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Summary of Contents for Unigas RX63
- Page 1 RX63 Gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039371CA Rel 0 02/2018...
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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
DIRECTIVES AND STANDARDS do not leave the equipment exposed to weather (rain, sun, etc.) 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 PART I: SPECIFICATIONS PART I: SPECIFICATIONS BURNERS FEATURES Note: the figure is indicative only. Control panel with startup switch Gas valves group Electrical panel Flange Blast tube - Combustion head Air pressure switch Adjusting cam (progressive/fully modulating bur- ners only) Actuator Fig.
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Page 6: Burner Model Identification
PART I: SPECIFICATIONS Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type RX63 Model MD. S. BURNER TYPE RX63 FUEL M - Natural gas B - Biogas L - LPG... - Page 7 PART I: SPECIFICATIONS BURNER TYPE RX63 M-.. RX63 L-.. 200 - 830 200 - 830 Output min. - max. kW Natural gas L.P.G. Fuel Category see next paragraph 3B/P 7.5 - 31 21 - 88 Gas flow rate min.-max. Stm...
- Page 8 Overall dimensions (mm) Burner flange Boiler recommended drilling template A (A A (A B (B ) B (B V (**) RX63 1207 1292 RX63 1207 1292 RX63 1207 1292 RX63 1207 1292 1062 *DN = gas valves size = standard blast tube = long blast tube (**) According to the gas train size and the burner type, MB-DLE or VGD valves are supplied.
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Page 9: Performance Curves
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C. Performance Curves RX63 To get the input in kcal/h, multiply value in kW by 860. Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine. - Page 10 Pressure in the Network / gas flow rate curves Natural Gas burners RX63 M-.. Caution: 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 11 PART I: SPECIFICATIONS Combustion head gas pressure curves depending on the flow rate 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 12 PART I: SPECIFICATIONS Pressure - rate in combustion head curves Curves are referred to pressure = 0mbar in the combustion chamber! RX63 M-..
- Page 13 PART II: INSTALLATION PART II: INSTALLATION 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 14 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 15 PART II: INSTALLATION GAS TRAIN CONNECTIONS The diagrams show the components of the gas trai included in the delivery and which must be fitted by the installer.The diagrams are in compliance with the current laws. WARNING: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED.
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Page 16: Assembling The Gas Train
PART II: INSTALLATION Assembling the gas train gas supply network ”direction” arrows for installation Keys 1A..1E Gasket Gas filter Gas valves group Bellows unit Manual valve Fig. 3 - Example of gas train To mount the gas train, proceed as follows: 1-a) in case of threaded joints: use proper seals according to the gas used;... -
Page 17: Mounting Positions
PART II: INSTALLATION MULTIBLOC DUNGS MB-DLE 405..412 Mounting 1. Mount flange onto tube lines: use appropriate sealing agent (see Fig. 6); 2. insert MB-DLE: note position of O rings (see Fig. 6); 3. tighten screws A, B, C and D (Fig. 4 - Fig. 5), accordind to the mounting positions (Fig. 7); 4. - Page 18 PART II: INSTALLATION Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) Mounting When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded); to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts; install the valve;...
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Page 19: 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 connec- ting 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 20 PART II: INSTALLATION Note on elecrtical supply If the power supply to the burner is 230V three-phase or 230V phase-phase (without a neutral), with the Siemens control box, between the terminal 2 (terminal X3-04-4 in case of LMV2x, LMV3x, LMV5x, LME7x) on the board and the earth terminal, an RC Siemens RC466890660 filter must be inserted.
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Page 21: Burner Safety
PART II: INSTALLATION BURNER SAFETY The burners - and the configurations described below - comply with the regulations in force regarding health, safety and the environ- ment. For more in-depth information, refer to the declarations of conformity that are an integral part of this Manual. DANGER! The safety elements and devices have been realized to protect from risks deriving from expected use, adjustment and maintenance. - Page 22 PART III: OPERATION PART III: OPERATION WARNING: before starting the burner up, be sure that the manual cutoff valves are open and check that the pressure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the mains switch is closed.
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Page 23: Gas Operation
PART III: OPERATION Fig. 13 - Burner front panel Keys Burner Modulator (only on fully modulating burners) Lock-out LED Hi-flame operation LED Lo-flame operation LED “Ignition transformer operation” LED “Fan motor overload tripped” LED “EV2 opening” LED “EV1 opening” LED “Gas pressure switch signal ”... - Page 24 PART III: OPERATION Fig. 14 - Burner front panel Keys Lock-out LED Hi-flame operation LED Lo-flame operation LED “Ignition transformer operation” LED “Fan motor overload tripped” LED “EV2 opening” LED “EV1 opening” LED “Gas pressure switch signal ” LED Gas proving system lockout signalling LED Main switch Reset pushbutton for control box Operation selector MAN - AUTO (operation in manual...
- Page 25 PART III: OPERATION ADJUSTING AIR AND GAS FLOW RATES WARNING! During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide); if this should happen, make the fuel decrease slowly until the normal combustion values are achieved.
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Page 26: Adjusting Procedure
PART III: OPERATION Adjusting procedure Turn the burner on by means of its main switch A: if the burner locks (LED B on in the control panel) press the RESET button (C) on the control panel. See chapter “Operation” for further details. check the fan motor rotation;... - Page 27 PART III: OPERATION Double-stage burners drive the burner to the low flame stage by means of the TAB thermostat; 10 To change the gas flow rate in order to get an efficient combustion, slacken the nut DB and adjust the opening angle of the gas butterfly valve by rotating the screw TG (clockwise rotation increases gas flow, anticlockwise rotation decreases it).
- Page 28 PART III: OPERATION Progressive burners Once the procedure till step 8 described is accomplished, go on as follows: set the low flame cam matching the high flame cam; 10 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position; The manual air damper control is not provided on these actuators.
- Page 29 PART III: OPERATION Fully-modulating burners .To adjust the fully-modulating burners, use the CMF switch on the burner control panel (see next picture), instead of the TAB thermo- stat as described on the previous paragraphs about the progressive burners. Go on adjusting the burner as described before, paying attention to use the CMF switch intead of TAB.
- Page 30 PART III: OPERATION Adjusting the gas valves group Multibloc MB-DLE VS T(VR) The multibloc unit is a compact unit consisting of two valves, gas pressure switch, pres- sure stabilizer and gas filter. The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns.
- Page 31 PART III: OPERATION Setting 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.
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Page 32: 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 33 PART IV: MAINTENANCE Removing the filter in the MULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2” Check the filter at least once a year! Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 19-Fig. 20) Δp> 10 mbar. Change the filter if the pressure difference between pressure connection 1 and 2 (Fig.
- Page 34 PART IV: MAINTENANCE Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 Check the filter at least once a year! Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 22-Fig. 23)is Δp > 10 mbar. Change the filter if the pressure difference between pressure connection 1 and 3 (Fig.
- Page 35 PART IV: MAINTENANCE Removing the combustion head Remove the burner cover C. Unscrew the screws V holding in position the Fig. 25 manifold G and pull out the complete group as shown in the picture. Note: for the subsequent assembly carry out the above described operations in the reverse order, checking the correct position of the OR ring.
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Page 36: Electrodes Adjustment
PART IV: MAINTENANCE Electrodes Adjustment Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion head. ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), other- wise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. -
Page 37: Seasonal Stop
PART IV: MAINTENANCE Checking the detection current (L.P.G.) 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. Control box Minimum detection signal Siemens LME21-22... -
Page 38: Wiring Diagrams
PART IV: MAINTENANCE WIRING DIAGRAMS Refer to the attached wiring diagrams. WARNING 1 - Electrical supply 230V / 400V 50Hz 3N a.c. 2 - Do not reverse phase with neutral 3 - Ensure burner is properly earthed... - Page 39 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...
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Page 40: Start-Up Program
APPENDIX SIEMENS LME11/21/22 CONTROL BOX tion of «t11») with the LME22..., fan motor «M» will be started. Waiting time Preconditions for burner startup During the waiting time, air pressure monitor «LP» and flame relay «FR» Burner control must be reset are tested for correct contact positions. - Page 41 LME11 control sequence LME21 control sequence B´ B´ SB / R SB / R W / GP W / GP (LR) BV2 7101d05/0206 Control sequence Waiting time LME22 control sequence Purge time B´ TSA Ignition safety time SB / R Preignition time W / GP Postignition time...
- Page 42 LME11 connection diagram Connection diagram Error message (alarm) Fuel valve PC control EK2 Remote lockout reset button RESET Flame signal Gas pressure switch Air pressure switch Load controller K2/1 K2/2 Fan motor Control thermostat/pressurestat Safety limit thermostat R / W Limit thermostat /pressure switch Ignition transformer 7101 24 /0606...
- Page 43 CONTROL PROGRAM IN THE EVENT OF FAULT CONTROL BOX LOCKED If a fault occurs, all outputs will immediately be deactivated (in less In the event of lockout, the LME.. remains locked and the red signal lamp than 1s). (LED) will light up.The burner control can immediately be reset. This state After an interruption of power, a restart will be made with the full pro- is also mantained in the case fo mains failure.
- Page 44 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 45 LME73.000Ax + PME73.831AxBC LME73.831AxBC Service instruction manual M12921CB Rel.1.2 02/2016...
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Page 46: General Features
GENERAL FEATURES LME/ is suitable for gas, light and heavy oil burners LME7 series has two devices: LME73.000 (hardware) and PME73.831AxBC (programmable unit). The LME73.831AxBC is also available: it has a built in software and it isa not programmable. LME7 is inside the control panel. If supplied, PME73.831BC is inside the LME7; The display AZL23.. -
Page 47: User Interface
User interface : Button A - Display preset output - In lockout position: Power value to the time of fault Info and Enter button - Reset in the event of fault, changeover visual diagnostic of the cause of fault (refer to chapter Diagnostics of cause of fault ) - button - Display flame signal current 2 or phases display - In lockout position: MMI phase to the time of fault... - Page 48 List of phase display on board LME : Phase number of Function 7-segment display Standby Standby, waiting for heat demand Mains ON / test phase (e.g. detector test) Startup Yellow Safety valve ON, air pressure switch test / POC test (timeout / locking Yellow Fan motor ON / air pressure switch test / settling time Yellow...
- Page 49 Operation : The lockout reset button (info button) (EK) is the key operating element for resetting the burner control and for activating / deactivating the diagnostics functions. The multicolor signal lamp (LED) is the key indicating element for visual diagnostics. Both lockout reset button (EK) and signal lamp (LED) are located in the control panel.
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Page 50: Program Sequence
Program sequence : Version 1: • Ignition load < low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 > 0 seconds) - Page 51 Program sequence : Version 2: • Ignition load > low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 = 0 seconds)
- Page 52 Phase Function number Lockout phase Standby, waiting for heat demand Operation, modulating operation Interval until release of load controller target (analog or 3-position step input) Under voltage Safety loop open Extraneous light on burner startup (timeout/locking after 30 seconds) Mains ON/test phase (e.g. detector test) Shutdown, actuator opens in CLOSE position (homerun) Safety valve ON, air pressure switch OFF, actuator opens in CLOSE position Part 1: Fan motor ON...
- Page 53 Error code table : Red blink code of fault signal lamp (LED) Possible cause 2 x blinks No establishment of flame at the end of the safety time (TSA) - Faulty or soiled flame detector - Faulty or soiled fuel valves - Poor adjustment of burner, no fuel - Faulty ignition equipment 3 x blinks...
- Page 54 Flame detection – detection electrode : Short-circuit current Max. AC 1 mA Required detector current Min. DC 2 μA, display approx. 45 % Possible detector current Max. DC 3 μA, display approx. 100 % Permissible length of detector cable (laid separately) 30 m (core-earth 100 pF/m) Measuring circuit Keys...
- Page 55 Gas proving system : Valve proving is dependent on input valve proving ON / OFF (X2-02). When a leak is detected, the gas valve proving function ensures that the gas valves will not be opened and that ignition will not be switched on. Lockout will be initiated. Valve proving with separate pressure switch (P LT) Step 1: td4 –...
- Page 56 Instruction, control and modify via AZL2x : The AZL2x.. display/programming unit is shown below: The keys functions are the following: Key F + A While pressing the two keys contemporarly, the code message will appear: by entering the proper password it is possible to access the Service mode. Info and Enter keys Used for Info and Service menues Used as Enter key in the setting modes...
- Page 57 The display will show these data: Lock+unlock codes Flame Open valves Ignition transformers energised Fan motor energised Oil pre-heater energised Plant heat request Parameter setting mode Info mode Service mode Closing actuator Opening actuator Unit measure While pushing the button together with whatever else button, LME73 locks out; the display shows On stand-by position, appears On operation, all the phases appears with their number.
- Page 58 List of phase with display AZL2x : Phase number Function Standby Standby, waiting for heat request Ph08 Power ON / test phase (e.g. detector test) Startup Ph21 Safety valve ON, air pressure switch test / POC test (timeout / locking after 5 seconds), actuator opens in low-fire position / CLOSE position Ph22 Fan motor ON or air pressure switch test / settling time...
- Page 59 Error code list with operation via internal AZL : Error code Clear text Possible cause Loc 2 No establishment of flame at the - Faulty or soiled fuel valves end of the safety time (TSA) - Faulty or soiled flame detector - Poor adjustment of burner, no fuel - Faulty ignition equipment Loc 3...
- Page 60 Entering the Parameter levels: y means of a proper use of the keys, it is possible to enter the various level parameters, as shown in the following flow chart :...
- Page 61 Info level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
- Page 62 Service level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. . If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
- Page 63 Process data Normalized speed Read only 100% 0.01 % Service Mains voltage Read only LME73.000A1: Service 175 V LME73.000A2: 350 V Flame intensity Read only 100% Service...
- Page 64 Parameter level (Heating engeneering) : This level lets the engineer to modify some burner parameters. It is protect with a 4 digit password (SO level) and a 5 digit password (OEM level) Password input : push F and A buttons together until the display shows "code" and 7 underlines. The left one flashes. By move the flashing underline until it is on the desired position and push "enter".
- Page 65 Repetition in the event of loss of flame during operation Edit 0 SO 0 = None 1 = None 2 = 1 x Repetition 241.00 Valve proving Edit 1 SO 0 = Off 1 = On 241.01 Valve proving Edit 0 SO 0 = During prepurge time (t1) 1 = During postpurge time (t8)
- Page 66 Power setting Analog input (feedback potentiometer ASZxx.3x required) Edit 0 SO 0 = 3-position step input 1 = 0...10 V 2 = 0...135 Ω 3 = 0...20 mA 4 = 4...20 mA with lockout at I <4 mA 5 = 4...20 mA WARNING Parameter Num.
- Page 68 Note: Specifications and data subject to change. Errors and omissions excepted.