PIN2 50...60 Hz, Imax 1.5 mA X5-01 Power signal for pressure switch-min- AC 230 V +10 % / -15 %, oil (DWmin-oil) PIN3 50...60 Hz, Imax 500 mA...
  • Page 98 Terminal Connection symbol Description of connection termi- nals Electrical rating group PIN1 Protective earth (PE) PIN2 Neutral conductor (N) X7-01 PIN3 Fuel valve 2 (oil) AC 230 V +10 % / -15 %, 50...60 Hz, 1 A, cos.0.4 PIN1 Protective earth (PE) PIN2 Neutral conductor (N) AC 230 V +10 % / -15 %, 50...60...
  • Page 99 Terminal Connection symbol Description of connection termi- nals Electrical rating group AC 230 V +10 % / -15 %, 50...60 PIN2 Firing on oil Hz, 1 A, cos.0.4 X8-01 PIN1 Firing on gas AC 230 V +10 % / -15 %, 50...60 Hz, 1 A, cos.0.4 PIN4 Protective earth (PE)
  • Page 100 Termi- nal group Connection symbol Description of connection termi- nals Electrical rating AC 230 V +10 % / -15 %, 50...60 Hz, PIN4 Neutral conductor (N) max 1 mA PIN3 Power signal transformer AC 12 V +10 % / -15 %, 50...60 Hz, X10-01 PIN2 AC power signal GO...
  • Page 101 (functional earth) PIN4 AC power supply from transformer to LMV5... system PIN3 AC 12 V +10 % / -15 %, 50...60 Hz PIN2 Reference ground (PELV) AC power supply from transformer to LMV5... system PIN1 AC 12 V +10 % / -15 %, 50...60 Hz Terminal Connection symbol Description of connection termi- nals...
  • Page 104 Note: Specifications and data subject to change. Errors and omissions excepted.
  • Page 105 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 106 Annex1 – Example for motor cable...
  • Page 108 Annex 2 – Example for sensor cable...
  • Page 111 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 112 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 113 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 115 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 116 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 117 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 118: 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 120      8      8      8...
  • Page 121 ß ß ß...
  • Page 122 ©...
  • Page 123 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 124 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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