CIB UNIGAS K750A Manual Of Installation - Use - Maintenance
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CIB UNIGAS K750A Manual Of Installation - Use - Maintenance

Gas-light oil burners
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K750A
K890A
K990A
LMV5x
Microprocessor controlled
Gas - Light oil burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039663CA 0.1 02/2023

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Summary of Contents for CIB UNIGAS K750A

  • Page 1 K750A K890A K990A LMV5x Microprocessor controlled Gas - Light oil burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039663CA 0.1 02/2023...

  • 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 PART I: SPECIFICATIONS PART I: SPECIFICATIONS BURNERS FEATURES Note: the figure is indicative only Control panel with startup switch Gas train Electrical panel Cover Photocell Blast tube + Combustion head Flange Actuator Silcencer 10 Air pressure switch 11 Combustion head adjusting screw 12 Oil manifold 13 Actuator 14 Pump...

  • Page 6: Burner Model Identification

    Burners are identified by burner type and model. Burner model identification is described as follows. Type K750A Model MD. SR. BURNER TYPE K750A- K890A - K990A MG - Natural gas-Light oil - LG - LPG-Light oil FUEL OPERATION (Available versions) MD - Fully modulating - PR - Progressive BLAST TUBE...

  • Page 7: Technical Specifications

    Technical Specifications K750A M- K890A M- K990A M- K750A L- K890A L- K990A L- BURNER TYPE 880 - 7500 1000 - 8900 1820 - 9900 880 - 7500 1000 - 8900 1820 - 9900 Output min. - max. kW MG - Natural gas-Light...
  • Page 8 Overall dimensions (mm) Boiler recommended dril- ling template Burner flange TIPO (AS) (BS) 1672 1695 1728 1002 1808 1082 2073 1347 1192 1672 1695 1745 1215 1728 1002 1808 1082 2073 1347 1192 1672 1695 1728 1002 1808 1082 2073 1347 1192...
  • Page 9 Overall dimensions (mm) K990A MG.MD.SR.RU.A.8.80.ES 1923 1393 1036 1093 1727 Burner flange Boiler recommended drilling template...
  • Page 10 PART I: SPECIFICATIONS Fig. 4 - 3I2MG-23 v0 Hydraulic diagram By others By burner constructor oil inlet oil outlet 19.1 combustion air M 48 gas inlet NOTE: The following items are optional: 19, 19.1, 20, 40, 41, 46 NOTE: The following items are included only on certain types of burner: 5,7,9,11,17 Flexible hose Flexible hose Manual valve...

  • Page 11: Performance Curves

    Potenza kW Data are referred to standard conditions: atmospheric pressure at 1013 mbar, ambient temperature at 15° C. Performance Curves K750A MG K890A MG K990A MG 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 12 Power kW Potenza / Output (kW) Pressure in the Network / gas flow rate curves (natural gas) K750A MG K890A MG K990A MG ATTENTION: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis (pressure value in the combustion chamber is not included).
  • Page 13 PART I: SPECIFICATIONS The values in the diagrams refer to GPL with a calorific value of 22300 kcal/Stm (15°C, 1013 mbar) and a density of 2.14 kg/ . When the calorific value and the density change, the pressure values should be adjusted accordingly. Natural gas pressure shown in diagram Where: Real gas pressure...
  • Page 14 PART I: SPECIFICATIONS Gas pressure burner head vs natural gas flow rate Curves are referred to pressure = 0 mbar in the combustion chamber! K750A K890A K990A The values in the diagrams refer to natural gas with a calorific value of 8125 kcal/Stm (15°C, 1013 mbar) and a density of...
  • Page 15 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 16 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 17 PART II: INSTALLATION GAS TRAIN CONNECTIONS WARNING: before executing the connections to the gas pipe network, be sure that the manual cutoff valves are closed. ATTENTION: it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the valves, during maintenance and cleaning operation of the filters (both the filters outside the valves group and the ones built-in the gas valves).

  • Page 18: Assembling The Gas Train

    PART II: INSTALLATION MultiBloc MB-DLE - Assembling the gas train Mounting Mount flange onto tube lines: use appropriate sealing agent Insert MB-DLE: note position of O rings Remove MultiBloc between the threaded flanges After installation, perform leakage and functional test Disassembly in reverse order MB-DLE 405..
  • Page 19 PART II: INSTALLATION DUNGS MBE Components and position of pressure switches PGMIN minimum gas pressure switch VD-V VD-R PGMIN minimum gas pressure switch (alternative VD-V VD-R to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded) Valve body (Flange)
  • Page 20 PART II: INSTALLATION Siemens VGD20.. e VGD40.. Components and position of pressure switches PGMIN minimum gas pressure switch SKP25 SKP25 PGMIN minimum gas pressure switch (alternative SKP15 SKP15 to 1) PGCP leakage control gas pressure switch PGMAX maximum gas pressure switch Actuator with integrated pressure stabiliser On-Off actuator Valve body (Threaded)
  • Page 21 PART II: INSTALLATION Siemens VGD Pressure taps Strainer (G 1/4") (G 1/8") (G 1/4") (G 3/4") (G 1/8") (G 1/4") (G 1/8") Legend pi Inlet pressure pm Pressure between valves po Outlet pressure OIL TRAIN CONNECTIONS Hydraulic diagrams for light oil supplying circuits GRAVITY CIRCUIT RING CIRCUIT 1 Manual valve...
  • Page 22 PART II: INSTALLATION Installation diagram of light oil pipes please read carefully the “warnings” chapter at the beginning of this manual. Fig. 3 - 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 Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could depo-  sit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) jun- ctions if possible.

  • Page 24: Electrical Connections

    PART II: INSTALLATION ELECTRICAL CONNECTIONS WARNING! Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse the phase and neutral connections. fit a differential thermal magnet switch adequate for connection to the mains. WARNING! before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be sure that the burner’s main switch is in 0 position (OFF) too.
  • Page 25 PART II: INSTALLATION BURNERS WITH INVERTER VARIANT (if provided) Type Model XXXXX M-. MD. xx. xx. x. x. xxx. EI. XXXXX M-. MD. xx. xx. x. x. xxx. EG. LMV5 DANFOSS XXXXX MG. MD. xx. xx. x. x. xxx. EK. XXXXX MG.
  • Page 26 PART III: OPERATION PART III: OPERATION DANGER! Incorrect motor rotation can seriously damage property and injure people. DANGER: 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 gas decrease slowly until the normal combustion values are achieved.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”.

  • Page 27: Gas Operation

    PART III: OPERATION K750A - Burner front panel Keys B1 Lock-out LED B2 Hi-flame operation LED B3 Lo-flame operation LED B4 “Ignition transformer operation” LED B7 Burner ignition LED G1 “EV2 opening” LED G2 “EV1 opening” LED G3 “Gas pressure switch signal ” LED...

  • Page 28: Start-Up Procedure

    PART III: OPERATION 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.  Test space evacuating: EV2 valve (burner side) opens and keep this position for a preset time ...
  • Page 29 PART III: OPERATION Setpoint 80°C Act.value 78°C Fuel Standby Main page check the fan motor rotation (see related paragraph). make the safety chain enabling the system to start up the combustion cycle starts: the system will show the operating stages - Prepurging (program phase no.30) - Driving to ignition position (program phase no.36) - Ignition position (program phase no.38)

  • Page 30: Fault History

    PART III: OPERATION By pressing the ESC key once, the Operational Status (first item in the main menu) menu is directly shown: Normal operation Status/Reset Fault History Lockout History the Operational Status menu provides the following items: Normal operation: by selecting this item and pressing the ENTER key, the main page is showed; press ESC to go back to the main menu.
  • Page 31 PART III: OPERATION From the main page, enter the main menu by pressing the ESC key twice: OperationalStat Operation ManualOperation Params & Display by means of the arrow keys, select “Params&Display”, press ENTER: the system will ask you to enter the proper password Access w-out PW Access Serv Access OEM...
  • Page 32 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 33: System Lockout

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

  • Page 34: Manual Mode

    PART III: OPERATION call the Technical Service and tell the message data. Cold start thermal shock (CSTP) If the generator cannot suffer thermal shocks, the CSTP (Cold Start Thermal Schock) function can be enabled. This function is already set by the Technical service (access by reserved password). if this function is enabled, when the burner starts upthe “Thermal shock protection activated”...

  • Page 35: Adjustments For Gas Operation

    PART III: OPERATION ADJUSTMENTS FOR GAS OPERATION Air flow and gas adjustment startup the burner by selecting GAS by means of the switch on the burner control panel  Adjust the air and gas flow rates, in according to the “air/gas ratio” curvepoints setting procedure on the LMV manual,. Check con- ...
  • Page 36 PART III: OPERATION ADJUSTING THE GAS VALVES GROUP Multibloc MB-DLE The multibloc unit is a compact unit consisting of two valves, gas pressure switch, pressure stabilizer and gas filter. C VS The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns.
  • Page 37 PART III: OPERATION Calibration air and gas pressure switches The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of the control box unlock pushbutton, placed on the bur- ner control panel.
  • Page 38 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 39 PART III: OPERATION Adjustment procedure for light oil operation The light oil flow rate can be adjusted choosing a by-pass nozzle that suits the boiler/utilisation output and setting the delivery and return pressure values according to the ones quoted on the table below and the diagram on Fig. 20 (as far as reading the pressure values, see next paragraphs).
  • Page 40 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 41 PART III: OPERATION Minimum oil pressure switch (when provided) The minimum oil pressure switch on the inlet line, checks that the pressure does not drop below a default value. The pressure switch must be set, say, at 10% under the pressure at the nozzle. Maximum oil pressure switch The oil pressure switch on the return line, checks that the pressure does not exceed a default value.
  • Page 42 PART III: OPERATION Center head holes gas flow regulation (natural gas burners) 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 43 PART IV: MAINTENANCE PART IV: MAINTENANCE WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND THE FUEL MANAUL CUTOFF VALVES CLOSED! ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL. 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;...
  • Page 44 PART IV: MAINTENANCE Thecnical procedure of self cleaning filters substitution (valid for all models) 1 Close the bowl valve before the self cleaning filter 2 Switch off any electrical equipment on board on the filter (example motorization or heaters) WARNING! Drain the system by unscrewing the drain screw on the bottom of the self cleaning filter 3 Disconnect the outlet pipe from the cover of the self cleaning filter 4 Remove the cover with all the filter pack, leaving only the bowl on the line 5 Clean any residue on the bottom of the bowl and clean the seat of the O-ring seal...

  • Page 45: Electrodes Adjustment

    PART IV: MAINTENANCE Removing the combustion head Remove the top H. Remove the UV detector out of its housing: disconnect electrode cables and the light oil flexible hoses. Loosen the screws V holding the gas manifold G, loosen the connectors E. Some models are provided with the T baffle.
  • Page 46 PART IV: MAINTENANCE Replacing the ignition electrodes ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boi- ler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. electrodes - type A To replace the ignition electrodes, proceed as follows:...

  • Page 47: Seasonal Stop

    PART IV: MAINTENANCE Checking the detection current To check the detection signal follow the scheme in the picture below. If the signal is less than the value indicated, check the position of the detection electrode or detector, the electrical contacts and, if necessary, replace the electrode or the detector. Minimum detection signal: 3.5Vdc Fig.
  • Page 48 PART IV: MAINTENANCE TROUBLESHOOTING GUIDE Gas operation * No electric power supply * Restore power supply * Main switch open * Close switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Reset or replace the thermostat * No gas pressure * Restore gas pressure...
  • Page 49 PART IV: MAINTENANCE TROUBLESHOOTNG GUIDE Light oil operation * No electric power supply * Wait for electric power supply is back * Main switch open * Close the switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Set or replace the thermostat * No gas pressure * Restore gas pressure...
  • Page 52 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 53 Siemens LMV5x Service Manual M12920CC rev 2.1 08/2017...
  • Page 54 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 55     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 56: 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 57 .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 58 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 59 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 61 1.4.1 Servomotor wiring example 1.4.2 Bus cable wiring on LMV5x and AZL doors. 1.4.3 EARTH connection example...
  • Page 62 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 63 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 64 LMV5x program structure...
  • Page 65 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 66: Changing Password

    Password 2.4.1 Access to service levels by password Depending on password (service or OEM), different parameters are visible. "Service" parameters, as per the actuator curves and the set-point values, are password protected. The operator must logon using the "9876" password. "User"...
  • Page 67 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 68 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 69 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 70 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 71 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 72 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 73 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 74: 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 75 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 76 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 77 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 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 86 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 87 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 88 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 89 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 90 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 92 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 93 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 94 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 95 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 96 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 97 (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 100 Note: Specifications and data subject to change. Errors and omissions excepted.
  • Page 101 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 102 Annex1 – Example for motor cable...
  • Page 104 Annex 2 – Example for sensor cable...
  • Page 107 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 108 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 109 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 111: Control Panel

    Example 2 LMV5... basic unit in the control panel, actuator on the burner; CAN bus cable «LMV5... → SA» > 20 m Jumper Control panel Burner ACT 1 ACT 2 ACT 3 ACT 4 Fixed internal bus termination SQM4... SQM4... SQM4...
  • Page 112 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 113 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 114: Inputs And Outputs

    O2 module In comparison with the LMV51... system, the extra components to be connected with the LMV52… system are the O module and the O sensor QGO... and, optionally, the combustion air and flue gas temperature sensors. The O module is to be connected to the basic unit via the CAN bus.
  • Page 116      8      8      8...
  • Page 117 ß ß ß...
  • Page 118 ©...
  • Page 119 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 120 PLL52... Flue gas temperature X86.3 Shield connection Temperature sensor X86.1 Pt / LG-Ni1000 PLL52... Pt / LG-Ni1000 X86.2 Signal reference X89-01.4 Protective earth (PE) Supply air temperature X89-01.5 Power supply neutral X87.3 conductor (L) Shield connection F 6.3AT Temperature sensor X87.1 X89-01.6 Power supply live Pt / LG-Ni1000...

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