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Unigas HTP2000 Installation Manual

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HTP2000
(15P1252)
LMV5x
Microprocessor-controlled
Gas - light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M099400CA Rel. 0.1 12/2015

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  • Page 1 HTP2000 (15P1252) LMV5x Microprocessor-controlled Gas - light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M099400CA Rel. 0.1 12/2015...
  • Page 2 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 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 Burner data plate Type Gas - Light oil burners For the following information, please refer to Model Year European Directives the data plate: S.Number -Regulation 2016/426/UE (appliances burning gaseous fuels) burner type and burner model: must be Output  Oil Flow -2014/35/UE (Low Tension Directive) reported in any communication with the Fuel...
  • Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS GENERAL FEATURES Note: the figure is indicative only 1. The main ramp 2. Panel with a mnemonic with a start switch 3. Electrical board 4. Cover 5. Nozzle + Head of combustion 6. Flange of fastening to the boiler 7.Servo-drive 8.
  • Page 6 PART I: SPECIFICATIONS Burner model identification Burner8s are identified by burner type and model. Burner model identification is described as foll Type HTP2000 Model MD. S. BURNER TYPE HTP2000 FUEL G - Light oil M - Natural gas OPERATION (Available versions)
  • Page 7 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 (*) I 2ELL (*) Only for I : the appliance was configured for the appliance category K (I2K) and is suitable for the use of G and G+ distribution gases according to the specifications as included in the NTA 8837:2012 Annex D with a Wobbe index of 43.46 –...
  • Page 8 Overall dimensions (mm) 2405 1898 2336 1375 FLANGE BURNER BOILER RECOMMENDED DRILLING TEMPLATE...
  • Page 9 Fig. 4 - 3I2MG-19 v0 Hydraulic diagram - nozzle M3 OIL TRAIN Filter Flexible hose Pump and pressure governor Electrical motor Solenoid valve Oil distributor Pressure gauge Pressure governor oil inlet Actuator Pressure switch One-way valve oil outlet Flexible hose Manual valve Pressure gauge MAIN GAS TRAIN...
  • Page 10 PART I: SPECIFICATIONS How to read the burner “Performance curve” To check if the burner is suitable for the boiler to which it must be instal- Campo di lavoro bruciatori lled, the following parameters are needed: Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65 furnace input, in kW or kcal/h (kW = kcal/h / 860);...
  • Page 11 PART I: SPECIFICATIONS Checking the proper gas train size To check the proper gas train size, it is necessary to the available gas pressure value upstream the burner’s gas valve. Then subtract Rp 2" (50) the backpressure. The result is called pgas. Draw a vertical line matching the furnace input value (600kW, in the example), quoted on the x-axis, as far as intercepitng the network pressure curve, DN65...
  • Page 12 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 13 PART I: SPECIFICATIONS...
  • Page 14 PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Packing The burners are despatched in wooden crates whose dimensions are: 2270mm x 1720mm x 1320mm (L x P x H) Packing cases of this type are affected by humidity and are not suitable for stacking. The following are placed in each packing case: burner with detached gas train;...
  • Page 15 PART II: INSTALLATION Fitting the burner to the boiler To perform the installation, proceed as follows: drill the furnace plateas decribed in paragraph (“Overall dimensions”); place the burner towards the furnace plate: lift and move the burner by means of its eyebolts placed on the top side (see”Lifting and moving the burner”);...
  • Page 16 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 17 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. Assembling the gas train gas supply network ”direction”...
  • Page 18 PART II: INSTALLATION to the burner connection to the gas supply network gas proving system connection (optional) SIEMENS VGD40.. Fig. 8 - pipe port (3) for connecting the pilot gas train to the valves group of the main gas train The procedures of installation fo the gas valves are showed in the next paragraphs, according to the gas train used: threaded gas trains with Siemens VGD20..
  • Page 19 PART II: INSTALLATION SKP1. SKP2. SIEMENS VGD..MOUNTING POSITIONS (spring) (cap) Fig. 9 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. Performance range (mbar) 0 - 22 15 - 120 100 - 250...
  • Page 20 PART II: INSTALLATION On LME73.831BC the valve proving is parameterized to take place on startup only. PGCP...
  • Page 21 PART II: INSTALLATION OIL TRAIN CONNECTIONS Hydraulic diagrams for light oil supplying circuits Fig. 10 - Gravity circuit Fig. 11 - Ring circuit Fig. 12 - 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.
  • Page 22 PART II: INSTALLATION Installation diagram of light oil pipes PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL. From tank To tank Fig. 13 - 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 23 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 24 PART III: OPERATION PART III: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNEC- TED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDE- RED IMPROPER AND THEREFORE DANGEROUS.
  • Page 25 PART III: OPERATION Fig. 14 - Burner control panel B2 B3 Keys Main switch (0=Off, 1=GAS, 2=OIL) Reset pushbutton for control box CMF switch (0=stop, 1=low flame, 2=high flame, 3=automatic) - fully modulating burners only Gas proving system reset pushbutton (only for burners with Siemens LDU11 provided) Lock-out LED Hi-flame operation LED Lo-flame operation LED...
  • Page 26 PART III: OPERATION Light oil operation The fan motor starts and the pre-purge phase as well. Since the pre-purge phase must be carried out at the maximum air rate, the  control box drives the actuator opening and when the maximum opening position is reached, the pre-purge time counting starts. At the end of the pre-purge time, the actuator is in the light oil ignition position: the ignition transformer is energised (lamp B4 on);...
  • Page 27 PART III: OPERATION Once the throttle valve is completely opened, acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler/utilisation: Start-up procedure Turn the burner on.
  • Page 28 PART III: OPERATION 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 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;...
  • Page 29 PART III: OPERATION 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; proceed as follows. From the main page, enter the main menu by pressing the ESC key twice: OperationalStat Operation...
  • Page 30 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 31 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 32 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 33 PART III: OPERATION For further details, see the LMV5x annexed manuals. Gas valves Siemens VGD - Version with SKP2. (provided with 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. Turn clockwise to increase the flow rate, counterclockwise to reduce it.
  • Page 34 PART III: OPERATION Adjusting the combustion head Attention! if it is necessary to change the head position, repeat the air and fuel adjustments described above. Only if necessary, change the combusiton head position: to let the burner operate at a lower output, loose the VB screw and move pro- gressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut.
  • Page 35 PART III: OPERATION Pump flow rate Nozzle flow rate...
  • Page 36 PART III: OPERATION Oil Flow Rate Settings Once the air and gas flow rates are adjusted, turn the burner off, switch to the oil operation (OIL, on the burner control panel). with the electrical panel open, prime the oil pump acting directly on the related CP contactor (see next picture): check the pump motor rotation and keep pressing for some seconds until the oil circuit is charged;...
  • Page 37 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 38 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 39 Center head holes gas flow regulation (natural gas burners) PART IV: MAINTENANCE To adjust the gas flow, partially close the holes, as follows: loosen the three V screws that fix the adjusting plate D; insert a screwdriver on the adjusting plate notches and let it move CW/CCW as to open/close the holes; once the adjustmet is performed, fasten the V screws.
  • Page 40 PART IV: MAINTENANCE Fig. 19 Detailed view of the combustion head with pilot (P) and ignition elecctrode (E) Observe the values shown on next picture. Fig. 20 Replacing the ignition electrode ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised.
  • Page 41 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 42 PART IV: MAINTENANCE TROUBLESHOOTING Heavy oil operationжидкого  MAIN SWITCH OPEN  LINE FUSE INTERVENTION   MAX. PRESSURE SWITCH FAULT  FAN THERMAL CUTOUT INTERVENTION  AUXILIARY RELAIS FUSES INTERVENTION      CONTROL BOX FAULT  SERVOCONTROL FAULT ...
  • Page 43 Gas operation TROUBLE CAUSE  MAIN SWITCH OPEN   LACK OF GAS   MAXIMUM GAS PRESSURE SWITCH DEFECTIVE    THERMOSTATS/PRESSURE SWITCHES DEFECTIVES  OVERLOAD TRIPPED INTERVENTION  AUXILIARIES FUSE INTERRUPTED      DEFECTIVE CONTROL BOX ...
  • Page 44 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 4 - Refer to the attached document “RECOMMENDATIONS FOR LMV5x CONNECTIONS”...
  • Page 47 PART IV: 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: Table Of Contents

        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)

    .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: Recommendations

    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

    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: Servomotor Wiring Example

    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: Azl Display/Programming Unit

    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

    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

    LMV5x program structure...

  • Page 61: Burner Id Number

    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: 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: Thermostatic Series And Safety Loop

    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: Actuators

    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

    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: Setting The Load Controller

    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: Setting The Probes And Set-Points

    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

    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

    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

    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: Vsd Standardization

    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: Special Positions

    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: Adjusting The Air/Fuel Ratio Curves

    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)

    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: Configurations For Burner With Fgr

    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: Address And Activate The Aux3 Servomotor

    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: Setting The Special Positions

    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: Fgr Mode Choice

    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: Main Parameter Of The Fgr Function

    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: Example Of Fgr Factor And Fgr Maps Factor On The Burner Regulation

    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: Cold Start Thermal Shock (Cstp)

    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: Burner Manual Operation

    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 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 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...
  • Page 117 KOSTAL INVERTER Connection and programming for electronically controlled burners with LMV2x/3x, LMV5x, ETAMATIC and INVERTER regulation Service Manual TECHNICAL INSTRUCTIONS M12938CA - Rel. 0 - 10/2021...
  • Page 118 Table of contents: INVERTER identification, 3 User interface communication (on request), 4 Electrical connections, 5 Motor connection variants for INVERTERS sizes A, B and C, 5 Motor connection variants for INVERTER size D, 6 Connection of INVERTER signals and commands, 7 Electrical connections and parameter configuration, 7 0-10V / 4-20mA analogue input configuration, 8 Configuration of control contact / INVERTER starting and stopping, 9...

  • Page 119: Inverter Identification

    IDENTIFICAZIONE INVERTER INVEOR Mx IVxx PWxx LPxx APxx GHxx DKxx COxx 1 Application circuit board: Drive controller series: INVEOR AP12 - Standard AP13 - CANopen Control: Installation location/size: motor-integrated - M, size: α, A, DK01 - Standard (without membrane keypad) B, C, D DK04 –...

  • Page 120: User Interface Communication (On Request)

    User interface COMMUNICATION (on request) The drive controller can be put in operation in the following ways: Attention: Contact the manufacturer to order the most suitable device. USB adaptor for PC Via the INVERTER PC software INVEOR MMI remote display: INVEOR MMI is a portable display on which all inverter parameters can be viewed and changed.

  • Page 121: Electrical Connections

    ELECTRICAL CONNECTIONS Motor connection variants for INVERTERS sizes A, B and C Star or delta connection for speed controller integrated on the motor Delta connection variant Star connection variant Nut MA = 5 Nm Circlip Plain washer Cable shoe Fig. 1...

  • Page 122: Motor Connection Variants For Inverter Size D

    Motor connection variants for INVERTER size D X1 terminal no. Designation Assignment Mains phase 1 Mains phase 2 Mains phase 3 Protective conductor Tab. 1 - X1 terminal assignment - 3 x 400 VAC X4 terminal no. Designation Assignment Protective conductor Mains phase 1 Mains phase 2 Mains phase 3...

  • Page 123: Connection Of Inverter Signals And Commands

    Connection of INVERTER signals and commands Input signal 4 ÷ 20 mA / 0 ÷ 10 V START INVERTER Jump er 5- Electrical connections and parameter configuration There are 2 relays on the INVERTER. Connecting terminals X7-1-2-3 and X6-1-2-3 are used for: LMV2/3x: Relay 1 is used as a safety contact on the safety loop series of the equipment.

  • Page 124: 0-10V / 4-20Ma Analogue Input Configuration

    0-10V / 4-20mA analogue input configuration Input signal 4 ÷ 20 mA / 0 ÷ 10 V Input AIn1 can be configured as voltage or current input. It is configured as 4‐20mA input current for LMV5‐Etamatic, and 0‐10V input voltage for LMV2x/3x. Specifies the input type, whether voltage or current.

  • Page 125: Configuration Of Control Contact / Inverter Starting And Stopping

    Configuration of control contact / INVERTER starting and stopping START INVERTER Jump er 5- Terminal Bringing 24V to terminal X5‐6 enables INVERTER operation and the contact that switches it on/off. X5‐3 (24V Out)… X5‐6 (Digit In1).. On LMV2/3x X5‐3 (24V Out) also powers the motor speed encoder.

  • Page 126: Configuration Of Inverter Start / Stop Parameters And Operating Mode

    Configuration of INVERTER start / stop parameters and operating mode Parameter Minimum input frequency in Hz. 1.020 Min. frequency (Hz) Set value = 0 Hz (LMV2x-3x / LMV5x) Set value = > 35 Hz (ETAMATIC) Maximum input frequency in Hz. 1.021 Max.

  • Page 127: Motor Data

    Motor data The motor data depend on the type of motor used. Refer to the data shown on the motor nameplate. Follow the steps below: - Enter the motor data; - Activate the motor recognition function; - If the operation ends successfully, enter the remaining parameters. During the recognition phase, the INVERTER measures some parameters and changes some settings.

  • Page 128: Output Signal Variant For Reading Motor Rpm (Optional)

    Activate the “Motor identification” function and follow the instructions proposed by the INVERTER, then change the parameters described below. The image shows the software screen on the PC. Parameter Open-loop asynchronous motor. 34.010 Control type Set value = 100 (open-loop asynchronous motor) 34.020 Flying restart Set value = 1 (enabled) Calculated by Inverter.
  • Page 129 NOTE If the system enters pendulum mode with LMV.. / ETAMATIC, adjust parameters 34.090 and 34.091 by increasing them, in particular parameter 34.090, in steps of 100mA/rad/sec. With LMV 2x/3x with INVERTER control, the device controls the standby rpm with param. 653. If, after the fan is switched off, the device LMV 2x/3x sees that the motor continues to run, error 83 diagnostic 32 NOTE appears.

  • Page 130: Brake Chopper Connections

    Brake chopper connections Braking resistor connection terminal Brake chopper connections Terminal no. Designation Assignment Braking resistor connection (+) Braking resistor connection (-) Optional assignment of brake chopper Parameter Braking resistor Enabled or disabled Braking resistors...
  • Page 131 Burner terminal block with interface INVERTER Versioni bruciatore con LMV2x/3x Connection to braking resistors when fitted Single-sided shielding LMVxx INVEOR Mx-xxxx-xxxx - LP02/LP04-... Versioni bruciatore con LMV5x o ETAMATIC Connection to braking resistors when fitted Single-sided shielding LMVxx LMV5x / ETAMATIC INVEOR Mx-xxxx-xxxx - LP02/LP04-...

  • Page 132: Burner Terminal With Inverter Interface

    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.

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