Unigas HTLX 1025.1 Installation Manual Download

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M039582CA 0.2 05/2021

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Microprocessor controlled

MANUAL OF INSTALLATION - USE - MAINTENANCE

LMV5x

Gas - light oil burners

HTLX 1025.1

HTLX 1030R

HTLX 1030.1

Summary of Contents for HTLX 1025.1

Page 1: ...M039582CA 0 2 05 2021 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Microprocessor controlled MANUAL OF INSTALLATION USE MAINTENANCE LMV5x Gas light oil burners HTLX 1025 1 HTLX 1030R HTLX 1030 1...

Page 2: ...e 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...

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 ga...

Page 4: ...s 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 7...

Page 5: ...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 PART I INSTALLATION MANUAL Bu...

Page 6: ...D control EI with no O2 trim control with VSD control EK with O2 trim control with VSD control BURNER TYPE HTLX1025 1 HTLX1030R HTLX1030 1 Output min max kW 1565 8600 1090 9250 1550 10600 Fuel MG Natu...

Page 7: ...PART I INSTALLATION MANUAL 7 Pressure in the Network gas flow rate curves GAS PRESSURE mbar HTLX1025 1 Stm3 h HTLX1030R Stm3 h GAS PRESSURE mbar HTLX1025 1 Stm3 h...

Page 8: ...40 1816 1219 520 446 496 709 175 660 672 845 M16 651 460 460 937 1000 204 733 1092 310 1175 448 329 100 1986 2086 848 30 445 545 1541 540 1816 1219 520 446 496 709 175 660 672 845 M16 651 460 460 937...

Page 9: ...TION Use intact and correctly dimensioned hoisting equipment conforms to the local regulations and health and safety regulations Do not stand under lifted loads Packing The burners are despatched in w...

Page 10: ...fy that a correct matching is possible with respect of the application involved To correctly match the burner to the boiler verify the type of the blast tube Verify the necessary input and the pressur...

Page 11: ...rforformed 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 da...

Page 12: ...mount the gas train proceed as follows NOTE the bellows unit the manual cutoff valve and the gaskets are not part of the standard supply WARNING before executing the connections to the gas pipe networ...

Page 13: ...BRUCIATORE 185 501939 PGMAX PGCP PGMI EV1 EV2 S EV2 EV1 PGMAX PGMIN VD R PGCP VD V VD V VD R PS PS pressure sensor Gas filter Example of gas train MBE A A C B B C 1 Mount flange into pipe systems Use...

Page 14: ...ax pressure switches set to 20 of the setpoint 2 Mounting on pipe Sensor position 5x DN according to MBE Pipe fitting with female thread size mount sensor with seal observe torque 3 The pressure senso...

Page 15: ...loor in order to prevent dust fall on the safety valve during maintenance operation SA SA TP D BS SKP1 SKP2 SIEMENS VGD Mounting positions T VR Performance range mbar neutral yellow red Spring colour...

Page 16: ...feed systems are provided install an automatic interception device see n 4 1 3 2 Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve NOTE in...

Page 17: ...as decribed before To change from a 1 pipe system to a 2 pipe system insert the by pass plug G as for ccw rota tion referring to the pump shaft Caution Changing the direction of rotation all connecti...

Page 18: ...ouplings should be sealed with removable sg component The number of jun ctions should be kept to a minimum as they are a possible source of leakage Do not use PTFE tape on the suction and return line...

Page 19: ...the pump being careful to avoid exchanging the inlet and return lines see the arrows marked on the pump that show the inlet and the return see prevoius paragraph Key 1 Inlet G3 4 2 Pressure gauge por...

Page 20: ...ck to the tank To change the delivery pressure act on the VRM adjusting screw of the pressure governor reading the oil pressure at the nozzle put a pressure gauge on the oil lance manifold CAUTION cap...

Page 21: ...enerator 2 Pressure outlet on the combustion chamber 3 Gas pressure outlet on the butterfly valve 4 Differential pressure gauge Measuring the gas pressure in the combustion head In order to measure th...

Page 22: ...t space to ambient pressure Test atmospheric pressure EV2 clo ses and keep this position for a preset time test time td1 The pressure switch PGCP has not to detect a rise of pressure Test space fillin...

Page 23: ...stments do not exceed a value that creates a hazardous condition to the burner Adjusting output pressure for positive pressure systems requires PS 10 40 or PS 50 200 Outlet pressure MIN 10 25 50 75 MA...

Page 24: ...rate ATTENTION To achieve the maximum flow rate close completely the return line FLOW RATE kg h DIMENSIONS Min Max 40 13 40 50 16 50 60 20 60 70 23 70 80 26 80 90 30 90 100 33 100 115 38 115 130 43 13...

Page 25: ...heck the pump motor rotation and keep pressing for some seconds until the oil circuit is charged 3 bleed the air from the M pressure gauge port Fig 6 by loosing the cap without removing it then releas...

Page 26: ...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...

Page 27: ...ll back nozzle 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 b...

Page 28: ...OR DISMANTLE ANY COMPONENT OF THE MACHINE OPERATE ONLY THE MAIN SWITCH WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH AND ON THE RESET BUTTON IN...

Page 29: ...n The fan motor starts and the pre purge phase as well Since the pre purge phase must be carried out at the maximum air rate the control box drives the actuator opening and when the maximum opening po...

Page 30: ...ws the main page and the system stops the safety chain is open waiting for the startup enabling signal standby Program phase no 12 Main page 3 check the fan motor rotation see related paragraph 4 make...

Page 31: ...wed about the last 21 faults occured Lockout History by selecting this item and pressing the ENTER key the Lockout History will be showed about the last 9 lockouts occured and the related date and hou...

Page 32: ...eys select Access w out pass access without password user level confirm by pressing ENTER The other levels require password reserved to the Technical Service to the Manifacurer etc The menu shown acce...

Page 33: ...that is the burner will light again at a temperature 1 lower than the set point Change value if needed by means of the arrow keys press ENTER to confirm and the press ESC to exit Press only ESC to ex...

Page 34: ...MM DD YY month day year choose the desired format and cofirm by pressing ENTER press ESC to exit PhysicalUnits it allows setting the measuring units for temperature and pressure Settable temperature u...

Page 35: ...to the maximum output Manual mode To by pass the thermal protection or not to let the buner operate in high flame stage maximum output after ignition the manual mode is provided To choose the manual...

Page 36: ...ipment manufacturer While making outlet pressure adjustments do not exceed a value that creates a hazardous condition to the burner Adjusting output pressure for positive pressure systems requires PS...

Page 37: ...lt in pressure stabilizer To increase or decrease gas pressure and therefore gas flow rate remove the cap T and use a screwdriver to adjust the regulating screw VR Turn clockwise to increase the flow...

Page 38: ...ed To calibrate the maximum pressure switch proceed as follows according to its mounting position remove the pressure switch plastic cover if the maximum pressure switch is mounted upstreaam the gas v...

Page 39: ...knob VRT Fasten VB screw when the adjustment is accomplished The diffuser position must be set during the commissioning according to the regulation needs The diffuser position is factory set as shown...

Page 40: ...lame or low flame according to the plant requirements Operation in high or low flame is signalled by LED N on the burner control panel NOTE if the burner is fitted with Dungs VPS504 the pre purgue pha...

Page 41: ...ing the nozzle whenever a questio nable flame shape appears Whenever the burner is used intensely we recommend preventively replacing the nozzle at the start of each heating season Clean and grease sl...

Page 42: ...loosen the two connectors E and remove the assembly as shown 4 Clean the combustion head by means of a vacuum cleaner scrape off the scale by means of a metallic brush Note to replace the combustion h...

Page 43: ...g adjusting the combustion head Adjust the electrodes posi tion according to the quotes shown othe next picture Checking the detection current To check the detection signal follow the scheme in the pi...

Page 44: ...ecessary 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 perfo...

Page 45: ...ssure switch damaged or bad links Check air pressure switch functions and links Burner control damaged Replace burner control BURNER LOCKS OUT WITHOUT ANY GAS FLOW Gas valves don t open Check voltage...

Page 46: ...of cables in the ignition transformer or into the electrodes Improve the installation Ignition transformer damaged Replace the transformer PUMP TOO NOISY Suction too high over 0 35 bar dirty filters...

Page 47: ...PART III MAINTENANCE 47...

Page 48: ...a 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 an...

Page 49: ...Siemens LMV5x Service Manual M12920CC rev 2 1 08 2017...

Page 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...8...

Page 57: ...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 58: ...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 59: ...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 60: ...12 2 2 LMV5x program structure...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...39...

Page 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 96: ...Note Specifications and data subject to change Errors and omissions excepted...

Page 97: ...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 98: ...Annex1 Example for motor cable...

Page 99: ......

Page 100: ...Annex 2 Example for sensor cable...

Page 101: ......

Page 102: ......

Page 103: ...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 104: ...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 105: ...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...

Page 106: ......

Page 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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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