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

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, 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.

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/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

4

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.

2

1

3

4

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.

5

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

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 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)

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

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

3

/h)

see next paragraph)

2.1 - 4.3 0.8 - 1.6 2.9 - 4.3

I

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

3

/h)

see next paragraph)

2.1 - 4.3 0.8 - 1.6 2.9 - 4.3

I

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

7

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

i

3

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

3

)

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

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

8

Overall dimensions (mm)

9

C.I.B. UNIGAS - M039121CE

Boiler drilling template

AB CDEFGHJKLMN O P Q R STmin.WXY

min. max. min. max. min. max. min. max. min. max.
NG35 S (1/2") 338 34 78 260 305 269 14 255 Ø80 Ø95 86 162 194 M8 155 86 138 110 277 322 109 154 168 27 400 275 Ø78,5
NG35 L (1/2") 416 34 156 260 383 269 14 255 Ø80 Ø95 86 162 194 M8 155 86 138 110 277 400 109 232 168 27 400 275 Ø78,5

NGX35 S (1/2") 338 58 98 240 280 269 14 255 Ø80 Ø95 86 145 194 M8 153 96 120 108 257 297 89 129 168 7 400 266 Ø80
NGX35 L (1/2") 338 58 178 160 280 269 14 255 Ø80 Ø95 86 145 194 M8 153 96 120 108 257 297 89 129 168 7 400 266 Ø80

S: standard blast tube
L: extended blast tube

C.I.B. UNIGAS - M039121CE

)

)

Performance Curves

Natural Gas Burners L.P.G. Burners

NG35 M-.TN...

2

1,5

1

0,5

0

-0,5

PRESSURE IN

-1
15 25 35 45

THE COMBUSTION CHAMBER mbar

Low NOx Natural Gas Burners

NGX35 M-.TN...

2

1,5

1

0,5

0

-0,5

PRESSURE IN

-1
25 30 35 40 45 50

THE COMBUSTION CHAMBER mbar

LG35 L-.TN...

2

1,5

1

0,5

0

-0,5

-1
15 25 35 45

kW

kW

kW

Pressure in the network - gas rate curves

Natural Gas Burners

NG35 M-.TN...

14
12
10

8
6
4
2

GAS PRESSURE mbar

0

2345

Low NOx Natural Gas Burners

NGX35 M-.TN...

14

12

10

8

6

Rp ½" (10 )

Rp ½" (15)

Gas rate Stm3/h

Rp ½" (10

Rp ½" (15

L.P.G. Burners
LG35 L-.TN...

6

5

4

3

2

1

0

0,5 0,75 1 1,25 1,5 1, 75

Rp ½" (10)

Rp ½" (15)

Gas rate Stm3/h

GAS PRESSURE mbar

4

2,5 3 3,5 4 4,5 5

Gas rate Stm3/h

10

C.I.B. UNIGAS - M039121CE

MOUNTINGS AND CONNECTION S

Packing

Burners are dispatched in cardboard packages whose dimensions sre:

z burners with no external air intake: 290mm x 260mm x 490mm (L x P x H)
z burners with external air inlet provided: 290mm x 330mm x 490mm

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 and in the event of scrapping of the latter, 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 burners described in this manual have been tested with combustion chambers that co mply with EN676 regulation and whose
dimensions are described in the diagram . In case the burner mu st 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 th e 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 pe netrate at least 50 - 100 mm into combustion chambe r 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

11

C.I.B. UNIGAS - M039121CE

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

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

Key

1 Burner
2 Multibloc valves group: Multibloc DUNGS (2 gas valves + gas pressure switch + filter + pressure governor)
3 Bellow joint
4 Manual cutoff valve

Once the train is installed, connect the gas valves group plug.

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.

12

C.I.B. UNIGAS - M039121CE

Electrical connections

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. STRICTLY OBSERVE THE DATA PLATE.

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 electrically connect the burner to the mains, find the burner plug.
The power supply connector diagram is shown in figure.

Key

CO Time counter
FFuse
IL Main switch
LB Burner lockout indicator light
LF Indicator light for burner operation
MA Power supply terminal block
N Neutral
TS Safety boiler thermostat/pressure switch

Power supply without neutral

If the burner power supply is 230V three-phase or 230V phase-phase (without a neutral), as fas as the Siemens LME2... control box,
the RC Siemens RC466890660 filter must be inserted between terminal 2 and the earth terminal on the board.

Key

C - Capacitor (22nF/250V)
LME - Siemens control box
R - Resistor (1Mohm)

RC466890660 - RC Siemens filter

13

C.I.B. UNIGAS - M039121CE

ADJUSTING THE AIR AND GAS FLOW RATES

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 INVALIDATE!

While performing the air and fuel adjustment, check the flow rate, measuring it on the counter or, if it is not possible, checking the com­bustion head pressure by means of a differential pressure gauge as described on the next paragraph.

NOTE: The combustion tests must be carried out with the cover mounted on the burner.

IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:

Recommended combustion parameters

Fuel

Natural gas 9 ÷ 10 3 ÷ 4.8

LPG 11 ÷ 12 2.8 ÷ 4.3

Recommended (%) CO

Recommended (%) O2

2

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 (percentage of residual O
dard limits). During this stage, the combustion head, the gas butterfly valve and the servocontrol are at the maximum opening. Refer to
Fig. 7, showing the correct way to measure the gas pressure, considering the values of pressure in comb usti on chamber, surveyed by
means of the pressure gauge or taken from the boiler’s Technical specifications.

in the flues as showed in the “Recommended combustion values” table and CO in the stan-

2

1

2

4

3

Fig. 7

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 outle t (Fig.
7-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pr essure outle t of the burner ( Fig. 7-3).
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 (quoted on the x axis) from the pressure measured in the com-

14

C.I.B. UNIGAS - M039121CE

bustion 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.

Pressure in the combustion head - gas flow rate diagrams

Natural Gas Burners
NG35

8

7

6

5

4

Gas pressure in

3

combustion head

2

1

2 2,5 3 3,5 4 4,5

L.P.G. Burners

LG35

6,5

6

5,5

5

4,5

4

combustion head

3,5

3

Gas pressure in

2,5

2

0,75 1,25 1,75

Low NOx Natural Gas Burners

NGX35

6

5,5

5

4,5

4

3,5

3

Gas pressure in

2,5

combustion head

2

1,5

1

22,533,54

Gas rate Stm

Gas rate Stm

Gas rate Stm

3

/h

3

/h

3

/h

15

C.I.B. UNIGAS - M039121CE

Gas MULTIBLOC control and safety group DUNGS MBC 65-DLE





99



3



Fig. 8

Fig. 9

3

3





Keys
A. measuring noozle P2 (Fig. 9) before valve D
B. pressure regulator
C. startup valve (no. 10 in Fig. 9)
D. maximum flow rate valve(no. 9 in Fig. 9)

Filter, valves, regulator and pressure switch are combined into the DUNGS Gas-MultiBloc.

Setting the startup gas flow rate

To adjust the gas flow rate at the startup, proceed as follows:
1 slacken screw A (Fig. 8) in measuring nozzle. Connect pressure gauge.
2 Set to the minimum the pressure regulator by turning adjustment screw B (Fig. 8) anticlockwise .
3 Turn the burner on.
4 Adjust the flame during the startup phase by means of the bypass C (see Fig. 8 n. 10). Turning clockwise the gas flow decrea ses,
turning counterclockwise the gas flow increases. Do not exceed in the start flow, otherwise the stabiliser B (Fig. 8) will be inefficacious.
NOTE: The adjustment screw C for the start flow restrictor is closed (factory setting). The start flow can be set by opening the restrictor
up to approx. 80% of the main flow

Setting the gas flow rate

Act on the pressure regulator to achieve the desired gas flow rate, by means of the Adjustment screw B (Fig. 8): turn the screw
clockwise to increase the flow rate, turn counter-clockwise to decrease it.

On completion of work on the MBC, perform a gas proving test.

Adjusting the maximum flow rate valve

The adjustment screw D for the main flow restrictor is completely open (facto ry setting): do not change its position. Once the adju­smetns are accomplished, close screw A (Fig. 8) in the measuring nozzle.

16

C.I.B. UNIGAS - M039121CE

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

Multibloc MB-DLE

The multibloc unit is a compact unit consisting of two valves, gas pressure
switch, pressure stabilizer and gas filter.

The valve is adjusted by means of the RP regulator afte r slackening the lockin g
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

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

17

C.I.B. UNIGAS - M039121CE

Adjusting the air flow rate

The air rate is set by means of V screw. The air damp er position is showed by the gra duated scale I, where the symbol “0” shows the
complete closed position of the air damper.

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.

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

Calibration is carried out as follows:

z Remove the transparent plastic cap.
z Once air and gas setting have been accomplished, startup the burner.
z While the burner is operating, rotate slowly and clockwise the adjusting ring nut VR, until the burner locks; read the pressure value

on the scale of the pressure switch and set it again to a value reduced by the 15%.

z Repeat the start-up cycle and check the burner 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 Remove the transparent plastic cap.
z While the burner is operating at the maximum output, test the gas pressure on the p ressure port of the minimum 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.

z Check that the burner is operating correctly.
z Screw down the pressure switch adjusting ring nut until the burner stops.
z Fully open the manual cutoff valve.
z Refit the transparent plastic cover on the pressure switch.

VR

VR

18

C.I.B. UNIGAS - M039121CE

Adjusting the combustion head

In order to adjust the combustion head, proceed as follows:
1 remove the bunrer cover;
2 set the combustion head by mean s of a screwdriver, working on the screw VRT: rotate counterclockwise to move the combustion

head forward, or rotate clockwise to move it backwards;
3 replace the burner cover.
The burner is adjusted in the factory with the combustion head in the position that refers to the "MAX" output. The maximum output set-

ting refers to the “fully-ahead” position of the combustion head, as far as standard models (Fig. 10), and to “fully-backward” position for
low NOx burners (Fig. 11). As for “fully-ahead” position, it means that the head is pla ced inside the boiler, “fully-backward” position
means that the head is towards the operator. To remove the combsution head, please refer to par. “Removing and cleaning the combu­stion head” on page 22. As far as the reduced outp ut operation, progressive ly move the combu siton head towa rds the “MIN” po siti on,
rotating clockwise the VRT screw (see next figure). The ID index shows how much the combustion head moved.

VRT

NG/LG35

NGX35

VRT VRT

Fig. 10

Fig. 11

19

C.I.B. UNIGAS - M039121CE

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

1 Turn on the burner by means of the boiler main switch.
2 Check the control box is not locked and, if necessary, reset it by means of the reset button R, on the burner cover.
3 Check the series of thermostats or pressure switches enables the burner to operate.
4 The burner starts and the control box drives the burner fan.
5 At the end of pre-purge phase the ignition transformer is energised, the gas solenoid valves are energised as well and the burner

starts up.

20

R

C.I.B. UNIGAS - M039121CE

PART III: MAINTENANCE

At least once a year carry out the maintenance operations listed below . In the case of seasonal servici ng, it is recommended to carry
out the maintenance at the end of each heating season; in the case of continuous o peration 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 Check and clean the filter inside the gas valves group (see next paragraph);
z remove, check and clean the combustion head (see page 22);
z check the ignition and detection electrodes; clean and adjust and, if necessary, replace them (see page 22);
z in case of doubt, check the detection circuit once the burner has started up, referring to the diagram on page 23.

NOTE: The check on the ignition and detection electrodes is carried out after removing the combustion head.

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. 12-Fig. 13)is ∆p > 10 mbar.

z

Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 12-Fig. 13) 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

= 360 mbar.

max.

Fig. 14

.

2

0

3
p

2

e

4
p

a

5
p

Br

61

6

➞

5

3

4

1
0

6

➞

53

4

1

03

p

e

Fig. 13

4
p

a

5
p

Br

Fig. 12

Fig. 14

21

C.I.B. UNIGAS - M039121CE

Disassembling the burner plate for the fan maintenance

To clean/replace the fan, follow the next procedure:
1 remove the burner plate C by unscrewing the V1, V2, V3 screws and the F fixing pin;
2 hang the plate in one of the ways showed on figure in order to make maintenance operations easier.

NOTE: When re-assembling the component plate, make sure that the pin for the air damper "P" enters its housing "B"

(see next picture).

V1

F

C

V2

V3

Removing the combustion head

To remove the combustion head, proceed as follows:

1 remove the burner cover;
2 unscrew the VT fixing screws;
3 disconnect the ignition cable CA; unscrew the fixing nuts D and shift the combustion head off its housing;
4 adjust the electrodes: to replace them, if necessary, disconnect the cables and unscrew VE;
5 remove the electrodes and replace them;
6 to clean the combustion head, use a vacuum cleaner; to scrape off the scale use a metallic brush;
7 replace all the items reversing the procedure.

VT

VE

D

CA

22

C.I.B. UNIGAS - M039121CE

Correct electrodes positioning

To guarantee a proper ignition, the measures indicated in must be respected.
Ensure the locking screw VE of the electrodes group is tight before refit the burner.

z Standard burners (mm)

4

3

2

1

z Low NOx burners (mm)

5

3

6

1 detection electrode
2 grounded electrode
3 ignition electrode
4 electrode fixing
5 ignition cable
6 detection cable

5

.

2

10

10

Fig. 15

9

0

90°

0

3

°

28

20

Checking the detection current

If the burner locks, execute the following inpesctions. To measure the detection signals refer to the diagrams below. 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 LME11 3 µA

Fig. 16

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”.

23

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

24

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

C.I.B. UNIGAS - M039121CE

●●

▲●●▲

●●●

▲

▲

C.I.B. UNIGAS - M039121CE

External air intake kit assembly (when provided)

The burner may be supplied with an external air intake with components contained in the kit provided separately (Code 3300023).
Proceed as follow for assembly.

z Remove the burner cover.
z Disassemble the burner plate.

V

Remove the two V screws that fasten
the grid to the volute and then remove
the grid.

V

V

V

Remove the air inlet by unscrewing the 4 V
screws.

T

Position the gasket supplied in the appropri­ate seat in the burner volute and insert the
"T" volute plug.

Position the gasket in the seat of the air
inlet and reassemble the air inlet.

Place the gasket in the seat of the burner
cover.

External air intake mounted on the burner.

It is recommended to cut the gasket obliquely in its splicing and gluing point in order to increase the contact surface.

z Reassemble the burner component plate and cover.

NOTE: When re-assembling the component plate, make sure that the air damper pin "P" en ters its housing "B" (see

pag. 22).
External air intake kit (Code 3300023 - spare parts list)

Description Quantity Code

Gasket 2 meters 2110409
External air intake 1 1012101
Volute plug 1 2210214
Self-tapping air intake fixing screws 2 523104008

25

C.I.B. UNIGAS - M039121CE

ELECTRICAL WIRING DIAGRAM

Electrical diagram 01-318 Rev. 5 - complete key

CO Time counter
ER Flame detection electrode
EV1 Gas electro-valve upstream (or valve group)
EV2 Gas electro-valve downstream (or valve group)
FFuse
IL Main switch
L Phase
LB Burner lockout indicator light
LF Indicator light for burner functioning
LME SIEMENS control box
MA Power supply terminal block
MV Fan motor
N Neutral
PA Combustion air pressure switch
PG Low gas pressure switch
ST Series of thermostats or pressure switches
TA Ignition transformer
TS Safety boiler thermostat/pressure switch
VPS DUNGS gas proving system (option)

*NOTE : Connection between terminals 7 and 9 only when SIEMENS LGB21.33 monitor device is used.

WARNING:

1 - Electrical supply 230V 50/60Hz 1N a.c.
2 - Do not reverse phase with neutral
3 - Ensure burner is properly earthed

26

Cod. 01-319 Rev. 5 - Single-stage burners

C.I.B. UNIGAS - M039121CE

27

BURNER EXPLODED VIEW

POS. DESCRIPTION POS. DESCRIPTION

1.1 SCREW 16 PIN

1.2 INTERNAL AIR DAMPER 18.2 CONTROL BOX SOCKET

1.5 AIR INTAKE 18.3 CONTROL BOX

1.6 AIR DAMPER INDEX 19.2 AIR PRESSURE SWITCH
2 GRID 20 IGNITION TRANSFORMER
3 STANDARD BLAST TUBE 21.1 NIPPLE
4 FLANGE 21.2 ELBOW

5.1 STANDARD COMBUSTION HEAD 21.3 GAS VALVES GROUP WITH GOVERNOR

5.2 DETECTION ELECTRODE 21.4 GAS PRESSURE

5.3 IGNITION ELECTRODE 21.5 CONNECTOR

5.5 IGNITION CABLE 21.6 CONNECTOR

5.6 IGNITION CABLE 22.2 RUBBER COVER FOR PUSH-BUTTON
6 FLANGE 22.3 COVER
7 MOTOR SUPPORT PLATE 24 CONNECTOR
13 GENERATOR GASKET 25 CABLE

30

14 FAN WHEEL 26 CONNECTOR
15 MOTOR

C.I.B. UNIGAS - M039121CE

31

C.I.B. UNIGAS - M039121CE

C.I.B. UNIGAS - M039121CE

SPARE PARTS

Desription Code

LG/NG35 NGX35

CONTROL BOX 2020466 2020466
DETECTION ELECTRODE 2080112 2080113
GROUNDED ELECTRODE 2080235 2080235
IGNITION ELECTRODE 2080268 2080268
GASKET 2110038 2110055
FAN WHEEL 2150048 2150048
AIR PRESSURE SWITCH 2160060 2160060
TRANSFORMER (COFI) 2170138 2170138
TRANSFORMER (DANFOSS) 2170233 2170233
MOTOR 2180705 2180705
VALVES GROUP DUNGS MBC 65 DLE (3/8”) 21903K2 21903K2
VALVES GROUP DUNGS MB-DLE 405 (1/2”) 2190339 2190339
GAS PROVING SYSTEM (option) 2191604 2191604
BLAST TUBE S* 30900H8 30900F2
BLAST TUBE L* 30900H9 30900F3
COVER 3010046 3010046
COMBUSTION HEAD S* 30600F3 30600K0
COMBUSTION HEAD L* 30600F4 30600L8
COMBUSTION HEAD & ELECTRODES S* 3501832 -
COMBUSTION HEAD & ELECTRODES L* 3501833 -
IGNITION CABLE S* 6050152 6050152
IGNITION CABLE L* 6050122 6050122
DETECTION CABLE 6050211 6050211

*S: standard blast tube
*L: extended blast tube

32

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 LMG 21.33 LME 21.33

LGB 22.33 LMG 22.33 LME 22.33

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

....................................

zzzzzz

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

t3n

t4

t3

TSA

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

6

LP

RESET

BV1

5

4

C control

P

9

7

Z

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

K3

7

Z

BV1

BV1

C control

P

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. [phone] - Fax [phone]

web site: www.cibunigas.it - e-mail: [e-mail]

Note: specifications and data are subject to change without notice. Errors and omissions excepted.