Unigas TP1030 Manual Download

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Summary of Contents for TP1030

Page 1: ...M039204CC Rel 2 1 04 2016 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Microprocessor controlled gas burners LMV5x MANUAL OF INSTALLATION USE MAINTENANCE TP1030 TP1050 TP1080...

Page 2: ...PECIAL INSTRUCTIONS FOR BURNERS z The burner should be installed in a suitable room with ventilation openings complying with the requirements of the regulations in force and sufficient for good combus...

Page 3: ...such as the development of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives 2009 142 EC Gas Directive 2006 95 CEC Low Tension Directive 2004 108 EC Electromagnetic...

Page 4: ...ments for house hold appliances electric tools and similar apparatus EN 746 2 Industrial thermoprocessing equipment Part 2 Safety requi rements for combustion and fuel handling systems EN 50165 Electr...

Page 5: ...SD control BURNER TYPE TP1030 TP1050 TP1080 Output min max kW 2500 13300 3500 15500 3500 19000 Fuel Natural gas Category see next paragraph Gas rate min max Stm3 h 265 1407 370 1640 370 2011 Controls...

Page 6: ...6 Country and usefulness gas categories GAS CATEGORY COUNTRY I2H AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH I2E LU PL I2E R B BE I2L NL I2ELL DE I2Er FR...

Page 7: ...0 TP1050 80 1864 544 1320 348 1898 1301 597 489 539 710 185 660 660 845 M16 651 460 1000 460 936 200 265 736 80 587 1092 322 1175 408 330 TP1050 100 1864 544 1320 348 1914 1317 597 489 539 710 185 660...

Page 8: ...8 Performance curves TP1030 TP1050 TP1080 To get the input in kcal h multiply value in kW by 860 Data are referred to standard conditions 1013mbar 15 C Performance range kW kW kW...

Page 9: ...he y axis pres sure value in the combustion chamber is not included To know the minimum pressure at the gas train inlet necessary to get the requested gas rate add the pressure value in the combustion...

Page 10: ...with gas train which is detached z gasket to be inserted between the burner and the boiler envelope containing this manual Control panel and fan packing according to the models Packing cases of this t...

Page 11: ...fan and the burner and according to the fan features as well Matching the burner to the boiler To correctly match the burner to the boiler verify the necessary input and the pressure in combustion cha...

Page 12: ...no 4 in the scheme above ATTENTION BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK BE SURE THAT THE MANUAL CUTOFF VALVES ARE CLOSED Gas train with valves group VGD 20 40 with built in gas pre...

Page 13: ...t be executed z connection from the filter with stabiliser to the gas supply network Fig 2 pipe port 3 for connecting the pilot gas train to the valves group of the main gas train connection to the ga...

Page 14: ...ordance with the direction of the arrow on the valve body z ensure that the bolts on the flanges are properly tightened z ensure that the connections with all components are tight z make certain that...

Page 15: ...m the gas valves group changes according to the spring provided with the valve group Fig 4 Fig 5 Fig 6 Performance range mbar 0 22 15 120 100 250 Spring colour neutral yellow red BS BS SKP1 SKP2 BS BS...

Page 16: ...r from the electrical board unscrewing the fixing screws 2 execute the electrical connections to the supply terminal board as shown in the following diagrams 3 check the direction of the fan motor see...

Page 17: ...essure outlet on the butterfly valve 4 Differential pressure gauge Measuring the gas pressure in the combustion head In order to measure the pressure in the combustion head insert the pressure gauge p...

Page 18: ...combustion head TP1080 Gas rate Stm3 h 0 10 20 30 40 50 60 70 80 90 100 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 0 20 40 60 80 1 00 1 20 1 40 1 60 400 500 600 700 800 900 1...

Page 19: ...njector gas valve flow rate proceed as follows 1 remove the protection on the bottom of the valve moving it counterclockwise see next picture 2 rotate clockwise the nut 1 as shown to close the valve c...

Page 20: ...s the data changing and jumps to the next menu parameter 4 SELECT keys they select a menu item and change the parameter values As far as the settings see the LMV5 related manual By following the air g...

Page 21: ...he combustion cycle starts the system will show the operating stages Prepurging program phase no 30 Driving to ignition position program phase no 36 Ignition position program phase no 38 Fuel the fuel...

Page 22: ...g it represents the lockout reset function Fault History by selecting this item and pressing the ENTER key the Lockout History will be showed about the last 21 faults occured Lockout History by select...

Page 23: ...select Params Display press ENTER the system will ask you to enter the proper password by means of the arrow keys select Access w out pass access without password user level confirm by pressing ENTER...

Page 24: ...ition controller To set these values select the item SD_ModOn SDOn by scrolling down the Load controller menu with the arrow keys and press ENTER the display will show The deafult value for this param...

Page 25: ...rtime mode desired and cofirm by pressing ENTER press ESC to exit Set the time zone Time EU US in the same way Languages it allows setting the current language choose the desired language and cofirm b...

Page 26: ...rts upthe Thermal shock protection activated message will be showed If this function is not enabled after startup the burner will rapidly increase the load according to the requested value and if nece...

Page 27: ...oes not increase if the CO values are higher than the limits laid down by law slowly open the cutoff valve as to get values lower than these limits z Check that the burner is operating correctly z Clo...

Page 28: ...28 System z remove the pressure switch plastic cover z adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch z replace the plastic cover Fig 9 VR...

Page 29: ...UNCTIONING OF THE BURNER THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE E G DISC...

Page 30: ...and remains constant 6 Then LMV has accomplished the control cycle and enables the burner to operate Otherwise LMV wil lock out the burner operation To reset press the reset button 7 Once the prepurge...

Page 31: ...as follows 1 remove the cap unscrewing the fixing screws A 2 remove the filtering cartridge B clean it using water and soap blow it with compressed air or replace it if necessary 3 replace the cartrid...

Page 32: ...spring in the gas valve group proceed as follows 1 Carefully twist the protection cap 1 and the O ring 2 2 remove the set value spring 3 from housing 4 3 Replace spring 3 4 Carefully insert the new se...

Page 33: ...ignition elecctrode E Fig 11 Detailed view of the combustion head with pilot P and ignition elecctrode E Observe the values quoted on figure Fig 12 ATTENTION avoid the ignition electrode to contact me...

Page 34: ...acing the detection photocell To clean replace the detection photocell proceed as follows 1 Disconnect the system from the electrical power supply 2 Shut off the gas supply 3 remove the photocell from...

Page 35: ...th detector QRI Minimum detection signal 3 5Vdc Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner main switch to 0 Off position 2 disconnect the power mains 3...

Page 36: ...er to the attached wiring diagrams WARNING 1 Electrical supply 400V 50Hz 3N a c 2 Do not reverse phase with neutral 3 Ensure burner is properly earthed 4 Refer to the attached document RECOMMENDATIONS...

Page 37: ...IMUM GAS PRESSURE SWITCH DEFECTIVE z z THERMOSTATS PRESSURE SWITCHES DEFECTIVES z z z OVERLOAD TRIPPED INTERVENTION z AUXILIARIES FUSE INTERRUPTED z DEFECTIVE CONTROL BOX z z z z z DEFECTIVE ACTUATOR...

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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 a...

Page 41: ...Siemens LMV5x Service Manual M12920CC rev 2 1 08 2017...

Page 42: ...harmful Before any cleaning or servicing operation disconnect the unit from the mains by turning the master switch OFF and or through the cut out devices that are provided Make sure that inlet or exh...

Page 43: ...2 Configuration of a pressure or a temperature probe type at X61 door 20 6 2 1 Configuration of a pressure or a temperature probe signal at X61 door 20 6 3 Configuration of the X62 door input signal...

Page 44: ...must be connected to earth PE Volt must be 0 V between N PE NOTE PE protection earth it is not FE FE functional earth 1 1 2 Protective Earth PE and Functional Earth FE Protective Earth PE Known as an...

Page 45: ...les and to the burner housing e g use a electrical insulating conduit or distance parts e g plastic material see also Appendix Example for wiring earthing and shielding the LMV5 System Prefer a double...

Page 46: ...lso Appendix Example for wiring earthing and shielding the LMV5 System 1 3 2 Shielding The LMV5 FE terminals for the shields are LMV5 internally connected with X52 4 this terminal must be connect exte...

Page 47: ...ables for the Load controller Temperature or Pressure sensor set point load output at the LMV5 X60 X61 X62 X63 Together in cable duct 2 for Line voltage e g Cable for Ignition transformer Cables for o...

Page 48: ...8...

Page 49: ...9 1 4 1 Servomotor wiring example 1 4 2 Bus cable wiring on LMV5x and AZL doors 1 4 3 EARTH connection example...

Page 50: ...urner will immediately turns off keys socket The user interface is made of display it shows menus and parameters ESC key previous level it goes back to the previous level menu or exits the programming...

Page 51: ...ition position phase 38 The burner remains in that position because this is the only one work point in memory The fuel air ratio curve must be set until the maximum load limit 100 output During the se...

Page 52: ...12 2 2 LMV5x program structure...

Page 53: ...ED TO NOT USE O2 MONITORING IF FGR IS INSTALLED AND ACTIVE 2 3 Burner ID number The burner ID number corresponds to the burner serial number NOTE in case of call to the Service Center always tell the...

Page 54: ...rmed by pressing Enter Display before the first password character is entered Enter Password The example displays when entering the third password character Enter Password S If the check of the passwo...

Page 55: ...nals 318 and 319 of the burner supply terminal block see below the system will lead to an immediate burner lockout In case of burner designed with automatic pull out system from the generator the burn...

Page 56: ...address an actuator choose the corresponding actuator and follow the instructions on display When the actuator green LED flashes it means that one of the following function is set according to the nu...

Page 57: ...o according to the next procedure By following the next table set both parameter OperatRampMod and TimeNoFlame to set the ramp up stop times for the VSD and the actuator opening speed from 0 to 90 Fol...

Page 58: ...al output from the LMV to the client DCS or PLC Output Value Selection are Load Load 0 O2 Pos Air Pos Fuel Pos Aux1 Pos Aux2 Pos Aux3 Speed VSD Flame Temp Pt1000 TempNi1000 Temp Pt100 Temp X61 Press X...

Page 59: ...level 5th level 6th level Description Params Display Menu level for making the parameter set tings LoadController Settings for the internal load controller Configuration General configuration of the l...

Page 60: ...ens End of pressure measuring range for input X61 0 99 9 bar 0 2000 C 0 99 9 bar 0 2000 C Set the probe value Example if a max 10bar Siemens sensor is used the voltage output signal will be 0 V at 0 b...

Page 61: ...6th level Description Params Display Menu level for making the t Params Display SD ModOn General configuration of the load SD ModOn SD ModOff General configuration of SD ModOff the display will show T...

Page 62: ...for internal load controller StandardParam Adaption very fast fast normal slow very slow It is possible to manually set the PID parameters to any value in the setting range shown below to activate a...

Page 63: ...100 Ni1000 or Pt 1000 temperature sensor is connected to X60 3 and X60 4 terminals ATTENTION basically these parameters provide a function similar to the safety thermostat one but can not replace it T...

Page 64: ...of the menu by means the Esc 1st level 2nd level 3rd level 4th level 5th level Range Description Params Display Menu level for making the parameter settings VSD Module Settings for the VSD module Conf...

Page 65: ...ogramming levels of the menu by means the Esc 1st level 2nd level 3rd level 4th level 5th level 6th level Description Params Display Menu level for making the para meter set tings RatioControl GasSett...

Page 66: ...corresponding to a hypothetic low flame stage Note points P1 and P2 are temporally mentioned 10 and 100 load independently from the actual load The operator can name the load on each point without re...

Page 67: ...of oil ATTENTION as for increasing by few degrees it means that the increasing must be performed in order to avoid great excess of air or defect of air Therefore the increasing operation must be perfo...

Page 68: ...ir actuator Do not exit by pressing Esc from the values column because data will not be stored Press arrows to select another actuator to be set for example press to choose Fuel Press keys to change t...

Page 69: ...the other points So it is necessary to check the adjustment of the points already set ATTENTION for proper operation it is necessary that the curve of each actuator does not reverse its slope ATTENTI...

Page 70: ...cts are the following 1 Pressures have reciprocal effects 2 The reduction of O2 can lead to a significant increase of NOx levels As a result of these reciprocal effects it is difficult if not impossib...

Page 71: ...ngs for firing on Gas or on Oil AirActuator GasActuat OilActuat AuxActuator AuxActuator 2 AuxActuator 3 AuxActuator 3 AuxActuator 3 MUST be chosen After the addressing activate the FGR servomotor 1st...

Page 72: ...Open 10 4 Setting the load controller mode see the previous chapter regolazione senza FGR WARNING If one of the intLC internal Load Controller option must be choice a temperature sensor cannot be con...

Page 73: ...ulation temperature Auxiliary actuator 3 maintains the ignition position until an adjustable temperature is reached parameter FRG On Temp During the operation the burner regulate its load as per the s...

Page 74: ...inimum amount of flue gas The position is also used to ensure a defined damper position for emergency operation or automatically deactivated flue gas recirculation FGR FGR MaxPos Fact Maximum limitati...

Page 75: ...on FGR factor of 50 leads to a 50 reduction of the damper positions If the temperature value of the smoke during the operation of the burner is higher than the temperature value during the commissioni...

Page 76: ...StageLoad 0 100 15 StageSetp_M od 1 100 Wcurrent 5 Stage Setp_Stage 1 100 Wcurrent 5 MaxTme Mod 1 63 min 3 min MaxTmeStage 1 63 min 3 min Cold start thermal shock protection maximum time per step mult...

Page 77: ...tion this function can be set at user level also see chapter manual operation the CSTP function is momentary excluded when enabling the automatic operation again the CSTP function previously set at Se...

Page 78: ...assword Description ManualOpe ration Menu level for activating manual operation with the preselected load Au tom Manual Off Selection of manual or automatic operation Automatic Burner on Burner off Us...

Page 79: ...39...

Page 80: ...V 10 15 50 60 Hz Imax 5 A PIN3 x Protective earth PE PIN4 x Supply voltage neutral conductor N PIN5 x Supply voltage live conductor L AC 230 V 10 15 50 60 Hz fuse 6 3 AT DIN EN 60 127 2 5 X4 01 Fuel s...

Page 81: ...5 mA PIN2 x Controller closes stage 3 AC 230 V 10 15 50 60 Hz Imax 1 5 mA PIN3 x Controller opens stage 2 AC 230 V 10 15 50 60 Hz Imax 1 5 mA PIN4 x Power signal for control of con troller AC 230 V 10...

Page 82: ...ductor N PIN3 Fuel valve 2 oil AC 230 V 10 15 50 60 Hz 1 A cos 0 4 X7 02 PIN1 x Protective earth PE PIN2 x Neutral conductor N PIN3 Fuel valve 3 oil AC 230 V 10 15 50 60 Hz 1 A cos 0 4 X7 03 PIN1 x Pr...

Page 83: ...oil AC 230 V 10 15 50 60 Hz 1 A cos 0 4 X9 01 PIN4 x Fuel valve 1 gas AC 230 V 10 15 50 60 Hz 2 A cos 0 4 PIN3 x Fuel valve 2 gas AC 230 V 10 15 50 60 Hz 2 A cos 0 4 PIN2 x Fuel valve gas AC 230 V 10...

Page 84: ...vely QRA2 QRA4 U QRA10 refer to section Description of inputs and out puts Umax X3 04 PINS Imax 0 5 mA X50 PIN6 x Reference ground PELV PIN5 x Communication signal CANL DC U 5 V Rw 120 level to ISO D...

Page 85: ...mperature sensor input PT100 X61 PIN5 x Functional earth for shield connec tion PIN4 x Reference ground PIN3 x Current input for temperature pressure signal 0 4 20 mA DC 0 4 20 mA PIN2 x Voltage input...

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Page 88: ...Note Specifications and data subject to change Errors and omissions excepted...

Page 89: ...d an earth external wire for the motor ground The cable for the 4 20mA signal that controls the VSD must be shielded only LMV5x side ends connected to the equipotential terminal If the VSD is not insi...

Page 90: ...Annex1 Example for motor cable...

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Page 92: ...Annex 2 Example for sensor cable...

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Page 95: ...E Power supply Line voltage Gas L1 High Voltage Transformer N M Power supply Line voltage FE X73 Speed sensor VSD Fan Motor Separate conduit shielded line voltage cable X70 X10 02 X9 01 X4 02 Separate...

Page 96: ...ion and current fuel throughput The LMV52 system uses an O2 sensor QGO20 an external O2 module and the standard components of the LMV51 sys tem The PLL O2 module is a detached measuring module for the...

Page 97: ...defined system cables AGG5 641 and AGG5 631 result from the points of intersection in the graph 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 0 5 1 25 2 3 5 7 8 AGG5 631 AG...

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Page 99: ...CAN bus cable 100 m Whenever the distance between the LMV5 and the last actuator exceeds 20 m or if more than one SQM48 is used on the burner refer to sizing chart Determination of maximum cable leng...

Page 100: ...N F T4 AC2 12 V 5 5 3 Not used M L Power trafo 2 AGG5 2 No bus termination No bus termination Bus termination 5 5 5 5 No bus termination No bus termination Installation in the control panel actuator...

Page 101: ...owered by a sec ond transformer to be located near the actuators and the O2 module Connect the power supply line from that transformer to the O2 module PLL52 in ex ample 3a SA6 in example 3b Auxiliary...

Page 102: ...n facility 18 8 1 Inputs and outputs Mounting panel shielding connection Communication and power supply for LMV52 Mounting panel shielding connection Communication and power supply Temperature sensor...

Page 103: ...l o w e d t o j o i n t h e f l u e g a s e s o n t h e i r w a y f r o m t h e b u r n e r t o t h e d e t e c t o r D F l o w v e l o c i t y 1 1 0 m s F l u e g a s t e m p e r a t u r e a t t h e...

Page 104: ...e p o u r B 1 B 2 B 2 T e n s i o n d e t h e r m o c o u p l e M U 3 S i g n a l d e l l m e n t d e c p m p e n s a t i o n d e t e m p r a t u r e G 2 A l i m e n t a t i o n d e l l m e n t d e c...

Page 105: ...k s i t i s r e c o m m e n d e d t o l e a v e t h e m e a s u r i n g s y s t e m Q G O a n d R P O s w i t c h e d o n D u r i n g t h e h e a t i n g u p p h a s e t h e d e t e c t o r c o u l d...

Page 106: ...A G O 2 0 0 0 2 A A R a u c h g a s e i n t r i t t B R a u c h g a s a u s t r i t t C K e r b e D F l a c h d i c h t u n g b e i l i e g e n d L 1 8 0 m m f o r A G O 2 0 0 0 1 A L 2 6 0 m m f o r...

Page 107: ...r h Transport DIN EN 60 721 3 2 Climatic conditions class 2K2 Mechanical conditions class 2M2 Temperature range 30 70 C Humidity 95 r h Operation DIN EN 60 721 3 3 Climatic conditions class 3K5 Mecha...

Page 108: ...GND SHIELD 12VAC1 12VAC2 CANH CANL GND SHIELD AZL5 x FE FE SQM4 LMV52 Brown brn White wh Yellow yl Green grn Black blk Brown brn White wh Yellow yl Green grn Black blk Flue gas temperature PLL52 PLL5...

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