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Unigas R92 Installation Manual

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Microprocessor controlled
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
R91
R92
R93
R512
R515
R520
R525
LMV5x
Gas burners
M039560CA 0.0 02/2021

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Summary of Contents for Unigas R92

  • Page 1 R512 R515 R520 R525 LMV5x Microprocessor controlled Gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039560CA 0.0 02/2021...

  • Page 2: General Introduction

    DANGERS, WARNINGS AND NOTES OF CAUTION THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER. INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.

  • Page 3: Directives And Standards

    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: Symbols Used

    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 Note: the figure is indicative only Control panel with startup switch Gas train Electrical panel Cover Blast tube + Combustion head Flange Silcencer Actuator Air pressure switch 10 Combustion head adjusting ring nut Gas operation: the gas coming from the supply line, passes through the valves group provided with filter and governor. This one forces the pressure in the utilisation limits.

  • Page 6: Burner Model Identification

    Burners are identified by burner type and model. Burner model identification is described as follows. Type Model MD. S. BURNER TYPE R91, R92, R93, R512, R515, R520, R525 FUEL M - Natural gas B - Biogas L - LPG OPERATION (Available versions)

  • Page 7: Technical Specifications

    PART I: SPECIFICATIONS Technical Specifications BURNER TYPE R91 M-.. R92 M-.. R93 M-.. 480 - 2670 480 - 3050 550 - 4100 Output min. - max. kW Natural gas Fuel see next paragraph Category 51 - 283 51 - 323...
  • Page 8 PART I: SPECIFICATIONS BURNER TYPE R91 L-.. R92 L-.. R93 L-.. 480 - 2.670 480 - 3.050 550 - 4.100 Output min. - max. kW Fuel Category 3B/P 17.9 - 100 17.9 - 114 20 - 153 min.- max. (Stm...
  • Page 9 PART I: SPECIFICATIONS BURNER TYPE R512 L-.. R515 L-.. R520 L-.. R525 L-...50 R525 L-...xx 600 - 4.500 770 - 5.200 1.000 - 6.400 2.000 - 6.700 2.000 - 8.000 Output min. - max. kW Fuel Category 3B/P 22 - 167 28 - 194 37 - 238 74 - 250...
  • Page 10 Overall dimensions (mm) O min O max Burner flange Boiler recommended drilling tem- plate AA AD AN Omin Omax 1356 136 35 550 100 441 866 506 1160 435 265 295 228 450 360 464 M12 424 300 532 148 384 624 190 649 228 185 1356 136 35 564 117 441 866 506 1406...
  • Page 11 Burner flange Boiler recommended drilling template R512 1499 1590 R512 1499 1613 R512 1499 1646 1002 R512 1499 1726 1082 R515 1499 1590 R515 1499 1613 R515 1499 1646 1002 R515 1499 1726 1082 R520 1499 1590 R520 1499 1613 R520 1499 1646...
  • Page 12 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 13 PART I: SPECIFICATIONS Performance CurvesPerformance Curves 1200 1600 2000 2400 2800 3200 1200 1600 2000 2400 2800 R512 500 1000 1500 2000 2500 3000 3500 4000 4500 1500 2500 3500 4500 R515 R520 1500 2500 3500 4500 5500 6500 7500 1500 2500 3500...
  • Page 14 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves (natural gas) R91 M-.. R92 M-.. R93 M-.. R512 M-.. R515 M-.. R520 M-.. R525 M-.. Rp2 R525 M-.. DN65-80-100 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 15 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves(LPG) R91 L-.. R93 L-.. R512 L-.. R520L-.. 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). 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 16 PART I: SPECIFICATIONS Combustion head gas pressure curves Combustion head gas pressure depends on gas flow and combustion chamber backpressure. When backpressure is subtracted, i depends only on gas flow, provided combustion is properly adjusted, flue gases residual O2 percentage complies with “Recommended combustion values”...
  • Page 17 Curves are referred to pressure = 0 mbar in the combustion chamber! R91 M-.. R92 M-.. 100 120 140 160 180 200 220 240 260 280 300 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 R93 M-..
  • Page 18 PART I: SPECIFICATIONS Pressure - rate in combustion head curves (LPG) Curves are referred to pressure = 0mbar in the combustion chamber! R91 L-.. R93 L-.. 100 110 120 130 140 150 160 R512 L-.. R520 L-.. 1 0 0 1 2 5 1 5 0 1 7 5...

  • Page 19: Transport And Storage

    PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Transport and storage ATTENTION! The equipment must be installed in compliance with the regulations in force, following the manufac- turer’s instructions, by qualified personnel. All handling operations must be carried out with appropriate resources and qualified personnel ATTENTION: Use intact and correctly dimensioned hoisting equipment, conforms to the local regulations and health and safety regulations.
  • Page 20 PART II: INSTALLATION Fitting the burner to the boiler To install the burner into the boiler, proceed as follows: make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; place the 4 stud bolts (5) on boiler’s door, according to the burner drilling template described on paragraph “Overall dimensions”;...
  • Page 21 PART II: INSTALLATION GAS TRAIN CONNECTIONS The diagrams show the components of the gas train included in the delivery and which must be fitted by the installer.The diagrams are in compliance with the current laws. Note: the figure is indicative only ”direction”...

  • Page 22: Gas Inlet

    PART II: INSTALLATION Gas train with valves group MB-DLE (2 valves + gas filter + pressure governor) BY OTHERS BY BURNER CONSTRUCTOR GAS INLET Gas train with valves group VGD with built-in gas pressure governor BY OTHERS SUPPLIED BY BURNER GAS INLET Gas train with valves group MB-DLE (2 valves + gas filter + pressure governor + pressure switch) + gas leakage pressure switch (PGCP)
  • Page 23 PART II: INSTALLATION Siemens VGD20.. e VGD40.. Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) - Connect the reference gas pipe (TP in figure; 8mm-external size pipe supplied loose), to the gas pressure nipples placed on the gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size.
  • Page 24 PART II: INSTALLATION MultiBloc MBE Example of gas train MBE ALLA V. FARFALLA 501939 GAS BRUCIATORE ø185 VD-R VD-V VD-R VD-V Gas filter PGMAX PGMAX PGMIN PGMIN PS pressure sensor PGCP PGCP VD-V VD-R Gas filter PGMIN PGCP PGMAX To mount the gas train, proceed as follows: 1) in case of threaded joints: use proper seals according to the gas used;...
  • Page 25 PART II: INSTALLATION Threaded train with MultiBloc MBE - Mounting 1. Mount flange into pipe systems. Use appropriate sealing agent. 1. Insert studs A. 2. Insert VB together with supplied O-rings. 2. Insert seals B. Check current position of O-rings. 3.

  • Page 26: Mounting Positions

    PART II: INSTALLATION MultiBloc MB-DLE - Assembling the gas train F”direction” arrows for gas supply network installation Keys 1 Gasket 2 Gas filter 3 Gas valves group 4 Bellows unit 41Manual valve MULTIBLOC DUNGS MB-DLE 405..412 Mounting 1. Mount flange onto tube lines: use appropriate sealing agent (see Fig. 12); 2.
  • Page 27 PART II: INSTALLATION 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 28: 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 29: Limitations Of Use

    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 30: Gas Operation

    PART III: OPERATION Fig. 13 - Burner front panel Keys Lock-out LED Hi-flame operation LED Lo-flame operation LED “Ignition transformer operation” LED “Fan motor overload tripped” LED “EV2 opening” LED “EV1 opening” LED “Gas pressure switch signal ” LED Main switch Operation selector MAN - AUTO (operation in manual or automatic mode): MIN = operation with minimum output MAX = operation at the maximum output...

  • Page 31: Start-Up Procedure

    PART III: OPERATION AIR FLOW AND FUEL ADJUSTMENT WARNING! During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation of carbon monoxide); if this should happen, make the fuel decrease slowly until the normal combustion values are achieved.

  • Page 32: Fault History

    PART III: OPERATION Act value: actual temperature value Load: load percentage (burner output) Flame: percentage of flame detection current. By pressing the ENTER key the display shows the second page: Fuel Second page Fuel: it shows (in degrees) the fuel actuator position. Air: it shows (in degrees) the air actuator position.
  • Page 33 PART III: OPERATION alternating by an error message as: O2 control and limiter automat deactivated To see the other Fault History pages, press the arrow keys. To exit the Fault History pages, press ESC. Lockout History To visualise the Lockout History, choose the related item and press ENTER. The message will be: 10.08.07 13.47 C:71...
  • Page 34 PART III: OPERATION ControllerParam Configuration Adaption SW Version Choose “ControllerParam” and press ENTER: the following menu is shown: ContrlParamList MinActuatorStep SW_FilterTmeCon SetPointW1 Choose “SetPointW1” and press ENTER: SetpointW1 Curr: 90° New: 90° Curr: it shows the current set-point; use the arrows keys to change. NOTE: the availabel range for this parameter depends on the probe provided;...
  • Page 35 PART III: OPERATION the display will show: SD_ModOff Curr:: 10.0% New: 10.0% The deafult value for this parameter is10% that is, the burner will turn off at a temperature 1% higher than the set-point. Change value, if needed, by means of the arrow keys; press ENTER to confirm and the press ESC to exit. Press only ESC to exit without changing.

  • Page 36: System Lockout

    PART III: OPERATION DateFormat Curr:: DD-MM-YY New: MM-DD-YY choose the desired format and cofirm by pressing ENTER; press ESC to exit. PhysicalUnits: it allows setting the measuring units for temperature and pressure UnitTemperature UnitPressure Settable temperature units: °C or °F Settable pressure units: bar or psi.
  • Page 37 PART III: OPERATION SetLoad Curr:: 0.0% New: 20.0% set the required percentage and confirm by pressing ENTER; press ESC to exit. choose “Autom/Manual/Off SetLoad Autom/Manual/Off Autom/Manual/Off Automatic Curr:: New: Burner On three modes are provided: Automatic: automatic operation Burner on: manual operation Burner off: burner in stand-by If the BurnerOn mode is choosen,the burner does not follow the modulator and probe settings, but operates at the set load.

  • Page 38: Assembling The Gas Train

    PART III: OPERATION MultiBloc MB-DLE - Assembling the gas train Note: the figure is indicative only ”direction” arrows for gas supply network installation Keys Gasket Gas filter Gas valves group Bellows unit Manual valve MULTIBLOC DUNGS Mounting Mount flange onto tube lines: use appropriate sealing agent MB-DLE 405..412 Insert MB-DLE: note position of O rings MB-DLE 415..420...

  • Page 39: Pressure Taps

    PART III: OPERATION MultiBloc MBE Regulation VD-R whith PS Setting scale is „Not“ linear! Various sensors available. Output pressure according to sensor‘s measuring range. Increasing pressure Adjust the outlet pressure to the value specified by the burner or equipment manufacturer! While making outlet pressure adjustments, do not exceed a value that creates a hazardous condition to the burner! Decreasing pressure...
  • Page 40 PART III: OPERATION Pressure taps 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 41 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 42: Routine Maintenance

    PART IV: MAINTENANCE PART IV: MAINTENANCE At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6 months.
  • Page 43 PART IV: MAINTENANCE Adjusting the gas valves group and removing the filter MB-DLE MB-DLE 415 - 420 B01 405..412 0 CoperFKLR GHO ¿OWro 1,3,4,6 TDSSR D YLWH *  2 AWWDFFR PLVXrDWRre 5 TDSSR D YLWH 0 0, 1, 2, 3, 4, 5 7DSSR D YLWH *  Prese di pressione Prese di pressione...
  • Page 44 PART IV: MAINTENANCE Removing the combustion head Remove the cover C.  Remove the electrodes cables;  Unscrew the 3 screws V which hold in position the gas manifold G.  Some models are provided with the T baffle. Move the gas manifold ahead and remove the baffle. ...
  • Page 45 PART IV: MAINTENANCE Adjusting the electrodes 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.), otherwise the boi- ler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. The gap between the ignition electrode and the grounded electrode must be 4mm (see figure).

  • Page 46: Seasonal Stop

    PART IV: MAINTENANCE 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. - The burner status is considered to be at its limit if it is technically impossible to continue using it due to non-compliance with safety requirements or a decrease in performance.
  • Page 47 PART IV: MAINTENANCE TROUBLESHOOTNG 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 48 PART IV: MAINTENANCE Removing the combustion head Remove the cover C.  Remove the electrodes cables;  Unscrew the 3 screws V which hold in position the gas manifold G.  Some models are provided with the T baffle. Move the gas manifold ahead and remove the baffle. ...
  • Page 49 PART IV: MAINTENANCE Minimum detection signal: 3.5Vdc Fig. 17 - Detection with detector QRI... 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. - The burner status is considered to be at its limit if it is technically impossible to continue using it due to non-compliance with safety requirements or a decrease in performance.
  • Page 50 PART IV: MAINTENANCE TROUBLESHOOTNG 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 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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