Related Manuals for Unigas TLX2020
Summary of Contents for Unigas TLX2020
- Page 1 TLX2020 TLX2030 TLX2040 LMV5x Microprocessor controlled Gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039571CA 0.1 11/2019...
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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 For the following information, please refer to Model Gas - Light oil burners Year the data plate: European Directives 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 BURNERS FEATURES The industrial burners of this series are designed for installations where a large fan or an air-smoke heat exchanger is required, to be installed separately from the burner to reduce noise. They can be provided with built-in or separate-mounted control panel (console or wall-mounted).
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Page 6: Burner Model Identification
Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type Model TLX2040 150. TLX2020, TLX2030, TLX2040 BURNER TYPE FUEL M - Natural gas OPERATION (Available versions) MD - Fully modulating BLAST TUBE... -
Page 7: Technical Specifications
PART I: SPECIFICATIONS Technical Specifications BURNER TYPE TLX2020 TLX2030 TLX2040 Output min - max kW 2000 - 16000 2400 - 20000 3900 - 31500 Fuel Natural gas Category (see next paragraph) 413 - 3333 Gas rate min.-max. (Stm3/h) 212 - 1693... - Page 8 TLX2040 M-.MD.S.xx.x.8.150.Ex Overall dimensions (mm) 2405 BL 650 mm BS 500 mm 1195 1373 1337 1847 80 160 109 BURNER FLANGE BOILER RECOMMENDED DRILLING TEMPLATE Air inlet flangei...
- Page 9 Overall dimensions (mm) TLX2040 M-.MD.S.RU.A.8.125.Ex 2265 1753 1196 1353 1337 1826 80 160 109 BURNER FLANGE BOILER RECOMMENDED DRILLING TEMPLATE Air inlet flangei...
- Page 10 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 11 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves(natural gas) TLX2020 TLX2030 Gas rate Stm Gas rate Stm TX2040 Gas rate Stm WARNING: the diagrams refers to natural gas. For different type of fuel please refer to the paragraph “Fuel” at the beginning of this chapter.
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Page 12: Fan Installation
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 13 PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Packing The burners are despatched in wooden crates whose dimensions are: 2100 X 1370 X H 1060 mm (Dimensions are indicative.) burner with detached gas train; gasket or ceramic fibre plait (according to burner type) to be inserted between the burner ...
- Page 14 PART II: INSTALLATION insulating material (ceramic fibre cord or refractory cement). Keys Burner Fixing nut Washer Ceramic fibre plait Stud bolt Blast tube Matching the burner to the boiler low NOx burners) The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose dimensions are described in the diagram .
- Page 15 PART II: INSTALLATION Connection diagram of the air pressure switch to the burner air conduct Burner air pressure switch Iron sleeve Ø 10 mm Male elbow fitting Ø 6 mm x 10 Copper tube Ø 6 mm x 1,5 mt Air conduct Nut for male elbow fitting Ø...
- Page 16 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 17 PART II: INSTALLATION MultiBloc MBE ALLA V. FARFALLA Example of gas train MBE 501939 GAS BRUCIATORE ø185 VD-R VD-V VD-R VD-V Gas filter PGMAX PGMAX PGMI PGMIN PS pressure sensor PGCP PGCP ATTENTION: once the gas train is mounted according, the gas proving test mus be performed, according to the procedure set by the laws in force.
- Page 18 PART II: INSTALLATION Mounting VD-R & PS-... ActuatorVD-V ActuatorVD-R M12 x 5 Pin The actuator VD-V does not need any adjustment (funzione ON-OFF) The actuator VD-R It must be combined with the PS sensor (include regolatore di pressione) VD-R + PS 1.
- Page 19 PART II: INSTALLATION SIEMENS VGD.. SKP1. SKP2. Mounting positions = BS PGMAX PGCP PGMIN Siemens VGD... con SKPx Example of gas train Gas filter version with SKP2 (built-in pressure stabilizer) Siemens VGD valves with SKP actuator: The pressure adjusting range, upstream the gas valves group, changes according to the spring provided with the valve group.
- Page 20 PART II: INSTALLATION Once the train is installed, connect the gas valves group and pressure switches plugs. Pilot gas train (if provided) The connection to the pilot gas train must be done according to the following scheme, valid for LPG. In case of natural gas, connect the pressure goveror (pos.
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Page 21: 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 22: 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 23: Adjusting Procedure
PART III: OPERATION Adjusting procedure Go on adjusting the burner. 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 system and monitoring the system data. The user interface is made of: 1. -
Page 24: Start-Up Procedure
PART III: OPERATION The Siemens AZL User Interface allows programming the Siemens LMV system and monitoring the system data. The user interface is made of: 1. display: it showes menus and parameters 2. ESC key (previous level): it goes back to the prevoius level menu or exits the programming mode without changing data. 3. -
Page 25: Fault History
PART III: OPERATION Setpoint 80°C Act.value 78°C Load Flame Main page Set point: temperature set-point 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. - Page 26 PART III: OPERATION 1 Class: 05Gas code Phase: Diag.: Lod: Start No. 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.
- Page 27 PART III: OPERATION BurnerControl RatioControl O2Contr./Guard. LoadController Choose “LoadController” and press ENTER: the following menu is shown: 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°...
- Page 28 PART III: OPERATION 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. Now choose SD_ModOff always scrolling down theLoad Controller menu, by menas of the arrow keys, and press ENTER. SetpointW1 SetpointW2 SD_ModOn...
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Page 29: System Lockout
PART III: OPERATION choose the desired language and cofirm by pressing ENTER; press ESC to exit. DateFormat: it allows setting the date format as DD-MM-YY (day-month-year) or MM-DD-YY (month-day-year) 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... - Page 30 PART III: OPERATION SetLoad Autom/Manual/Off SetLoad: to set the required load percentage 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 Curr:: Automatic New: Burner On three modes are provided: Automatic: automatic operation Burner on: manual operation...
- Page 31 PART III: OPERATION Adjusting the combustion head Burner is factory-set according to its combustion head model. Attention! If it is necessary to change the head position, repeat the air and gas adjustments described at steps 1-9 in paragraph related to air/fuel ratio adjustments according to the actuator model. .The combustion head position affects the flame stability.The diffuser position must be set during the commissioning according to the regulation needs.
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Page 32: Pressure Taps
PART III: OPERATION Regulation VD-R whith PS MultiBloc MBE 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 Decreasing pressure... - Page 33 PART III: OPERATION Adjusting the pilot gas flow rate: gas valve Brahma EG12xR and pressure governor To change the pilot gas valve flow rate, proceed as follows: remove the protection on the bottom of the valve, moving it counterclockwise (see next picture); rotate clockwise the nut 1 as shown in to close the valve or counterclockwise to open.
- Page 34 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.
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Page 35: 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 36 PART IV: MAINTENANCE MultiBloc MBE MultiBloc VD 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 Flame detection probe To clean/replace the detection photocell, proceed as follows: Disconnect the system from the electrical power supply. Shut off the fuel supply; remove the photocell from its slot (see next figure); clean the bulbe if dirty, taking care not to touch it with bare hands; if necessary, replace the bulb;...
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Page 38: Seasonal Stop
PART IV: MAINTENANCE Replacing the ignition electrode To replace the ignition electrode, proceed as follows: Remove the burner cover Disconnect the electrode (E) cable (CE) Remove the combustion head (see par. “Removing the combustion head”) Loose screw (B) that fasten the ignition electrode (E) to the burner pilot (P) Remove the electrode and replace it, referring to the values quoted on figure ATTENTION: avoid the electrode to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. - Page 39 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 40 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 41 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 42 Annex1 – Example for motor cable...
- Page 44 Annex 2 – Example for sensor cable...
- Page 47 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 48 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 49 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.
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Page 51: 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 52 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 53 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.
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Page 54: 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 56 8 8 8...
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- Page 58 ©...
- Page 59 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 60 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...