CIB UNIGAS G335A Manual Of Installation - Use - Maintenance
  1. Manuals
  2. Brands
  3. CIB UNIGAS Manuals
  4. Burner
  5. G335A
  6. Manual of installation - use - maintenance

CIB UNIGAS G335A Manual Of Installation - Use - Maintenance

Gas - light oil burners, microprocessor controlled
Hide thumbs Also See for G335A:
Table of Contents

Advertisement

Quick Links

Download this manual
G258A
G335A
G380A
G400A
Gas - Light oil burners
LMV 5x
Microprocessor controlled
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039653CA 0.0 11/2022

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the G335A and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for CIB UNIGAS G335A

Summary of Contents for CIB UNIGAS G335A

  • Page 1 G258A G335A G380A G400A Gas - Light oil burners LMV 5x Microprocessor controlled MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039653CA 0.0 11/2022...

  • 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: Directives And Standards

    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 Note: the figure is indicative only Control panel with startup switch Combustion head adjusting ring nut Electrical panel Cover Blast tube + Combustion head Flange Actuator Silencer Gas train 10 Pump motor 11 Fan motor 12 Photocell 13 Air pressure switch...

  • Page 6: Burner Model Identification

    Type G380A Model PR. SR. 1 BURNER TYPE G258A, G335A, G380A, G400A MG - Natural gas-Light oil 2 FUEL 3 OPERATION (Available versions) PR - Progressive, MD - Fully modulating SR = Standard blast tube + ABS polymer (silenced) air intake...

  • Page 7: Technical Specifications

    PART I: SPECIFICATIONS Technical Specifications BURNER TYPE G258A G335A G380A G400A 165 - 2580 280 - 3350 295 - 3800 580 - 4000 Output min. - max. kW Fuel MG - Natural gas-Light oil (see next paragraph) Category 17,5 - 273...
  • Page 8 G400A 1496 1139 G400A 1496 1385 G400A 1496 1416 1002 G400A 1496 1499 1085 B*: SPECIAL blast tube lengths must be agreed with Cib Unigas BS = standard blast tube BL = long blast tube DN = gas valves size...
  • Page 9 3I2MG-21 v0 Hydraulic diagram LEGEND POS OIL TRAIN Filter Flexible hose Pump and pressure governor Electrical motor Solenoid valve oil inlet Solenoid valve Oil distributor oil outlet Pressure gauge Pressure governor Pressure switch One-way valve 16.1 One-way valve 16.1 Flexible hose Manual valve Pressure gauge combustion air...

  • Page 10: Performance Curves

    This value must be lower or equal to the pgas value, calcula- ted before. Power kW Potenza / Output (kW) Performance Curves G258A MG G335A MG G380A MG G400A MG To get the input in kcal/h, multiply value in kW by 860.
  • Page 11 Pressure in the Network / gas flow rate curves Performance Curves G258A MG G335A MG G380A MG G400A 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). To know the minimum pressure at the gas train inlet, necessary to get the requested gas rate, add the pressure value in the combustion chamber to the value read on the y-axis.
  • 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 Gas pressure burner head vs natural gas flow rate Curves are referred to pressure = 0 mbar in the combustion chamber! G258A M- G335A M- G380A M- G400A M-...
  • Page 14 PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Transport and storage If the product must be stored, avoid humid and corrosive places. Observe the temperatures stated in the burner data table at the begin- ning of this manual. The packages containing the burners must be locked inside the means of transport in such a way as to guarantee the absence of dangerous movements and avoid any possible damage.
  • Page 15 PART II: INSTALLATION 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 4 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;...
  • Page 16 PART II: INSTALLATION GAS TRAIN CONNECTION The following diagrams show some examples of possible gas trains with the components supplied with the burner and those fitted by the installer. The gas trains and the connection of the burner to the fuel supply line must be done in accordance with current local regu- lations.
  • Page 17 PART II: INSTALLATION GAS TRAIN CONNECTIONS WARNING: before executing the connections to the gas pipe network, be sure that the manual cutoff valves are closed. ATTENTION: it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the valves, during maintenance and cleaning operation of the filters (both the filters outside the valves group and the ones built-in the gas valves).

  • Page 18: Assembling The Gas Train

    PART II: INSTALLATION MultiBloc MB-DLE - Assembling the gas train Mounting Mount flange onto tube lines: use appropriate sealing agent Insert MB-DLE: note position of O rings Remove MultiBloc between the threaded flanges After installation, perform leakage and functional test Disassembly in reverse order MB-DLE 405..
  • Page 19 PART II: INSTALLATION DUNGS MBE Components and position of pressure switches PGMIN minimum gas pressure switch VD-V VD-R PGMIN minimum gas pressure switch (alternative VD-V VD-R to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded) Valve body (Flange)
  • Page 20 PART II: INSTALLATION Siemens VGD20.. e VGD40.. Components and position of pressure switches PGMIN minimum gas pressure switch SKP25 SKP25 PGMIN minimum gas pressure switch (alternative SKP15 SKP15 to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded)

  • Page 21: Overall Dimensions (Mm)

    PART II: INSTALLATION Siemens VGD Pressure taps Legend pi Inlet pressure Strainer pm Pressure between val- (G 1/4") (G 1/8") (G 1/4") (G 3/4") (G 1/8") (G 1/4") (G 1/8") po Outlet pressure Overall dimensions (mm) - BURNERS WITH INVERTER VARIANT (if provided)
  • Page 22 PART II: INSTALLATION BURNERS WITH INVERTER VARIANT (if provided) DANFOSS FC101 INVEOR M DANFOSS FC102 The manufacturer provides: KOSTAL: on-board or wall-mounted (in the latter case the kit is required) DANFOSS: wall-mounted Both can be equipped with a braking resistor. The burner terminal box is prepared to receive certain signals (for connection to the inverter, see the dedicated connection diagram).
  • Page 23 PART II: INSTALLATION AGG 5.310 Speed Sensor is a speed sensor kit used to monitor the speed of a motor. This kit is used to mount the speed sensor directly on the motor casing. The procedures of installation fo the gas valves are showed in the next paragraphs, according to the gas train used: 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 24 PART II: INSTALLATION 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 25 PART II: INSTALLATION Installation diagram of light oil pipes please read carefully the “warnings” chapter at the beginning of this manual. Fig. 4 - Double-pipe system 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 26 PART II: INSTALLATION About the use of fuel pumps Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth,  thus obstructing them. After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of the ...
  • Page 27 PART II: INSTALLATION Suntec TA.. Oil viscosity 3 ÷ 75 cSt Oil temperature 0 ÷ 150°C Min. suction pressure - 0.45 bar to avoid gasing Max. suction pressure 5 bar Max. return pressure 5 bar Rotation speed 3600 rpm max. 1.

  • Page 28: Electrical Connections

    PART II: INSTALLATION ELECTRICAL CONNECTIONS WARNING: (only for double stage and progressive burners) The burner is provided with an electrical bridge between terminals 6 and 7; when connecting the high/low flame thermostat, remove this bridge before connecting the thermostat. 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.
  • Page 29 PART II: INSTALLATION Siemens CD attached to the burner C - Capacitor (22 nF , 250 V) LMV2/3... - LMV5... LME / LMV - Siemens control box R - Resistor (1 MΩ) M: Terminal 2 (LGB, LME), Terminal X3-04-4 ( LMV2x, LMV3x, LMV5, LME7x) RC466890660 - RC Siemens filter Configuration with separate electrical panel (optional)
  • Page 30 PART III: OPERATION PART III: OPERATION IN THE EVENT OF A BLOCKAGE, THE CAUSE MUST BE ASSESSED. IF THE FLAME BACKFIRE WARNING LIGHT IS ON, IT IS IMPERATIVE TO CHECK THE INTEGRITY AND GOOD CONDITION OF THE COMBUSTION HEAD AS DESCRIBED IN THE MAINTENANCE SECTION BEFORE UNLOCKING THE APPLIANCE.

  • Page 31: Fuel Selection

    PART III: OPERATION Keys B1 Lock-out LED B2 Hi-flame operation LED B4 B5 B3 Lo-flame operation LED B4 “Ignition transformer operation” LEDG1“EV2 opening” LED B2 B3 G2 “EV1 opening” LED G3 “Gas pressure switch signal ” LED G4 Gas proving system lockout signalling LED S4 Fuel selection S7 CMF switch 0=stop 1=high flame2=low flame 3=automatic-fully modulating burnersonlyO1EVG1...

  • Page 32: Adjusting Procedure

    PART III: OPERATION Adjustments - brief description The air and fuel rates adjustments must be performed at the maximum ouptput first (“high flame”): see the LMV5.. 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 33: Start-Up Procedure

    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 34: Fault History

    PART III: OPERATION Setpoint 80°C Act.value 78°C Load Flame Main page Set point: temperature set-point Act value: actual temperature value Load: load percentage (burner output) Flame: percentage of flame detection current. By pressing the ENTER key the display shows the second page: Fuel Second page Fuel: it shows (in degrees) the fuel actuator position.
  • Page 35 PART III: OPERATION 1 Class: 05Gas code Phase: Diag.: Lod: Start No. alternating by an error message as: O2 control and limiter automat deactivated To see the other Fault History pages, press the arrow keys. To exit the Fault History pages, press ESC. Lockout History To visualise the Lockout History, choose the related item and press ENTER.
  • Page 36 PART III: OPERATION BurnerControl RatioControl O2Contr./Guard. LoadController Choose “LoadController” and press ENTER: the following menu is shown: ControllerParam Configuration Adaption SW Version Choose “ControllerParam” and press ENTER: the following menu is shown: ContrlParamList MinActuatorStep SW_FilterTmeCon SetPointW1 Choose “SetPointW1” and press ENTER: SetpointW1 Curr: 90°...
  • Page 37 PART III: OPERATION 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. Now choose SD_ModOff always scrolling down theLoad Controller menu, by menas of the arrow keys, and press ENTER. SetpointW1 SetpointW2 SD_ModOn...

  • Page 38: System Lockout

    PART III: OPERATION choose the desired language and cofirm by pressing ENTER; press ESC to exit. DateFormat: it allows setting the date format as DD-MM-YY (day-month-year) or MM-DD-YY (month-day-year) DateFormat DD-MM-YY Curr:: New: MM-DD-YY choose the desired format and cofirm by pressing ENTER; press ESC to exit. PhysicalUnits: it allows setting the measuring units for temperature and pressure UnitTemperature UnitPressure...
  • Page 39 PART III: OPERATION SetLoad Autom/Manual/Off SetLoad: to set the required load percentage SetLoad Curr:: 0.0% New: 20.0% set the required percentage and confirm by pressing ENTER; press ESC to exit. choose “Autom/Manual/Off SetLoad Autom/Manual/Off Autom/Manual/Off Curr:: Automatic New: Burner On three modes are provided: Automatic: automatic operation Burner on: manual operation...
  • 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 table below and the diagram on Fig. 20 (as far as reading the pressure values, see next paragraphs).
  • 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 cS 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 ADJUSTING THE GAS VALVES GROUP Multibloc MB-DLE The multibloc unit is a compact unit consisting of two valves, gas pressure switch, pressure stabilizer and gas filter. C VS The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns.
  • Page 45 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 46 PART III: OPERATION HEAD ADJUSTING Regulating the combustion head The burner is factory-adjusted with the combustion head in the "MAX" position, accordingly to the maximum power. To operate the bur- ner at a lower power, progressively shift back the combustion head, towards the "MIN" position, screwing the screw VRT. The ID index shows how much the combustion head moved.

  • 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 Gas filter maintenance WARNING: Before opening the filter, close the manual cutoff valve downstream the filter and bleed the gas; check that inside the filter there is no pressurised gas. Per pulire o sostituire il filtro gas procedere nel modo seguente: MB-DLE MB-DLE 415 - 420 B01...
  • Page 49 PART IV: MAINTENANCE MultiBloc VD-V VD-R Mounting to push position 1. Position VD on VB, fig. 2+3. 2. Slide VD forward up to the stop, fig. 4. 3. Screw VD on with 2 M5 screws for each, max. 5 Nm/44 in.-lb., fig. 5/6. 4.
  • Page 50 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 51: Electrodes Adjustment

    PART IV: MAINTENANCE Electrodes Adjustment Adjust the electrodes position, according to the quotes shown othe next picture ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. A = 4 7÷8 B = 8...

  • Page 52: Seasonal Stop

    PART IV: 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 53 PART IV: MAINTENANCE TROUBLESHOOTING GUIDE Gas operation * No electric power supply * Restore power supply * Main switch open * Close switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Reset or replace the thermostat * No gas pressure * Restore gas pressure...
  • Page 54 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 * Restore 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 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 58 Annex1 – Example for motor cable...
  • Page 60 Annex 2 – Example for sensor cable...
  • Page 63 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 64 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 65 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 67: 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 68 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 69 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 70: 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 72      8      8      8...
  • Page 73 ß ß ß...
  • Page 74 ©...
  • Page 75 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 76 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...

This manual is also suitable for:

G258aLmv 5 seriesG380aG400a

Table of Contents