5a. Gas pressure switch, mini
5b. Gas pressure switch, maxi
When Bio gas is used, Bentone shall always be contacted.
6a. Main valve
6b. Safety valve
1)
7. Valve proving system
9. Air pressure switch
10. Gas burner control
Pos. 5b, 7: Components not required
according to EN 676.
1)
Required over 1200 kW according
to EN 676.
172 415 04 03-01
Page 7
MOUNTING ON THE BOILER
Remove the combustion unit from the
burner. Fit the enclosed flange and
gasket to the boiler.If new fixing holes
must be drilled, use the fixing flange as
a pattern.
REMOVAL OF VALVE UNIT FROM
BURNER
Remove the plug-in contact from the
multi-bloc. Loosen the union nut.
REMOVAL OF FAN HOUSE UNIT
FROM BURNER.
Loosen the screws. Swing out the fan
house. Remove the ionisation and ignition cables from the electrodes. Remove the bolt on the flange.
INSTALLATION EXAMPLE
Connect the gas to the burner by
means of the ball valve. Ensure that the
union nut, ball valve and tubing make
it easy to remove the burner for inspection and service.
172 205 36 93-01
Page 8
ELECTRIC EQUIPMENT
GAS BURNER CONTROL: LGB21/LMG21
WIRING DIAGRAM
If there is no plug-in contact (X2) on
the boiler, connect to the contact
enclosed. In case the twin thermostat
is in series on incoming phase L1,
a loop between the terminals T1 and
T2 is necessary.
COMPONENT LIST
A1Gas burner control
A2Twin thermostat
B1Ionization electrode
F1Fuse
H1Alarm, 220 V
172 425 16 99-02Mains connection in accordance with local regulations.
Page 9
ELECTRIC EQUIPMENT
CONTROL DIAGNOSIS UNDER FAULT CONDITIONS AND LOCKOUT INDICATION
GAS BURNER CONTROL: LMG ...
Operating concept
Diagnosis of cause of fault
Red LED on
FS
AL
During the time the cause of
the fault is diagnosed, the
control outputs are deactivated.
- The burner remains shut
down
- Exception: fault status signal «AL» at terminal 10
The burner is switched on
only after a reset is made.
- Press lockout reset button
for 0.5...3 seconds
• Burner control has initiated lockout • Reset
> Red fault LED onPress lockout reset button for 0.5 ...3 s
• Diagnosis of cause of fault
- Wait >10 s
- Press lockout reset buttonj for >3 s
- Read blink code of red fault LED
AL
>«Error code table»
After lockout, the red fault LED is steady on. For reading the cause of fault, refer to the
blink code given in the following table:
LED on (waiting time 10 s)
Fault
Press lockout reset button
for > 3 s
Blink code
Off
Approx.
3 s
Blink code
Error code table
Blink codePossible cause
2 x• No establishment of flame at the end of «TSA»
••- Faulty or soiled detector electrode
- Faulty or soiled fuel valves
- Poor adjustment of burner
3 x• Air pressure monitor does not close
•••- «LP» faulty
- «LP» incorrectly adjusted
- Fan motor does not run
4 x• Air pressure monitor does not open or extraneous light on
burner startup
•••• -«LP» faulty
- «LP» incorrectly adjusted
5 x• Extraneous light during pre-purging
•••••- Or internal device fault
7 x• Loss of flame during operation
•••••••- Poor adjustment of burner
- Faulty or soiled fuel valves
- Short-circuit between detector electrode and ground
8...17 x• Free
••••••••
..................
••••••••••
•••••••
18 x• Air pressure monitor opens during pre-purging or operation
••••••••••- «LP» incorrectly adjusted
••••••••- Four time s loss of fla me dur ing op erati on (LMG25)
19 x• Faulty output contact
••••••••••- Wiring error
•••••••••- External power supply on output terminal
20 x• Internal device fault
••••••••••
••••••••••
172 425 57 01-01
Page 10
MEASURES AND CHECKS BEFORE START-UP, 1-STAGE BURNER
INNER ASSEMBLY
Ensure that the ignition and ionisation electrodes are correctly adjusted. The sketch shows the correct
measurements.
GAS QUALITY
Ensure that the burner head is meant
for the gas quality to be used (see
fig.).
VENTING
The gas line is vented by loosening
the screw on the test nipple for the
inlet pressure. Connect a plastic hose
and conduct the gas into the open.
After having vented the gas line tighten the screw again.
LEAKAGE CONTROL
When making a leakage control of the
gas supply system the solenoid valve
should be closed. Connect a pressure gauge to the test nipple Pa, see fig.
The test pressure in the system should
be 1,5x max. inlet pressure or min.
150 mbar. If any leakage, locate the
source by means of soapy water or a
leak location spray. After tightening
repeat the test.
LEAKAGE CONTROL
ELECTRIC FUNCTION TEST:
Ensure that phase and neutral are not
reversed. The gas shut-off cock
should be closed.To prevent the gas
pressure switch from locking out it
should be linked temporarily.
After the main switch has been switched on and the thermostats have
been adjusted the pre-purging period
begins (30-35sec.). At the end of this
period the pre-ignition period starts
(0,5-2,5 sec. dependent on the design of the gas control). The gas valve
is energized and opens and flame is
established. At the end of the safety
time (2-3 sec.) the gas control locks
out. The solenoid valve and the motor
will be "dead". Remove the link from
the gas pressure switch after the test
is finished.
NOTE! APPLIES ONLY TO GAS
BURNER CONTROL LFL1.
When using LPG (Propane) the burner should be connected for postpurge. Move connection to terminal 6
to terminal 7 in the base of LFL1.
172 205 33 97-02
Page 11
MEASURES AND CHECKS BEFORE START-UP
INNER ASSEMBLY
Town gas
INNER ASSEMBLY
Natural gas, LPG
LGP
INNER ASSEMBLY
Biogas (UV-detector)
2,5
Natural gas
8
172 205 78 98-01
Page 12
DETERMINA TION OF GAS VOLUME FOR THE INST ALLA TION
Specifications on natural gas, town
gas and bio gas vary. For more exact
information please contact the gas
distributor.
Gas qualitykWh/Nm
Net calorific value
Natural gas10.337 1448 865
Propane26.093 64722 350
Butane34.3123 57129 492
Town gas4.917 6534 213
Bio gas7.025 2196 019
EXAMPLE HOW TO CALCULATE THE GAS VOLUME (NATURAL GAS)
V =Gas volume Nm3/h
Q =Boiler output 120 kW
Hu=Calorific value of the gas A. 37 144 kJ/Nm3, B. 10.3 kWh/Nm
=Expected efficiency 90%
Ex. A
.
Q 3 600
V =
H
u
=
.
.
120 3 60012,9 Nm3/h
37 144 0,90
.
3
3
kJ/Nm
3
kcal/Nm
3
Ex. B
12012,9 Nm3/h
V =
10,3 0,90
.
If the barometer height, pressure and temperature of the gas deviate very much
from the normal values this must be taken into account as follows:
f=273 + t .1013,25
273B + P
u
t=Temperature of the gas at the gas meter (15°C)
B =Barometer height (945 mbar)
Pu=Pressure of the gas at the gas meter (15,0 mbar)
f=273 + 151013,25
.
273945 + 15
f1.11
The gas volume read on the gas meter actually reads 1,11 . 12,9 = 14,4 m3/h.
Loosen the fixing screw a. Turn the
hydraulic device b:
to the right = the gas flow is reduced
to the left = the gas flow is increased
Do not forget to tighten the fixing screw
again.
The flow adjustment can also be made
by means of the governor. Adjust the
outlet pressure to a value giving the
desired gas flow on the fully open
valve. At small capacities (gas flows) it
is also necessary to adjust as abore.
ADJUSTMENT OF GOVERNOR
Adjust outlet pressure from governor
by means of a screw . Min. and max.
outlet pressures corresponds to appr.
60 turns of the spring. It is not possible
to change pressure springs in order to
change the outlet pressure.
Turn to the right = the outlet pressure
is increased
Turn to the left = the outlet pressure is
reduced
FLOW ADJUSTMENT
ADJUSTMENT OF START GAS
FLOW
Remove the protective cover c.
Turn the adjustment knob d (use the
protective cover as a tool) to the desired start gas flow.
Turn to the right = the start gas flow is
reduced
Turn to the left = the start gas flow is
increased
ADJUSTMENT OF GOVERNOR
ADJUSTMENT OF START GAS
FLOW
172 505 02 97-02
Page 14
GENERAL INSTRUCTIONS
ADJUSTMENT OF BURNER
The burner is from the factory pre-set
to an average value that must then be
adjusted to the boiler in question.
All burner adjustments must be made in
accordance with boiler manu-facturers
instructions.These must include the
checking of flue gas temperatures,
average water temperature and CO2 or
O2 concentration.
GENERAL INSTRUCTIONS
The installation of the gas burner must
be carried out in accordance with
current regulations and standards. The
installers of gas burners should therefore be acquainted with all regulations
and ensure that the installation complies with the requirements. The installation, mounting and adjustment should
be made with the greatest care and
only the correct gas should be used.
OPERATING INSTRUCTIONS
The operating instructions accompanying
the burner should be left in a prominent
position in the boiler room.
SERVICE
A general rule is that the lower capacity the smaller the opening between
brake plate and combustion device.
Service should only be carried out by
qualified personnel. Replacement
parts should be of the same make
and approved by the same authoriti-
COMMISSIONING OF INSTALLATION
Control of the combustion. The combustion quality is checked by means
of a flue gas analysis device. Adjust
the burner to appr. 20% excess air in
accordance with the table. Check the
flue gas temperature. Calculate the
es as the original. If the burner is
converted to fire another gas quality it
must be re-commissioned. If town
gas is to be fired the combustion head
must be converted and the gas train
adjusted to suit (e.g.a larger gas armature or a different spring in the
governor may be required).
efficiency. Check also the actual gas
volume on the gas meter so that the
correct input is achieved.
Gas qualityCO2%0
%max. CO2%
2
lambda 1,2
Natural gas10,03,511,9
LPG11,53,513,9
INSTRUCTIONS
The user should be thoroughly instructed in the function of the gas
burner and the whole installation. The
supplier must instruct the user.
INSPECTION AND MAINTENANCE
Daily inspection is advisable.
START UP
After the burner has been fitted to the
boiler and the electric connection, the
leakage control, the venting and the
electric function test have been carried out, the burner will be ready for
start-up.
Howerer, study the sections dealing
with adjustments of multi-bloc, combustion air and combustion head.
Open the ball valve and switch on the
main switch. If the burner starts the
actual adjustment can be made.
ADJUSTMENT OF BURNER HEAD
The burner is equipped with an adjustment device changing the position
of the brake plate in the burner head.
This is used to adjust the correct pressure drop over the combustion device
in order to obtain a good pulsation free
combustion.
Which position to use depends on
input and overpressure in the boiler.
172 305 28 97-01
Page 15
GENERAL INSTRUCTIONS, 1-STAGE BURNER
AIR ADJUSTMENT
Loosen the stop screw and turn the
knob along the scale to the desired
position and tighten the screw. Check
the air adjustment by making a flue
gas analysis.
ADJUSTMENT OF BRAKE PLATE
-Loosen the screw on the adjustment device.
-To reduce the opening: turn the
knob to the left.
-To increase the opening: turn the
knob to the right.
The adjustment of the position of the
brake plate affects the air flow. It is
therefore always necessary to make
a fine adjustment of the air by means
of the adjustment device of the burner.
CONTROL OF BURNER HEAD
To check the burner head, brake plate and electrodes proceed as follows:
Loosen the nuts a. Swing out the
burner. Remove the screw b and the
knob for adjustment of burner head.
Loosen the screw c so much so that
the inner assembly can be pulled out.
AIR ADJUSTMENT
CONTROL OF BURNER HEAD
ADJUSTMENT OF INNER ASSEMBLY
172 305 31 94-01
Page 16
GENERAL INSTRUCTION
FLAME MONITORING AND MEASUREMENT OF IONISATION CURRENT
The burner is monitored according to
the ionisation principle. Check the ionisation current on start-up and on
each service call.
The reason for a low ionisation current
may be leaking currents, bad connection to earth, dirt or a faulty position of
the flame electrode in the burner head.
Sometimes also a faulty gas/air mixture may cause too weak a ionisation
current.
The ionisation current is measured by
means of a microampere meter (µA)
connected in series with the flame
electrode and the gas burner control.
Connect the µA-meter, see figure.
Min. required ionisation current according to table. In practice this current must be considerably higher, preferably more than 10 µA. All the gas
burners are equipped with a ionisation
cable that can be slit which facilitates
the connection of the µA-device.
ADJUSTEMNT OF MAX. GAS PRESSURE SWITCH
The burner is equipped with a max. gas
pressure switch only on request. It
should stop the burner if the gas pressure exceeds the set value. The burner
can then only be re-started manually
(gas burner control or overpressure
switch).
Remove the protective cover. Connect
a pressure gauge for measuring the
rated gas pressure. Decide on pressure at which the gas pressure switch
should switch off. Turn the adjustment
knob to this value. Tolerance on the
scale ±15%.
Gas controlConnection to terminalMin. ionisation
in gas controlcurrent required
LMG12 µ A
LGB110 µ A
LFL2410 µ A
MMI 81025 µ A
TMG 740-315 µ A
ADJUSTMENT OF AIR PRESSURE
SWITCH
The air presure switch should stop the
burner if the air volume is reduced.
The air proving device shall be adjusted in such a way that if there is
insufficient air supply at the highest or
lowest burner operating stage, the
device operates before the supervised
pressure is less than 80% of the pressure at the controlled stage and the CO
content of the combustion products
exceeds 1% by volume.
AIR PRESSURE SWITCH:
Adjustment range ca:
1-10 mbarLGW 10
2,5-50 mbarLGW 50
GAS PRESSURE SWITCHES:
Adjustment range:
2,5-50 mbarGW 50
5-150 mbarGW 150
ADJUSTMENT OF MIN. GAS PRESSURE SWITCH
The min. pressure switch should react
if the gas pressure is too low and
prevent the burner from starting. Too
low a gas pressure during operation
should stop the burner. The burner
may start again when the rated gas
pressure has been reached.
Remove the protective cover. Connect
a pressure gauge for measuring the
rated pressure. Decide on pressure at
which the gas switch should switch off.
Set this pressure by means of the
valve. Carefully turn the knob (see
figure) until the gas pressure switch
switches off. The value shown on the
scale should then approximately correspond with the value shown on the
pressure gauge. Tolerance on scale
appr. ± 15 %. Open the ball valve.
FLAME MONITORING
GAS PRESSURE SWITCH, AIR
PRESSURE SWITCH
172 305 25 00-01
Page 17
HANDING OVER OF THE INST ALLA TION
-Make repeated start attempts to
ensure that the adjustments function.
-Close the ball valve during operation to check that the gas switch
switches off at the set value.
-Remove the hose for the air pressure switch to check that the burner
locks out.
-Check that all protective covers
and measurement nipples are
mounted and fastened.
-Fill out necessary test reports.
-Instruct the persons in charge of the
operation on the service and maintenance of the installation and what
to do should any troubles occur.
-Inspection and service must only
be carried out by authorized
people.
FAULT LOCATION, FUNCTIONAL
TROUBLES
Trouble free operation is dependent on
three factors: electricity, gas and air
supply. Should there be any changes
in the ratio between these three factors
there is a risk of break downs. It has
been proved that most break downs are
caused by simple faults. Before calling
the service engineer, the following
should therefore be checked:
-Is the gas cock open?
-Are all fuses in order and the current switched on?
-Are the thermostats correctly set?
-Are pressostats, overheating protection etc. in operating position
and not locked-out?
-Is the gas pressure sufficient?
-Is the gas burner control in start
position?
-Has the gas control or the motor
protector locked out? - Reset.
-Is the circulation pump in operation?
-Is there a supply of fresh air to the
installation?
If integral components are of a different make from what is stated in this
manual, see the enclosed loose-leaf.
172 305 17 93-01
Page 18
FAUL T LOCA TION GUIDE
Gas burner
The basis for trouble free operation can only be ensured
by the correct combined effect of the three factors:
electricity, gas flow and combustion air. Should any of
these factors change troubles may arise.
It has been proved that many troubles have rather simple
causes. Before calling the serviceman the following
checks should be made:
1. Are the gas cocks of the installation open?
2. Are the fuses in order and the current switched on?
3. Are the controls (room thermostat, boiler thermostat
etc.) correctly adjusted?
4. Is the gas pressure to the burner sufficient?
5. Is the gas relay of the burner ready for start and not
locked out?
6. Is the air supply to the burner sufficient?
CAUSE
To facilitate fault location we have drawn up a scheme
showing the most frequent faults in a gas burner installation and the remedies.
REMEDY
The burner does not start
No gas
No voltage
The burner motor fails to start
The gas relay is defective
Burner motor is running but no ignition after the prepurge time has elapsed
No voltage on the terminals
The ignition electrodes in contact with each other or with
earth
The porcelain of the electrodes is broken
Check that all gas cocks are open.
Check fuses, thermostats and electrical connections.
The thermal protection has locked out. Motor defective.
Replace
Check the contact. Replace faulty relay
Adjust
Replace the electrodes
1(4)
170 091 16 97-01
Page 19
CAUSE
REMEDY
The cable shoes have bad contact
The ignition cables are damaged
The ignition transformer is damaged, no voltage on the
secondary side
The ignition cable and the ionisation cable have been
transposed.
No flame establishment in spite of a trouble free start
The gas solenoid valve defective
The gas solenoid valve does not open in spite of its
obtaining voltage
No voltage to the solenoid valve
No electrical connection through the air pressure switch
The starting load is not correctly adjusted
Improve the contact
Replace
Replace the transformer
Change
Replace
Replace coil or the whole valve if necessary.
Check the contact
Test the adjustment and the function of the air pressure
switch.
Reduce or increase the gas supply, reduce the quantity
of air.
Gas relay defective
Air pressure switch incorrectly adjusted or defective
No reponse as the cams of the servomotor are not
correctly adjusted or out of position.
The burner locks out after the safety time has elapsed
in spite of flame establishment
No ionisation current or the UV-cell in wrong position
The supervision part of the gas relay is defective
Replace
Check the adjustment and readjust.
Adjust the ionisation electrode and the UV-cell, examine
cables and connections.
Replace the relay
2(4)
Page 20
CAUSE
REMEDY
Voltage lower than 185 V
The ignition electrodes are disturbing the ionisation
current
Bad earthing
Phase and neutral transposed
The burner locks out during pre-purge
Air pressure switch defective or incorrectly adjusted.
The starting load is not correctly adjusted
The gas pressure is too low
Pulsations at start
The ignition electrodes are wrongly adjusted
The gas pressure is too high
Contact the electricity authorities.
Adjust the ignition electrodes, repole the ignition transfor-
mer if necessary.
Arrange for proper earthing.
See wiring diagram and change.
Reduce or increase the gas supply. Reduce the quantity
of air.
Increase the pressure. Contact the gas supply company
if necessary.
Readjust.
Check and adjust by means of a pressure gauge and a
pressure adjustment valve.
The flue gas side is blocked
Pulsations during operation
The burner is not correctly adjusted
The burner is dirty
Defective chimney
The burner is operating correctly but locking out
now and then
The ionisation current is too low
The UV-cell is in a wrong position
Voltage drop at certain times
Air pressure switch defective or incorrectly adjusted
Check the chimney flue.
Readjust
Clean the burner.
Check and change the dimensions if necessary.
Check. Must be at least 4 µ A according to the relay
manufacturer but should be 8-20 µ A.
Adjust.
Must not drop more than 15% of the rated current. Contact
the electricity authorities if necessary.
Spark-over in ignition electrodes
Replace the electrodes
3(4)
Page 21
CAUSE
REMEDY
The ambient temperature of the gas relay is too high
The ignition spark is too weak
Bad combustion
Bad draught conditions
The flue gas temperature is too high
The CO
The CO-content is too high
Excess air when using natural gas and gasoil (propane,
butane
Air shortage
The holes in the gas nozzle are clogged
The fresh air intake is too small
-content is too low
2
Heat insulate, max. 60° C.
Check the transformer
Check the chimney
The boiler is overloaded. Reduce the quantity of gas.
Check the boiler with regard to leaks. Choke the draught
if it is too high.
Choke the air.
Open the air supply. Check the flue gas damper.
Clean.
Check and enlarge.
The flame is not burning straight because the burner head
is out of position
Condensation in boiler and chimney
The flow gas temperature is too low or the quantity of gas
is not sufficient
Check the burner head and readjust.
Increase the flue gas temperature by increasing the
to which this declaration relates is in conformity with the following standard(s) or the normative socument(s)
(title and/or number and date of issue of the standard(s) or other normative document(s)