Unigas LG35, IDEA Series, NG35, NGX35 Manual Of Installation - Use - Maintenance

LG/NG/NGX35

IDEA Series

Gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

M039121CE Rev. 4 04/2009

ГОРЕЛКИ

C.I.B. UNIGAS - M039121CE

TABLE OF CONTENTS

WARNINGS ............................................................................................................................................................... 3

PART I: INSTALLATION .................................... ....................................... ... ... .... ...................................................... 5

GENERAL FEATURES ...................................................................................................................................................................5

How to interpret the burner’s “Performance curve” ............................................... ... ....................................................................... 6

Specifications ..................................................................................................................................................................................7

Country and usefulness gas categories ..........................................................................................................................................8

Overall dimensions .........................................................................................................................................................................9

Performance Curves .....................................................................................................................................................................10

Pressure in the network - gas rate curves ....................................................................................................................................10

MOUNTINGS AND CONNECTIONS ............................................................................................................................................11

Fitting the burner to the boiler .......................................................................................................................................................11

Matching the burner to the boiler ..................................................................................................................................................11

Installing the gas train ...................................................................................................................................................................12

Electrical connections ...................................................................................................................................................................13

Power supply without neutral ........................................................................................................................................................13

ADJUSTING THE AIR AND GAS FLOW RATES .........................................................................................................................14

Combustion head pressure curves vs. the gas flow rate ..............................................................................................................14

Measuring the gas pressure in the combustion head ...................................................................................................................14

Pressure in the combustion head - gas flow rate diagrams ..........................................................................................................15

Gas MULTIBLOC control and safety group DUNGS MBC 65-DLE ..............................................................................................16

Setting the startup gas flow rate ...................................................................................................................................................16

Setting the gas flow rate ...............................................................................................................................................................16

Adjusting the maximum flow rate valve .........................................................................................................................................16

Gas Valves Group DUNGS MB-DLE 405 (1/2” gas train burners) ...............................................................................................17

Adjusting the air flow rate ..............................................................................................................................................................18

Adjusting the air and gas pressure switches ................................................................................................................................. 18

Calibration of air pressure switch (only for single stage burners) .................................................................................................18

Calibration of minimum gas pressure switch ................................................................................................................................18

Adjusting the combustion head .....................................................................................................................................................19

PART II: OPERATION ..................................... ....................................... ... ... ... ........................................................ 20

OPERATION .................................................................................................................................................................................20

PART III: MAINTENANCE ........................ .... ...................................... .... ... ... ........................................................... 21

ROUTINE MAINTENANCE ...........................................................................................................................................................21

Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................21

Disassembling the burner plate for the fan maintenance ............................................................................................................ 22

Correct electrodes positioning ......................................................................................................................................................23

Checking the detection current .....................................................................................................................................................23

Seasonal stop ............................................................................................................................................................................... 23

TROUBLESHOOTING ..................................................................................................................................................................24

External air intake kit assembly (when provided) ..........................................................................................................................25

ELECTRICAL WIRING DIAGRAM ................................................................................................................................................26

BURNER EXPLODED VIEW ........................................................................................................................................................28

SPARE PARTS .............................................................................................................................................................................30

APPENDIX ............................. ................................................................. ................................................................. 31

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, or other fuel). z Observe caution with hot burner components. These are, usually,

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

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.

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/CEE on electromagnetic compatibility

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

Heavy oil burners

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

Gas - Light oil 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.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods

Gas - Heavy oil 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.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics and test methods

C.I.B. UNIGAS - M039121CE

PART I: INSTALLATION

GENERAL FEATURES

This series burners can be arranged to use external combustion air on request. In this case the burner will be supplied with a watertight and airtight air intake, that can be linked outside the installation room by means of an exetensible du ct. Combustion air can be easily set by the adjusting screw without removing the cover. The cover, easily removable, is heat resistant (ABS material). The easy-readable index allows a fine adjustment oa the comburent air, without removing the burner cover. All components can be fitted into a backing plate which can be easily moved and attached to special fixings within the burner to make maintenance easier.

Fig. 1

Keys

1 Control box 2 Combustion head (inside) 3 Omponents plate 4 Air pressure switch

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. 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.

C.I.B. UNIGAS - M039121CE

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 followin g 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: kW 600 Backpressure: mbar 4 In the “Performance curve” diagram (Fig. 2), draw a vertical line matching the furnace input value and an h orizontal line matching th e

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

Contropressione in camera di

-1 100 200 300 400 500 600 700 800 900

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 gas valve. Then subtract the backpressure. The result is called p

gas. Draw a vertical line matching the furnace input value (600kW, in the example), quoted on the x-

axis, as far as intercepitng the network pressure 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 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)

pressure (mbar)

rete / Minimum inlet gas

Minima pressione gas in

100 200 300 400 500 600 700 800 900

Potenza / Output (kW)

Rp 2" (50)

DN65

Fig. 3

C.I.B. UNIGAS - M039121CE

Burner model identification

Burners are identified by burner type and mode l. Burner model ide ntification is described as follows. Type NG35 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

M - Natural gas L - LPG

TN - Single stage (4) BLAST TUBE S - standard L - Extended (5) DESTINATION COUNTRY (6) BURNER VERSION

* - see data plate

A - Standard

Z - with external air intake (7) EQUIPMENT

0 = 2 gas valves

1= 2 Gas valves + gas proving system (option) (8) GAS CONNECTION 10 = Rp3/8 15 = Rp1/2

Specifications

BURNERS

NG35 M-.TN..10 LG35 L-.TN..10 NGX35 M-.TN..10

Output min.- max. kW 20 - 41 20 - 41 27 - 41 Fuel Natural gas L.P.G. Natural gas Gas category (

Gas rate

min.- max. (Stm

/h)

see next paragraph)

2.1 - 4.3 0.8 - 1.6 2.9 - 4.3

3B/P

(see next paragraph)

Gas pressure min. - max mbar (Note2) - 65 Power supply 230V 1N ac 50 Hz Total power consumption W 380 Electric motor W 75 Protection IP40 Approx. weight kg 12.5 Valves size - Gas connection 3/8” - Rp1/2 Operation Single stage Operating temperature °C Storage Temperature °C Working service *

BURNERS

NG35 M-.TN..15 LG35 L-.TN..15 NGX35 M-.TN..15

-10 ÷ +50

-20 ÷ +60

Intermittent

Output min.- max. kW 20 - 41 20 - 41 27 - 41 Fuel Natural gas L.P.G. Natural gas Gas category (

Gas rate

min.- max. (Stm

/h)

see next paragraph)

2.1 - 4.3 0.8 - 1.6 2.9 - 4.3

3B/P

(see next paragraph)

Gas pressure min. - max mbar (Note2) - 360 Power supply 230V 1N ac 50 Hz Total power consumption W 380 Electric motor W 75 Protection IP40 Approx. weight kg 12.5 Valves size - Gas connection 1/2” - Rp1/2 Operation Single stage Operating temperature °C Storage Temperature °C Working service *

-10 ÷ +50

-20 ÷ +60

Intermittent

C.I.B. UNIGAS - M039121CE

Note1:

All gas flow rates are referred to Stm value H

= 34.02 MJ/Stm3); for L.P.G. (nett calorific value Hi= 93.5 MJ/Stm

/h (1013 mbar pressure, 15 °C temperature) and are valid for G20 gas (nett calorific

)

Note2: Maximum gas pressure = 65mbar (with Rp3/8 - Rp1/2 and Dungs MBC065DLE valves)

= 360mbar (with Rp1/2 and Dungs MB-DLE 405 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

Unigas LG35, IDEA Series, NG35, NGX35 Manual Of Installation - Use - Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual