CIB UNIGAS RX2050 - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The RX2050 is a series of microprocessor-controlled gas burners designed for various heating applications, including industrial and civil heating systems, and sanitary hot water generation. These burners are equipped with LMV 5x control systems and are available in versions that include Flue Gas Recirculation (FGR) for enhanced efficiency and reduced emissions.

Function Description

The RX2050 gas burners operate by drawing gas fuel through a gas train, which includes a filter, safety valves, a gas pressure regulator, and a butterfly valve. The pressure regulator ensures the gas pressure remains within the combustion head's operational limits. Air is supplied by a fan, which can be either onboard or separate depending on the burner configuration, and is channeled through an air damper.

Both the air damper and the gas butterfly valve are actuated by servomotors, which adjust according to pre-programmed load curves. This precise control ensures the correct proportion of fuel and air flows, optimizing flue gas parameters and combustion efficiency. The adjustable combustion head further refines burner performance by controlling flame geometry.

Fuel and air are routed through separate channels within the combustion head before mixing and igniting inside the combustion chamber. Ignition is initiated by electrodes that generate a high-voltage spark; some configurations may also utilize a pilot flame. Pre-ventilation of the combustion chamber is typically implemented in accordance with gas directives. An onboard or separate control panel allows the operator to monitor each operating phase of the burner.

For FGR versions, flue gas is recirculated to the combustion air to reduce NOx emissions. The FGR system includes a stainless steel FGR pipe, a bellow unit, and an FGR butterfly valve, all managed by the LMV 5x control system. Temperature probes for flue gas temperature compensation are installed on the chimney to ensure accurate control.

The LMV5x control system is a sophisticated microprocessor-based unit that manages and monitors all burner functions. It allows for precise control of air/fuel ratio curves, special positions (ignition, prepurge, home, postpurge), and load control. The system can be configured for internal or external load control, and supports various temperature and pressure probes. It also features an integrated proving system for gas valves and can manage variable speed drives (VSD) for fan motors, further optimizing energy consumption and combustion.

Important Technical Specifications

The RX2050 series offers a wide output range, from 2500 to 15200 kW for standard models and 2500 to 12160 kW for FGR models. It operates on natural gas with a gas rate of 265 to 1608 Stm³/h (standard) and 265 to 1287 Stm³/h (FGR). The maximum gas pressure is 500 mbar.

The burners require a three-phase power supply (V400V 3N ~ 50Hz) with a total power consumption of 37.5 kW and an electric motor power of 37.0 kW. The protection rating is IP40. The operating temperature range is -10°C to +50°C, and storage temperature is -20°C to +60°C. The burners are designed for continuous working service.

Gas train connections are available in 3" / DN80, 4" / DN100, and 5" / DN125, depending on the model. The burners are suitable for indoor operation with a maximum relative humidity of 80%. For safety reasons, burners with electrodes must stop automatically every 24 hours.

The LMV5x control system supports various configurations, including:

Micro-processor control: ES (no O2 trim, no VSD), EI (no O2 trim, with VSD), EK (with O2 trim, with VSD).
FGR versions: EF (LMV5x, temperature-compensated FGR, no O2 monitoring, no inverter), EG (electronic cam, inverter, temperature-compensated FGR, no O2 monitoring), ER (electronic cam, inverter, temperature-compensated FGR, with O2 monitoring).

Usage Features

The RX2050 burners are designed for user-friendly operation with a control panel that provides access to various menus and parameters. Operators can monitor operating phases, check system status, and adjust settings. The LMV5x system allows for password-protected access levels (user, service, OEM) to prevent unauthorized changes to critical parameters.

Key operational phases include:

Start-up: The AZL display guides the operator through system tests, prepurging, driving to ignition position, ignition, fuel release, and driving to low flame.
Load control: The burner can operate in automatic, manual, or standby modes. In manual mode, a fixed load percentage can be set.
Air/fuel ratio curves: These curves are factory-set but can be adjusted by qualified personnel during commissioning to optimize combustion efficiency and emissions. The system supports up to 10 curve points for precise control across the load range.
Special positions: Ignition, prepurge, home, and postpurge positions for actuators can be set to ensure safe and efficient operation.
Cold start thermal shock protection (CSTP): This function, if enabled, allows for a slow heating process to prevent thermal shocks in steam boilers or other generators, maintaining the burner at minimum output during startup.

Maintenance Features

Routine maintenance is crucial for the longevity and safe operation of the RX2050 burners. It is recommended to perform maintenance at least once a year, or every 6 months for continuous operation. All maintenance operations must be carried out with the mains disconnected and fuel cutoff valves closed.

Key maintenance tasks include:

Cleaning: Regularly clean the fan, air box, protective mesh, and screw conveyor to ensure free airflow.
Combustion head inspection: Check the combustion head for integrity, ensuring all parts are intact and the mesh is adhered. Replace the head or nozzle if damaged.
Electrode examination: Inspect ignition and detection electrodes, clean them, adjust if necessary, and replace if worn.
Gasket replacement: Replace the gasket between the combustion head and burner body flange, and between the burner and generator, if necessary.
Gas filter maintenance: Check and clean the gas filter cartridge at least once a year, or more frequently if the pressure difference across the filter exceeds 10 mbar. Replace the cartridge if needed.
Actuator inspection: Check the condition of the motor and replace bearings if abnormal noises occur.
Gas train inspection: If gas train parts are disassembled for maintenance, a gas proving test must be performed after reassembly.

The LMV5x system also provides diagnostic tools, including a fault history and lockout history, which can assist in troubleshooting and identifying recurring issues. These features help service personnel diagnose problems efficiently and ensure the burner operates within safety parameters.