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PART IV: MAINTENANCE

Содержание TLX512-FGR

Страница 1: ...M039592CA Rel 0 02 2021 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES Microprocessor controlled MANUAL OF INSTALLATION USE MAINTENANCE LMV5x Gas burners TLX512 FGR TLX515 FGR TLX520 FGR TLX525 FGR...

Страница 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...

Страница 3: ...ixtures DIRECTIVES AND STANDARDS Gas burners European directives Regulation 2016 426 UE appliances burning gaseous fuels 2014 35 UE Low Tension Directive 2014 30 UE Electromagnetic compatibility Direc...

Страница 4: ...quipment of machi nes EN 60335 2 Electrical equipment of non electric appliances for house hold and similar purposes Safety requirements Burner data plate For the following information please refer to...

Страница 5: ...he geometry of the flame Fuel and comburent are routed into separated ways as far as the zone of flame generation combustion chamber The air comburent and fuel gas are forced into the combustion chamb...

Страница 6: ...loc MBE Minimum gas pressure see gas curves Warning Burners are suitable only for indoor operation with a maximum relative humidity of 80 GAS CATEGORY COUNTRY I2H AT ES GR SE FI IE HU IS NO CZ DK GB I...

Страница 7: ...6 235 100 1385 1485 536 25 639 145 430 530 955 314 1444 1082 362 360 400 328 494 175 460 532 707 M14 552 390 390 693 390 802 160 642 942 353 942 356 235 TLX520 50 1385 1485 536 25 594 100 430 530 955...

Страница 8: ...Then subtract the backpressure The result is called pgas Draw a vertical line matching the furnace input value 600kW in the example quoted on the x axis as far as intercepitng the network pressure cur...

Страница 9: ...minimum output may be different from the Performance curve minimum Pressure in the Network gas flow rate curves natural gas GAS PRESSURE IN THE NETWORK mbar TLX512 FGR Gas rate Stm3 h TLX515 FGR Gas...

Страница 10: ...ure gauge or taken from the boiler s Technical specifications Measuring gas pressure in the combustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one...

Страница 11: ...erforformed 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 d...

Страница 12: ...9 B 1 boiler 2 burner 3 fan ventilator 4 cold combustion air regulation damper 5 differential pressure switch 6 condensate drain 7 FGR regulation damper 8 FGR temperature probe 9 economizer A Flue ga...

Страница 13: ...ive on the flange 5 install the burner into the boiler 6 fix the burner to the stud bolts by means of the fixing nuts according to the picture below 7 After fitting the burner to the boiler ensure tha...

Страница 14: ...in combustion chamber are included in the burner performance curve otherwise the choice of the burner must be revised consulting the burner manufacturer To choose the blast tube lenght consider the fo...

Страница 15: ...must be provided according to the flue gas damper size provided in the supply The damper for the flue gas and the one for ambient air both provided supplied loose must be installed onto a coupling tha...

Страница 16: ...on to the air canalization downstream the Draught fan using the pipe supplied 3 Connect the pressure switch to the burner s junction box or control panel if onboard by providing a cable to connect the...

Страница 17: ...h PGCP Legend 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...

Страница 18: ...open the fuel cock to avoid breaking the pressure regulator ALLA V FARFALLA GAS 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 f...

Страница 19: ...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 sensor i...

Страница 20: ...r 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 SKP...

Страница 21: ...without a neutral for the flame detection it is necessary to connect the RC circuit Siemens between the terminal 2 terminal X3 04 4 in case of LMV2x LMV3x LMV5x LME7x of the base and the earth termina...

Страница 22: ...ON position the main switch on the burner control panel 2 Check the flame control device is not locked and eventually reset it 3 Check the series of thermostats or pressure switches enables the burner...

Страница 23: ...ut changing data 3 ENTER key next level it confirms 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...

Страница 24: ...pen Flame the flame lights up Driving to low flame the actuator drives to low flame NOTE the C and A on the Once the ignition cycle ends the main page is shown Main page Set point temperature set poin...

Страница 25: ...story will be showed about the last 9 lockouts occured and the related date and hour Alarm act deact enable disable the horn in case of alarm Fault History To visualise the Fault History select it and...

Страница 26: ...press ENTER the following menu is shown Choose ControllerParam and press ENTER the following menu is shown Choose SetPointW1 and press ENTER Curr it shows the current set point use the arrows keys to...

Страница 27: ...u by menas of the arrow keys and press ENTER the display will show The deafult value for this parameter is10 that is the burner will turn off at a temperature 1 higher than the set point Change value...

Страница 28: ...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 units C o...

Страница 29: ...ion the manual mode is provided To choose the manual mode Manual Operation use the SELECT arrow keys Items to be set are the following SetLoad to set the required load percentage set the required perc...

Страница 30: ...o act on the holes figure B to improve the flame stability and NOx CO emission values If necessary close open the holes in figure B using the screws kit given with the burner WARNING During commission...

Страница 31: ...nts 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 MAX PS...

Страница 32: ...g nut VR set the value read on step 2 increased by the 30 replace the plastic cover Calibration of low gas pressure switch As for the gas pressure switch calibration proceed as follows Be sure that th...

Страница 33: ...gnition 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 combus...

Страница 34: ...ion head by a compressed air blow or in case of scale scrape it off by a scratchbrush Note to replace the combustion head reverse the procedure described above having care to place correctly the O rin...

Страница 35: ...Quotes Shown On The Next Picture ATTENTION avoid the ignition and detection electrodes to contact metallic parts blast tube head etc other wise the boiler s operation would be compromised Check the el...

Страница 36: ...the outside and remove the combustion head D 6 loose the screw of th eignition electrodes support E 7 remove the electrodes and replace them paying attention to the measures showed in figure F G 8 re...

Страница 37: ...mbustion head 2 by means of an allen key loose the fixing screws of the detection electrode ER and replace it 3 replace the combustion head ATTENTION avoid the electrode to get in touch with metallic...

Страница 38: ...ion electrodes to contact metallic parts blast tube head etc other wise the boiler operation would be compromised Check the electrodes position after any intervention on the combustion head electrodes...

Страница 39: ...laws in force in your country about the Disposal of materials WIRING DIAGRAMS Refer to the attached wiring diagrams WARNING 1 Electrical supply 230V 50Hz 1 a c 400V 50Hz 3N a c 2 Do not reverse phase...

Страница 40: ...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...

Страница 41: ...PART IV MAINTENANCE 41...

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Страница 44: ...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...

Страница 45: ...Siemens LMV5x Service Manual M12920CC rev 2 1 08 2017...

Страница 46: ...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...

Страница 47: ...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...

Страница 48: ...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...

Страница 49: ...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...

Страница 50: ...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...

Страница 51: ...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...

Страница 52: ...8...

Страница 53: ...9 1 4 1 Servomotor wiring example 1 4 2 Bus cable wiring on LMV5x and AZL doors 1 4 3 EARTH connection example...

Страница 54: ...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...

Страница 55: ...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...

Страница 56: ...12 2 2 LMV5x program structure...

Страница 57: ...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...

Страница 58: ...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...

Страница 59: ...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...

Страница 60: ...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...

Страница 61: ...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...

Страница 62: ...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...

Страница 63: ...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...

Страница 64: ...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...

Страница 65: ...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...

Страница 66: ...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...

Страница 67: ...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...

Страница 68: ...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...

Страница 69: ...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...

Страница 70: ...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...

Страница 71: ...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...

Страница 72: ...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...

Страница 73: ...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...

Страница 74: ...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...

Страница 75: ...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...

Страница 76: ...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...

Страница 77: ...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...

Страница 78: ...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...

Страница 79: ...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...

Страница 80: ...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...

Страница 81: ...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...

Страница 82: ...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...

Страница 83: ...39...

Страница 84: ...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...

Страница 85: ...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...

Страница 86: ...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...

Страница 87: ...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...

Страница 88: ...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...

Страница 89: ...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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Страница 92: ...Note Specifications and data subject to change Errors and omissions excepted...

Страница 93: ...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...

Страница 94: ...Annex1 Example for motor cable...

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Страница 96: ...Annex 2 Example for sensor cable...

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Страница 99: ...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...

Страница 100: ...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...

Страница 101: ...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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Страница 103: ...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...

Страница 104: ...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...

Страница 105: ...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...

Страница 106: ...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...

Страница 107: ...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...

Страница 108: ...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...

Страница 109: ...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...

Страница 110: ...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...

Страница 111: ...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...

Страница 112: ...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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