CIB UNIGAS LG120, NG120, NGX120, LG140, NG140 Manual Of Installation - Use - Maintenance
...
LG/NG/NGX120
LG/NG140
LG/NG/NGX200
Idea Series
Gas burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -
M039155CD Rel. 3.2 10/2012
ГОРЕЛКИ
TABLE OF CONTENTS
WARNINGS ............................................................................................................................................................... 3
PART I: INSTALLATION ........................................................................................................................................... 5
GENERAL FEATURES ................................................................................................................................................................... 5
How to interpret the burner’s “Performance curve” ......................................................................................................................... 6
Checking the proper gas train size ................................................................................................................................................ 6
Specifications .................................................................................................................................................................................. 7
Low NOx burners .......................................................................................................................................................................... 10
Country and usefulness gas categories ........................................................................................................................................ 10
Overall dimensions ....................................................................................................................................................................... 11
Performance curves ...................................................................................................................................................................... 12
Pressure/rate in the network curves ............................................................................................................................................. 13
Low NOx gas burners ................................................................................................................................................................... 14
MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 15
Fitting the burner to the boiler ....................................................................................................................................................... 15
Matching the burner to the boiler .................................................................................................................................................. 15
Installing the gas train ................................................................................................................................................................... 17
Electrical connections ................................................................................................................................................................... 17
Power supply without neutral ........................................................................................................................................................ 20
ADJUSTING THE AIR AND GAS FLOW RATES ......................................................................................................................... 21
Combustion head pressure curves vs. the gas flow rate .............................................................................................................. 21
Measuring the gas pressure in the combustion head ................................................................................................................... 21
Pressure in combustion head - gas flow rate curves .................................................................................................................... 22
SETTING GAS AND AIR FLOW RATE ........................................................................................................................................ 23
Startup Output ............................................................................................................................................................................... 23
Adjustments - brief description ...................................................................................................................................................... 23
Adjustment procedure ................................................................................................................................................................... 24
Single stage burners ..................................................................................................................................................................... 25
Double stage, progressive and fully-modulating burners .............................................................................................................. 25
Fully modulating burners ............................................................................................................................................................... 25
Adjusting the gas valves group fo single-stage and double-stage burners ................................................................................... 26
Progressive, fully-modulating burner adjustments ........................................................................................................................ 27
Gas Proving System VPS504 (Option) ......................................................................................................................................... 28
Adjusting the air and gas pressure switches ................................................................................................................................. 29
Adjusting the air pressure switch .................................................................................................................................................. 29
Calibration of minimum gas pressure switch ................................................................................................................................ 29
PART II: OPERATION ............................................................................................................................................. 30
OPERATION ................................................................................................................................................................................. 30
PART III: MAINTENANCE ....................................................................................................................................... 31
ROUTINE MAINTENANCE ........................................................................................................................................................... 31
Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................ 31
Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420.............................................................................................. 32
Cleaning or replacing the Krom-Scroeder CG2 25 V valve filter ................................................................................................... 32
Disassembling the burner plate to service the burner fan ........................................................................................................... 33
Removing the combustion head ................................................................................................................................................... 33
Correct electrodes positioning ...................................................................................................................................................... 34
Checking the detection current ..................................................................................................................................................... 35
Seasonal stop ............................................................................................................................................................................... 35
Burner disposal ............................................................................................................................................................................. 35
TROUBLESHOOTING .................................................................................................................................................................. 36
SPARE PARTS............................................................................................................................................................................. 37
BURNER EXPLODED VIEW........................................................................................................................................................ 38
WIRING DIAGRAMS .................................................................................................................................................................... 42
APPENDIX
2
WARNINGS
THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE
USER.
INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.
THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION
OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
1) GENERAL INTRODUCTION
z The equipment must be installed in compliance with the regulations
in force, following the manufacturer’s instructions, by qualified personnel.
z Qualified personnel means those having technical knowledge in the
field of components for civil or industrial heating systems, sanitary
hot water generation and particularly service centres authorised by
the manufacturer.
z Improper installation may cause injury to people and animals, or
damage to property, for which the manufacturer cannot be held liable.
z Remove all packaging material and inspect the equipment for inte-
grity.
In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devices, plastic
bags, foamed polystyrene, etc), should not be left within the reach of children, as they may prove harmful.
z 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.
z Make sure that inlet or exhaust grilles are unobstructed.
z In case of breakdown and/or defective unit operation, disconnect the
unit. Make no attempt to repair the unit or take any direct action.
Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly authorised
by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair the unit’s
safety.
To ensure equipment efficiency and proper operation, it is essential that
maintenance operations are performed by qualified personnel at regular
intervals, following the manufacturer’s instructions.
z When a decision is made to discontinue the use of the equipment,
those parts likely to constitute sources of danger shall be made har-
mless.
z In case the equipment is to be sold or transferred to another user, or
in case the original user should move and leave the unit behind,
make sure that these instructions accompany the equipment at all
times so that they can be consulted by the new owner and/or the
installer.
z For all the units that have been modified or have options fitted then
original accessory equipment only shall be used.
z This unit shall be employed exclusively for the use for which it is
meant. Any other use shall be considered as improper and, there-
fore, dangerous.
The manufacturer shall not be held liable, by agreement or otherwise, for
damages resulting from improper installation, use and failure to comply
with the instructions supplied by the manufacturer.
2) SPECIAL 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 combustion.
z Only burners designed according to the regulations in force should
be used.
z This burner should be employed exclusively for the use for which it
was designed.
z Before connecting the burner, make sure that the unit rating is the
same as delivery mains (electricity, gas oil,
z Observe caution w
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 stopped.
When the decision is made to discontinue the use of the burner, the user
ith hot burner components. These are, usually,
or other fuel).
shall have qualified personnel carry out the following operations:
a Remove the power supply by disconnecting the power cord from the
mains.
b) Disconnect the fuel supply by means of the hand-operated shut-off
valve and remove the control handwheels from their spindles.
Special warnings
z Make sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.
z Before the burner is started and, thereafter, at least once a year,
have qualified personnel perform the following operations:
a set the burner fuel flow rate depending on the heat input of the
appliance;
b set the flow rate of the combustion-supporting air to obtain a combu-
stion efficiency level at least equal to the lower level required by the
regulations in force;
c check the unit operation for proper combustion, to avoid any harmful
or polluting unburnt gases in excess of the limits permitted by the
regulations in force;
d make sure that control and safety devices are operating properly;
e make sure that exhaust ducts intended to discharge the products of
combustion are operating properly;
f on completion of setting and adjustment operations, make sure that
all mechanical locking devices of controls have been duly tightened;
g make sure that a copy of the burner use and maintenance instruc-
tions is available in the boiler room.
z In case of a burner shut-down, reser the control box by means of the
RESET pushbutton. If a second shut-down takes place, call the
Technical Service, without trying to RESET further.
z The unit shall be operated and serviced by qualified personnel only,
in compliance with the regulations in force.
3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED
3a) ELECTRICAL CONNECTION
z For safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.
z It is vital that all saftey requirements are met. In case of any doubt,
ask for an accurate inspection of electrics by qualified personnel,
since the manufacturer cannot be held liable for damages that may
be caused by failure to correctly earth the equipment.
z Qualified personnel must inspect the system to make sure that it is
adequate to take the maximum power used by the equipment shown
on the equipment rating plate. In particular, make sure that the
system cable cross section is adequate for the power absorbed by
the unit.
z No adaptors, multiple outlet sockets and/or extension cables are per-
mitted to connect the unit to the electric mains.
z An omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.
z The use of any power-operated component implies observance of a
few basic rules, for example:
- do not touch the unit with wet or damp parts of the body and/or with
bare feet;
- do not pull electric cables;
- do not leave the equipment exposed to weather (rain, sun, etc.)
unless expressly required to do so;
- do not allow children or inexperienced persons to use equipment;
z The unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact qualified
personnel to replace.
When the unit is out of use for some time the electric switch supplying all
the power-driven components in the system (i.e. pumps, burner, etc.)
should be switched off.
3
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
GENERAL
z The burner shall be installed by qualified personnel and in com-
pliance with regulations and provisions in force; wrong installation
can cause injuries to people and animals, or damage to property, for
which the manufacturer cannot be held liable.
z Before installation, it is recommended that all the fuel supply system
pipes be carefully cleaned inside, to remove foreign matter that might
impair the burner operation.
z Before the burner is commissioned, qualified personnel should ins-
pect the following:
a the fuel supply system, for proper sealing;
b the fuel flow rate, to make sure that it has been set based on the
firing rate required of the burner;
c the burner firing system, to make sure that it is supplied for the desi-
gned fuel type;
d the fuel supply pressure, to make sure that it is included in the range
shown on the rating plate;
e the fuel supply system, to make sure that the system dimensions are
adequate to the burner firing rate, and that the system is equipped
with all the safety and control devices required by the regulations in
force.
z When the burner is to remain idle for some time, the fuel supply tap
or taps should be closed.
SPECIAL INSTRUCTIONS FOR USING GAS
Have qualified personnel inspect the installation to ensure that:
a the gas delivery line and train are in compliance with the regulations
and provisions in force;
b all gas connections are tight;
c the boiler room ventilation openings are such that they ensure the air
supply flow required by the current regulations, and in any case are
sufficient for proper combustion.
z Do not use gas pipes to earth electrical equipment.
z Never leave the burner connected when not in use. Always shut the
gas valve off.
z In case of prolonged absence of the user, the main gas delivery
valve to the burner should be shut off.
Precautions if you can smell gas
a do not operate electric switches, the telephone, or any other item
likely to generate sparks;
b immediately open doors and windows to create an air flow to purge
the room;
c close the gas valves;
d contact qualified personnel.
z Do not obstruct the ventilation openings of the room where gas
appliances are installed, to avoid dangerous conditions such as the
development of toxic or explosive mixtures.
DIRECTIVES AND STANDARDS
Gas burners
European directives:
- Directive 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 (Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements.
Light oil burners
European directives:
- Directive 2006/95/EC on low voltage;
-
Directive 2004/108/
Harmonised standards :
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 (Electrical equipment of non-electric appliances for household and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
European directives:
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-CEI EN 60335-1 Household and similar electrical appliances - SafetyPart
1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
European directives:
- Directive 90/396/CEE Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 Gas Burners
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
European directives:
- Directive 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
CEE on elec
Gas - Light oil burners
Gas - Heavy oil burners
tromagnetic compatibility
Heavy oil burners
4
CIB UNIGAS - M039155CD
PART I: INSTALLATION
GENERAL FEATURES
Burners of this series are provided with a removable cover made of ABS, a heat and crash proof plastic material. The design of the shifitng flange assures a n efficient tightness and room savin g. The i nspection glass al lows checking the flame d uring operation. All the
mechanical components are mopunted on a removable plate that makes routine maintenance operation easier. The combustion head
position can be easily adjusted by means of a indexed screw and the peculiar air intake lower the noise levels. Single-stage or doublestage models are available.
1
2
10
3
4
1 Blast tube-combustion head ass.y
2 Burner flange
3 Control panel with startup switch
4 Air intake
5 Actuator (double-stage burners only)
6 Air pressure switch
7 Cover
8 Printed board circuit
9 Control box
10 Gas valves group
9
8
7
6
5
Fig. 1
The gas coming from the supply line, passes through the valves group provided with filter and stabiliser. This one forces the pressure in
the utilisation limits. In th e double-stage, progressive and fully-modulating burners, the electric servocontrol (5) moves proportionally
the air damper: it uses an adjusting cam with variable shape. This one allows the optimisation of the gas flue values, as to get an efficient combustion. The combustion head positioning determines the burner output. Fuel and comburent are routed into separated ways
as far as the zone of flame generation (combustion chamber). The air (comburent) and fuel (gas, gas oil, heavy oil) are forced into the
combustion chamber.
5
CIB UNIGAS - M039155CD
How to interpret the burner’s “Performance curve”
To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed:
z furnace input, in kW or kcal/h (kW = kcal/h / 860);
z backpressure (data are available on the boiler’s ID plate or in the user’s manual).
Example:
Furnace input: 600kW
Backpressure: 4mbar
In the “Performance curve” diagram (Fig. 2), draw a vertical line matching the furnace input value and an horizontal line matching the
backpressure value. The burner is suitable if the intersection point A is inside the performance curve.
Camp o di l avoro bruci at o ri
Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65
8
7
6
5
4
3
2
1
combustione mbar
0
Contropressione in camera di
-1
100 200 300 400 500 600 700 800 900
A
Pote nza kW
Fig. 2
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C.
Checking the proper gas train size
To check the proper gas train size, it is necessary to know the available gas pressure value upstream the burner’s gas valve. Then subtract
the backpressure. The result is called p
the x-axis, as far as intercepitng the network pressure curve, according to the installed gas train (DN65, in the example). From the interception point, draw an horizontal line as far as matching, on the y-axis, the value of pressure necessary to get the requested furnace
input. This value must be lower or equal to the p
gas. Draw a vertical line matching the furnace input value (600kW, in the example), quoted on
gas value, calculated before.
Tipo / Type P6 0
M-...50 (Multibloc DUNGS MB-DLE 420 B01)
M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)
25
20
15
10
pressure (mbar)
5
rete / Minimum inlet gas
Minima pressione gas in
0
100 200 300 400 500 600 700 800 900
Potenza / Output (kW)
Rp 2" (50)
DN65
Fig. 3
6
CIB UNIGAS - M039155CD
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type NG200 Model M-. TN. S. .* A. 0. 15
(1) (2) (3) (4) (5) (6) (7) (8)
(1) BURNER TYPE
NG - Natural gas burner LG - L.P.G. burner
NGX - Low NOx burners
(2) FUEL
(3) OPERATION(Available versions) TN - Single stage
M - Natural gas L - LPG
AB - Double stage
PR - Progressive MD - Fully modulating
(4) BLAST TUBE S - standard L - Extended
(5) DESTINATION COUNTRY
(6) BURNER VERSION
* see data plate
A - Standard
Y - with external air intake
(7) EQUIPMENT
0 = 2 gas valves
1= 2 Gas valves + gas proving system (optional if burner output < 1200 kW)
(8) GAS CONNECTION 15 = Rp1/2 20 = Rp 3/4 25 = Rp1
Specifications
BURNERS NG120..TN..15 NG120..TN..20 NG120..TN..25 LG120 L-.TN...15 LG120 L-.TN...20
Output min.- max. kW
Fuel
Category
Gas rate
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
min.-max.(Stm
Natural gas L.P.G.
(see next paragraph)
3
/h)
1/2” - Rp 1/2 3/4” - Rp 3/4 1” - Rp 1 1/2” - Rp 1/2 3/4” - Rp 3/4
6.4 - 12.7 2.3 - 4.6
60 - 120
(Note2)
230V - 50 Hz
0.48
0.18
IP40
18
Single stage
-10 ÷ +50
-20 ÷ +60
Intermittent
I
3B/P
BURNERS NG140..TN..15 NG140..TN..20 NG140..TN..25
Output min.- max. kW
Fuel
Category
Gas rate
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
min.-max.(Stm
3
/h)
1/2” - Rp 1/2 3/4” - Rp 3/4 1” - Rp 1
60 - 170
Natural gas
(see next paragraph)
6.4 - 18
(Note2)
230V - 50 Hz
0.48
0.18
IP40
18
Single stage
-10 ÷ +50
-20 ÷ +60
Intermittent
7
CIB UNIGAS - M039155CD
BURNERS LG140..TN..15 LG140..TN..20 LG140..TN..25
Output min.- max. kW
Fuel
Category
Gas rate
min.-max.(Stm
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
3
/h)
1/2” - Rp 1/2 3/4” - Rp 3/4 1” - Rp 1
60 - 170
L.P.G.
I
3B/P
2.3 - 6.5
(Note2)
230V - 50 Hz
0.48
0.18
IP40
18
Single stage
-10 ÷ +50
-20 ÷ +60
Intermittent
BURNERS NG200..TN...20 NG200..TN..25 LG200..TN..20 LG200..TN..25
Output min.- max. kW
Fuel
Category
Gas rate
min.-max.(Stm
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
Natural gas L.P.G.
(see next paragraph)
3
/h)
3/4” - Rp 3/4 1” - Rp 1 3/4” - Rp 3/4 1” - Rp 1
9 - 21 3.3 - 7.7
85 - 200
(Note2)
230V - 50 Hz
0.48
0.18
IP40
20
Single stage
-10 ÷ +50
-20 ÷ +60
Intermittent
I
3B/P
BURNERS NG140..xx..15 NG140..xx.20 NG140..xx.25 LG140..xx.15
Output min.- max. kW
Fuel
Category
Gas rate
min.-max.(Stm
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
3
/h)
1/2” - Rp 1/2 3/4” - Rp 3/4 1” - Rp 1 1/2” - Rp 1/2
8
35 - 170 40 - 170
Natural gas L.P.G.
(see next paragraph)
3.7 - 18 1.5 - 6.5
(Note2)
230V - 50 Hz
0.48
0.18
IP40
18
Double stage - Progressive - Fully modulating
-10 ÷ +50
-20 ÷ +60
Intermittent
I
3B/P
CIB UNIGAS - M039155CD
BURNERS NG200..xx..20 NG200..xx..25 LG200..xx..20 LG200..xx..25
Output min.- max. kW
Fuel
Category
Gas rate
min.-max.(Stm
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
Natural gas L.P.G.
3
/h)
4.4 - 21 1.5 - 7.7
3/4” - Rp 3/4 1” - Rp 1 3/4” - Rp 3/4 1” - Rp 1
Double stage - Progressive - Fully modulating
42 - 200
(see next paragraph)
(Note2)
230V - 50 Hz
0.48
0.18
IP40
20
-10 ÷ +50
-20 ÷ +60
Intermittent
BURNERS LG140..xx..15 LG140..xx.20 LG140..xx.25
Output min.- max. kW
Fuel
Category
Gas rate
min.-max.(Stm
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
3
/h)
1/2” - Rp 1/2 3/4” - Rp 3/4 1” - Rp 1
Double stage - Progressive - Fully modulating
40 - 170
L.P.G.
I
3B/P
1.5 - 6.5
(Note2)
230V - 50 Hz
0.48
0.18
IP40
18
-10 ÷ +50
-20 ÷ +60
Intermittent
Note1:
All gas flow rates are referred to Stm
calorific value H
= 34.02 MJ/Stm3); for L.P.G. (net calorific value Hi = 93.5 MJ/Stm3)
i
3
/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (nett
Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC valves)
= 100 mbar (with Krom-Schroeder CG2.. valves)
Minimum gas pressure = see gas curves.
* NOTE ON THE WORKING SERVICE: the SIEMENS LME.. control box automatically stops after 24h of continuous working.
The control box immediately starts up, automatically.
9
CIB UNIGAS - M039155CD
Low NOx burners
BURNERS NGX120 M-.TN...20 NGX120 M-.xx...20
Output min.- max. kW
Fuel
Category
Gas rate
min.-max.(Stm
3
/h)
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
BURNERS NGX200..TN..20 NGX200..TN..25 NGX200..xx..20 NGX200..xx..25
Output min.- max. kW
Fuel
Category
Gas rate
min.-max.(Stm
Gas pressure min.-max.mbar
Power supply
Total power consumption kW
Electric motor kW
Protection
Approx. weight kg
Valves size - Gas connection
Operation
Operating temperature °C
Storage Temperature °C
Working service *
3
/h)
3/4” - Rp 3/4 1” - Rp 1 3/4” - Rp 3/4 1” - Rp 1
75 - 120 35 - 120
Natural gas
(see next paragraph)
8.0 - 12.7 3.7 - 12.7
(Note2)
230V - 50 Hz
0.48
0.18
IP40
20
3/4” - Rp 3/4
Single stage Double stage - Progressive - Fully modulating
-10 ÷ +50
-20 ÷ +60
Intermittent
85 - 150 40 - 150
Natural gas Natural gas
(see next paragraph)
9 - 16 4.2 - 16
(Note2
230V - 50 Hz
0.48
0.18
IP40
20
Single stage Double stage - Progressive - Fully modulating
-10 ÷ +50
-20 ÷ +60
Intermittent
Note1:
All gas flow rates are referred to Stm
calorific value H
= 34.02 MJ/Stm3); for L.P.G. (net calorific value Hi = 93.5 MJ/Stm3)
i
3
/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (nett
Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC valves)
= 100 mbar (with Krom-Schroeder CG2.. valves)
Minimum gas pressure = see gas curves.
* NOTE ON THE WORKING SERVICE: the SIEMENS LME.. control box automatically stops after 24h of continuous working.
The control box immediately starts up, automatically.
Country and usefulness gas categories
GAS
CATEGORY
I
2H
I
2E
I
2E( R ) B
I
2L
I
2ELL
I
2Er
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
LUPL-----------------------
BE------------------------
NL------------------------
DE------------------------
FR------------------------
COUNTRY
10
Overall dimensions (mm)
Burner flange and boiler drilling plate
CIB UNIGAS - M039155CD
11
NG120- (S) 15 560 85 170 390 475 374 Ø101 Ø128 161 188 245 M8 188 109 158 133 382 467 202 287 180 32 537 340 Ø108
NG120- (L) 15 660 85 270 390 575 374 Ø101 Ø128 161 188 245 M8 188 109 158 133 382 567 202 387 180 32 537 340 Ø108
NG140- (S)
NG140- (L) 20 660 85 270 390 575 374 Ø101 Ø128 161 188 245 M8 188 109 158 133 382 567 202 387 180 32 537 340 Ø108
NG140- (S) 25 560 85 170 390 475 374 Ø101 Ø128 161 188 245 M8 188 109 158 133 426 511 202 287 224 32 565 340 Ø108
NG14- (L) 25 660 85 270 390 575 374 Ø101 Ø128 161 188 245 M8 188 109 158 133 426 611 202 387 224 32 565 340 Ø108
NG200- (S) 20 560 85 170 390 475 374 Ø117 Ø137 161 188 245 M8 188 109 158 133 382 467 202 287 180 32 537 340 Ø108
NG200- (L) 20 660 85 270 390 575 374 Ø117 Ø137 161 188 245 M8 188 109 158 133 382 567 202 387 180 32 537 340 Ø108
NG200- (S) 25 560 85 170 390 475 374 Ø117 Ø137 161 188 245 M8 188 109 158 133 426 511 202 287 224 32 565 340 Ø108
NG200- (L) 25 660 85 270 390 575 374 Ø117 Ø137 161 188 245 M8 188 109 158 133 426 611 202 387 224 32 565 340 Ø108
NGX120- (S) 15 560 85 170 390 475 374 Ø108 Ø128 161 188 245 M8 188 109 158 133 382 467 202 287 180 32 537 340 Ø108
NGX120- (L) 15 660 85 270 390 575 374 Ø108 Ø128 161 188 245 M8 188 109 158 133 382 567 202 387 180 32 537 340 Ø108
NGX120- (S) 25 560 85 170 390 475 374 Ø108 Ø128 161 188 245 M8 188 109 158 133 382 467 202 287 180 32 537 340 Ø108
NGX120- (L) 25 660 85 270 390 575 374 Ø108 Ø128 161 188 245 M8 188 109 158 133 382 567 202 387 180 32 537 340 Ø108
NGX200- (S) 25 560 85 170 390 475 374 Ø114 Ø134 161 188 245 M8 188 109 158 133 382 467 202 287 180 32 537 340 Ø108
NGX200- (L) 25 660 85 270 390 575 374 Ø114 Ø134 161 188 245 M8 188 109 158 133 382 567 202 387 180 32 537 340 Ø108
*S = standard blast tube
L = extended blast tube
DN A Bmin. Bmax. Cmin. Cmax. D G H J K L M N Omin. Omax. P Q R S Tmin. W X Y
20 560 85 170 390 475 374 Ø101 Ø128 161 188 245 M8 188 109 158 133 382 467 202 287 180 32 537 340 Ø108
DN A Bmin. Bmax. Cmin. Cmax. D G H J K L M N Omin. Omax. P Q R S Tmin. W X Y
CIB UNIGAS - M039155CD
Performance curves
z Natural gas burners z LPG burners
NG120 M-.TN...
5
4
3
2
1
PRESSURE IN
0
-1
50 60 70 80 90 100 110 120 130 140 150
COMBUSTION CHAMBER mbar
kW
NG140 M-.TN...
5
4
3
2
1
PRESSURE IN
0
-1
40 80 120 160 200
COMBUSTION CHAMBER mbar
kW
NG140 M-.xx...
5
4
3
2
1
PRESSURE IN
PRESSURE IN
0
-1
20 60 100 140 180 220
COMBUSTION CHAMBER mbar
NG200 M-.TN...
6
5
4
3
2
1
0
-1
50 75 100 125 150 175 200 225 250
COMBUSTION CHAMBER mbar
kW
kW
NG200 M-.xx...
6
5
4
3
2
1
PRESSURE IN
0
-1
25 50 75 100 125 150 175 20 0 225 250
COMBUSTION CHAMBER mbar
kW
To get the input in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C.
LG120 L-.TN...
5
4
3
2
1
0
-1
50 60 70 80 90 100 110 120 130
LG140 L-.TN...
5
4
3
2
1
0
-1
50 70 90 110 130 150 170 190 210
LG140 L-.xx...
5
4
3
2
1
0
-1
30 50 70 90 110 130 150 170 190 210
LG200 L-.TN...
6
5
4
3
2
1
0
-1
80 100 120 140 160 180 200 220 240
LG200 L-.xx...
6
5
4
3
2
1
0
-1
30 50 70 90 110 130 150 170 190 210 230
kW
kW
kW
kW
kW
12
CIB UNIGAS - M039155CD
Pressure/rate in the network curves
z Natural gas Burners z LPG burners
NG120 M-.TN...
20
15
10
5
0
GAS PRESSURE mbar
6 7 8 9 10 11 12 13 14 15
Rp ½" ( 15)
Rp ¾" ( 20)
Rp 1" (25)
LG120 L-.TN...
12
10
8
6
4
2
0
2345
Gas rate Stm3/h
NG140 M-.TN...
25
20
15
10
Rp ¾" (20)
Rp 1" (25)
LG140 L-.TN...
24
22
20
18
16
14
12
10
8
5
0
GAS PRESSURE mbar
5 7 9 11131517192123
NG140 M-.xx...
25
20
15
10
5
0
GAS PRESSURE mbar
2 4 6 8 10 12 14 16 18 20 22 24
Gas rate Stm3/h
Rp ¾" (20)
Rp 1" (25)
6
4
2
0
23456789
LG140 L-.xx...
24
22
20
18
16
14
12
10
8
6
4
2
0
123456789
Gas rate Stm3/h
NG200 M-.TN...
25
20
15
10
5
0
GAS PRESSURE mbar
5 1015202530
Rp ¾" (20)
Rp 1" (25)
Gas rate Stm3/h
NG200 M-.xx...
25
20
15
10
5
0
GAS PRESSURE mbar
246810121416182022242628
Rp ¾" (20)
Rp 1" (25)
Gas rate Stm3/h
LG200 L-.TN...
28
24
20
16
12
8
4
0
345678910
LG200 L-.xx...
28
24
20
16
12
8
4
0
12345678910
Rp ½" ( 15)
Rp ¾" ( 20)
Gas rate Stm3/h
Rp ½" (15)
Rp ¾" (20 )
Rp 1" (25)
Gas rate Stm3/h
Rp ½" (15)
Rp ¾" (20)
Rp 1" (25)
Gas rate Stm3/h
Rp ½" (15)
Rp ¾" (20 )
Rp 1" (25)
Gas rate Stm3/h
Rp ½" (15)
Rp ¾" (20)
Rp 1" (25)
Gas rate Stm3/h
13
Low NOx gas burners
z Performance curves
CIB UNIGAS - M039155CD
NGX120 M-.TN....
5
4
3
2
1
PRESSURE IN
0
-1
70 80 90 100 110 120 130
COMBUSTION CHAMBER mbar
NGX200 M-.TN...
6
5
4
3
2
1
PRESSURE IN
0
-1
80 100 120 140 160 180
COMBUSTION CHAMBER mbar
NGX120 M-.AB...
5
4
3
2
1
0
-1
25 50 75 100 125
kW
NGX200 M-.xx...
6
5
4
3
2
1
0
-1
20 40 60 80 100 120 140 160 180
kW
kW
kW
To get the input in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C.
z Pressure in the network - gas flow rate curves
NGX120 M-.TN...
30
25
20
15
10
5
GAS PRESSURE mbar
0
7 8 9 10 11 12 13
NGX200 M-.TN...
16
12
8
Rp ½" ( 15)
Rp ¾" ( 20)
Rp 1" (25)
Gas rate Stm3/h
Rp ¾" (20)
Rp 1" (25)
NGX120 M-.AB....
30
25
20
15
10
5
0
25 50 75 100 125
NGX200 M-.xx...
16
12
8
Rp ½" (15)
Rp ¾" (20)
Rp 1" (25)
Gas rate Stm3/h
Rp ¾" (20)
Rp 1" (25)
4
GAS PRESSURE mbar
0
8 1012141618
Gas rate Stm3/h
4
0
4 6 8 1012141618
Gas rate Stm3/h
14
CIB UNIGAS - M039155CD
MOUNTINGS AND CONNECTION S
Packing
The burners are dispatched in cardboard packages whose dimensions are:
z Standard Blast tube: 600mm x 370mm x 400mm (L x P x H)
z Extended Blast tube: 750mm x 370mm x 400mm (L x P x H)
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing case.
1 burner with detached gas train;
1 gasket to be inserted between the burner and the boiler;
1 envelope containing this manual.
To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials.
Fitting the burner to the boiler
To install the burner into the boiler, proceed as follows:
1 on the boiler’s door hole, fix the 4 stud bolts according to the drilling template showed on paragraph “Overall dimensions”
2 fix the flange of the burner to the boiler;
3 install the burner into the boiler;
4 according to the reference showed on Fig. 5, fix the flange to the boiler’s stud bolts D, without completely fastening;
5 loosen the VS screws in order to let the blast tube move back and forth;
6 install the burner making the blast tube move into the flange as to reach the right position according to the boiler/utilisation
7 fasten the VS screws:
8 tighten the 4 stud blolts D completely;
9 seal the space between the blast tube and the refractory lining with appropriate insulating material (ceramic fibre cord or refractory
cement).
D
VS
D
Fig. 4 Fig. 5
Matching the burner to the boiler
The burne rs describ ed in th is manual have been tested with combustion cha mbers that co mply with EN676 re gulation and whose
dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in diameter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with respect of the application involved. To correctly match the burner to the boiler verify the necessary input and the pressure 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 follow the instructions of the boiler manufacturer. In absence of these consider the following:
z Cast-iron boilers, 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.
z 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 necessary to use a suitably-
sized
15
CIB UNIGAS - M039155CD
spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).
Key
a) Heat output in kW
b) Lenght of the flame tube in meters
c) Flame tube firing intensity in MW/m
3
d) Combustion chamber diameter (m)
Fig. 6 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.
Fig. 6
16
CIB UNIGAS - M039155CD
Installing the gas train
ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE
MANUAL CUTOFF VALVES ARE CLOSED. READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING
OF THIS MANUAL.
The following diagram shows the gas train components which are included in the delivery and those which must be fitted by the customer. The diagram complies with regulations in force.
MANUFACTURER
INSTALLER
12
3
4
KeyKey
1 Burner
2 Valves group
3 Bellow joint
4 Manual cutoff valve
NOTE: the bellow joint, the manual cock and the gaskets are not part of the standard supply.
Once the train is installed, connect the gas valves group plug and the gas pressure switch one (on the valve group as well). Pay atten-
tion not to exchange them.
Electrical connections
ATTENTION: once the gas train is mounted according to the diagram, the gas proving test mus be performed, according to
the procedure set by the laws in force.
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 adequate for connection to the mains.
ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be
sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the
“Electrical connections” section.
WARNING: if the cable that connects the thermostats and the control box should be longer than 3 meters, insert a
sectioning relay following the attached electrical wiring diagram..
To execute the electrical connections, proceed as follows:
1 find the pulg or the plugs, according to the model, that comes out from the burnrer:
z 7 pins plug for power supply (all models)
z 4 pins plug (for AB - double stage burners);
z 7 pins plug (for MD - fully modulating burners);
2 execute the electrical connections to the plugs, according to hte burner model (see next paragraph);
3 now the burner is ready to start up.
.The burner is fitted with a bridge between terminals T6 and T8 on the 4-poles plug-TAB (external side link, male
connector); if the TAB high/low flame thermostat must be connected, remove the bridge between terminals,
before connecting the thermostat.
IMPORTANT: before operating the burner, be sure all connectors are linked as indicated in the diagrams.
17
CIB UNIGAS - M039155CD
Connectors identification
Burner power supply connector HIGH/LOW flame connector
Single stage burner connector Double-stage burner connectors
7-pins connector
Key
C1 LOW FLAME TIME METER
C2 HIGH FLAME TIME METER
FU1 FAN MOTOR LINE FUSE
FU3 LINE FUSE
IL BURNER LINE SWITCH
IM FAN MOTOR LINE SWITCH
KM1 FAN MOTOR CONTACTOR
LAF BURNER IN HIGH FLAME INDICATOR LIGHT
LB INDICATOR LIGHT FOR BURNER LOCK-OUT
7-pins and 4-pins connectors
LBF BURNER IN LOW FLAME SIGNALLING LAMP
MV FAN MOTOR
ST THERMOSTATS O PRESSURE SWITCHES SERIE
TAB HIGH LOW FLAME THERMOSTAT/PRESSURE SWITCH
TS SAFETY THERMOSTAT/PRESSURE SWITCH
CONN-MOTORE FAN MOTOR CONNECTOR
CONN-LINEA BURNER POWER SUPPLY CONNNECTOR
CONN-TAB HIGH-LOW FLAME CONNECTOR
($) IF "TAB" USED REMOVE THE BRIDGE BETWEEN TERMINALS
T6-T8
18
z
Fully-modulating burners connectors:
CIB UNIGAS - M039155CD
Fig. 7 - Probes connection by 7-pole connector
Key
C1 LOW FLAME TIME METER
FU1 LINE FUSE FOR FAN MOTOR
FU3 LINE FUSE
FU4 AUXILIARY FUSE
IL BURNER LINE SWITCH
IM FAN MOTOR LINE SWITCH
KM1 FAN MOTOR REMOTE CONTACTOR
SIEMENS RWF40 MODULATION REGULATOR
LB BURNER LOCKOUT SIGNALLING LAMP
LBF BURNER IN LOW FLAME SIGNALLING LAMP
MV FAN MOTOR
SD-0÷10V VOLTAGE SIGNAL
SD-0/4÷20mA CURENT SIGNAL
SD-PRESS PRESSURE PROBE
SMA MAN/AUTO SELECTOR
SMF OPERATION SELECTOR MIN-0-MAX
ST PRESSURE SWITCHES OR THERMOSTATS SERIE
TS SAFETY THERMOSTAT/PRESSURE SWITCH
19
CIB UNIGAS - M039155CD
Power supply without neutral
If the power supply to the burner is 230V phase-phase (without the neutral wire), with the Siemens LME.. control box, between the terminal 2 on the board and the earth terminal, an RC Siemens RC466890660 filter must be inserted.
Key
C - Capacitor (22nF/250V)
R - Resistor (1Mohm)
(***) RC466890660 - RC Siemens filter
(Code: 2531003)
Fig. 9
As far as b urners w ith no PCB provid ed, the RC Siemens circuit must be inserted between terminal 2 and the earth terminal of the
Simens LME.. control box.
C
R
SIEMENS
SIEMENS
LME2..
20
CIB UNIGAS - M039155CD
ADJUSTING THE AIR AND GAS FLOW RATES
Combustion head pressure curves vs. the gas flow rate
Curves are referred to pressure= 0mbar in the combustion head!
The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner in the combustion stage (3% of residual O
butterfly valve and the servocontrol are at the maximum opening. Refer to Fig. 10, showing the correct way to measure the gas pressure, considering the values of pressure in combustion chamber, surveyed by means of the pressure gauge or taken from the boiler’s
Technical specifications.
in the flues and CO values in the limits set by law). During this stage, the combustion head, the gas
2
1
2
4
3
Fig. 10
Key
1 Boiler
2 Gas pressure outlet on the boiler
3 Gas pressure 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 probes: one into the boiler’s pressure outlet (Fig.
10-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig. 10-
3). On the basis of the measured differential pressure, it is possible to get the maximum flow rate: in the pressure - rate curves (showed
on the next paragraph), it is easy to get the burner output in kW or Stm3/h (quo ted on the x axis) from the pressure measured in the
combustion head (quoted on the y axis).
NOTE: THE PRESSURE-RATE CURVES ARE APPROXIMATE; FOR A PROPER SETTING OF THE GAS RATE, PLEASE REFER
TO THE GAS METER READING.
21
CIB UNIGAS - M039155CD
Pressure in combustion head - gas flow rate curves
Natural gas Burners
NG120
6
4
2
Gas pressure in
combustion head
0
2 4 6 8 10 12 14
Gas rate Stm3/h
NG140
10
8
6
4
2
Gas pressure in
combustion head
0
2468101214161820
L.P.G. Burners
LG120
8
6
4
Gas rate Stm3/h
NG200
12
10
8
6
4
2
0
4 6 8 1012141618202224
Gas rate Stm3/h
2
Gas pressure in
combustion head
0
0,5 1, 5 2,5 3,5 4, 5 5,5
LG140
16
14
12
10
8
6
4
Gas pressure in
combustion head
2
0
0,5 1,5 2,5 3, 5 4,5 5,5 6, 5 7,5
Gas rate Stm3/h
Gas rate Stm
3
LG200
16
14
12
10
8
6
4
2
0
1,5 2,5 3,5 4,5 5,5 6,5 7,5 8,5
/h
22
Gas rate Stm3/h
Low NOx burners
NGX120
8
CIB UNIGAS - M039155CD
NGX200
8
6
4
2
Gas pressure in
combustion head
0
2468101214
6
4
2
0
4 6 8 10 12 14 16 18
Gas rate Stm3/h
SETTING GAS AND AIR FLOW RATE
To perform the adjustments, unscrew the fixing screws and remove the burner cover.
ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pressure upstream the gas train comp li es the value quoted on paragraph “Technical specifications”. Be sure that the
mains switch is closed.
.ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation
of carbon monoxide); if this should happen, make the gas decrease slowly until the normal combustion values are achieved.
WARNING: NEVER LOOSE THE SEALED SCREWS! OTHERWISE, THE DEVICE WARRANTY WILL BE IMMEDIATELY INVALIDATE!
Gas rate Stm3/h
Startup Output
The start-up heat output shall not exceed 120 kW (single stage burners) or 1/3 of n ominal output (double-stage, progressive or fully
modulating burners). In order to comply with these requirements, burners are provided with butterfly valve and/or slow-opening safety
valve. On double-stage, progressive or modulating burners, the low flame ouptut must be higher than the minimum ouptut quoted in the
performance curve (page 12).
IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:
Recommended combustion parameters
Fuel
Recommended (%) CO
Recommended (%) O2
2
Natural gas 9 ÷ 10 3 ÷ 4.8
LPG 11 ÷ 12 2.8 ÷ 4.3
Adjustments - brief description
Adjust the air and gas flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respectively.
z Check that the combustion parameters are in the suggested limits.
z Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a dif-
ferential pressure gauge, as described on par. see “Measuring the gas pressure in the combustion head” on page 21.
z Then, adjust the combustion values corresponding to the points between maximum and minimum: set the shape of the adjusting
cam foil. The adjusting cam sets the air/gas ratio in those points, regulating the opening-closing of the throttle gas valve.
z Set, now, the low flame output, acting on the low flame microswitch of the actuator in order to avoid the low flame output increasing
too much or that the flues temperature gets too low to cause condensation in the chimney.
To change the burner setting during the testing in the plant, follows the next procedure, according to the model provided.
23
CIB UNIGAS - M039155CD
Adjustment procedure
1 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 safely achieve the high flame stage.
2 startup the burner by turning its main switch A to on: if the burner locks (LED B on in the control panel) press the RESET button (C)
on the burner cover.
3 Start the burner up by means of the thermostat series and wait until the pre-purge time comes to an end and that the burner starts
up;
4 drive the burner to high flame stage, by means fo the thermostat TAB (except single-stage burners).
5 go on adjusting air and gas flow rates: check, continuosly, the flue gas analisys, as to avoid combustion with little air; dose the air
according to the gas flow rate change following the steps quoted below;
6 Then move progressively the microswitch to higher values until it reaches the high flame position; always check the combustion
values and eventually adjusting the gas by means of the valves group stabiliser.
As for the setting, refer to the following chart.
cams is carried out working by a screwdriver on the VS screw placed internally to the cam.
On this actuator, the manual control of the air damper is not provided; the setting of the
IV
I
II
III
High flame position (set to 90°) I
Low flame and ignition position IV
Stand-by position (set to 0°)
Not used III
BERGER STA4.5B0.3 - BERGER STA13B0.36
II
VS
Berger STA4.5BO.37/6 - STA13B3.41
7 acting on the pressure stabil iser of the valves grou p, adjust the gas flow rate in the high flame stage (according to the burner
model page 26-26) as to meet the values requested from the boiler/utilisation:
Pressure controller is provisionally factory-set. The setting values must be locally adjusted to machine conditi on s.
8 The burner is fa ctory set with the combustion head at the p osition th at refers to the "MAX" outpu t. The maximum ou tput setting
refers to the “fully-ahead” position of the combustion head, as far as standard models (Fig. 12), and to “fully-backward” position for
low NOx burners (Fig. 13). As for “fully-ahead” position, it means that the head is placed inside the boiler, “fully-backward” position
means that the head is towards the operator. As far as the re duced output op eration, progressively move the combusiton head
towards the “MIN” position, rotating clockwi se the VRT screw (Fig. 11). The ID index sho ws ho w much the combustion head
moved.
VRT
ID
Fig. 12 - Head in “fully-ahead
position”
Fig. 11
Fig. 13 - Head in “fully-
backward position”
9 To adjust the ai r fl ow rate, proceed as follows, according to the burner operation (single-stage, double-stage, progressive or fully-
modulating):
10 once the combustion head is adjusted, remove the actuator cover (except single-stage models) and set it to the ignition position,
(ignition position= 0° on the air damper index ID);
24
CIB UNIGAS - M039155CD
Single stage burners
To execute the air flow rate adjustment, proceed as follows:
11 loosen VR screw (see picture below)
12 move the ID index along the graduated slot towards + or -, in order to increase or decrease the air flow-rate, according to the requi-
red combustion values; fasten the VR screw again.
DR
VR
ID
Double stage, progressive and fully-modulating burners
13 The comburent air adjustment must be performed by means of th e servocontrol. The se rvocontrol rotation must be e qual to 90°
(page 23). The air damper’s opening in the high flame stage is imposed by the adjusting cam on Fig. 14. To adjust the air flow rate,
slacken the nut RA (Fig. 14) and move the lever VRA through the slot
the desired rate is obtained; lock then the nut RA in this position.
14 Drive the burner to the low flame operation, by the TAB boiler thermostat.
15 To eventually
round plate C by means of the screw V3 (turn clockwise to decrease the gas rate or counterclockwise to increase it). The index S
shows the opening angle.
change the gas flow rate, slacken the screw V1 (Fig. 94) and set the opening angle of the buttefly valve rotating the
as shown in
Fig. 14
, to increase or decrease the air rate, until
V3
S
C
V2
VRA
MIN
MAX
V1
RA
Fig. 14
Fully modulating burners
To set the air flow rate in the low flame stage and in the middle points, proceed as follows (see also pag. 27).
1Press the EXIT key for 5 seconds on the modulator (pag. 30): when the LED (with the printed hand), press the arrow key to pro-
gressively move the actuator to the maximum opening position;
2 stop the stroke every time it reaches each screw V: to set the air rate, act on the screw that matches the bearing.
3 Press the EXIT key to get out of the manual mode.
Fig. 15
25
CIB UNIGAS - M039155CD
Adjusting the gas valves group fo single-stage and double-stage burners
Multibloc MB-DLE
The multibloc unit is a compact uni t consisting of two valves, gas p ressure switch, pressure stabilizer and gas filter.
The valve is adjusted by means of the RP regulator after slackening the locking screw VB
by a number of turns. By unscrewing the regulator RP the valve opens, screwing the valve
closes. To set the fast opening remove cover T, reverse it upside down and use it as a tool
to rotate screw VR. Clockwise rotation reduces start flow rate, anticlockwise rotation increases it.
Do not use a screwdriver on the screw VR!
The pressure stabilizer is adjusted by operating the screw VS located under the cover C.
By screwing down the pressure is increased and by unscrewing it is reduced.
Note: the screw VSB must be removed only in case of replacemente of the coil.
VB
T(VR)
VS
C
VSB
RP
Fig. 16
Fig. 17 Fig. 18
Key
1 Electrical connection for valves
2 Operation display (optional)
3 Pressure governor closing tap
4 Start setting cap
5 Hydraulic brake and rate regulator
6Coil
7 Test point connection G 1/8
8 Test point connection G 1/8 downstream of valve 1, on both sides
9 Output flange
10 Test point connection M4 downstream of valve 2
11 Gas flow direction
12 Test connection G 1/8 downstream of valve 1, on both sides
13 Vent nozzle pressure regulator
14 Filter (below cover)
15 Input flange
17 Pressure switch
18 Pressure switch electric connection
26
CIB UNIGAS - M039155CD
Progressive, fully-modulating burner adjustments
Progressive and fully-modulating burners are provided with the combination control KROM-SCHROEDER CG2.
Use a 2.5mm allen key to perform all the adjustments: do not use force!
The pressu re switch is fa ctory-set to 14 mba r as deli vered. As fa r as the next adj ustment see “Ad justing the air an d gas p ressure
switches” on page 29)
Transmission ratio V (see pictures Fig. 19 - Fig. 20)
gas : air = 3:1
Zero point N = 0.
B (pG)
Adjustments
A
p
F
p
L
Fig. 19
1 Start burner with low fire: if the burner does not start, turn N (see picture Fig. 20) slightly in the direction + and repeat the start.
2 Test gas pressure p
3 Test air pressure p
at B (see picture Fig. 19).
G
(see picture Fig. 19) at the burner and adjust the gas pressure at N according to the specifications of the bur-
L
ner manufacturer.
4 Set the burner gradually to high fire and adjust the gas pressure at V (see picture Fig. 20) in accordance with the boiler input.
5 Set the air rate by means of the actuator: open the air damper until the required flow rate is achieved.
N
V
Fig. 20
Low flame adjustment
6 Set burner to low fire.
7 Carry out the flue gas analysis and set the gas pressure to the desired analysis values at the N port.
8 Set the burner to high fire and set the gas pressure to the desired analysis value at the V port.
9 Repeat analysis with low and high fire; if necessary, correct N and V (see picture Fig. 20) .
10 Finely adjust the gas pressure switch (see related paragraph).
11 Block all test points .
Do not block connection p
if not used (see picture Fig. 19).
F
Note: air pressure p
minus combustion chamber pressure p
L
must be at least 0.4 mbar!
F
V = Do not set transmission ratio to high! The gas pressure at B is smaller than the gas pressure at A (see picture Fig. 19) minus the
pressure drop of the combination control.
27
CIB UNIGAS - M039155CD
C
In order to avoid the governor vibrating, keep the pressure loss across the governor as small as possible by means of a low inlet pressure or by fitting an orifice module, an adjusting valve or the like between CG ... V and burner. Setting V to 2 or larger will dampen the
vibrations.
Testing the adjustability
1 Set burner to high fire.
2 Measure the gas pressure at A and B (see picture Fig. 19).
3 Slowly close the manual valve upstream of the combination control until the gas inlet pressure at A drops by 2 mbar (tow n gas 1
mbar).
4 The gas outlet pressure at B must n ot dro p by more than 0.5 mbar. Otherwise, check and correct the setting or the choice of
device.
5 If the adjustability is insufficient, the installation must not be operated.
6 Reopen the manual valve.
Gas Proving System VPS504 (Option)
The VPS504 check the operation of the seal of the gas shut off valves. This check, carried out as soon as the boiler thermostat gives a
start signal to the burner, creates, by means of the diaphragm pump inside it, a pressure in the test space of 20 mbar higher than the
supply pressure.
To install the DUNGS VPS504 gas proving system on the MD-DLE valves group, proceed as follows:
1 turn off gas supply.;
2 Switch off power supply.
3 remove the Multibloc’s screw plugs (Fig. 21-A);
4 iInsert sealing rings (10,5 x 2,25) into VPS 504 (Fig. 22-B, Fig. 21-B)
5 Torque screws 3, 4, 5, 6 (M4 x16) Fig. 21-C
Only use screws with metric thread on reassembly (modification, repair).
6 On completion of work, perform a leak and functional test.
L
LB
C
B
Fig. 21 Fig. 22
When wishing to monitor the test, install a pressure gauge ranged to that of the pressure supply point PA (Fig. 22). If the test cycle is
satisfactory, after a few seconds the consent light LC (yellow) comes on. In the opposite case the lockout light LB (red) comes on. To
restart it is necessary to reset the appliance by pressing the illuminated pushbutton LB.
A
PA
28
CIB UNIGAS - M039155CD
Adjusting the air and gas pressure switches
The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of
the control box unlock pushbutton, placed on the burner control panel.
The gas pressure switches check the pressure to avoid the burner operate when the pressure value is not in the requested pressure
range.
Adjusting the air pressure switch
To calibrate the air pressure switch, proceed as follows:
z Remove the transparent plastic cap.
z Once air and gas setting have been accomplished, startup the burner.
z During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout,
then read the value on the pressure switch scale and set it to a value reduced by 15%.
z Repeat the ignition cycle of the burner and check it runs properly.
z Refit the transparent plastic cover on the pressure switch.
Calibration of minimum gas pressure switch
As for the gas pressure switch calibration, proceed as follows:
z Be sure that the filter is clean.
z Remove the transparent plastic cap.
z While the burner is ope rating at th e maximum output, test the gas pressure on the p ressure port of th e mi nimum gas pressure
switch.
z Slowly close the manual cutoff valve (placed upstream the pressure switch, see gas train installation diagram), until the detected
pressure is reduced by 50%. Pay attention that the CO value in the flue gas does 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 Clockwise turn the pressure switch adjusting ring nut (as to increase the pressure value) until the burner stops.
z Slowly fully open the manual cutoff valve.
z Refit the transparent plastic cover on the pressure switch.
VR
29
CIB UNIGAS - M039155CD
PART II: OPERATION
LIMITATIONS OF USE
THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.
THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO
QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE BURNER.
A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND
SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING 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. DISCONNECTION, EVEN
PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER).
NEVER OPEN 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 CASE OF A BURNER SHUT-DOWN, RESET THE CONTROL BOX BY MEANS OF THE RESET PUSHBUTTON. IF A SECOND
SHUT-DOWN TAKES PLACE, CALL THE TECHNICAL SERVICE, WITHOUT TRYING TO RESET FURTHER.
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
BEFORE STARTING UP THE BURNER, BE SURE THAT THE MAIN SWITCH IS ON AND THE MANUAL SHUTOFF VALVES ARE OPEN. CAREFULLY READ THE WARNINGS IN THIS MANUAL.
z Startup the burner by the boiler master power switch;
z as for double-stage models, turn the burner main switch A to On;
z make sure that the control box has not shut down and reset if necessary by means of the reset button R by pressing the clear rub-
ber seal on the burner cover;
z make sure that the set of thermostats (or pressure-switches) triggers burner operation (in double-stage models L1 LED lights on)
z the burner starting cycle begins: the control box switches on the burner fan;
z at the end of the pre-purge time, the ignition transformer switches (in double-stage models LT LED lights on); few seconds later
the solenoid valve is powered and the burner starts up;
z the ignition transformer stays on for a few seconds after the ignition of the flame (post-ignition time) and at the end of this time it is
switched off.
Double-stage burners: after the start-up, the burner remains in the low flame operation (in double-stage models, L1 on) or switches to
the high flame stage (in double-stage models, L2 on), according to the plant needs.
A
L2
L1
LT
Double-stage, progressive and fully-modulating (with RWF40 burner control) models
30
CIB UNIGAS - M039155CD
PART III: MAINTENANCE
At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry
out the main tenance at the e nd of each heating season; in the case of continuous operation the maintenance is carried out every 6
months.
WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND
THE FUEL MANAUL CUTOFF VALVES CLOSED!
ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL.
ROUTINE MAINTENANCE
z Clean and examining the gas filter cartdrige, if necessary replace it (Fig. 23 on).
z Removal, examination and cleaning of the combustion head (see Fig. 30 on).
z Check the ignition and detection electrodes, clean and adjust if necessary (see page 34). In case of doubr, check the detection cur-
rent according to the schemes in page 35.
z Cleaning and greasing of sliding and rotating parts.
ATTENTION: when servicing, if it was necessary to disassemble the gas train parts, remember to execute the gas proving test,
once the gas train is reassembled, according to the procedure imposed by the law in force.
Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412
z Check the filter at least once a year!
z Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 23-Fig. 24)is ∆p > 10 mbar.
z
Change the filter if the pressure difference betwe en pressure connection 1 and 3 (F ig. 23-Fig. 24) is twice as high compared to the last
check.
You can change the filter without removing the fitting.
1 Interrupt the gas supply closing the on-off valve.
2 Remove screws 1 ÷ 4 using the Allen key n. 3 and remove filter cover 5 in
3 Remove the filter 6 and replace with a new one.
4 Replace filter cover 5 and tighten screws 1 ÷ 4 without using any force and fasten.
5 Perform leakage and functional test, p
2
6
1
0
➞
5
3
4
= 360 mbar.
max.
6
➞
53
4
Fig. 23
Fig. 25
.
3
0
03
p
2
e
1
p
e
Fig. 24
4
p
a
5
p
Br
61
4
p
a
5
p
Br
Fig. 25
31
CIB UNIGAS - M039155CD
Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2”
z Check the filter at least once a year!
z Change the filter if the pressure difference between pressure connection 1 and 2 (
z
Change the filter if the pres sure difference between pressure connec tion 1 and 2 (Fig. 26-Fig. 27) is twice as high comp ared to the last
check.
You can change the filter without removing the fitting.
1 Interrupt the gas supply closing the on-off valve.
2 Remove screws 1 ÷ 6 (
Fig. 28
).
3 Change filter insert.
4 Re-insert filter housing, screw in screws 1 ÷ 6 without using any force and fasten.
5 Perform leakage and functional test, p
= 360 mbar.
max.
Fig. 26-Fig. 27
) ∆p> 10 mbar.
3
0
0
p
2
e
4
p
a
5
p
Br
61
5
1
5
1
03
p
e
4
p
a
5
p
Br
Fig. 27
4
2
3
4
2
3
Fig. 26
E
D
A
C
B
Fig. 28
Cleaning or replacing the Krom-Scroeder CG2 25 V valve filter
Once a year check the valve filter:
1 close manual valve
2 Loosen all 4 screws (1 in Fig. 29); unscrew two of them depending on the room available and pull out filter unit (2 in Fig. 29)
3 Clean or replace filter pad and strainer and refit.
4 Check connection flanges for tightness. Soap sealings.
Fig. 29
32
CIB UNIGAS - M039155CD
Disassembling the burner plate to service the burner fan
Before proceeding to maintenance/replacing operations, follow the next procedure:
1 remove the component plate "C" by unscrewing the V1, V2, V3, V4 screws and the "F" securing pin (Fig. 30);
2 remove the rubber cable holder by unscrewing V5 and V6 in Fig. 31;
3 free rod T (see Fig. 32);
4 disconnect the connector CV, Fig. 34;
5 place the plate in one of the ways showed in order to facilitate maintenance operations.
NOTE: When re-assembling the component plate, make sure that the pin for the air damper "P" enters its housing "B"
(see figure).
V1
Fig. 30
V2
LOCKED
T
C
V5
F
UNLOCKED
V3
V6
Fig. 31
Fig. 32
CV
Fig. 33
Fig. 34
Fig. 35
Removing the combustion head
ATTENTION: avoid the ignition and detection electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. The gap between
the ignition electrode and the ground is 4÷5 mm.
After the disassembling the burner plate, the combustion head can be removed as follows:
1 unscrew the fixing screwa VT;
2 disconnect the ignition cable CA; unscrew the fixing nuts D and remove the combustion head from its housing;
3 adjust the electrodes; to replace them, if necessary, disconnect the cables and unscrew VE;
4 remove the electrodes and replace them
5 clean the combustion head by means of a vacuum cleaner; use a metallic brush to scrape off the scale;
6 reassemble all the items in the reversed order, observing the electrodes position (see next paragraph).
33
CIB UNIGAS - M039155CD
VE
CA
VT
D
Correct electrodes positioning
To get a goo d ign ition, it is necessary to observe the mea sures showed in the ne xt pictures. Be sure to fa sten the electrodes fixing
screw VE, before reassembling the burner.
Standard burners
VE
Low NOx burners
VE
VE
34
CIB UNIGAS - M039155CD
Checking the detection current
If the burner locks, execute the following inpesctions. To measure the detection signals refer to the diagrams in the following picture . If
the signal is less than the value shown, check the position of the detection electrode, the electrical contacts and if necessary replace
the detection electrode.
Flame
Detection electrode
Connector
µA DC SCALE
2
Control box Minimum detection signal
Siemens LME21-22 3 µA
Seasonal stop
To stop the burner in the seasonal stop, proceed 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”.
35
TROUBLESHOOTING
CAUSE
THE BURNER
DOESN’TSTART
MAIN SWITCH OPEN
LACK OF GAS
MAXIMUM GAS PRESSURE SWITCH DEFECTIVE (IF
PROVIDED)
THERMOSTATS/PRESSURE SWITCHES DEFECTIVE
OVERLOAD TRIPPED INTERVENTION
AUXILIARIES FUSE INTERRUPTED
CONTROL BOX FAULTY
DEFECTIVE SERVOCONTROL (IF PROVIDED)
AIR PRESSURE SWITCH FAULT OR BAD SETTING
36
MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS
FILTER DIRTY
IGNITION TRANSFORMER FAULT
IGNITION ELECTRODES BAD POSITION
DETECTION ELECTRODE BAD POSITION
BUTTERFLY VALVE BAD SETTING
DEFECTIVE GAS GOVERNOR
GAS VALVE DEFECTIVE
BAD CONNECTION OR DEFECTIVE HIGH/LOW FLAME
THERMOSTAT OR PRESSURE SWITCH (IF PROVIDED)
WRONG SETTING SERVO CONTROL CAM
UV PROBE DIRTY OR DEFECTIVE (IF PROVIDED)
PHASE-NEUTRAL INVERTED
PHASE-PHASE SUPPLY OR PRESENCE OF VOLTAGE ON
THE NEUTRAL CONDUCTOR(*)
●
●●
●●
●● ●
●
●
●● ● ● ●
●● ● ▲
●●●●
●●●● ●
● = with any control box;
▲ = with only LGB2../LMG2../LME11/LME2..
(*) In such cases, insert the circuit SIEMENS “RC466890660” (See chapter “Electrical connections”).
CONTINUE WITH PRE-
PURGE
●
●
●●
●●● ●
●
●● ●
DOESN’T START AND
LOCK-OUT
DOESN’T START AND
REPEATS THE CYCLE
STARTS AND REPEATS
TROUBLE
THE CYCLE
STARTS AND LOCK-OUTВ
THE FLAME MONITOR
DEVICE DOESN’T
GIVECONSENT TO START
DOESEN’T SWITCH TO
HIGH FLAME
DOESEN’T RETURN IN
LOW FLAME
HE SERVO CONTROL IS
LOCK AND VIBRATE
LOCK-OUT DURING
OPERATION
TURNS OF AND REPEATS
CYCLE DURING
OPERATION
CIB UNIGAS - M039155CD
●●
▲●●▲
●●●
▲
▲
CIB UNIGAS - M039155CD
SPARE PARTS
Desription Code
LG/NG120 LG/NG140 LG/NG200
COVER 1011807 1011807 1011807
CONTROL BOX (one-stage regulation) 2020466 2020467 2020467
CONTROL BOX (double-stage regulation) - 2020468 2020468
DETECTION ELECTRODE 2080108 2080108 2080108
GROUND ELECTRODE 2080234 2080234 2080234
INGNITION ELECTRODE 2080218 2080218 2080218
GASKET 2110031 2110031 2110031
FAN WHEEL 2150077 2150077 2150070
AIR PRESSURE SWITCH 2160053 2160053 2160053
DANFOSS TRANSFORMER 2170233 2170233 2170233
COFI TRANSFORMER 2170138 2170138 2170138
MOTOR mod. AACO 2180296 2180296 2180296
MOTOR mod. AEG 2180715 2180715 2180715
VALVE GROUP DUNGS MB-DLE 405 (1/2”) 2190339 - VALVE GROUP DUNGS MB-DLE 407 (3/4”) - 2190340 2190340
VALVE GROUP DUNGS MB-DLE 410 (1”) - 2190341 2190341
VALVE GROUP KROM-SCROEDER CG2..V (1”) - 2190262 2190262
GAS PROVING SYSTEM (option) 2191604 2191604 2191604
ACTUATORE (double-stage models only) - 2480057 2480057
BLAST TUBE (S*) 30900H4 30900H4 30900H6
BLAST TUBE (L*) 30900H5 30900H5 30900H7
COMBUSTION HEAD (natural gas) (S*) 30600M0 30600M0 30600M2
COMBUSTION HEAD (natural gas) (L*) 30600M1 30600M1 30600M3
COMBUSTION HEAD (L.P.G.)(S*) 30600M4 30600M4 30600M2
COMBUSTION HEAD (L.P.G.) (L*) 30600M5 30600M5 30600M3
COMBUSTION HEAD WITH ELECTRODES (S*) 3501847 3501847 3501849
COMBUSTION HEAD WITH ELECTRODES (L*) 3501848 3501848 3501850
COMBUSTION HEAD WITH ELECTRODES (L.P.G.) (S*) 3501857 3501857 3501859
COMBUSTION HEAD WITH ELECTRODES (L.P.G.) (L*) 3501858 3501858 3501860
INGNITION CABLE 6050154 6050154 6050154
DETECTION CABLE 6050211 6050211 6050211
z Other spare parts for Low NOx series
Desription Code
NGX120 NGX200
BLAST TUBE (S* 30900N2 30900N4
BLAST TUBE (L*) 30900N3 30900N5
COMBUSTION HEAD LOW NOx (S*) 30600M8 30600N0
COMBUSTION HEAD LOW NOx (L*) 30600M9 30600N1
COMBUSTION HEAD WITH ELECTRODES) LOW NOx (S* 3501853 3501855
COMBUSTION HEAD WITH ELECTRODES LOW NOx (L*) 3501854 3501856
*S: standard blast tube
*L: extended blast tube
37
SINGLE-STAGE BURNER EXPLODED VIEW
1.1 HALF FLANGE
1.2 HALF FLANGE
2 BLAST TUBE
3.1 COVER FIXING SCREW
3.2 COVER
3.3 UNLOCK BUTTON RUBBER COVER
4.1 INDEX BLOCKING SCREW
4.2 INDEX HOLDER
4.3 BUSH
4.4 SCREW
4.5 SELF-BLOCKING NUT
4.6 WASHER
4.7 WASHER
5.1 EXTENSION SCREW
5.2 GAS PRESSURE INTAKE
5.3 ÎELBOW
5.4 REDUCTION
5.5 VALVE GROUP
5.6 VALVE GROUP FLANGE
6CONTROL BOX
7.1 HOUSING
7.2 BOX ASSEMBLY
7.3 4-WAYS FAIRLEAD
7.4 AIR DAMPER ASSEMBLY
7.5 AIR FLAP
7.6 BUSH
7.7 BUSH
7.8 AIR DAMPER PIN
7.9 PLATE SRVICING PIN
8 GASKET
9.1 MOTOR PLATE
9.2 FAN WHEEL
9.3
9.4 MOTOR
9.5 PLATE FIXING PIN
9.6 AIR PRESSURE SITCH BRACKET
10.1 BRACKET
10.2 CONTROL BOX BOARD
10.3 TRANSFORMER
11.1 NUT
11.2 FAIRLEAD
11.3 GAS PRESSURE INTAKE
11.4 INSPECTION GLASS
11.5.1 COMBUSTION HEAD
11.5.2 DETECTION ELECTRODE
11.5.3 INGNITION ELECTRODE
11.6 INGNITION CABLE
11.7 SCREW
11.8 NUT
11.9 FLANGE
12 TERMINAL
13 TERMINAL
AIR PRESSURE SWITCH
CIB UNIGAS - M039155CD
DESCRIPTION
38
CIB UNIGAS - M039155CD
39
CIB UNIGAS - M039155CD
DOUBLE-STAGE BURNER EXPLODED VIEW
DESCRIPTION
1.1 - 1.2 HALF FLANGE
2 BLAST TUBE
3.1 COVER FIXING SCREW
3.2 COVER FIXING SCREWCOVER
3.3 UNLOCK BUTTON RUBBER COVERUNLOCK BUTTON RUBBER COVER
4.1 INDEX BLOCKING SCREW
4.2 GAS PRESSURE INTAKE
4.3 ELBOW
4.4 REDUCTION
4.5 VALVE GROUP
4.6 VALVE GROUP FLANGE
5 FAIRLEAD
6 CONTROL BOX
7.1 HOUSING
7.2 BOX ASSEMBLY
7.3 4-WAYS FAIRLEAD
7.4 AIR DAMPER ASSEMBLY
7.5 AIR FLAP
7.6 BUSH
7.8 - 7.9 PINS
7.10 ROD
7.11 BUSH
8 GASKET
9.1 WASHER
9.2 - 9.3 SCREWS
9.4 ACTUATOR BRACKET
9.5 SPACERS
9.6 ACTUATOR
9.7 ROD
9.8 - 9.9 JOINT
9.10 BRACKET
9.11 BUSH
9.12 AIR DMAPER CAM
10.1 MOTOR PLATE
10.2 FAN WHEEL
10.3 AIR PRESSURE SWITCH
10.4 MOTOR
10.5 PLATE FIXING PIN
10.6 AIR PRESSURE SWITCH BRACKET
11 PANEL ASS.Y
12.1 BRACKET
12.2 CONTROL BOX HOLDER
12.3 IGNITION TRANSFORMER
12.4 EARTHING PLATE
12.5 PBC
13.1 NUT
13.2 FAIRLEAD
13.3 INSPECTION GLASS
13.4.1 COMBUSTION HEAD
13.4.2 DETECTION ELECTRODE
13.4.3 INGNITION ELECTRODE
13.5
13.6 DETECTION CABLES
13.7 SCREW
13.8 NUT
13.9 FLANGE
14 - 15 CONNECTOR
40
CIB UNIGAS - M039155CD
41
CIB UNIGAS - M039155CD
WIRING DIAGRAMS
Complete key
C1 Operation time counter first stage
C2 Operation time counter second stage
CO Operation time counter
ER Flame detection electrode
EV1 Gas network side solenoid valve (or valves group)
EV2 Burner side solenoid valve (or valves group)
FFuse
FR Photoresistor
FU2-FU3 Line fuse
IG Main switch
IL Line switch
L Phase
LAF-LAF1 Burner in high flame operation light
LB Flame lockout light
LBF Burner in low flame operation light
LF Burner in operation signaling light
LME SIEMENS control box
LTA Ignition transformer operation light
MA Burner supply terminal board
MV Fan motor
N Neutral
PA Air pressure switch
PG Minimum gas pressure switch
PS Reset pushbutton for flame control device
SATRONIC DK0976-DKW976Control box
SATRONIC DKW972 Control box
ST Group of thermostats or pressure switches
STA4.5B0.37/63N21L BERGER actuator for air damper
SW1 Second stage pushbutton
TA Ignition transformer
TAB High-low flame thermostat (if fitted remove the bridge between terminals 6 and 7 on terminal board MA)
TS Safety thermostat or pressure switch on boiler
VPS Dungs gas proving system (optional)
Note: connect the bridge between terminals 7 and 9, only if LGB21.33 is used
ACTUATOR CAMS
SIEMENS
SQN30.151
I ST2 RED I high flame
II ST0 BLUE II stand by
III ST1 ORANGE IV low flame
V MV BLACK III Not used
WARNING:
1 - Power supply 230V 50/60Hz 2N a.c.
2 - Don’t reverse phase with neutral
3 - Be sure the burner is properly hearted
BERGER
STA6BB3.41
SIEMENS
SQN70.224A20
BERGER
STA4.5B0.37
STA13B0.36
Wiring diagram cod. 01-319 - Single stage burners
Wiring diagram 18-069 - High-Low flame / Progressive burners
Wiring diagram 18-166 - Fully-modulating burners
42
APPENDIX: COMPONENTS CHARACTERISTICS
Y
.
.
.
SIEMENS LME11/21/22 CONTROL BOX
The series of equipment LME.. is used for the starup and supervisione of
1- or 2- stage gas burners. The series LME..is interchangeable with the
series LGB.. and LMG.., all diagrams and accessories are interchangeable, the main features are:
z Indications of error codes by a signalling multicolor LED in the lockout
reset button;
z Programmer fix times for the digital management of signals.
Comparative table
Status Color code Color
Undervoltage Yellow - red
Fault, alarm Red
Error code output
(refer to “Error code
table”)
z S z S z S z S z S
....................................
S S S S
Flashing red
LGB Series LMG Series LME Series
--- LMG 25.33 LME 11.33
LGB 21.33
LGB 22.33 LMG 22.33 LME 2
LMG 21.33 LME 21.33
2.33
Preconditions for burner startup
z Burner control must be reset
z All contacts in the line are closed, request for heat
z No undervoltage
z Air pressure switch LP must be in its “no-load” position
z Fan motor or AGK25 is closed
z Flame detector is darkened and there is no extraneous light
Undervoltage
Safety shutdown from the operating position takes place should mains
voltage drop below about AC 175 V (at UN = AC 230 V)
Restart is initiated when mains voltage exceeds about AC 185 V (at UN =
AC 230 V).
Controlled intermittent operation
After no more than 24 hours of continuous operation, the burner control
will initiate automatic controlled shutdown followed by a restart.
Reversed polarity protection with ionization
If the connections of live conductor (terminal 12) and neutral conductor
(terminal 2) aremixed up, the burner control will initiate lockout at the end
of the safety time “TSA”.
Control sequence in the event of fault
If lockout occurs, the outputs for the fuel valves, the burner motor and the
ignition equipment will immediately be deactivated (< 1 second).
Operational status indication
In normal operation, the different operating states are showed by means
of the multicolor LED, inside the lockout reset button:
red LED
yellow LED
green LED
LED
.......
..
Steady on
Off
During startup, status indication takes place according to the table:
Status Color code Color
Waiting time tw, other
waiting states
Ignition phase, ignition
controlled
....................................
zzzzzz
Off
Flashing yellow
START-UP PROGRAM
As far as the startup program, see its time diagram:
A Start command (switching on)
This command is triggered by control thermostat / pressure controller
«R». Terminal 12 receives voltage and the programming mechanism
starts running. On completion of waiting time «tw» with the LME21..., or
after air damper «SA» has reached the nominal load position (on completion of «t11») with the LME22..., fan motor «M» will be started.
tw Waiting time
During the waiting time, air pressure monitor «LP» and flame relay «FR»
are tested for correct contact positions.
t11 Programmed opening time for actuator «SA»
(Only with LME22...) The air damper opens until the nominal load position
is reached. Only then will fan motor «M» be switched on.
t10 Specified time for air pressure signal
On completion of this period of time, the set air pressure must have built
up, or else lockout will occur.
t1 Prepurge time
Purging the combustion chamber and the secondary heating surfaces:
required with low-fire air volumes when using the LME21... and with nomi-
nal load air volumes when using the LME22.... The diagrams show the so-
called prepurge time «t1» during which air pressure monitor «LP» must
indicate that the required air pressure is available. The effective prepurge
time «t1» comprises interval end «tw» through «t3».
t12 Programmed closing time for actuator «SA»
(Only with LME22...)During «t12», the air damper travels to the low-fire
position.
t3 Preignition time
During «t3» and up to the end of «TSA», flame relay «FR» is forced to
close. On completion of «t3», the release of fuel is triggered at terminal 4.
TSA Ignition safety time
On completion of «TSA», a flame signal must be present at terminal 1.
That flame signal must be continuously available until shutdown occurs,
or else flame relay «FR» will be deenergized, resulting in lockout.
t4 Interval BV1 and BV2-LR
Time between the end of TSA and the signal to the second fuel valve BV2
or to the load controller LR
B - B' Interval for flame establishment
C Burner operation position
C - D Burner operation (heat production)
D Controlled by "R" shutdown
Operation, flame ok Green
Operation, flame not
ok
Extraneous light on
burner startup
......................................
S S S S S
Flashing green
Green - red
The burner stops and the control device is ready for a new startup.
LME11 control sequence
7
SB / R
A
/ GP
AL
M
Z
BV1
LP
FS
EK2
tw
t10
t1
LME21 control sequence
A
SB / R
W / GP
AL
M
Z
BV1
(LR) BV2
LP
FS
t10
tw
t1
LME22 control sequence
.
A
B
t3
B´
t3n
C
D
12
10
3
7
4
6
1
8
t4
TSA
B
t3
t3n
B´ C
t4
D
12
10
3
7
4
5
6
1
7101d05/0206
SB / R
W / GP
AL
LK
M
Z
11
SA
BV1
LR) BV2
LP
FS
EK2
I
t10
tw
t1
t12
t11
Control sequence
tw Waiting time
t1 Purge time
TSA Ignition safety time
t3 Preignition time
t3n Postignition time
t4 Interval between BV1 and BV2/LR
t10 Specified time for air pressure signal
11
t11 Programmed opening time for actuator SA
t12 Programmed closing time for actuator SA
B
B´ C
t3
t3n
TSA
t4
D
7101d02/0606
12
10
3
7
9
4
5
6
11
1
8
LME11 connection diagram
NT
K1
K2/1
10
2
12
R / W
T
GP
AL
M
STB
H
Si
L
N
LME21 connection diagram
NT
Connection diagram
AL Error message (alarm)
C control
P
EK
RESET
BV Fuel valve
EK2 Remote lockout reset button
FS Flame signal
GP Gas pressure switch
LP Air pressure switch
LR Load controller
M Fan motor
R Control thermostat/pressurestat
SB Safety limit thermostat
W Limit thermostat /pressure switch
Z Ignition transformer
EK
FSV
1
8
ION
K2/2
3
K3
4
BV1
5
C control
P
9
7
Z
6
LP
RESET
11
p
a
EK
K1
K2/1
R / W
GP
STB
L
N
12
T
H
Si
10
2
AL
LME22 connection diagram
NT
K1
K2/1
10
2
R / W
GP
12
T
3
AL
M
3
M
K2/2
K2/2
8
EK
8
EK
FSV
1
ION
FSV
1
ION
Nur LME23...
12
br
bl
QRC
12
sw
K4
K3
p
a
RESET
p
a
11
EK
11
SA
6
9
LP
6
9
LP
7
4
5
Z
P
K3
7
Z
BV1
BV1
C control
4
BV2
K4
5
BV2
STB
L
N
H
Si
CONTROL PROGRAM IN THE EVENT OF FAULT
z If a fault occurs, all outputs will immediately be deactivated (in less
than 1s).
z After an interruption of power, a restart will be made with the full pro-
gram sequence.
z If the operating voltage drops below the undervoltage thresold, a
safety shutdown is performed.
z If the operating voltage exceeds the undervoltage thresold, a restart
will be performed.
z In case of extraneous light during “t1”, a lockout occurs.
z In case of extraneous light during “tw”, there is a prevention of startup
and a lockout after 30 seconds.
z In case of no flame at the end of TSA, there will be max. 3 repetitions
of the startup cycle, followed by a lockout at the end of TSA, for mod.
LME11..; directly a lockout at the end of TSA for LME21-22 models.
z For LME11 model: if a loss of flame occurs during operation, in case of
an establishment of flame at the end of TSA, there will be max. 3 repetitions, otherwise a lockout will occur.
z For LME21-22 models: if a loss of flame occurs during operation, there
will be a lockout.
z If the contact of air pressure monitor LP is in working position, a pre-
vention of startup and lockout after 65 seconds will occur.
z IIf the contact of air pressure monitor LP is in normal position, a
lockout occurs at the end of t10.
z If no air pressure signal is present after completion of t1, a lockout will
occur.
CONTROL BOX LOCKED
ERROR CODE TABLE
2 blinks **
No establishment of flame at the end of TSA
- Faulty or soiled fuel valves
- Faulty or soiled flame detector
- Inadequate adjustement of burner, no fuel
- Faulty ignition equipment
The air pressure switch does not switch or remains in idle position:
3 blinks ***
- LP is faulty
- Loss of air pressure signal after t10
LPis welded in normal position.
-
4 blinks **** - Extraneous light when burner starts up.
5 blinks *****
- LP is working position.
6 blinks ***** Free.
7 blinks ******* Loss of flame during operation
- Faulty or soiled fuel valves
- Faulty or soiled flame detector
- Inadequate adjustement of burner
8 ÷ 9 blinks Free
10 blinks ********** Faulty output contacts
- Wiring error
- Anomalous voltage on ouput terminals
- Other faults
14 blinks ************** - CPI contact not closed.
In the event of lockout, the LME.. remains locked and the red signal lamp
(LED) will light up.The burner control can immediately be reset. This state
is also mantained in the case fo mains failure.
DIAGNOSITICS OF THE CASUE OF FAULT
z Press the lockout reset button for more than 3 seconds to activate the
visual diagnostics.
z Count the number of blinks of the red signsl lamp and check the fault
condition on the “Error code table” (the device repeats the blinks for
regular intervals).
During diagnostics, the control outputs are deactivated:
- the burner remains shut down;
- external fault indication is deactivated;
- fault status is showed by the red LED, inside the LME’s lockout reset
buttonaccording to the “Error code table”:
RESETTING THE BURNER CONTROL
When lockout occurs, the burner control can immediately be reset, by
pressing the lockout reset button for about 1..3 seconds. The LME.. can
only be reset when all contacts in the line are closed and when there is no
undervoltage.
LIMITATION OF REPETITIONS (only for LME11.. model)
If no flame is established at the end of TSA, or if the flame is lost during
operation, a maximum of 3 repetitions per controller startup can be performed via “R”, otherwise lockout will be initiated. Counting of repetitions is
restarted each time a controlled startup via “R” takes place.
TECHNICAL CHARACTERISTICS
Mains voltage 120V AC +10% / -15%
230V AC +10% / -15%
Frequency 50 ... 60 Hz +/- 6%
Power consumption 12VA
External primary fuse max. 10 A (slow)
input current at terminal 12 max. 5 A
Thermostats cable length max. 3 m
Index of protection IP40 (to be ensured during mounting)
Operating conditions -20... +60 °C, < 95% UR
Storage conditions -20... +60 °C, < 95% UR
Weight approx. 160 g
C.I.B. UNIGAS S.p.A.
Via 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 and data subject to change. Errors and omissions excepted.
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