CIB UNIGAS HTP1030 Manual Of Installation - Use - Maintenance
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CIB UNIGAS HTP1030 Manual Of Installation - Use - Maintenance

Lmv5 microprocessor-controlled gas - light oil dual fuel burners
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HTP1030
HTP1050
HTP1080
LMV5
Microprocessor-controlled
Gas - light oil
dual fuel burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039248CA REV. 0.4 08/2016

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  • Page 1 HTP1030 HTP1050 HTP1080 LMV5 Microprocessor-controlled Gas - light oil dual fuel burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039248CA REV. 0.4 08/2016...

  • 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

    do not leave the equipment exposed to weather (rain, sun, etc.) DIRECTIVES AND STANDARDS unless expressly required to do so; Gas burners European directives do not allow children or inexperienced persons to use equipment; -2009/142/EC (Gas Directive) The unit input cable shall not be replaced by the user. -2014/35/UE (Low Tension Directive) In case of damage to the cable, switch off the unit and contact qualified -2014/30/UE (Electromagnetic compatibility Directive)

  • Page 4: Symbols Used

    -EN 60204-1:2006 (Safety of machinery – Electrical equipment of machi- nes.) Failure to observe the warning may -CEI EN 60335-1 (Specification for safety of household and similar electri- result in serious injuries or death. DANGER! cal appliances); -CEI EN 60335-2-102 (Household and similar electrical appliances. Safety.

  • Page 5: General Features

    PART I: SPECIFICATIONS PART I: SPECIFICATIONS GENERAL FEATURES This series of industrial burners is designed for all those applications that require big-sized air fans or air-flue heat exchangers to be installed in sound-proof areas to reduce noise. They can be provided with built-in or separately-mounted control panel (console or wall- mounted).

  • Page 6: Example Of Installation

    PART I: SPECIFICATIONS Example of installation Burner Gas train Pumping unit Electric panel 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 7 PART I: SPECIFICATIONS How to choose the burner To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed: fuel furnace input, in kW or kcal/h (kW = kcal/h / 860); boiler type;...

  • Page 8: Technical Specifications

    Burners are identified by burner type and model. Burner model identification is described as follows. Type HTP1030 Model M-. PR. (1) BURNER TYPE HTP1030 - HTP1050 - HTP1080 (2) FUEL MG - Natural gas-light oil (3) OPERATION Available versions PR - Progressive...
  • Page 9 PART I: SPECIFICATIONS Country and usefulness gas categories COUNTRY CATEGORY ES GR SE NO CZ DK GB CY EE MT SK BG RO TR CH 2E( R ) B 2ELL...
  • Page 10 Overall dimensions (mm) Air inlet flange Burner flange Boiler recommended drilling jig *DN = gas valves size HTP1030 2114 848 542 1572 387 1679 1219 460 185 671 660 845 1000 460 947 209 274 80 551 1092 1175 385...
  • Page 11 Fig. 3 - 3I2MG71 v0 Hydraulic diagram - nozzle M3 ON BOARD ITEMS SUPPLIED LOOSE ITEMS OIL TRAIN Filter preassembling unit on a self standing skid Pressure governor Electrical motor Flexible hose Solenoid valve Flexible hose oil inlet One-way valve Pressure switch oil outlet Pressure governor...
  • Page 12 Fig. 4 - 3I2MG72 v0 Hydraulic diagram - nozzle type G ON BOARD ITEMS SUPPLIED LOOSE ITEMS OIL TRAIN Flexible hose Filter Pump preassembling unit on a self standing skid Electrical motor Pressure governor Flexible hose Solenoid valve Flexible hose Oil distributor 3-way solenoide valve oil inlet...

  • Page 13: Performance Curves

    PART I: SPECIFICATIONS Performance curves HTP1030 2000 4000 6000 8000 10000 12000 14000 HTP1050 2000 4000 6000 8000 10000 12000 14000 16000 HTP1080 4000 6000 8000 10000 12000 14000 16000 18000 20000 Performance range To get the input in kcal/h, multiply value in kW by 860.
  • Page 14 PART I: SPECIFICATIONS Pressure in the network / gas rate curves HTP1030 DN80 DN100 1 50 1 00 DN125 1 000 1 1 00 1 200 1 300 1 400 Gas rate Stm HTP1050 DN80 DN100 DN125 1 00 1 000...
  • Page 15 The burners are despatched in wodden crates whose dimensions are: HTP1030 - HTP1050: 2180 mm x 1180 mm x 1210 mm (L x P x H) HTP1080: 2180 mm x 1580 mm x 1560 mm (L x P x H) Packing cases of this type are affected by humidity and are not suitable for stacking.

  • Page 16: Fan Installation

    PART II: INSTALLATION Fitting the burner to the boiler To perform the installation, it is necessary to drill the boiler door as described on paragraph “Overall dimensions”; screw the studbolts (5) on the boiler door, according to the drilling plate (see paragraph “Overall dimensions”); move the burner towards the boiler: lift the burner by means of the eyebolts placed on its top side;...
  • Page 17 PART II: INSTALLATION Matching the burner to the boiler 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 18 PART II: INSTALLATION GAS TRAIN CONNECTIONS Referring to the P&ID of the burner, execute the connection. WARNING: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED. The pilot gas train is already installed to the burner, the following connections must be executed: connection from the filter with stabiliser to the gas supply network to the burner connection to the gas supply...
  • Page 19 PART II: INSTALLATION Assembling the gas grain To assemble the main gas train, proceed as follows: gas supply network ”direction” arrows for installation Keys 1A..1E Gasket Gas filter Gas valves group Bellow joint Manual cock Fig. 7 - Example of gas train in case of flanged joints: place a gasket (no.
  • Page 20 PART II: INSTALLATION SIEMENS VGD..MOUNTING POSITIONS SKP1. SKP2. 7631z05/0101 Fig. 11 Fig. 9 Fig. 10 Fig. 8 Fig. 12...
  • Page 21 PART II: INSTALLATION Pressure adjusting range The pressure adjusting range, downstream the gas valves group, changes according to the spring provided with the valve group. Keys 1 spring 2 cap Siemens SKP actuator Siemens VGD valves with SKP actuator: 0 - 22 15 - 120 100 - 250 Performance range (mbar)
  • Page 22 PART II: INSTALLATION OIL TRAIN CONNECTIONS Hydraulic diagrams for light oil supplying circuits Fig. 13 - Gravity circuit Fig. 14 - Suction circuit Manual valve Light oil filter Light oil feeding pump One way valve Flexible hoses Relief valve NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n. 18 - Fig. 15).
  • Page 23 PART II: INSTALLATION BURNER 1SEE THE BURNER 2SEE THE BURNER P&ID BURNER P&ID PRESSURE GOVERNOR UNIT OIL PUMPING UNIT HEATING MEDIUM INLET MAIN TANK INLET HEATING MEDIUM OUTLET Main tank PRESSURE GOVERNOR UNIT Manual valve OIL PUMPING UNIT Manual valve Pressure governor Filter Needle valve...
  • Page 24 PART II: INSTALLATION PUMP SUNTEC T The gear set draws oil from the tank and transfers it to an external valve that regulates the oil pressure. Bleed The plug of the pressure gauge port must be loosened until the air is evacuated from the system. Note The bypass plug G inserted beween high pressure and shaft seal is only intended to change the pump rotation, check the presence of this plug with a 4 mm Allen key in the pressure outlet of the pump.
  • Page 25 PART II: INSTALLATION Pressure governor Suntec TV Pressure adjustment Remove cap-nut 1 and the gasket 2, unscrew the lock nut 4. To increase pressure, twist adjusting screw 3 clockwise. To decrease the pressure, twist screw counterclockwise. Tight the lock nut 4, refit the gasket 2 and the cap nut 1.

  • Page 26: Electrical Connections

    PART II: INSTALLATION Electrical connections WARNING! Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse the phase and neutral connections. fit a differential thermal magnet switch adequate for connection to the mains. WARNING! before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be sure that the burner’s main switch is in 0 position (OFF) too.
  • Page 27 PART III: OPERATION PART III: OPERATION ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres- sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. 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.
  • Page 28 PART III: OPERATION Choose the type of fuel by turning the switch, on the burner control panel. CAUTION: if the fuel chosen is light oil, be sure the cutoff valves on the feed and return pipes are open. Check the control box is not locked; if so, reset it by means of the reset LMV button. Check the series of thermostats and pressure switches allow the burner to start.
  • Page 29 PART III: OPERATION ADJUSTMENTS 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”. Be sure that the mains switch is closed. ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide);...
  • Page 30 PART III: OPERATION Curves are referred to pressure = 0mbar in the combustion chamber! HTP1030 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Gas rate Stm HTP1050 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700...
  • Page 31 PART III: OPERATION IMPORTANT! the combustion air excess must be adjusted according to the in the following chart: Recommended combustion parameters Recommended (%) CO Recommended (%) O Fuel Natural gas 9 ÷ 10 3 ÷ 4.8 Light oil 11.5 ÷ 13 2.9 ÷...
  • Page 32 PART III: OPERATION Adjusting the maximum gas pressure switch (when provided) To calibrate the maximum pressure switch, proceed as follows according to its mounting position: remove the pressure switch plastic cover; if the maximum pressure switch is mounted upstreaam the gas valves: measure the gas pressure in the network, when flame is off; by means of the adjusting ring nut VR, set the value read, increased by the 30%.

  • Page 33: Adjustments For Gas Operation

    PART III: OPERATION ADJUSTMENTS FOR GAS 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- ferential pressure gauge, as described on par.
  • Page 34 PART III: OPERATION Setpoint 80°C Act.value 78°C Fuel Standby Main page check the fan motor rotation (see related paragraph). make the safety chain enabling the system to start up the combustion cycle starts: the system will show the operating stages - Prepurging (program phase no.30) - Driving to ignition position (program phase no.36) - Ignition position (program phase no.38)

  • Page 35: Fault History

    PART III: OPERATION By pressing the ESC key once, the Operational Status (first item in the main menu) menu is directly shown: Normal operation Status/Reset Fault History Lockout History the Operational Status menu provides the following items: Normal operation: by selecting this item and pressing the ENTER key, the main page is showed; press ESC to go back to the main menu.
  • Page 36 PART III: OPERATION From the main page, enter the main menu by pressing the ESC key twice: OperationalStat Operation ManualOperation Params & Display by means of the arrow keys, select “Params&Display”, press ENTER: the system will ask you to enter the proper password Access w-out PW Access Serv Access OEM...
  • Page 37 PART III: OPERATION Setpoint Actual value SDoff SDon To set these values, select the item SD_ModOn (SDOn), by scrolling down the “Load controller” menu with the arrow keys and press ENTER: SetpointW1 SetpointW2 SD_ModOn SD_ModOff the display will show: SD_ModOn Curr:: 1.0% New:...

  • Page 38: System Lockout

    PART III: OPERATION confirm by pressing ENTER: Times Languages DateFormat PhysicalUnits Times: it sets the “Summer (SUM) Time / Winter (WIN) Time” operation and the continent (EU - Europe; US - United States) Sum/Winter Time Time EU/US choose the Summertime/Wintertime mode desired and cofirm by pressing ENTER; press ESC to exit. Set the time zone (Time EU/US) in the same way.

  • Page 39: Manual Mode

    PART III: OPERATION call the Technical Service and tell the message data. Cold start thermal shock (CSTP) If the generator cannot suffer thermal shocks, the CSTP (Cold Start Thermal Schock) function can be enabled. This function is already set by the Technical service (access by reserved password). if this function is enabled, when the burner starts upthe “Thermal shock protection activated”...
  • Page 40 PART III: OPERATION Adjustment 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 diagram (as far as reading the pressure values, see next paragra- phs).
  • Page 41 PART III: OPERATION Pump flow rate Nozzle flow rate Fig. 18 - Bergonzo B nozzle - example with 850kg/h nozzle...
  • Page 42 PART III: OPERATION Fig. 19 - Bergonzo nozzle - example with 850kg/h nozzle 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).
  • Page 43 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 44 PART III: OPERATION Light oil circuitOil 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 45: 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 46 PART IV: MAINTENANCE Replacing the spring in the gas valve group To replace the spring in the gas valve group,proceed as follows: Carefully twist the protection cap 1 and the O-ring 2. remove the “set value” spring 3 from housing 4. Replace spring 3.
  • Page 47 PART IV: MAINTENANCE Adjusting the ignition electrode Important Note: check the ignition electrode after each removing of the combustion head. ATTENTION: avoid the ignition electrode to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrode position after any intervention on the combustion head. Fig.
  • Page 48 PART IV: MAINTENANCE Replacing the ignition electrode ATTENTION: avoid the ignition electrode to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrode position after any intervention on the combustion head. To replace the ignition electrode, proceed as follows: remove the burner cover disconnect the electrode (E) cable (CE);...

  • Page 49: Seasonal Stop

    PART IV: MAINTENANCE Checking the detection current 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 50 PART IV: MAINTENANCE TROUBLESHOOTNG GUIDE - Gas operation * No electric power supply * Wait until 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 51 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 52 PART IV: MAINTENANCE...

  • Page 53: Wiring Diagrams

    PART IV: MAINTENANCE WIRING DIAGRAMS Refer to the attached wiring diagrams. WARNING 1 - Electrical supply 400V 50Hz 3N a.c. 2 - Do not reverse phase with neutral 3 - Ensure burner is properly earthed...
  • Page 54 PART IV: MAINTENANCE...
  • Page 55 PART IV: MAINTENANCE...
  • 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: 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 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: 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 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: 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 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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