Unigas TG90 Manual Of Installation - Use - Maintenance Download Page 1

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MANUAL OF INSTALLATION - USE - MAINTENANCE

TG90-TG91-TG92

TG510-TG515
TG520-TG525

Light oil burners

M039212CA Rel.0.6 02/2019

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Summary of Contents for TG90

Page 1: ...MANUAL OF INSTALLATION USE MAINTENANCE TG90 TG91 TG92 TG510 TG515 TG520 TG525 Light oil burners M039212CA Rel 0 6 02 2019 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ ...

Page 2: ...be employed exclusively for the use for which it was designed Before connecting the burner make sure that the unit rating is the same as delivery mains electricity gas oil or other fuel Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stoppe...

Page 3: ... gaseous fuels 2014 35 UE Low Tension Directive 2014 30 UE Electromagnetic compatibility Directive 2006 42 EC Machinery Directive Harmonized standards UNI EN 676 Automatic forced draught burners for gaseous fuels EN 55014 1 Electromagnetic compatibility Requirements for house hold appliances electric tools and similar apparatus EN 60204 1 2006 Safety of machinery Electrical equipment of machines C...

Page 4: ...as oil and solid fuel burning appliances having electrical connections UNI EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction National Standard UNI 7824 Atomizing burners of the monobloc type Characteristics and test methods Industrial burners European directives Regulation 2016 426 UE appliances burning gaseous fuels 2014 35 UE Low Tension Direc...

Page 5: ...assing through the nozzle The pump main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which a separate regulating valve is provided Other pumps are provided with two pressure regulators one for the high and one for low pressure in double stage systems with ...

Page 6: ...ted in the exmple 9600kW Once the models are founded out the choice regards technical and economical features Technical features can be summarised in a higher modulation ratio fewer start ups less consumption fewer swigings in the generator temperature and pressure values Burner model identification Burners are identified by burner type and model Burner model identification is described as follows...

Page 7: ...0V 3N 50Hz Fan motor kW see fan ID plate Pump motor kW 1 1 0 55 1 1 Total power consumption kW 1 6 1 05 1 6 Index of protection IP40 Operation Progressive Fully modulating Operating temperature C 10 50 Storage temperature C 20 60 Working service Intermittent BURNERS TG510 TG515 TG520 TG525 Output min max kW 1314 3953 1628 4884 2326 6977 2000 9750 Light oil rate min max kg h 111 331 137 411 196 588...

Page 8: ... installation first place the bellows unit between flanges then remove the spacers Canvas has to be stretched after the installation but not stressed ATTENTION the air duct dimensioning must be perforformed according to the flow rate the temperature the distance between the fan and the burner and according to the fan features as well ATTENTION It is suggested to install the fan on vibration dampin...

Page 9: ...B S B L C CC D E F G H I JJ K KK L M N OminOmax OO P T W Y Z TG90 1356 1506 454 301 366 275 340 490 1090 307 840 307 533 234 276 228 175 360 510 685 M14 424 300 300 610 300 35 865 228 180 TG91 1317 1490 454 301 366 275 300 488 1017 307 840 307 533 238 268 228 175 360 510 685 M12 417 280 310 610 295 28 865 228 180 TG92 1311 1484 454 301 366 275 294 491 1017 307 840 307 533 266 296 228 175 360 510 6...

Page 10: ...N O OO P PP QQ W Y Z TG510 1485 1705 536 25 x x 383 448 295 300 520 1175 858 316 542 329 369 328 185 460 534 719 M14 552 390 693 390 x x 954 328 235 TG515 1485 1705 536 25 x x 383 448 295 300 520 1175 858 316 542 350 390 328 185 460 534 719 M14 552 390 693 390 x x 954 328 235 TG520 1485 1705 536 25 x x 383 448 295 300 520 1175 858 316 542 370 410 328 185 460 534 719 M14 552 390 693 390 x x 954 328...

Page 11: ... screws avoid any misalignement between the blast tube axis and the com bustion head axis 7 install the burner to the boiler 8 fix the burner to the stud bolts by means of the fixing nuts according to Fig 3 9 After fitting the burner to the boiler ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material ceramic fibre cord or refractory cem...

Page 12: ...three pass flue boilers with the first pass in the rear part the blast tube must protrude no more than 100 mm into the combustion chamber Pressurised boilers with flame reversal in this case the blast tube must penetrate at least 50 100 mm into combustion chamber in respect to the tube bundle plate The length of the blast tubes does not always allow this requirement to be met and thus it may be ne...

Page 13: ...ere gravity or ring feed systems are provided install an automatic interception device see n 4 Fig 7 Fig 4 Gravity circuit Fig 5 Ring circuit Fig 6 Suction circuit Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve ...

Page 14: ...mended in the case of gravity feed as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rotation referring to the pump shaft Caution Changing the direction of rotation all connections on top and side are reversed Bleed Bleeding in two pipe operation is automatic it is assured by a bleed flat on the piston In one pipe operation the plug of a pres...

Page 15: ...aragraph Suntec TA Oil viscosity 3 75 cSt Oil temperature 0 150 C Min suction pressure 0 45 bar to avoid gasing Max suction pressure 5 bar Max return pressure 5 bar Rotation speed 3600 rpm max Suntec T Viscosity 3 75 cSt Oil temperature 0 150 C Minimum suction pressure 0 45 bar to prevent gasing Maximum suction pressure 5 bar Rated speed 3600 rpm max Key 1 Inlet G3 4 2 Pressure gauge port G1 4 3 V...

Page 16: ...itial commissioning a dry operation is foreseen for a considerable length of time for example when there is a long suction line to bleed To avoid damages inject some lubrication oil into the vacuum inlet Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the joint noise and overloading the gears Pipes should not contain ai...

Page 17: ... is feeded at constant pressure while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see prevoius paragraph Fig 9 Stand by Fig 10 Prepurge Fig 11 Low flame Fig 12 High flame Key 1 Oil pump 2 Oil solenoid valve 3 Nozzl...

Page 18: ...urners are provided for three phase 400 V supply and in the case of three phase 230 V supply it is necessary to modify the electrical connections inside the terminal box of the electric motor and replace the thermal cutout relay 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...

Page 19: ...NOZZLE SUPPLY PRESSURE 25 bar ATTENTION To achieve the maximum flow rate close completely the return line DIMENSIONS FLOW RATE kg h Indicative pessure on return bar Min Max 40 13 40 19 50 16 50 22 60 20 60 20 70 23 70 23 80 26 80 23 90 30 90 22 100 33 100 22 115 38 115 21 130 43 130 22 145 48 145 21 160 53 160 21 180 59 180 22 200 66 200 21 225 74 225 22 250 82 250 22 275 91 275 22 300 99 300 23 3...

Page 20: ...is provided set the return pressure at 11bar supply at 20bar on the delivery to get a 220kg h flow rate If the return pressure needed is 5bar instead act on the V adjusting screw on the pressure gover nor The flow rate will then be about 95kg h see the example showed on the Bergonzo diagram ...

Page 21: ...21 FLUIDICS KW3 60 NOZZLE SUPPLY PRESSURE 20 bar VISCOSITY AT NOZZLE 5 cSt Pressure on return bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve ...

Page 22: ...0 bar VISCOSITY AT NOZZLE 5 cSt Pressure on return bar Flow rate kh h Pressure on return bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve The nominal size of the nozzle is indicated at the ends of the curve ...

Page 23: ... Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve Pressure on return bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve Pressure on return bar Flow rate kh h The nominal size of the nozzle is indicated at the ends of the curve ...

Page 24: ...n and keep pressed for some seconds until the oil circuit is charged 3 bleed the air from the M pressure gauge port Fig 13 by loosing the cap without removing it then release the contactor Fig 13 4 Before starting the burner up drive the high flame actuator microswitch matching the low flame one in order to let the burner ope rates at the lowest output to achieve safely the high flame stage 5 Turn...

Page 25: ...out changing the air flow rate set during the gas operation adjustments see prevoius paragraph checking always the combustion parameters the adjustment is to be performed by means of the SV adjusting cam screw see picture when the cam has reached the high flame position 12 To adjust the air flow rate in the high flame stage loose the RA nut and screw VRA as to get the desired air flow rate moving ...

Page 26: ... cam III towards the minimum to meet the next screw on the adjusting cam and repeat the previous step go on this way as to reach the desired low flame point 19 The low flame position must never match the ignition position that is why cam III must be set 20 30 more than the ignition posi tion Turn the burner off then start it up again If the adjustment is not correct repeat the previous steps Fully...

Page 27: ...n repeat the adjustments described above Minimum oil pressure switch when provided The minimum oil pressure switch on the inlet line checks that the pressure does not drop below a default value The pressure switch must be set say at 10 under the pressure at the nozzle Oil pressure switch adjustment Follow the below instruction according to the pressure switch installed Calibration of air pressure ...

Page 28: ...N EMERGENCY SWITCH AND ON THE RESET BUTTON IN THE EVENT OF REPEATED LOCKOUTS DO NOT PERSIST WITH THE RESET BUTTON AND CONTACT QUALIFIED PER SONNEL WHO WILL PROCEED TO ELIMINATE THE MALFUNCTION WARNING DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR COUPLING FLANGE CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT OPERATION 1 Set to the ON position the switch o...

Page 29: ...ceramic insulators clean adjust and replace if necessary page 31 remove and clean the oil nozzles IMPORTANT do not clean the nozzles using metallic or sharp utensils use only solvents or steam at the end of maintenance operations refit the burner turn it on and check the combustion If in doubt replace the defec tive nozzle s In case of intensive use of the burner the nozzles must be replaced at th...

Page 30: ...um cleaner to scrape off the scale use a metallic brush Note to replace the combustion head reverse the procedure described above Removing the oil gun Once the combustion head is removed as described before remove the oil gun as foloows 1 unscrew the connectors from the 2 oil pipes E in figure using 2 spanners to avoid loosening the connections attached to the distri butor block 2 loosen the screw...

Page 31: ...s 5 remove the electrodes and replace them referring to the values quoted on Fig 16 Cleaning and replacing the detection photoresistor When cleaning the photoresistive detector always use a clean cloth If necessary remove it from its slot to replace it ATTENTION avoid the ignition electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler s operation would be compromis...

Page 32: ... as follows 1 turn the burner s main switch to 0 Off position 2 disconnect the power mains 3 close the fuel cock of the supply line Burner disposal In case of disposal follow the instructions according to the laws in force in your country about the Disposal of materials series 9x LMO series 5xx LAL25 Minimum current intensity with flame LMO 45µA LAL25 8µA Maximum current intensity without flame LM...

Page 33: ...CLE DURING OPE RATION MAIN SWITCH OPEN LINE FUSE INTERVENTION MAX PRESSURE SWITCH FAULT FAN THERMAL CUTOUT INTERVENTION AUXILIARY RELAIS FUSES INTERVENTION CONTROL BOX FAULT SERVOCONTROL FAULT SMOKEY FLAME IGNITION TRANSFORMER FAULT IGNITION ELECTRODE DIRTY OR WRONG POSITIONED DIRTY NOZZLE FUEL SOLENOID VALVE DEFECTIVE PHOTORESISTOR DIRTY OR DEFECTIVE HI LO FLAME THERMOSTAT DEFECTIVE WRONG POSITIO...

Page 34: ... t5 Interval On completion of t5 terminal 20 receives power At the same time control outputs 9 to 11 and input 8 are galvanically separated from the LAL s control section LAL is now protected against reverse voltages from the load control circuit With the release of LR at terminal 20 the startup sequence of the LAL ends After a few idle steps steps with no contact position changes the sequence swi...

Page 35: ...4 A max 20 A peak Internal fuse T6 3H250V according to IEC 127 External fuse max 10 A Weight Device 1000 g Plug in base 165 g Sequence diagram Key t1 Prepurge time with air damper fully open t2 Safety time t3 Preignition time short Z connected to terminal 16 T3 Preignition time long Z connected to terminal 15 t3n Postignition time Z connected to terminal 15 t4 Interval between voltage at terminals...

Page 36: ...hing on by R W SB takes place Operation Lock out reset button EK is the key operating element for resetting the burner control and for activating deactivating the diagnostic functions The multicolour LED is the key indicating element for both visual diagnosis and interface diagnosis s Red l Yellow o Green Key m Off l Yellow o Green s Red Diagnosis of cause of fault After lock out the red fault sig...

Page 37: ...ck R Control thermostat or pressurestat SB Safety limit thermostat Si External primary fuse W Limit thermostat or pressure switch Z Ignition transformer t4 Interval from flame signal to release BV2 TSA Ignition safety time tw Waiting time for oil pre heating B Time of flame establishment C Operating position D Controlled shut down by R µC1 Microcontroller 1 µC2 Microcontroller 2 1 2 6 7 4 5 10 11 ...

Page 38: ...d separately 20m LMO14 LMO24 LMO44 Terminal 1 5 A 5 A 5 A Terminals 3 and 8 3 A 5 A 5 A Terminals 4 5 and 10 1 A 1 A 1A Terminals 6 1 A 1 A 2A Flame supervision with QRB and QRC QRB QRC Min detector current required with flame 45 µA 70 µA Min detector current permitted without flame 5 5 µA 5 5 µA Max possible with flame tipically 100 µA 100 µA Measurement circuit for detector current Key µA DC DC ...

Page 39: ......

Page 40: ...ia 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: ...LME73 000Ax PME73 831AxBC LME73 831AxBC Service instruction manual M12921CB Rel 1 2 02 2016 ...

Page 42: ...t reset button info button 3 multicolor signal lamp LED for operations and fault notifications 3 x 7 segment display for service fault and operating state information Interface for program module no function Passwords protect the different parameter levels against unauthorized access Basic settings that the plant operator can make on site require no password Functions Undervoltage detection Electr...

Page 43: ...press and simultaneously No adoption of value One menu level up Keep depressed for 1second for backup restore function First startup when PME is supplied or PME replacement First startup 1 insert a new PME 2 turn the power on The diplay shows rst and PrC one after the other 3 keep pushing the INFO button more than 3 seconds run appears PME parameters will be transferred to LME 4 at the end End and...

Page 44: ...ty time and load controller LR release P50 Green P50 Green 2nd safety time TSA2 P54 Green P54 Green P259 01 Actuator opens in low fire P54 Green P54 Green P260 Actuator closes in low fire oP1 Green oP1 Green Interval until release of load controller target analog or 3 position step input Operation oP Green Operation modulating operation Shutdown P10 Yellow Shutdown actuator opens in CLOSE position...

Page 45: ...ZL2 display and operating unit Visual diagnostics In normal operation the different operating states are indicated in the form of color codes according to the color code table given below Color code table for multicolor signal lamp LED State Color code Color Waiting time tw other waiting states OFF Ignition phase ignition controlled Blinking yellow Operation flame o k Green Operation flame not o k...

Page 46: ...Program sequence Version 1 Ignition load low fire Prepurging in high fire Parameter 515 1 condition parameter 259 01 0 seconds 6 ...

Page 47: ...Program sequence Version 2 Ignition load low fire Prepurging in high fire Parameter 515 1 condition parameter 259 01 0 seconds 7 ...

Page 48: ...ng after mains ON lockout Part 2 Prepurge time t1 with extraneous light test 36 Actuator closes in ignition load 38 Preignition t3 40 Postignition time t3n parameter 257 0 3 seconds 42 Flame detection 44 Interval t4 End of safety time TSA and burner valve 2 ON 50 2nd safety time t9 54 Parameter 259 01 Actuator opens in low fire Parameter 260 Actuator closes in low fire 72 End of operation checking...

Page 49: ...nection Misadjustment 7 x blinks Too many losses of flame during operation limitation of repetitions Faulty or soiled flame detector Faulty or soiled fuel valves Poor adjustment of burner 8 x blinks Free 9 x blinks Free 10 x blinks Wiring error or internal error output contacts other faults 12 x blinks Valve proving LT Fuel valve 1 V1 leaking 13 x blinks Valve proving LT Fuel valve 2 V2 leaking 14...

Page 50: ...954 approx 12 Operation Intensity Parameter 954 approx 13 Operating voltage AC 280 V 15 Mains frequency 50 60 Hz 6 Required detector current Min 70 μA Possible detector current Operation Max 700 μA Perm length of detector cable Normal cable laid separately Max 100 m Multicore cable not permitted Keys A Exposure to light C Electrolytic condenser 100 470 μF DC 10 25 V M Microammeter Ri max 5 000 Ω W...

Page 51: ...st not exceed a certain level Step 3 td3 Filling of test space Gas valve on the mains side opens to fill the test space Step 4 td2 Test gas pressure When the gas valve has closed the gas pressure in the test space must not drop below a certain level Controllo tenuta con pressostati separati Keys td1 Test atmospheric pressure td2 Test gas pressure td3 Filling of test space td4 Evacuation of test sp...

Page 52: ...t 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 Used as Reset key in the burner operation mode Used to enter a lower level menu Key Used for one menu level down Used to decrease a value Key Used for one menu level up Used to increase a a value Keys ESC By pressing and at the same time the ESCAPE function is perfor...

Page 53: ...n motor energised Ignition transformers energised Parameter setting mode Info mode Service mode Closing actuator Unit measure Opening actuator 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 54: ...y time ignition transformer OFF flame check Ph44 Interval End of safety time and fuel valve 1 V1 ON Ph50 2nd safety time TSA2 Ph54 P259 01 Actuator opens in low fire Ph54 P260 Actuator closes in low fire oP1 Interval until release of load controller target analog or 3 position step input Operation oP Operation modulating operation Shutdown Ph10 Shutdown actuator opens in CLOSE position home run Ph...

Page 55: ...ir pressure switch wel ded in working position Time out air pressure switch LP Air pressure switch LP is welded in working position Loc 6 Fault of actuator Actuator faulty or blocked Faulty connection Wrong adjustment Loc 7 Loss of flame Too many losses of flame during operation limitation of repetitions Faulty or soiled fuel valves Faulty or soiled flame detector Poor adjustment of burner Loc 8 F...

Page 56: ...16 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 57: ...from level writing from level 100 General 102 Identification date Read only Info 103 Identification number Read only 0 9999 1 Info 113 Burner identification Read only x xxxxxxxx 1 Info 164 Numbers of startups resettable Resettable 0 999999 1 Info Info 166 Total number of startups Read only 0 999999 1 Info 170 00 Switching cycles actuator relay K12 Read only 0 999999 1 Info 170 01 Switching cycles ...

Page 58: ...Edit Value range Resolution Factory setting Password level Password level number Min Max reading from level writing from level 700 Error history 701 Current error Read only Service 00 Error code 2 255 1 01 Startup meter reading 0 999999 1 02 MMI phase 03 Power value 0 100 1 702 Error history former 1 Read only Service 00 Error code 2 255 1 01 Startup meter reading 0 999999 1 02 MMI phase 03 Power ...

Page 59: ...19 900 Process data 936 Normalized speed Read only 0 100 0 01 Service 951 Mains voltage Read only 0 V LME73 000A1 175 V 1 V Service LME73 000A2 350 V 954 Flame intensity Read only 0 100 1 Service ...

Page 60: ...x PME73 831AxBC LME73 831AxBC Edit Value range Resolution Factory setting Password level Password level number Min Max reading from level writing from level 0 Internal parameter 41 Heating engineers password 4 characters Edit xxxx xxxx OEM 42 OEM s password 5 characters Edit xxxxx xxxxx OEM 60 Backup restore Edit Restore Backup SO 100 General 123 Min power control step Edit 1 10 0 1 SO SO 140 Mode...

Page 61: ...10 290 SO OEM 254 Response time detector error Edit 0 1 1 0 SO OEM 0 1 s 1 3 s 257 Gas Postignition time t3n 0 3 seconds Edit 0 s 13 23 s 0 147 s 2 205 SO OEM 259 00 Opening time of actuator t11 timeout for lockout Edit 0 s 1237 s 4 851 s 67 914 SO OEM 259 01 Opening time of actuator from ignition load to low fire position Edit 0 s 37 485 s 0 147 s 14 994 SO OEM 259 02 Opening time of actuator fro...

Page 62: ...ASZxx 3x required Edit 0 5 1 0 SO 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 41 42 60 123 140 242 243 244 245 259 01 Adjustable parameters from SO or OEM levels for LME73 831AxBC 22 ...

Page 63: ...23 ...

Page 64: ...Note Specifications and data subject to change Errors and omissions excepted ...

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