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Unigas HTLX 1025.1 Installation Manual

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HTLX 1025.1
HTLX 1030R
HTLX 1030.1
LMV5x
Microprocessor controlled
Gas - light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039582CA 0.2 05/2021

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Summary of Contents for Unigas HTLX 1025.1

  • Page 1 HTLX 1025.1 HTLX 1030R HTLX 1030.1 LMV5x Microprocessor controlled Gas - light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039582CA 0.2 05/2021...

  • 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: General Features

    Burners provided with built-in control panel are designed for IP40 index of protection. For other values of IP, please contact the CIB UNIGAS Technical Dpt. Note: the picture shows one of the possible installations. Fan, electrical panel and pumping unit can be placed according to the custo- mer needs.

  • Page 6: Burner Specifications

    PART I: INSTALLATION MANUAL BURNER SPECIFICATIONS Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type HTLX1025.1 Model MD. S. (1) BURNER TYPE HTLX1025.1, HTLX1030R, HTLX1030.1 (2) FUEL MG - Natural gas-Light oil (3) OPERATION MD - Fully modulating (4) BLAST TUBE...
  • Page 7 PART I: INSTALLATION MANUAL Pressure in the Network / gas flow rate curves HTLX1025.1 HTLX1030R HTLX1025.1...
  • Page 8 BS - BL AIR INLET FLANGE BURNER FLANGE *DN = gas valves size NOTE: the overall dimensions are referred to burners provided with Siemens VGD valves. B*: SPECIAL blast tube lengths must be agreed with Cib Unigas TIPO (AS) (AL) (BS)

  • Page 9: Transport And Storage

    PART I: INSTALLATION MANUAL MOUNTING AND CONNECTING THE BURNER Transport and storage ATTENTION! The equipment must be installed in compliance with the regulations in force, following the manufac- turer’s instructions, by qualified personnel. All handling operations must be carried out with appropriate resources and qualified personnel ATTENTION: Use intact and correctly dimensioned hoisting equipment, conforms to the local regulations and health and safety regulations.

  • Page 10: Fan Installation

    PART I: INSTALLATION MANUAL Fitting the burner to the boiler To install the burner into the boiler, proceed as follows: make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; place the stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;...
  • Page 11 PART I: INSTALLATION MANUAL Connection diagram of the air pressure switch to the burner air conduct Copper tube connection Ø 6 mm: - Drill the air duct (with hole from Ø 10 mm); - Fit sleeve A (Ø 10 mm) and weld it on channel E; - Assemble in sequence the B-D details on the tube (Ø...
  • Page 12 PART I: INSTALLATION MANUAL 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. Note: the figure is indicative only ”direction”...
  • Page 13 PART I: INSTALLATION MANUAL MultiBloc MBE ALLA V. FARFALLA Example of gas train MBE 501939 GAS BRUCIATORE ø185 VD-R VD-V VD-R VD-V Gas filter PGMAX PGMAX PGMI PGMIN PS pressure sensor PGCP PGCP ATTENTION: once the gas train is mounted according, the gas proving test mus be performed, according to the procedure set by the laws in force.
  • Page 14 PART I: INSTALLATION MANUAL Mounting VD-R & PS-... ActuatorVD-V ActuatorVD-R M12 x 5 Pin The actuator VD-V does not need any adjustment (funzione ON-OFF)  The actuator VD-R It must be combined with the PS sensor (include  regolatore di pressione) VD-R + PS 1.
  • Page 15 PART I: INSTALLATION MANUAL SIEMENS VGD.. Mounting positions = BS SKP1. SKP2. version with SKP2 (built-in pressure stabilizer) Siemens VGD valves with SKP actuator: The pressure adjusting range, upstream the gas valves group, changes according to the spring provided with the valve group. To replace the spring supplied with the valve group, proceed as fol- lows: - Remove the cap (T)
  • Page 16 PART I: INSTALLATION MANUAL 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 17 PART I: INSTALLATION MANUAL Installation diagram of light oil pipes PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL. From tank To tank Double-pipe system Рис. 1 The burner is supplied with filter and flexible hoses, all the parts upstream the filter and downstream the return flexible hose, must be installed by the customer.
  • Page 18 PART I: INSTALLATION MANUAL Diesel filters Item Note Connection Max. operating Max. operating Filtering Protec- pressure temperature degree tion 20151PE (*) 3/8” 1 bar -20, 60 °C 100 μ 20201PL (*) 3/8” 1 bar -20, 60 °C 100 μ GA70501 1”...

  • Page 19: Pressure Adjustment

    PART I: INSTALLATION MANUAL Inlet G3/4 Pressure gauge port G1/4 Vacuum gauge port to measure the inlet vacuum G1/4 To pressure adjusting valve G3/4 "Note: pump with “C” rotation. Suntec TV Pressure governor Pressure adjustment Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase pressure, twist adjusting screw 3 clockwise.
  • Page 20 PART I: INSTALLATION MANUAL Connecting the burner to the oil pumping unit Suntec T+TV Follow the scheme in the picture below to connect the burner to the oil pumping unit. The pump sends the oil coming from the tank to the burner.
  • Page 21 PART I: INSTALLATION MANUAL 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 22 PART I: INSTALLATION MANUAL Pressure in combustion head - gas flow rate curves HTLX1025.1 HTLX1030R HTLX1025.1 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. ...

  • Page 23: Pressure Taps

    PART I: INSTALLATION MANUAL 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 24 PART I: INSTALLATION MANUAL FLUIDICS NOZZLE: REFERENCE DIAGRAM (INDICATIVE ONLY) Atomisation angle FLOW RATE kg/h DIMENSIONS Pressure on return (bar) Pressure on return (psi) Up to 100kg/h Over 100kg/h Flow rate NOZZLE SUPPLY PRESSURE = 25 bar - - - - - -- - - Atomisation angle according to the return pressure Tab.
  • Page 25 PART I: INSTALLATION MANUAL Once the air and gas flow rates are adjusted, turn the burner off, turn the burner on again by means of the CM selector to switch to the light 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 26 PART I: INSTALLATION MANUAL 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 27: Oil Circuit

    PART I: INSTALLATION MANUAL Oil circuit The fuel is pushed into the pump 1 to the nozzle 3 at the delivery pressure set by the pressure governor. The solenoid valve 2 stops the fuel immission into the combustion chamber. The fuel flow rate that is not burnt goes back to the tank through the return circuit. The spill-back nozzle is feeded at constant pressure, while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam.
  • Page 28 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 29: Adjustments For Gas Operation

    PART II: OPERATION ADJUSTMENTS FOR GAS OPERATION Air flow and gas adjustment startup the burner by selecting GAS by means of the switch on the burner control panel  Adjust the air and gas flow rates, in according to the “air/gas ratio” curvepoints setting procedure on the LMV manual,. Check con- ...

  • Page 30: Start-Up Procedure

    PART II: OPERATION Adjustments - brief description The air and fuel rates adjustments must be performed at the maximum ouptput first (“high flame”): see the LMV related manual. Check that the combustion parameters are in the suggested limits.  Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a dif- ...

  • Page 31: Fault History

    PART II: OPERATION O2: oxygen percentage Ld: load percentage (burner output). 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...
  • Page 32 PART II: 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 33 PART II: 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.

  • Page 34: System Lockout

    PART II: 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 35: Manual Mode

    PART II: 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 36 PART II: 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 37 PART II: OPERATION MultiBloc MBE Pressure taps 1, 2, 3, 5 Sealing plug For system accessories Fig. 13 Gas valve Siemens VGD - Version with SKP2. (Built-in pressure stabilizer) To increase or decrease gas pressure, and therefore gas flow rate, remove the cap T and use a screwdriver to adjust the regulating screw VR.
  • Page 38 PART II: 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 39 PART II: 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 40 PART III: MAINTENANCE PART III: MAINTENANCE OPERATION ATTENTION: 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”. Read care- fully the “WARNINGS”...

  • Page 41: Routine Maintenance

    PART III: MAINTENANCE ROUTINE MAINTENANCE Check and clean the gas filter cartridge, if necessary replace it (see next paragraghs);  Check and clean the fuel filter cartdrige, replace if necessary.  Check and clean the filter inside the light oil pump: filter must be thoroughly cleaned at least once in a season to ensure correct ...
  • Page 42 PART III: MAINTENANCE MultiBloc MBE MultiBloc VD 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.

  • Page 43: Electrodes Adjustment

    PART III: MAINTENANCE Cleaning/replacing the electrodes ATTENTION: avoid the electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrodes position after any intervention on the combustion head. To remove the oil gun, proceed as follows: remove the combustion head as described on the prevoius paragraph;...

  • Page 44: Seasonal Stop

    PART III: MAINTENANCE Flame detection probe To clean/replace the detection photocell, proceed as follows: Disconnect the system from the electrical power supply. Shut off the fuel supply; remove the photocell from its slot (see next figure); clean the bulbe if dirty, taking care not to touch it with bare hands; if necessary, replace the bulb;...
  • Page 45 PART III: 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 46 PART III: 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 47 PART III: MAINTENANCE...
  • Page 48 C.I.B. UNIGAS S.p.A. Via L.Galvani, 9 - 35011 Campodarsego (PD) - ITALY Tel. +39 049 9200944 - Fax +39 049 9200945/9201269 web site: www.cibunigas.it - e-mail: cibunigas@cibunigas.it Note: specifications and data subject to change. Errors and omissions excepted.
  • Page 49 Siemens LMV5x Service Manual M12920CC rev 2.1 08/2017...
  • Page 50 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 51     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 52: 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 53 .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 54 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 55 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 57 1.4.1 Servomotor wiring example 1.4.2 Bus cable wiring on LMV5x and AZL doors. 1.4.3 EARTH connection example...
  • Page 58 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 59 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 60 LMV5x program structure...
  • Page 61 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 62: Changing Password

    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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70: Pid Control Parameters

    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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 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 86 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 88 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 89 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 90 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 91 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 92 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 93 (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 96 Note: Specifications and data subject to change. Errors and omissions excepted.
  • Page 97 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 98 Annex1 – Example for motor cable...
  • Page 100 Annex 2 – Example for sensor cable...
  • Page 103 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 104 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 105 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 107: 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 108 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 109 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 110: 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 112      8      8      8...
  • Page 113 ß ß ß...
  • Page 114 ©...
  • Page 115 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 116 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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