CIB UNIGAS KP72 Manual Of Installation - Use - Maintenance
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CIB UNIGAS KP72 Manual Of Installation - Use - Maintenance

Dual fuel gas - heavy oil burners, micro-processor controlled lmv2x/3x
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KP60
KP72
KP73
Dual fuel gas - heavy oil burners
Micro-processor controlled
LMV2x/3x
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039657CA 0.1 09/2023

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Summary of Contents for CIB UNIGAS KP72

  • Page 1 KP60 KP72 KP73 Dual fuel gas - heavy oil burners Micro-processor controlled LMV2x/3x MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039657CA 0.1 09/2023...

  • Page 2: Risk Analysis

    DANGERS, WARNINGS AND NOTES OF CAUTION - Faults in the fuel supply system; - Use of the burner even after an error and/or fault has occurred; - Repairs and/or overhauls incorrectly carried out; This manual is supplied as an integral and essential part of - Modification of the combustion chamber with inserts that prevent the the product and must be delivered to the user.
  • Page 3 GENERAL INSTRUCTIONS DEPENDING ON FUEL USED those parts likely to constitute sources of danger shall be made harm- less. ELECTRICAL CONNECTION In case the equipment is to be sold or transferred to another user, or in  For safety reasons the unit must be efficiently earthed and installed as ...

  • Page 4: Symbols Used

    BURER DATA PLATE .Do not touch any mechanical moving parts with your hands Consump or any other part of your body. Injury hazard Do not touch any parts containing fuel (i.e. tank and pipes). Type For the following information, please refer to Scalding hazard Model the data plate:...
  • Page 5 Type KP60 Model (1) BURNER TYPE KP60 - KP72 - KP73 M - Natural gas - L - LPG N - Heavy oil, viscosity <= 50cSt (7° E) @ 50° C (2) FUEL D - Heavy oil, viscosity <= 400cSt (50° E) @ 50° C P - Petroleum, viscosity 89cSt (12°...

  • Page 6: Specifications

    PART I: INSTALLATION MANUAL Specifications BURNERS KP60 KP60 Output min. kW - max. kW 160 - 880 Fuel Gas category (see next paragraph) 3B/P Heavy oil viscosity See “Burner model identification” table 2 max Oil train inlet pressure Gas rate min.
  • Page 7 PART I: INSTALLATION MANUAL BURNERS KP72 ..0.xx KP72 ..1.xx KP73 Output min. kW - max. kW 330 - 1200 330 - 1550 300 - 2100 M- Natural gas Fuel P - Petroleum, viscosity 89cSt (12° E) @ 50° C Gas category...
  • Page 8 Overall dimensions - (mm) Burner flange Boiler recommended drilling template Reccomended counterflange 1213 493 1251 160 1213 493 1251 160 KP60 1213 493 1251 160 1213 493 1436 160 A COUNTERFLANGE IS MANDATORY:a gasket must be placed between the generator and the counterflange...
  • Page 9 Overall dimensions - (mm) Reccomended counterflange O min O max O min O max Burner flange Boiler recommended drilling template Omin Omax KP72 xx-...0. 1299 1100 KP72 xx-...0. 1299 1230 KP72 xx-...0. 1299 1245 KP72 xx-...1. 1299 1225 KP72 xx-...1.
  • Page 10 Overall dimensions - (mm) O min O max Boiler recommended drilling template Reccomended counterflange Omin Omax KP73 1320 140 495 1378 475 KP73 1320 140 495 1302 475 KP73 1320 140 495 1308 475 *DN = gas valves size ATTENTION: the counterflange is an optional supplied only on request. A gasket must be placed between the generator and the counterflange...
  • Page 11 KP73 - 3I2MD22 v1 Hydraulic diagram LEGEND 3LMMD22 BY OTHERS OIL TRAIN Filter Pump and pressure governor BY CIB UNIGAS Electrical motor 33 Pressure gauge with manual valve oil inlet Electrical preheater tank Pb4 Temperature probe Pb1 Temperature probe Pb3 Temperature probe...
  • Page 12 KP60, KP72 Fig. 1 - 3I2MD24 v1 Hydraulic diagram SUPPLIED LOOSE ITEMS ON BOARD ITEMS LEGEND - 3LMMD24 rev.1 OIL TRAIN Filter Pump and pressure governor oil inlet Electrical motor Electrical preheater tank oil outlet Temperature probe Temperature probe Temperature probe...
  • Page 13 PART I: INSTALLATION MANUAL GAS TRAIN CONNECTION ATTENTION: Before executing the connections to the gas pipe network, be sure that the manual cutoff valves are closed. The following diagrams show some examples of possible gas trains with the components supplied with the burner and those fitted by the installer.

  • Page 14: Performance Curves

    PART I: INSTALLATION MANUAL Performance curves KP60 KP72 ...0.xx KP72 ...1.xx KP73 KP73 - L- To get the output 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 15 Performance curve minimum Pressure in the Network / gas flow rate curves Gas burners  KP60 /hGas rate Stm KP72 ...0.xx KP72 ...1.xx /hGas rate Stm /hGas rate Stm KP73 /hGas rate Stm...
  • Page 16 PART I: INSTALLATION MANUAL KP73 - L- /hGas rate Stm Caution: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis (pres- sure 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 17 NOTE: THE PRESSURE-RATE CURVES ARE GIVEN AS INFORMATION ONLY; FOR A PROPER SETTING OF THE GAS RATE, PLEASE REFER TO THE GAS METER READING. Pressure in combustion head - gas rate curves KP60 ... Gas rate Stm KP65 KP72 Gas rate Stm Gas rate Stm KP73 Gas rate Stm...

  • Page 18: Transport And Storage

    PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Transport and storage If the product must be stored, avoid humid and corrosive places. Observe the temperatures stated in the burner data table at the begin- ning of this manual. The packages containing the burners must be locked inside the means of transport in such a way as to guarantee the absence of dangerous movements and avoid any possible damage.
  • Page 19 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 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;...
  • Page 20 PART II: INSTALLATION The burner is designed to work positioned according to the picture below. Set the upper side of the burner flange in a horizontal posi- tion, in order to find the correct inclination of the pre-heating tank. For different installations, please contact the Technical Department. SIDE UP SIDE DOWN...
  • Page 21 PART II: INSTALLATION GAS TRAIN CONNECTIONS WARNING: before executing the connections to the gas pipe network, be sure that the manual cutoff valves are closed. ATTENTION: it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the valves, during maintenance and cleaning operation of the filters (both the filters outside the valves group and the ones built-in the gas valves).

  • Page 22: Mounting Positions

    PART II: INSTALLATION MultiBloc MB-DLE - Assembling the gas train Mounting Mount flange onto tube lines: use appropriate sealing agent Insert MB-DLE: note position of O rings Remove MultiBloc between the threaded flanges After installation, perform leakage and functional test Disassembly in reverse order MB-DLE 405..
  • Page 23 PART II: INSTALLATION DUNGS MBE Components and position of pressure switches PGMIN minimum gas pressure switch VD-V VD-R PGMIN minimum gas pressure switch (alternative VD-V VD-R to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded) Valve body (Flange)
  • Page 24 PART II: INSTALLATION Siemens VGD20.. e VGD40.. Components and position of pressure switches PGMIN minimum gas pressure switch SKP25 SKP25 PGMIN minimum gas pressure switch (alternative SKP15 SKP15 to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded)
  • Page 25 PART II: INSTALLATION Siemens VGD Pressure taps Strainer (G 1/4") (G 1/8") (G 1/4") (G 1/8") (G 1/4") (G 3/4") (G 1/8") Legend pi Inlet pressure pm Pressure between valves po Outlet pressure Integrated proving system (burners equipped with LME7x, LMV, LDU) This paragraph describes the integrated proving system operation sequence: At the beginning both the valves (EV1 and EV2) must be closed.
  • Page 26 PART II: INSTALLATION Double-pipe and single-pipe system The pumps that are used can be installed both into single-pipe and double-pipe systems. Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is driven to the nozzle: a part comes out from the nozzle while the othe part goes back to the pump.

  • Page 27: Oil Pumps

    PART II: INSTALLATION Oil pumps KP60 - KP65 - KP72: Pumps for heavy-oil viscosity up to 7° E at 50° C (burner model MN.)  Suntec E4 - E6 - E7 1001 Oil viscosity 2.8 ÷ 450 cSt Oil temperature 0 ÷...
  • Page 28 PART II: INSTALLATION Diesel filters (available on request) Item Note Connection Max. operating Max. operating tempera- Filtering Protection pressure ture degree 300 μ GA70501 1” 4 bar 90 °C IP65 Assembling the light oil flexible hoses To connect the flexible light oil hoses to the pump, proceed as follows, according to the pump provided: remove the closing nuts A and R on the inlet and return connections of the pump;...
  • Page 29 PART II: INSTALLATION RECOMMENDATIONS TO DESIGN HEAVY OIL FEEDING PLANTS This paragraph is intended to give some suggestions to make feeding plants for heavy oil burners. To get a regular burner operation, it is very important to design the supplying system properly. Here some suggestions will be mentioned to give a brief description. The term “heavy oil”...
  • Page 30 PART II: INSTALLATION Viscosity units conversion table Saybolt Cinematics Saybolt Redwood Engler Degrees Seconds Redwood Seconds viscosity Seconds Seconds no.1 (°E) Universal no..2 (Admiralty) Centistokes (cSt) Furol (SSF) (Standard) (SSU) 2.56 1.16 32.1 1.31 36.2 1.58 44.3 5.83 10.3 1.88 52.3 6.77 13.1...
  • Page 31 PART II: INSTALLATION VISCOSITY vs TEMPERATURE DIAGRAM FOR COMBUSTIBLE OILS 1000 PUMPING LIMIT TEMPERATURE (°C) LIGHT OIL 1,3°E AT 20°C HEAVY OIL 2,4°E AT 50°C HEAVY OIL 4°E AT 50°C HEAVY OIL 7,5°E AT 50°C HEAVY OIL 10°E AT 50°C HEAVY OIL 13°E AT 50°C HEAVY OIL 22°E AT 50°C HEAVY OIL 50°C...
  • Page 32 PART II: INSTALLATION Indicative diagram showing the oil temperature at burner pump inlet vs. oil viscosity Example: if the oil has a 50°E @ 50°C viscosity, the oil temperature at the pump inlet should be 80°C (see diagram). OIL TEMPERATURE FOR PUMP FEEDING TEMPERATURE (°C) Fig.
  • Page 33 Fig. 7 3ID00014 v2 Hydraulic diagram - Two or more burners configuration BURNER 2 SEE THE BURNER 1 SEE THE BURNER P&ID BURNER P&ID HEATING MEDIUM INLET HEATING MEDIUM OUTLET PRESSURE GOVERNOR UNIT OIL PUMPING UNIT DAILY TANK UNIT OIL PUMPING UNIT PIPE HEATING SYSTEM: SEE THE SPECIFIC HEATING MEDIUM INLET MAIN TANK INLET...
  • Page 34 Fig. 8 - 3ID0023 v2 - Hydraulic diagram - Single burner configuration BURNER 1 SEE THE BURNER P&ID OIL TRAIN Main tank OIL PUMPING UNIT Manual valve Filter Pump coupled to electrical motor Safety valve HEATING MEDIUM INLET One-way valve HEATING MEDIUM OUTLET Manual valve Pressure gauge...

  • Page 35: Electrical Connections

    PART II: INSTALLATION Electrical connections 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. ATTENTION: 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 36 PART II: INSTALLATION Connecting the oil heating resistors 2.4 - 4.5 kW 8 - 12 kW 400 V 230V 400 V 230V Fig. 9 Fig. 10 18 - 24 kW ELECTRIC MOTOR CONNECTION 400 V 230V 400 V 230V Fig. 12 Fig.

  • Page 37: User Interface

    PART II: INSTALLATION User interface The AZL2x.. display is shown below: The keys functions are the following: Service mode Info mode Parametere setting mode Plant heat request Oil pre-heater energised Fan motor energised Ignition transformers energised Open valves Flame Lock+unlock codes Closing actuator Opening actuator Unit measure...
  • Page 38 PART II: INSTALLATION Manifacturer level (OEM)  PHASES LIST During operation, the following program phases are shown. The meaning for each phase is quoted in the table below Fase / Funzione Function Ph00 Fase blocco Lockout phase Ph01 Fase di sicurezza Safety phase Ph10 t10 = tempo raggiungimento posizione riposo...

  • Page 39: Info Level

    PART II: INSTALLATION Info level To enter the Info level, proceed as follows: in any menu position, press keys + and - at the same time, then the program will start again: the display will show OFF. until the display will show InFo, Press the enter (InFo) key then il will show the first code (167) flashing, on the right side it will show the data entered.

  • Page 40: Service Level

    PART II: INSTALLATION If a message like the one below is shown during operation, it means that the burner is locked out and the Errore code is shown (in the example “error code:4”); this message is alternating with another message Diagnostic code (in the example “diagnostic code:3”).

  • Page 41: Parameter Description

    PART II: INSTALLATION The service level shows all the information about flame intensity, actuators position, number and lock codes: Parameter Description Flame intensity % output, if set = automatic operation Actuators position, 00=combustibile; 01= aria Lock-outs number 701..725 Lock-outs History (see chapter 23 in the LMV2x manual) .the first parameter will be “954”: the percentage of flame is shown on the right.
  • Page 42 PART II: INSTALLATION ADJUSTING THE GAS VALVES GROUP Multibloc MB-DLE The multibloc unit is a compact unit consisting of two valves, gas pressure switch, pressure stabilizer and gas filter. C VS The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns.
  • Page 43 PART II: INSTALLATION Calibration air and gas pressure switches The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of the control box unlock pushbutton, placed on the bur- ner control panel.
  • Page 44 PART II: INSTALLATION Adjusting the combustion head KP60 - KP72 Only if necessary, change the combusiton head position. The burner is factory-set with the head in its MAX position (maximum output). To let the burner operate at a lower output, turn clockwise the VRT screw and move progressively the combustion head back towards the MIN position.Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above.
  • Page 45 PART II: INSTALLATION Oil thermostat adjustment Progressive and fully modulanting oil burners are equipped with electronic multi-thermostat Danfoss MCX, whose operation is con- trolled by thyristor. (for details refer to the attached technical documentation) Fig. 14 - Danfoss MCX Fig. 15 - Probe connections (Danfoss MCX) The oil viscosity at the nozzle, should be about 1,5 °E, which guarantees correct and safe functioning of the burner.
  • Page 46 PART II: INSTALLATION Adjustment in the heavy oil operation The heavy 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 chart below and the diagram on Fig. 30-Fig. 31. FLUIDICS KW3...60°...
  • Page 47 PART II: INSTALLATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cS The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar)
  • Page 48 PART II: INSTALLATION FLUIDICS KW3...60° NOZZLE SUPPLY PRESSURE = 20 bar. VISCOSITY AT NOZZLE = 5 cSt The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the curve Pressure on return (bar) The nominal size of the nozzle is indicated at the ends of the...
  • Page 49 PART II: INSTALLATION Adjustment procedure for light oil operation The light oil flow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the table below and the diagram on Fig. 20 (as far as reading the pressure values, see next paragraphs).
  • Page 50 In order to get the maximum oil flow rate, adjust the pressure (reading its value on the PG pressure gauge) , checking always the combustion parameters. Turn the burner off; then start it up again. If the adjustment is not correct, repeat the previous steps. Pressure gauge port KP60-KP72 Pressure gauge port Pressure gauge port KP73...

  • Page 51: Limitations Of Use

    PART II: OPERATION PART II: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNEC- TED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDE- RED IMPROPER AND THEREFORE DANGEROUS.
  • Page 52 PART II: OPERATION ner's output. If the monitored variable (pressure or temperature) of the boiler/generator/oven fluid exceeds a preset value, the machine switch-off phase is started. The flame control unit moves the servomotor to the low flame position (minimum power supplied), closes the safety valves and starts the post-ventilation phase, if any.
  • Page 53 PART II: OPERATION Burner front panel KP60-72 High flame mode indicating light Low flame mode indicating light Ignition transformer operation Main switch/operation mode (Gas / Oil) Fan motor overload tripped intervention Burner lockout iindicationg light Stand-by mode indicating light Gas valve EV2 operation Gas valve EV1 operation Gas pressure switch consent Pre-heater resistor switch...

  • Page 54: Routine Maintenance

    PART III: MAINTENANCE PART III: 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 55 PART III: MAINTENANCE Per pulire o sostituire il filtro gas procedere nel modo seguente: MB-DLE MB-DLE 415 - 420 B01 405..412 0 Filter cover 0 CoperFKLR GHO ¿OWro 1, 3,4 , 6 Screw plug G 1/8 1,3,4,6 TDSSR D YLWH *  2 Meter connection 2 AWWDFFR PLVXrDWRre 5 Screw plug M14...
  • Page 56 PART III: MAINTENANCE MultiBloc VD-V VD-R Mounting to push position 1. Position VD on VB, fig. 2+3. 2. Slide VD forward up to the stop, fig. 4. 3. Screw VD on with 2 M5 screws for each, max. 5 Nm/44 in.-lb., fig. 5/6. 4.
  • Page 57 PART III: MAINTENANCE Thecnical procedure of self cleaning filters substitution (valid for all models) 1 Close the bowl valve before the self cleaning filter 2 Switch off any electrical equipment on board on the filter (example motorization or heaters) WARNING! Drain the system by unscrewing the drain screw on the bottom of the self cleaning filter 3 Disconnect the outlet pipe from the cover of the self cleaning filter 4 Remove the cover with all the filter pack, leaving only the bowl on the line 5 Clean any residue on the bottom of the bowl and clean the seat of the O-ring seal...

  • Page 58: Electrodes Adjustment

    PART III: MAINTENANCE Electrodes Adjustment (KP60, KP72) 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 59 PART III: MAINTENANCE Note: to remount the burner, floow the same procedure in the reversed order. 1 Inlet G Gas manifold 2 Return H Cover 3 Gun opening L Oil gun E Oil piping connections V Screws Removing the oil gun, replacing the nozzle and the electrodes (KP73) ATTENTION: avoid the electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised.
  • Page 60 PART III: MAINTENANCE Adjusting the electrodes position (KP73) Adjust the electrodes position, according to the quotes shown in the next picture Keys electrodes air pipe ignition gas pipe nozzle Fig. 18 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.

  • Page 61: Seasonal Stop

    PART III: MAINTENANCE Cleaning and replacing the detection photocell Burner service term - In optimal operating conditions, and with preventive maintenance, the burner can last up to 20 years. - Upon expiry of the burner service term, it is necessary to carry out a technical diagnosis and, if necessary, an overall repair.
  • Page 62 PART III: MAINTENANCE TROUBLESHOOTING Heavy oil operation  MAIN SWITCH OPEN  LINE FUSE INTERVENTION   MAX. PRESSURE SWITCH FAULT  FAN THERMAL CUTOUT INTERVENTION  AUXILIARY RELAIS FUSES INTERVENTION      CONTROL BOX FAULT  SERVOCONTROL FAULT ...
  • Page 63 PART III: MAINTENANCE Gas operation TROUBLESHOOTING TROUBLE CAUSE MAIN SWITCH OPEN            LACK OF GAS            MAXIMUM GAS PRESSURE SWITCH DEFEC- ...
  • Page 64 C.I.B.UNIGAS S.p.A. Via L.Galvani ,9 - 35011Campodarsego (PD) - ITALY Tel. +39 049 9200944 - Fax +39 049 9200945 website:www.cibunigas.it-e-mail:cibunigas@cibunigas.it Note: specifications and data subject to change. Errors and omissions excepted.
  • Page 65 AZL2x - LMV2x/3x Burner Management System Service manual 03/2023 M12916CD Rev. 3.4...
  • Page 66 INDEX MICROPROCESSOR CONTROLLED SYSTEM..........................6 User interface....................................6 Parameters level (heating engineer)............................... 8 Setting menu....................................9 Block 000: Internal Parameter ..............................10 Block 100: General information..............................10 Block 200: Burner control................................13 Block 400: Setting air/fuel ratio curves............................25 Block 500: Air/fuel ratio control ..............................26 Block 600: Actuators ..................................
  • Page 67 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 PRO- DUCT INSTALLATION AND MAINTENANCE.
  • Page 68 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; - Directive 2009/142/EC - Gas Appliances; The unit input cable shall not be replaced by the user.
  • Page 69 -EN 55014-1Electromagnetic compatibility - Requirements for household appliances, electric tools and similar apparatus. -UNI EN 676 (Gas Burners; -CEI EN 60335-1(Household and similar electrical appliances - Safety. Part 1: General requirements; - EN 50165 Electrical equipment of non-electric appliances for household and similar purposes.
  • Page 70 MICROPROCESSOR CONTROLLED SYSTEM The control system is made of the Siemens LMV central unit that performs all the burner control functions and of the Siemens AZL local programming unit that interfaces the system with the user. Keys Burner AZL2.. Air actuator Fuel actuator LMV2..
  • Page 71 The keys functions are the following: Key F Used to adjust the “fuel” actuator position (Fuel): : While pressing the F key, the “fuel” actuator position can be changed by means of the + and - keys. Key A Used to adjust the “air” actuator position (Air): While pressing the A key, the “air”...
  • Page 72 Parameters level (heating engineer)
  • Page 73 Setting menu The seeting menu is divided into different blocks: Bloc. Descrizione Description Password Internal parameters OEM / Service Informazioni generali General OEM / Service / Info Controllo bruciatore Burner control OEM / Service Controllo bruciatore (solo LMV26) Burner control (LMV26 only) OEM / Service Curve rapporto Ratio curves...
  • Page 74 Block 000: Internal Parameter Param. Descrizione Description Password Password livello assistenza (ingegnere del Password heating engineer (4 characters) calore) Password livello OEM (costruttore del brucia- Password OEM (5 characters) tore) Start backup / restore via AZL2.../ PC sof- tware (set parameter to 1) Index 0: Create backup Index 1: Execute restore Error dia- Start backup/restore via AZL2x/PC gnostics via negative values...
  • Page 75 Frequenza di rete Mains frequency 0 = 50 Hz 0 = 50 Hz Service / Info 1 = 60 Hz 1 = 60 Hz Luminosità display Display brightness Service / Info Tempo dopo il quale, se non viene premuto nessun tast il software esce dalla modalita Timeout for menu operation (default value = programmazione (valore fabbrica = 60min - 60min - range: 10 - 120 min)
  • Page 76 Numero totale di partenze (non azzerabile) Total number of startups Service / Info Volume combustibile (azzerabile da OEM) Fuel volume (resettable by OEM) Service / Info Fuel 1(secondo combustibile)Ore di eserci- Fuel 1: Operation hours resettable Service / Info zio (azzerabile da Service) Fuel 1 (secondo combustibile) Numero di Fuel 1: Number of startups resettable Service / Info...
  • Page 77 Block 200: Burner control Param. Descrizione Description Password Modalità funzionamento bruciatore ( rampa Burner operating mode (fuel train, modula- combustibile, modulante / multistadio, servo- ting / multistage, actuators, etc..) comandi, ecc.) __= non definito (cancellazione curve) __= undefined (delete curves) 1 = accensione diretta a gas (G mod) 1 = gas direct ignition (G mod) 2 = accensione tramite pilota gas con attacco...
  • Page 78 15 = gas rampa Gp1 modulante pneumatico 15 = Gp1 mod pneu without actuator senza servomotori (Gp1 mod pneu) 16 = Gp2 mod pneu without actuator 16 = gas rampa Gp2 modulante pneumatico 17 = Lo 2-stage without actuator senza servomotori (Gp2 mod pneu) 18 = Lo 3-stage without actuator 17 = olio LO 2 stadi senza servomotori 19 = G mod gas actuator only...
  • Page 79 Gas: sonda rilevazione fiamma attivo (valore Gas: active detector flame evaluation (default fabbrica = 1) value = 1) OEM / Service 0 = QRB../QRC.. 1 = ION / QRA.. Gas: Preventilazione (valore fabbrica = 1) Gas: Pre-purging (default value = 1) 1 = attivo 1 = active 0 = non attivo...
  • Page 80 Gas: Pressostato gas di minima (default = 1) Gas: Pressure switch-min input 0 = inattivo 0 = inactive 1 = pressostato gas di minima (a monte val- 1 = pressure switch-min (upstream of fuel vola V1) valve 1 (V1)) 2 = controllo perditavalvole via pressostato 2 = valve proving via pressure switch-min OEM / Service (montato tra le valvole V1 e V2)
  • Page 81 Gas: tempo pressione atmosferica controllo Gas: proving test time atmospheric pres- tenuta (valore fabbrica = 10s - range impo- sure (default value = 10s - range:0.2s - 60s) stazione:0.2s - 60s) Gas: tempo riempimento controllo tenuta Gas: proving test filling time (default value = (valore fabbrica = 3s - range imposta- 3s - range:0.2s - 10s) zione:0.2s - 10s)
  • Page 82 Olio: Intervallo 1 (valore fabbrica = 2s - Oil: Interval 1 (default value = 2s - OEM / Service range impostazione:0.2s - 60min) range:0.2s - 60min) Olio: tempo di sicurezza 2 (TSA2) (valore Oil: safety time 2 (TSA2) (default value = 3s fabbrica = 3s - range impostazione:0.2 - 10s) - range:0.2 - 10s) Olio: Intervallo 2 (valore fabbrica = 2s -...
  • Page 83 Block 300: Burner control (only with LMV26) Param. Descrizione Description Password Combustibile 1 : Modalità funzionamento bru- Fuel 1 : Burner operating mode (fuel train, ciatore ( rampa combustibile, modulante / modulating / multistage, actuators, etc..) multistadio, servocomandi, ecc.) __= non definito (cancellazione curve) __= undefined (delete curves) 1 = accensione diretta a gas (G mod) 1 = gas direct ignition (G mod)
  • Page 84 11 = olio 2 stadi con accensione tramite pilota 11 = LoGp 2-stage (LOGp 2-stage) 12 = Lo mod 2 fuel valves 12 = olio modulante con 2 valvole combusti- 13 = LoGp mod 2 fuel valves bile (LOmod 2 valvole) 14 = G mod pneu without actuator 13 = olio modulante con 2 valvole combusti- 15 = Gp1 mod pneu without actuator...
  • Page 85 Combustibile 1 - Gas: tempo di preaccen- Fuel 1 - Gas: Preignition time (default value = sione (valore fabbrica = 2s - range imposta- 2s - range: 0.2s - 60min) OEM / Service zione:0.2s - 60min) Combustibile 1 - Gas: tempo di sicurezza 1 Fuel 1 - Gas: Safety time 1 (TSA1) (default (TSA1) (valore fabbrica = 3s - range impo- value = 3s - range: 0.2 - 10s)
  • Page 86 Limite ripetizioni perdita di fiamma (valore Repetition limit loss of flame (default value= 2 fabbrica = 2 - range impostazione:1 - 2) - range:1 - 2) Fuel 1 - Gas: execution proving test (default Combustibile 1 - Gas: esecuzione controllo value= 2) tenuta (valore fabbrica = 2) 0 = no controllo tenuta...
  • Page 87 Fuel 1 - Oil: prepurging (default value = 1) Combustibile 1 - Olio: preventilazione (valore fabbrica = 1) 0 = deactivated 1 = attivo 1 = activated 0 = non attivo 0 = deactivated OEM / Service In ambito civile la norma EN267 rende obbli- WARNING: in the civil field, the prepurge is gatoria la preventilazione.
  • Page 88 Limite ripetizioni perdita di fiamma (valore Repetition limit value loss of flame (default fabbrica = 2 - range impostazione:1 - 2) value = 2 - range:1 - 2) Fuel 1 - Oil: time oil ignition (default value = Combustibile 1 - Olio: tempo iniezione olio (valore fabbr.
  • Page 89 Block 400: Setting air/fuel ratio curves Param. Descrizione Description Password Curve controllo servocomando combustibile Ratio control curve fuel actuator (F): it acces- (F): si accede alla lista dei punti da impostare ses to the parameter list of the points to be set OEM / Service (da P0 a P9) - consultare paragrafo “Imposta- (P0 to P9) - see paragrapf “Setting the curves”...
  • Page 90 Block 500: Air/fuel ratio control Param. Descrizione Description Password No-flame position fuel actuator Posizione servocomando combustibile in assenza di fiamma (no-flame) Indice 0 = posizione di sosta = 0° Index 0 = no-load position = 0° OEM / Service Indice 1 = posizione preventilazione = 0° Index 1 = prepurge position = 0°...
  • Page 91 Activation of VSD / PWM fan (PWM = Pulse- Width Modulation) Activation of VSD / PWM fan OEM / Service 0=deactived 1=actived (PWM = Pulse-Width Modulation) Parameter 544 Modulation Modulation Modulation Modulation Actuator Actuating speed param- Max. delta between the curve points eter 613 OEM / Service Actuator...
  • Page 92 Block 600: Actuators Param. Descrizione Description Password Impostazione punto di riferimento Selection of reference point Indice 0 = combustibile Index 0 = fuel Indice 1 = aria Index 1 = air 0 = chiuso (<0°) 0 = closed (<0°) 1 = aperto (>90°) 1 = open (>90°) Direzione rotazione del servocomando Actuator’s direction of rotation...
  • Page 93 Tipo di riferimento dei servocomandi index 0 = fuel (default = 0 (riferimento stan- dard) Type of referencing index 1 = air (default = 0 (riferimento stan- Index 0 = fuel dard) Index 1 = air 0 = standard 0 = standard 1 = fermo entro il raggio utile 1 = stop within usable range 2 = fermi interni (SQN1...)
  • Page 94 Configurazione uscita analogica % di carico Configuration of analog output (default value (valore fabbrica = 0) = 0) 0 = DC 0..10 V 0 = DC 0..10 V OEM / Service 1 = DC 2..10 V 1 = DC 2..10 V 2 = DC 0/2..10 V 2 = DC 0/2..10 V ATTENTION: as for SQM3x actuators, set the direction according to the acutator function.
  • Page 95 Block 700: Error history Param. Descrizione Description Password Storico errori: 701 - 725.01.codice Error history: 701 - 725.01.code Service / Info Storico errori: 701 - 725.02.codice diagnostico Error history: 701 - 725.02.diagnostic code ° Service / Info Storico errori: 701 - 725.03.classe errore Error history: 701 - 725.03.error class °...
  • Page 96 Block 900: Process data Param. Descrizione Description Password Potenza attuale (valore fabbrica = 0% - range Current output (default value = 0% - range = impostazione = 0-100%) 0-100%) Service / Info Indice 0 = combustibile Index 0 = fuel Indice 1 = aria Index 1 = air Posizione incrementale servocomandi (valore...
  • Page 97 Actuators references An incremental transducer is used to ensure position feedback. Referencing of the actuators must be performed after power-on. In addition, at the end of each shutdown in phase 10, the actuators are referenced to ensure that individual stepping errors, which could lead to shutdown, do not accumulate.

  • Page 98: Commissioning The Burner

    COMMISSIONING THE BURNER The LMV2x complete programming must be performed on units that has never been set before or reset units (e.g. spare parts). The programming procedure is performed by setting the following main parameters: if LMV.. is a spare part, insert burner ID (parameter 113) at least 4 digit. type of fuel train (parameter “201”) air/fuel ratio curvepoints (Block “400”) maximum load percentage (parameter “546”)
  • Page 99 the types of fuel trains are the following: Param. Descrizione Description Password Modalità funzionamento bruciatore ( rampa Burner operating mode (fuel train, mod / multi- comb., mod. / multistadio, servocom., ecc.) stage, actuators, etc.) __= non definito (cancellazione curve)___= __= undefined (delete curves) 1 = accensione diretta a gas (G mod) 1 = gas direct ignition(G mod) 2 = accensione tramite pilota gas con attacco...
  • Page 100 Lo 3-stage In the example the Gmod gas train has been set (Configuration “1”). Choose the fuel train by pressing ENTER, then press “+” / “-”. Press ENTER to confirm: number “1” will appear on the right side of the display.
  • Page 101 CAUTION: at the first burner adjustment, it is recommended to set the maximum output P9 at the same value (or little higher) of the ignition point, in order to safely reach point P9 next (see next paragraph). By pressing “+” the display will show: The burner is ready to startup.

  • Page 102: Warm Setting

    Warm setting Once pressed button “enter” and the chain thermostats open (X5-03 terminals), the LMV.. show Ph12.Then close the chain termostat and the unit performs the prepurge cycle (see “Phases List”) and stops at the ignition point P0 without ignition anyway. By pressing “+”, the burners lights abd the air/fuel ratio can be properly set in presence of flame.

  • Page 103: Cold Setting

    P5, keep pressing “-” unitl “Calc” is displayed. The curve will be processed again downwards point P1. Fuel deviation between two following points: 25°max. 12 press “-” to go through the lower points and check the combustion values, if necessary change the points as described above. 13 By pressing ESC, at the end of the points adjusments, the parameter “546”...
  • Page 104 BURNER STARTUP WITH LMV2x ALREADY PROGRAMMED Once the LMV turns on, the AZL display will show The burners is basically factory set. The air/fuel ratio curve is set with the maximum output point P9 a little higher or equal to P0. To adjust the burner on the plant site, adjust the maximum output point to the flow rate values really requested.
  • Page 105 Set the air/fuel ratio curvepoints as described on chapter “Programming the LMV2x” Note: the other phases are Ph60 = operation (OP= in modulation) Ph62 = travelling to shutdown Ph70 = off but in prepurge after the burntime Ph72 = travelling to postpurging Ph74 = postpurge (countdown is displayed) Press ESC the parameter “546”...
  • Page 106 Reset / manual lockout The system can be manually locked by simultaneously pressing the ENTER (InFo) button and any other button on the AZL2..This function allows the user to stop the system from the operating level should an emergency occur. When making a reset, the following actions are carried out: Alarm relay and the fault display are off ...
  • Page 107 Entering the Parameter levels By means of a proper use of the keys, it is possible to enter the various level parameters, as shown in the following flow chart: The burner and consequently the LMV2x.. are factory set; the air and fuel curves as set as well.
  • Page 108 Info level To enter the Info level, proceed as follows: in any menu position, press keys + and - at the same time, then the program will start again: the display will show OFF. , until the display will show InFo, Press the enter (InFo) key then il will show the first code (167) flashing, on the right side it will show the data entered.
  • Page 109 10 Press InFo for more than three seconds or for more than three seconds orto return to the normal display. If a message like the one below is shown during operation, it means that the burner is locked out and the Errore code is shown (in the example “error code:4”); this message is alternating with another message Diagnostic code (in the example “diagnostic code:3”).
  • Page 110 Service level To enter the Service mode, press InFo until the display will show: The service level shows all the information about flame intensity, actuators position, number and lock codes: Parameter Description Flame intensity % output, if set = automatic operation Actuators position, 00=combustibile;...
  • Page 111 PHASES LIST Fase /Phase Funzione Function Ph00 Fase blocco Lockout phase Ph01 Fase di sicurezza Safety phase Ph10 t10 = tempo raggiungimento posizione riposo t10 = home run Ph12 Pausa Standby (stationary) t22 = tempo di salita ventilatore (motore ventilatore t22 = fan ramp up time (fan motor = ON, safety Ph22 = ON, valvola intercettazione di sicurezza = ON)
  • Page 112 BACKUP PARAMETER WITH AZL2x On the AZL2x you can save the configuration to download on another appliance LMV. To do this: access up, press F and A at the same time enter the password following the procedure on chapter “Programming LMV2x”. Press ENTER until the display will show: with the button go to the group 000 of the parameters and press...
  • Page 113 RESTORE PARAMETER FROM AZL2x TO LMV.. To copy the previously saved configuration on AZL2x proceed as follows: access up, press F and A at the same time enter the password following the procedure on chapter “Programming LMV2x”. Press ENTER until the display will show: To copy the configuration from AZL2x to LMV.
  • Page 114 ERROR CODE TABLE...
  • Page 129 WIRING DIAGRAM Wiring connection for LMV20 Electrical supply Burner flange Fanmotor input Safety loop Lokout signal Continuous fan operator Valve External valveSV gnition transformer Valve Operation sgnal Reset Reserve Common Increase output Pressure switch leakage test Decrease input gasPGCP ON/OFF thermosta Minimum gas pressure switch Air pressure switch LUFT...
  • Page 130 Wiring variants for LMV27 ConnectorX75 2 - Fuel meter input 1 - Supply fuel meter ConnectorX5-02 ConnectionsPmax...
  • Page 131 Wiring variants for LMV26 ConnectorX08-04 / X09-04 2 - Fuel 0 1 - Fuel1 ConnectorX75 2 - Fuel meter input 1 - Supply fuel meter ConnectorX64 5 -Power supply speed sensor 4 -Speed sensor input 3 - PWM (Pulse Width Modulation) speed output 2 - GND (signal reference) 1 -Controller input (4÷20mA) ConnectorX74...
  • Page 132 Wiring variants for LMV37 ConnectorX75 2 - Fuel meter input 1 - Supply fuel meter ConnectorX5-02 Connections Pmax ConnectorX64 5 -Power supply speed sensor 4 -Speed sensor input 3 - PWM (Pulse Width Modulation) speed output 2 - GND (signal reference) 1 -Controller input (4÷20mA) ConnectorX74 5 -Supply...
  • Page 136 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 and data subject to change. Errors and omissions excepted.

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