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Unigas TLX92R Manual Of Installation - Use - Maintenance

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TLX92R
TLX92.1
TLX512.1
TLX515.1
TLX520.1
Gas burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
M039551CD 0.0 11/2022

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Summary of Contents for Unigas TLX92R

  • Page 1 TLX92R TLX92.1 TLX512.1 TLX515.1 TLX520.1 Gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039551CD 0.0 11/2022...

  • Page 2: Responsabilità E Garanzia

    PERICOLI, AVVERTENZE E NOTE DI ATTENZIONE - intervento di personale non abilitato; - esecuzione di modifiche non autorizzate all’apparecchio; - utilizzo del bruciatore con dispositivi di sicurezza difettosi, applicati in Il manuale di installazione, uso e manutenzione costituisce maniera scorretta e/o non funzionanti; parte integrante ed essenziale del prodotto e deve essere - installazione di componenti supplementari non collaudati unitamente al consegnato all'utilizzatore.
  • Page 3 Non ostruire le griglie di aspirazione o di dissipazione e verificare la corretta funzionalità del condotto di evacuazione dei pro-  dotti della combustione; In caso di guasto e/o di cattivo funzionamento dell'apparecchio, disatti-  varlo, astenendosi da qualsiasi tentativo di riparazione o di intervento f controllare al termine delle regolazioni che tutti i sistemi di bloccag- diretto.

  • Page 4: Simboli Utilizzati

    e che l'impianto di alimentazione del combustibile sia dimensionato norme vigenti in materia di sicurezza, salute ed ambiente. Per qualsiasi approfondimento, consultare le dichiarazioni di conformità che sono parte per la portata necessaria al bruciatore e che sia dotato di tutti i dispo- integrante di questo Manuale.
  • Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS BURNERS FEATURES Gas train Cover Blast tube + Combustion head Flange Actuator Combustion head adjusting ring nut Air pressure switch Sector variable Air inlet flange 10 Bellows 11 Burner junction box Gas operation: From the supply line the gas fuel passes through the gas train (filter, safety valves, gas pressure regulator and butterfly valve). The pressure regulator sets the gas pressure within the combustion head utilization limits.

  • Page 6: Burner Type

    Burners are identified by burner type and model. Burner model identification is described as follows. Type TLX92R Model PR. S. BURNER TYPE TLX92R, TLX92.1, TLX512.1, TLX515.1, TLX520.1 FUEL M - Natural gas OPERATION (Available versions) PR - Progressive BLAST TUBE...
  • Page 7 PART I: SPECIFICATIONS Fuel The burner technical specifications, described in this manual, refer to natural gas (calorific net value Hi = 9,45 kWh/Stm , density ρ = 0,717 Kg/Stm ). For different fuel such as LPG, town gas and biogas, multiply the values of flow and pressure by th corrective factors shown in the table below.
  • Page 8 Overall dimensions (mm) TLX92.1 1279 1273 77.5 77.5 77.5 77.5 AIR INLET FLANGEI BURNER FLANGE BOILER RECOMMENDED DRILLING TEMPLATE...
  • Page 9 Overall dimensions (mm) TLX92R (1.50) 1279 1242 77.5 77.5 77.5 77.5 AIR INLET FLANGEI BURNER FLANGE BOILER RECOMMENDED DRILLING TEMPLATE...
  • Page 10 Overall dimensions (mm) TLX512.1 (1.65) 1558 Ø 927.5 FLANGIA CANALE ARIA AIR INLET FLANGE AIR INLET FLANGEI BURNER FLANGE BOILER RECOMMENDED DRILLING TEMPLATE...
  • Page 11 Overall dimensions (mm) TLX515.1 (1.65) 1524 1465 M 14 BURNER FLANGE BOILER RECOMMENDED AIR INLET FLANGEI DRILLING TEMPLATE...
  • Page 12 Overall dimensions (mm) TLX520.1 (1.65) 1558 Ø 927.5 BURNER FLANGE BOILER RECOMMENDED AIR INLET FLANGEI DRILLING TEMPLATE...
  • Page 13 PART I: SPECIFICATIONS GAS TRAIN CONNECTION The following diagrams show some examples of possible gas trains with the components supplied with the burner and those fitted by the installer. The gas trains and the connection of the burner to the fuel supply line must be done in accordance with current local regu- lations.
  • Page 14 This value must be lower or equal to the pgas value, cal- culated before. Power kW Potenza / Output (kW) Pressure in the Network / gas flow rate curves (natural gas) TLX92R M-.. TLX92.1 M-.. TLX512.1 M-..
  • Page 15 Gas pressure burner head vs natural gas flow rate Curves are referred to pressure = 0 mbar in the combustion chamber! TLX92R M-.. TLX92.1 M-.. TLX512.1 M-.. TLX515.1 M-..

  • Page 16: Fan Installation

    PART I: SPECIFICATIONS Fan installation ATTENTION! The bellows unit provided is made of canvas and is provided with blocking spacers to avoid breaking it during installation: first place the bellows unit between flanges, then remove the spacers. Canvas has to be stretched after the installation, but not stressed.
  • Page 17 PART II: INSTALLATION PART II: INSTALLATION 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 18 PART II: INSTALLATION Handling the burner WARNING! The handling operations must be carried out by specialised and trained personnel. If these opera- tions are not carried out correctly, the residual risk for the burner to overturn and fall down still persists. To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).
  • Page 19 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 20 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 21: 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 22 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 23 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 24 PART II: INSTALLATION Siemens VGD Pressure taps Legend pi Inlet pressure Strainer pm Pressure between val- (G 1/4") (G 1/8") (G 1/4") (G 3/4") (G 1/8") (G 1/4") (G 1/8") po Outlet pressure...

  • Page 25: 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 26 PART III: OPERATION PART III: OPERATION IN THE EVENT OF A BLOCKAGE, THE CAUSE MUST BE ASSESSED. IF THE FLAME BACKFIRE WARNING LIGHT IS ON, IT IS IMPERATIVE TO CHECK THE INTEGRITY AND GOOD CONDITION OF THE COMBUSTION HEAD AS DESCRIBED IN THE MAINTENANCE SECTION BEFORE UNLOCKING THE APPLIANCE.

  • Page 27: Gas Operation

    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 28 PART III: OPERATION acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler/utilisation: - Siemens VGD valves group: remove cap T and act on the VR adjusting screw to increase or decrease the pressure and consequently the gas rate;...
  • Page 29 PART III: OPERATION 14 If necessary, adjust the combustion head position (see the dedicated paragraph).. Attention! if it is necessary to change the head position, repeat the air and gas adjustments described above. 15 The air and gas rate are now adjusted at the maximum power stage, go on with the point to point adjustement on the SV1 (gas side) adjusting cam as to reach the minimum output point.
  • Page 30 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 31 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 32 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 33 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. .The combustion head position affects the flame stability.The diffuser position must be set during the commissioning according to the regulation needs.

  • Page 34: 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 35 PART IV: MAINTENANCE Gas filter maintenance WARNING: Before opening the filter, close the manual cutoff valve downstream the filter and bleed the gas; check that inside the filter there is no pressurised gas. Per pulire o sostituire il filtro gas procedere nel modo seguente: MB-DLE MB-DLE 415 - 420 B01...
  • Page 36 PART IV: MAINTENANCE MultiBloc VD-V VD-R Mounting to push position 1. Position VD on VB, fig. 2+3. 2. Slide VD forward up to the stop, fig. 4. 3. Screw VD on with 2 M5 screws for each, max. 5 Nm/44 in.-lb., fig. 5/6. 4.
  • Page 37 PART IV: MAINTENANCE Head adjusting screw Threaded rod Fixing screw Gas manifold ”O” ring Cover Electrodes Adjustment Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion head. ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), other- wise the boiler’s operation would be compromised.
  • Page 38 PART IV: MAINTENANCE adjust the electrodes position according to the electrodes type installed on the burner. follow the quotes shown on the next picture. > > electrodes - type A electrodes - type B electrodes - type C R = Detection electrode = 6 mm ~ 7 mm ~ 7 mm A = Ignition electrodes = 10 mm...
  • Page 39 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. To replace the ignition electrodes, proceed as follows: electrodes - type A remove the burner cover...
  • Page 40 PART IV: MAINTENANCE ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrode position after any intervention on the combustion head. Replacing the detection electrode (natural gas burners) To replace the detection electrode, proceed as follows: remove the combustion head according to the procedure on paragraph “Removing the combustion head”;...

  • Page 41: 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 42 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 43 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 44 PART IV: MAINTENANCE...
  • Page 45 LME73.000Ax + PME73.831AxBC LME73.831AxBC Service instruction manual M12921CB Rel.1.2 02/2016...

  • Page 46: General Features

    GENERAL FEATURES LME/ is suitable for gas, light and heavy oil burners LME7 series has two devices: LME73.000 (hardware) and PME73.831AxBC (programmable unit). The LME73.831AxBC is also available: it has a built in software and it isa not programmable. LME7 is inside the control panel. If supplied, PME73.831BC is inside the LME7; The display AZL23..

  • Page 47: User Interface

    User interface : Button A - Display preset output - In lockout position: Power value to the time of fault Info and Enter button - Reset in the event of fault, changeover visual diagnostic of the cause of fault (refer to chapter Diagnostics of cause of fault ) - button - Display flame signal current 2 or phases display - In lockout position: MMI phase to the time of fault...
  • Page 48 List of phase display on board LME : Phase number of Function 7-segment display Standby Standby, waiting for heat demand Mains ON / test phase (e.g. detector test) Startup Yellow Safety valve ON, air pressure switch test / POC test (timeout / locking Yellow Fan motor ON / air pressure switch test / settling time Yellow...
  • Page 49 Operation : The lockout reset button (info button) (EK) is the key operating element for resetting the burner control and for activating / deactivating the diagnostics functions. The multicolor signal lamp (LED) is the key indicating element for visual diagnostics. Both lockout reset button (EK) and signal lamp (LED) are located in the control panel.

  • Page 50: Program Sequence

    Program sequence : Version 1: • Ignition load < low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 > 0 seconds)
  • Page 51 Program sequence : Version 2: • Ignition load > low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 = 0 seconds)
  • Page 52 Phase Function number Lockout phase Standby, waiting for heat demand Operation, modulating operation Interval until release of load controller target (analog or 3-position step input) Under voltage Safety loop open Extraneous light on burner startup (timeout/locking after 30 seconds) Mains ON/test phase (e.g. detector test) Shutdown, actuator opens in CLOSE position (homerun) Safety valve ON, air pressure switch OFF, actuator opens in CLOSE position Part 1: Fan motor ON...
  • Page 53 Error code table : Red blink code of fault signal lamp (LED) Possible cause 2 x blinks No establishment of flame at the end of the safety time (TSA) - Faulty or soiled flame detector - Faulty or soiled fuel valves - Poor adjustment of burner, no fuel - Faulty ignition equipment 3 x blinks...
  • Page 54 Flame detection – detection electrode : Short-circuit current Max. AC 1 mA Required detector current Min. DC 2 μA, display approx. 45 % Possible detector current Max. DC 3 μA, display approx. 100 % Permissible length of detector cable (laid separately) 30 m (core-earth 100 pF/m) Measuring circuit Keys...
  • Page 55 Gas proving system : Valve proving is dependent on input valve proving ON / OFF (X2-02). When a leak is detected, the gas valve proving function ensures that the gas valves will not be opened and that ignition will not be switched on. Lockout will be initiated. Valve proving with separate pressure switch (P LT) Step 1: td4 –...
  • Page 56 Instruction, control and modify via AZL2x : The AZL2x.. display/programming unit is shown below: The keys functions are the following: Key F + A While pressing the two keys contemporarly, the code message will appear: by entering the proper password it is possible to access the Service mode. Info and Enter keys Used for Info and Service menues Used as Enter key in the setting modes...
  • Page 57 The display will show these data: Lock+unlock codes Flame Open valves Ignition transformers energised Fan motor energised Oil pre-heater energised Plant heat request Parameter setting mode Info mode Service mode Closing actuator Opening actuator Unit measure While pushing the button together with whatever else button, LME73 locks out; the display shows On stand-by position, appears On operation, all the phases appears with their number.
  • Page 58 List of phase with display AZL2x : Phase number Function Standby Standby, waiting for heat request Ph08 Power ON / test phase (e.g. detector test) Startup Ph21 Safety valve ON, air pressure switch test / POC test (timeout / locking after 5 seconds), actuator opens in low-fire position / CLOSE position Ph22 Fan motor ON or air pressure switch test / settling time...
  • Page 59 Error code list with operation via internal AZL : Error code Clear text Possible cause Loc 2 No establishment of flame at the - Faulty or soiled fuel valves end of the safety time (TSA) - Faulty or soiled flame detector - Poor adjustment of burner, no fuel - Faulty ignition equipment Loc 3...
  • Page 60 Entering the Parameter levels: y means of a proper use of the keys, it is possible to enter the various level parameters, as shown in the following flow chart :...
  • Page 61 Info level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
  • Page 62 Service level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. . If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
  • Page 63 Process data Normalized speed Read only 100% 0.01 % Service Mains voltage Read only LME73.000A1: Service 175 V LME73.000A2: 350 V Flame intensity Read only 100% Service...
  • Page 64 Parameter level (Heating engeneering) : This level lets the engineer to modify some burner parameters. It is protect with a 4 digit password (SO level) and a 5 digit password (OEM level) Password input : push F and A buttons together until the display shows "code" and 7 underlines. The left one flashes. By move the flashing underline until it is on the desired position and push "enter".
  • Page 65 Repetition in the event of loss of flame during operation Edit 0 SO 0 = None 1 = None 2 = 1 x Repetition 241.00 Valve proving Edit 1 SO 0 = Off 1 = On 241.01 Valve proving Edit 0 SO 0 = During prepurge time (t1) 1 = During postpurge time (t8)
  • Page 66 Power setting Analog input (feedback potentiometer ASZxx.3x required) Edit 0 SO 0 = 3-position step input 1 = 0...10 V 2 = 0...135 Ω 3 = 0...20 mA 4 = 4...20 mA with lockout at I <4 mA 5 = 4...20 mA WARNING Parameter Num.
  • Page 68 Note: Specifications and data subject to change. Errors and omissions excepted.

This manual is also suitable for:

Tlx92.1Tlx512.1Tlx515.1Tlx520.1

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