ZANTINGH RKB User manual

YOU CAN COUNT ON OUR EXPERTISE
OPERATING AND
INSTRUCTION MANUAL
ZANTINGH
FORCED GAS BURNER
RKB –LMV5 & 7”-TOUCHSCREEN

Page. 2
LMV5000.EN202001V6
\
IMPORTANT read this first!
The operating instructions are an integral part of the product. The instructions contain
important information on the commissioning, usage and operation of the product.
Please read the operating instructions carefully.
The guarantee becomes null and void if the operating instructions are not followed.
Zantingh B.V. cannot be held liable for these damages.
Store this manual carefully near the system!
Contents: Page
1. INTRODUCTION 3
2. REGULATION 3
3. IMPORTANT NOTES 3
3.1 Maintenance 4
3.2 Instruction manual instructions 4
4. SYSTEM COMPONENTS 5
4.1 Burner component 5
4.2 Air fan component 5
4.3 Gas train 5
4.4 Pilot gas line 6
4.5 Control panel 7
4.6 Control switches and reset buttons on the control panel 7
4.7 Frequency control 7
5. START SEQUENCE 8
6. SIEMENS BURNER CONTROL LMV5x OPERATION 10
6.1 AZL display description and operation 11
6.2 Operation 7” touch screen 16
6.3 Settings for limited maximum load via the touch screen 21
7. BURNER FAILURE REPORT 22
8. TROUBLESHOOTING 26
9. SWITCH FROM GAS TO OIL AND BACK (If applicable) 27
11. WARRANTY CONDITIONS 30

Page. 3
LMV5000.EN202001V6
1. INTRODUCTION
Dear Customer,
We would like to thank you for purchasing our product.
We provide this manual to ensure the distribution of all important information for your
safety, optimal profit and product lifetime.
Please read the instructions carefully before installing or operating the product.
The safety and instructions in this manual must be followed to ensure that
installation, commissioning, operation and maintenance are safe and in accordance
to (local) standards and regulations..
Our technical department can provide additional information and support.
If you have any questions, please contact us.
Phone general: [phone]
Phone service: [phone]
E-mail: [email protected]
2. REGULATION
BELANGRIJK:
IMPORTANT:
A certified heating or electrical installer should instal the product. The instructions
meet the applicable (local) standards and regulations. Please contact your Zantingh
representative or local service department in case of doubt.
3. IMPORTANT NOTES
-Commissioning a Zantingh burner ought to be performed with the utmost
precision and by Zantingh authorized personnel.
-Any commissioning work or change of settings of the burner system by somebody
other than by the people mentioned above, can lead to a dangerous situation and
have consequences on product liability and warranty.
-Changes to the burner system may only be implemented conform instructions
after receiving confirmation in writing from Zantingh.
-A burner system is a combination of:
•Electrical engineering
•Gas engineering
•Central heating engineering
•Measurement and control engineering
- Take care of your burner system as if it is the heart of your company. Restrict
authorization to trained personnel only.

Page. 4
LMV5000.EN202001V6
Always switch off the main switch and make sure that it cannot be switched on when
performing any activity on the system!
In case of fire or any other emergency:
•When accessible close the gas valve (A1) of the gas train and switch
off the main switch on the burner panel.
•When there’s a fire in the boiler room you need to switch off the
electric power using the “fire switch” mounted on the wall outside the
boiler room.
3.1 Maintenance
To assure the safe and proper operation of the burner, it is recommended that the
burner be inspected and serviced at least once a year by a qualified service
engineer.
Never perform any maintenance or any other activity on the burner (system) without
adequate knowledge and understanding of the system.
Remarks:
-De burner system is supplied according to applicable safety regulations, but it is
the end user’s responsibility to ensure safety through annual maintenance work
on the system, according to applicable regulations.
-To ensure the good operation of the heating system, the boiler room has to be
kept clean. It may not be used for storage purposes. The parts which may need
maintenance work need to be accessible at all times.
-Keep the air supply grille and air extraction openings free and clean. Inadequate
air ventilation can lead to hazardous situations.
-The boiler room has to be illuminated using mounted electrical lighting, to make
sure that all parts of the system can be properly maintained even without daylight.
-Any water leaks have to be repaired immediately.
-If you have any doubts concerning the control or operation of the system, please
contact your burner technician or supplier.
3.2 Instruction manual instructions
To understand this manual better you need to know which type of burner has been
installed (TR or RKB) and which type of system it controls. This information is
provided on the nameplate on the right-hand side of the burner.

Page. 5
LMV5000.EN202001V6
4. SYSTEM COMPONENTS
4.1 Burner component
The burner component is in welded steel-plated housing. Under the burner housing
there’s an air valve section, it controls the air supply to the burner. A servomotor
drives the valves. The load controller or burner controller controls the servomotor.
The combustion air level is measured and monitored using air-pressure switches
(LD2). If you have a burner type TR the pressure switches are located on the upper
side of the burner. If you have a burner type RKB the switches are mounted under
the burner housing. The primary and secondary burner combustion devices are
situated in the cylindrical part of the burner. The flame monitoring device is mounted
on the side of the cylindrical part. The pilot burner is positioned at the centre of the
burner head. The pilot burner includes an electrical ignition. A high-voltage
transformer is included in the burner housing for electrical ignition. The gas supply
connection to a servomotor-driven gas quantity control valve is located under the
cylindrical part of the burners.
4.2 Air fan component
The air fan is positioned under the burner. The air fan supplies the required
combustion air. This air fan has a directly coupled and balanced fan wheel. The fan
wheel is driven by an electromotor. The air fan of a TR burner is directly connected to
the air-valve section. The air van of an RKB burner is separate and stands on the
floor.
The connection is made using a flexible sleeve. Vibration isolators are used when
mounting the air fan on the floor. An electrical circuit in the burner control panel and
the frequency controller provide the variable speed of the electromotor. The air fan
can, therefore, provide the required air quantity based on the measured air quantity.
The standard air fan includes an inlet grid to prevent coming into contact with moving
parts. A plate silencer is provided on the air fan inlet for noise reduction purposes.
Cylindrical noise silencers are available as an option.
4.3 Gas train
The gas train controls the gas supply from the distribution network. Several monitor
and control units are mounted on the gas train to control the burner gas supply.
The maximum supply pressure for the system is indicated on the burner
nameplate.
Shut-off valve (pos. A1)
De shut-off valve (A1) shuts off the gas supply to the burner system in case of:
•Fire or other emergencies.
•Maintenance work on the gas train equipment.
•Leakage of or between parts after the valve.
•Shutting down the burner system for a long period of time.

Page. 6
LMV5000.EN202001V6
Filter (pos. F1)
The filter (F1) prevents dirt and welding globules from the gas supply line from getting
into the equipment of the gas train. This protects the equipment from damage caused
by contamination.
Safety valves (pos. VA1 and VA2)
These safety valves automatically open/close the gas supply to the burner. Two gas
safety valves (VA1 + VA2) are used for safety reasons.
The second safety valve (VA2) has an integrated gas pressure regulator that makes
sure the gas pressure on the burner head is constant.
Minimum gas pressure safety device (pos. LD1)
The pressure switch (LD1) is activated when the main gas pressure reach under the
minimum limit value. The setting value is determined during the commissioning of the
burner.
Maximum gas pressure safety device (pos. HD)
The HD pressure switch monitors the maximum burner/boiler capacity and is
mounted on the burner head to control the burner load by means of air pressure.
The settings of the pressure switches is determined when commissioning the burner
system.
Manometer (pos. M) en press-button valve (pos. K2)
By pushing on the press-button valve the supplied inlet pressure can be read off the
manometer.
Manometer (pos. M) and push button valve (pos. K2)
Press the push button valve to read the supplied inlet pressure on the manometer.
4.4 Pilot gas line
Shut-off valve (pos. K1)
The ball valve (K1) is used to bleed the gas supply line. The bleed line has to include
a separate pipe through the roof to the outside air. The opening has to be protected
against contamination, dirt and rain.
Plug off the ball valve if there is no bleeding line.
Pilot gas solenoid valves (pos. MK1/MK2)
The pilot gas solenoid valves automatically open or close the gas supply to the pilot
burner (pos. AB).

Page. 7
LMV5000.EN202001V6
4.5 Control panel
The control panel includes all electrically controlled operation, monitoring and control
units of the burner, air fan, gas train, boiler and other secondary connected devices.
The electric circuits of all devices and units are connected to the control panel in such
a way that the total system can operate safely.
These circuits can be classified into the following main groups:
•Boiler/safety circuit.
•Thermostat (start) circuit.
•Burner control.
•Load control.
•External control (Fiduface).
•Failure indicator lights.
•Motor groups/fuses.
•Control switches and reset buttons.
•Optional CO2-circuit and CO-detector circuit.
4.6 Control switches and reset buttons on the control panel
The control panel includes a few switches and press button valves:
•Fire on/off switch.
•Selector switch for load control with the following two options:
1 = Automatic, modulated by load controller.
4 = External, the burner load and on/off status is controlled by the climate or
process computer.
•Reset, resets all failures.
The following control panel switches are optional:
•Selector switch gas/oil.
•Selector switch heat/steam.
•CO2dosing on/off.
•Flue gas valve open/closed.
4.7 Frequency control
A circuit in the control panel controls the air fan electromotor. A frequency control
unit, not included on the control panel, controls the air fan rotational speed based on
the burner load. The speed is controlled directly from the burner control unit by
sending a 0-10 V/4-20 mA signal to the frequency control unit.
Common settings:
Frequency for low flame approx. 25 Hz (= ± 1400 cycles).
Frequency for high flame approx. 50 Hz (= ± 2800 cycles).

Page. 8
LMV5000.EN202001V6
5. START SEQUENCE
When the gas pressure is nominal, the correct power is supplied to the control panel,
the safety valves are closed, the on/off thermostat emits an “on” signal and all other
boiler values are within the limits, the burner will start when the burner on/off switch is
set to 1.
The start-up sequence is as follows:
A. After switching the system on, the air fan starts at low speed, sometimes after a
short delay.
B. Once the air fan is at nominal speed, the servomotor of the air quantity control
valve (pos. HR2) opens fully. When the servomotor that controls the air quantity
control valve doesn’t make the complete pre-set stroke, the air quantity control
valve will not be sufficiently opened. The burner will be shut off and the system
goes into lockout. An error message is displayed. The air fan will be set to
maximum speed (50 Hz) approximately linear to the air valves to ventilate the
system.
C. If the air quantity control valve is opened the pre-purge cycle starts. During the 30
seconds pre-purge cycle the boiler furnace is ventilated, to clear any remaining
flue gas. During the pre-purge cycle the position of the air quantity control valve
and of the air pressure are checked continuously.
D. At the end of the pre-purge cycle the air fan is set to low speed (+/- 25 Hz) and
the air quantity control valve is positioned to the start/low flame position.
The gas quantity control valve (pos. HR1) controlled by a servomotor is also
positioned to the start/low flame position. The minimum air pressure is checked
during operation by a second air pressure switch (pos. LD2 low).
F. All the air and gas controls are in now in the start position. The next step is to
light the pilot flame. A few seconds after reaching the start position the ignition
transformer is switched on. It make an electrical spark between the ignition
electrodes.
G. After three (3) seconds the pilot gas valve (pos. MK) opens and the spark lights
the gas. After another five (5) seconds the flame monitoring device checks
whether the UV scanner detects a pilot flame. The 5 seconds period during which
the pilot flame is lighted is called the first safety time. At the end of the first safety
time the pilot flame should be burning stable and the electrical spark is switched
off. The flame monitoring unit checks the flame continuously during operation.
If the flame is not formed in the first safety time the flame monitoring unit goes
into lockout and an error message is displayed on the electronic module.
G. If the flame monitoring unit detects the pilot flame, the system continues the
ignition procedure after a short time period. The main safety valves (pos. VA1
and VA2) open to ignite the main flame. The pneumatic gas pressure regulator,
which is mounted on the second safety valve (pos. VA2), makes sure the correct
output gas pressure for the burner load is obtained.

Page. 9
LMV5000.EN202001V6
Five (5) seconds after opening the safety valves the pilot gas is shut off.
The main flame has to be stable, itis checked by the flame monitoring unit
continuously.
The 5 seconds during which the pilot valve (pos. MK) and the main valves (pos.
VA1 and VA2) are in the open position is called the second safety time. If the
flame is not formed within this time the flame guard goes into lockout and an
error message is displayed on the electronic module.
The maximum gas pressure switch (pos. HD1) ensures an easy steady start of
the main flame. It is only active when starting the flame. The minimum gas
pressure switch (pos. LD1) monitors the supply gas pressure continuously at the
lowest applicable level.
H. After the main flame has formed and the start sequence of the burner control
panel is successfully gone through, the burner is “in operation” on low flame.
Approx. 35 seconds after opening the main valves the load controller starts
setting the load.
I. If the load control switch on the control panel is set to 1 Auto, the burner load and
switching on and off will be controlled by the load control unit.
The maximum gas pressure switch (pos. HD) monitors the maximum burner load
by measuring the gas pressure.

Page. 10
LMV5000.EN202001V6
6. SIEMENS BURNER CONTROL LMV5x OPERATION
The LMV5 is a microprocessor-based burner management system with matching
system components for the control and supervision of forced draft burners of
medium to high capacity.
The following components are integrated in the LMV5:
•Burner control with gas valve proving system
•Electronic fuel-air ratio control
•PID temperature or pressure controller (boiler controller / load controller)
•Variabel speedrive (VSD module)
The system components are interconnected via a bus system. Communication
between the bus users takes place via a safety-related, system-bound data bus (for
safety reasons, integration of the bus into external CAN bus systems is not possible).
All safety-related digital outputs of the system are permanently monitored via a
contact feedback network.
Basicdiagram
Example: Dual Fuel burner
- Gas: Modulating
- Oil: 2-stage

Page. 11
LMV5000.EN202001V6
6.1 AZL display description and operation
The LMV5 is operated and programmed with the help of the AZL5 or with the
touchscreen.
The AZL5 with LCD clear text and menu-driven operation affords straightforward
operation and targeted diagnostics. For making diagnostics, the LCD shows the
operating states, the type of fault and the point in time the fault occurred.
The parameter setting levels for the burner / boiler manufacturer and heating
engineer are password-protected to prevent unauthorized access. Basic settings
that the plant operator can make on site do not require a password.
In case of failure, before resetting, write down the text/code which appears in the
display of the AZL unit. See “Display and error messages”(separate AZL manual).
Please also write down the burner type and manufacturing year. Please contact our
service department. They will first attempt to solve the problem via the telephone call.
Display and settings
Menu structure:
Main menu level
AZL

Page. 12
LMV5000.EN202001V6
Description of the buttons and display
Setpoint change
The end user is allowed to change a number of settings in the display of the LMV.
This text contains information about these changes.
Press the buttons < and > + ENTER to read and to select values.
The arrow buttons < and> can be used to change the setpoint value (required boiler
temperature in ºC).
Main menu:
<
Display of current functioning level
<
Operation → Setpoint → Setpoint W1 → Act.: 80
Nw: 80
Set the new value with the buttons < and >. Press ENTER to confirm the value.
Change maximum load
Operation →User Max Load →User MaxLoadMod →Act.: 100
Nw.: 100
Set the new value with the buttons < and >. Press ENTER to confirm the value.
Temperature settings
Check the maximum operating temperature before you enter changes. When the
temperature is too high the maximum limit thermostat will activate a lockout.
Default settings for the LMV:
Setpoint plus 6 degrees Celsius; burner stops.
Setpoint minus 2 degrees Celsius; burner start.

Page. 13
LMV5000.EN202001V6
Display of normal operation
Below, the most important displays of normal operation and examples of Lockout
and start prevention messages and Parameterization are defined. In normal
operation, the display shown is the default display which automatically appears and
which is maintained as long as no settings are made and no unusual events like
faults or start preventions occur.
The change from other displays to the normal display can be made by pressing the
Info button.
IMPORTANT:
For a detailed description and service of the error and diagnosis codes, please refer
to the annex AZL user interface.
H O M E R U N ( P h a s e 1 0 )
L
M
V
5
x
H
o
m
e
R
u
n
1
0
S
t
a
r
t
N
o
1
2
3
4
5
6
F
0
5
.
1
A
0
2
.
4
0
4
.
3
S T A N D B Y ( P h a s e 1 2 )
S
e
t
p
o
i
n
t
1
2
5
°
C
A
c
t
V
a
l
u
e
1
2
4
°
C
F
u
e
l
O
i
l
S
t
a
n
d
b
y
1
2
Example: Display of lockouts in the lockout history
In the event lockout occurs, the display alternates at 5-second intervals. Press Enter to select 1
of the 2 display texts. In that case, the alternating cycle is interrupted.
Example: Lockout due to a gas pressure signal in connection with gas valve proving.
1
1
8
.
0
6
.
9
9
1
0
:
3
5
C
:
3
1
D
:
0
0
P
:
8
1
S
t
a
r
t
N
o
:
1
2
3
4
5
6
L
o
a
d
:
2
5
.
0
G
a
s
G
a
s
P
r
e
s
s
u
r
e
V
a
l
v
e
P
r
o
v
i
n
g
:
V
a
l
v
e
o
n
G
a
s
S
i
d
e
l
e
a
k
i
n
g
C = error code D = diagnostics
P = phase DK = gas valve proving

Page. 14
LMV5000.EN202001V6
Example: Display of errors in the error history
In contrast to the lockout history, the error history contains the errors of all error classes and not only
the lockouts.
If an error occurs, the display alternates at 5-second intervals.
1
2
C l a
s
s
:
0
3
G
A
S
C
o
d
e : 2
1
P h
a
s
e
:
2
4
D
i
a
g : 0
0
L o
d
:
0
.
0
S
t
a
r t
N
o
:
1
2
3
4
5
6
Example: Safety loop
open
S a f e t y L o o p o p e n
Lockout and error messages
Example: Immediate display of lockouts
In the event lockout occurs, the display alternates at 5-second intervals.
L o
c
k
o
u
t
G a
s
P
r
e
s
s
u
r
e w
V a
l
v
e
P
r
o
v
i
n g :
V a
l
v
e
o
n
G
a
s
S i
d
e
l
e
a
k
i
n
g
Example: Immediate display of safety shutdowns
In the event of safety shutdown, the display alternates at 5-second intervals.
S a
f
e t
y
S
h
u
t d
o w
n
G a
s
P
r
e s
s
u
r e
h
a
s
d r
o
p p
e
d
b
e
l o
w
m i
n
i m
u
m
L
i m i
t

Page. 15
LMV5000.EN202001V6
Example: Immediate display of warnings
In the event of warnings, the display alternates at 5-second intervals.
S l o p e t o o s
t
e
e p
Example: Immediate display of start preventions
In the event of start preventions, the display alternates at 5-second intervals.
S t a r t P r e v e
n
t
i o
n
A i r P r e s s u r e o n
W a r n i n g

Page. 16
LMV5000.EN202001V6
6.2 Operation 7” touch screen
The Siemens touch screen is a digital display with status of the connected circuits
(boiler safeties) and burner status.
Home
The main screen displays current information. No safety related settings can be
changed.
Menustructure:

Page. 17
LMV5000.EN202001V6
Pressing the boiler will give acces to the actual stystem status.
Green is functional, red is fault/error.
Pressing one of the menu items displays the error history.
Pressing the burner image in the Home screen displays the burner error log.

Page. 18
LMV5000.EN202001V6
Setpoint/Actuel
Display of actual value and setpoint.
Log
Display of error and error history. Important error codes for diagnoses.
System
Display of most important system data.

Page. 19
LMV5000.EN202001V6
Service
Display of memo’s/remarks from engineers.
Trend
Display of burner load, flame signal and boiler temperature.
Combustion
Display of boiler temperature, actual load and output.

Page. 20
LMV5000.EN202001V6
Actuators
Position of the actuators and related load in %.
In / outputs
Display of which in- or outputs are closed or open.
Also the burner phase error code (Siemens LMV code) will be displayed.