Unigas NG70 M-.AB 15, NG70 M-.TN 10, NG90 M-.AB 10, NG90 M-.AB 15, NG70 M-.TN 15 Technical Manual Of Installation, Use And Maintenance

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LG/NG/NGX70

LG/NG90

Idea Series

Gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

M039135CG Rev. 6 07/2008

ГОРЕЛКИ

C.I.B. UNIGAS - M039135CG

TABLE OF CONTENTS

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

PART I - INSTALLATION .......................................................................................................................................... 5

Specifications .................................................................................................................................................................................. 5

Country and usefulness gas categories .......................................................................................................................................... 7

Performance curves ...................................................................................................................................................................... 10

Pressure in the network / gas flow rate curves ........................................................................................................................... 11

MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 13

Packing ......................................................................................................................................................................................... 13

Fitting the burner to the boiler ....................................................................................................................................................... 13

Matching the burner to the boiler................................................................................................................................................... 13

Installing the gas train ................................................................................................................................................................... 14

ELECTRICAL CONNECTIONS .................................................................................................................................................... 15

Power supply without neutral ........................................................................................................................................................ 16

ADJUSTING THE AIR AND GAS FLOW RATES ......................................................................................................................... 17

Combustion head pressure curves vs. the gas flow rate .............................................................................................................. 17

Measuring the gas pressure in the combustion head ................................................................................................................... 17

Plugs for pressure measurement .................................................................................................................................................. 18

Pressure in combustion head - gas rate curves ............................................................................................................................ 18

Adjusting the air and gas flow rates .............................................................................................................................................. 19

Startup Output ............................................................................................................................................................................... 19

Adjusting procedure ...................................................................................................................................................................... 19

Adjusting the combustion head ..................................................................................................................................................... 20

Adjustements for single-stage burners ......................................................................................................................................... 20

Double-stage burners ................................................................................................................................................................... 21

Calibration of air and gas pressure switches ................................................................................................................................ 23

Calibration of air pressure switch (only for single stage burners) ................................................................................................. 23

Calibration of air pressure switch (double-stage, progressive and fully-modulating) .................................................................... 23

Calibration of low gas pressure switch .......................................................................................................................................... 23

Adjusting the high gas pressure switch (when provided) .............................................................................................................. 23

PART II: OPERATION ............................................................................................................................................. 24

OPERATION ................................................................................................................................................................................. 24

PART III: MAINTENANCE ....................................................................................................................................... 25

ROUTINE MAINTENANCE........................................................................................................................................................... 25

Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................ 25

Removing the combustion head ................................................................................................................................................... 26

Correct electrodes positioning ...................................................................................................................................................... 27

Checking the detection current ..................................................................................................................................................... 27

Seasonal stop ............................................................................................................................................................................... 27

TROUBLESHOOTING .................................................................................................................................................................. 28

SPARE PARTS ........................................................................................................................................................................... 29

BURNER EXPLODED VIEW ........................................................................................................................................................ 30

WIRING DIAGRAMS .................................................................................................................................................................... 32

APPENDIX

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 - M039135CG

PART I - INSTALLATION

Burner model identification

Burners are identified by burner type and model. Burner model identification is described as follows.

Type NG90 Model M-. AB. S. .* A. 0. 15

(1) (2) (3) (4) (5) (6) (7) (8)

NG - Natural gas burner

(1) BURNER TYPE

(2) FUEL M - Natural gas L - LPG (3) OPERATION

(4) BLAST TUBE S - standard L - extended

(5) DESTINATION COUNTRY * - see data plate

(6) BURNER VERSION A - Standard

(7) EQUIPMENT

(8) GAS CONNECTION

LG - L.P.G. burner NGX - Natural gas Low NOx burners

TN - Single stage AB - Double stage

0 = 2 gas valves 1= 2 Gas valves + gas proving system (option) 10= 3/8” = Rp1/2 15= 1/2” = Rp1/2 20= 3/4” = Rp3/4

Specifications

BURNERS

Output min. - max. kW

Fuel

Category (see next paragraph)

Gas rate

Gas pressure min.-max. mbar (see Note 2)

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

Output min. - max. kW

Fuel

Category (see next paragraph)

Gas rate

Gas pressure min.-max. mbar (see Note 2)

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

/h)

NG70

M-.TN...10

3.2 - 7.4 4.2 - 9

3/8 / ”Rp1/2 1/2” / Rp1/2 3/8” / Rp1/2 1/2” / Rp1/2 3/4” / Rp3/4

NG70

M-.AB...10

3/8” / Rp1/2 1/2” / Rp1/2 1/2” / Rp1/2 1/2” / Rp1/2 3/4” / Rp3/4

NG70

M-.TN...15

30 - 70 40 - 85

NG70

M-.AB...15

19 - 68 22 - 85

2 - 7 2.3 - 9

NG90

M-.TN...10

Natural gas

230V 1N.ac - 50 Hz

0.40

0.10

IP40

Single stage

-10 ÷ +50

-20 ÷ +60

Intermittent

NG90

M-.AB...10

Natural gas

230V 1N.ac - 50 Hz

0.40

0.10

IP40

High-low flame

-10 ÷ +50

-20 ÷ +60

Intermittent

NG90

M-.TN...15

NG90

M-.AB...15

NG90

M-.TN...20

NG90

M-.AB...20

C.I.B. UNIGAS - M039135CG

BURNERS LG70 L-.TN...10 LG70 L-.TN...15 LG90 L-.TN...10 LG90 L-.TN...15

Output min. - max. kW

Fuel

CATEGORY

2E( R ) B

2ELL

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

OVERALL DIMENSIONS (mm) (NG70 - NG90)

C.I.B. UNIGAS - M039135CG

Rp A B C D E F G H J K L M N O P Q R S Tmin. W X Y

NG70 ..S.. NG70 ..L.. NG90 ..S.. NG90 ..L..

1/2" 365 34 78 287 332 365 75 291 Ø80 Ø95 99 162 218 M8 155 86 138 110 285 330 118 163 168 14 438 299 Ø78,5 1/2" 443 34 156 287 410 365 75 291 Ø80 Ø95 99 162 218 M8 155 86 138 110 285 408 118 241 168 14 438 299 Ø78,5 1/2" 365 34 70 295 331 365 75 291 Ø80 Ø95 102 162 218 M8 155 86 138 110 293 329 125 203 168 2 441 299 Ø78,5 1/2" 443 34 148 295 409 365 75 291 Ø80 Ø95 102 162 218 M8 155 86 138 110 293 407 125 239 168 2 441 299 Ø78,5

S: standard blast tube L: extended blast tube

Burner flange and boiler drilling template

min. max. min. max. min. max. min. max. min. max.

NGX70

C.I.B. UNIGAS - M039135CG

Burner flange and boiler drilling template

Blast tube

Standard

Extended

AB CDEFGHJKLMNOPQ RSTWX

min. max. min. max. min. max. min. max. min. max.

NGX70 393 76 299 304 14 291 Ø80 Ø98 99 145 218 M8 153 96 120 108 296 130 167 7 438 291

NGX70 461 66 149 294 377 304 14 291 Ø80 Ø98 99 145 218 M8 153 96 120 108 292 375 125 208 167 2 438 291

Performance curves

L.P.G. Burners

NG70 M-.TN...

2,5

1,5

0,5

-0,5

-1

BACKPRESSURE IN

20 30 40 50 60 70 80

COMBUSTION CHAMBER mbar

C.I.B. UNIGAS - M039135CG

NG70 M-.AB...

2,5

1,5

0,5

-0,5

-1 10 20 30 40 50 60 70 80

NG90 M-.TN...

2,5

1,5

0,5

-0,5

-1

BACK PRESSURE IN

30 40 50 60 70 80 90 100

COMBUSTION CHAMBER mbar

L.P.G. Burners

LG70 L-.TN...

2,5

1,5

0,5

-0,5

-1

BACK PRESSURE IN

20 30 40 50 60 70 80

COMBUSTION CHAMBER mbar

NG90 M-.AB...

2,5

1,5

0,5

-0,5

-1 10 20 30 40 50 60 70 80 90

LG70 L-.AB...

2,5

1,5

0,5

-1 10 20 30 40 50 60 70 80

LG90 L-.TN...

2,5

1,5

0,5

-0,5

-1

BACK PRESSURE IN

30 40 50 60 70 80 90 100

CCOMBUSTION CHAMBER mbar

LG90 L-.AB...

2,5

1,5

0,5

-0,5

-1 10 20 30 40 50 60 70 80 90

C.I.B. UNIGAS - M039135CG

Low NOx burners

NGX70 M-.TN...

2,5

1,5

0,5

-0,5

-1

BACK PRESSURE IN

35 45 55 65 75

COMBUSTION CHAMBER mbar

NGX70 M-.AB...

2,5

1,5

0,5

-0,5

-1 10 20 30 40 50 60 70 80

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.

Pressure in the network / gas flow rate curves

L.P.G. Burners

NG70 M-.TN...

GAS PRESSURE mbar

2345 6789

NG90 M-.TN...

40 35

15 10

GAS PRESSURE mbar

45678910

L.P.G. Burners

LG70 L-.TN...

GAS PRESSURE mbar

11,5 22,53

Rp ½" (10)

Rp ½" (15)

Gas rate Stm3/h

Rp ½" (10)

Rp ½" (15)

Rp ¾" (20)

Gas rate Stm3/h

Rp ½" (10)

Rp ½" (15)

Gas rate Stm3/h

NG70 M-.AB...

1234 56 78

Rp ½" (10)

NG90 M-.AB...

45 40

Rp ½" (10)

35 30

25 20

15 10

5 0

234567 8910

LG70 L-.AB...

0,5 1 1,5 2 2,5 3

Rp ½" (10)

Rp ½" (15)

Gas rate Stm3/h

Rp ½" (15)

Rp ¾" (20)

Gas rate Stm3/h

Rp ½" (15)

Gas rate Stm3/h

C.I.B. UNIGAS - M039135CG

)

LG90 L-.TN...

GAS PRESSURE mbar

1 1,5 2 2,5 3 3,5 4

Low NOx burners

NGX70 M-.TN...

26 24 22 20 18 16 14 12 10

GAS PRESSURE mbar

45678

Rp ½" (10)

Rp ½" (15

Rp ½" (15)

Gas rate Stm3/h

Rp ¾" (20

Gas rate Stm3/h

LG90 L-.AB...

Rp ½" (10)

Rp ½" (15)

Gas rate Stm3/h

NGX70 M-.AB...

26 24 22 20 18 16 14 12 10

8 6 4 2 0

23456 78

Rp ½" (15)

Rp ¾" (20)

Gas rate Stm3/h

C.I.B. UNIGAS - M039135CG

MOUNTINGS AND CONNECTIONS

Packing

.The burners are despatched in cardboard packages whose dimensions are: 400mm x 300mm x 520mm (L x P x H) Packing cases of this type are affected by humidity; the maximum number of cases to be stacked is indicated outside the packing. The following are placed in each packing case. 1 Burner with gas train; 1 gasket to be inserted between the burner and the boiler; 1 envelope containing this manual

When disposing of the burner packing and if the packing is scrapped follow the procedures laid down in the current legislation regarding the 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. 2, 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).

VS D

Fig. 1 Fig. 2

Matching the burner to the boiler

The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation 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

C.I.B. UNIGAS - M039135CG

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

d) Combustion chamber diameter (m)

Fig. 3 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat input in kW.

Fig. 3

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

INSTALLERINSTALLER

Keys

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.

C.I.B. UNIGAS - M039135CG

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.

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.

To execute the electrical connections, proceed as follows: find the pulg or the plugs, according to the model, that comes out from the burnrer:

z7 pins plug for the power supply (for all models); z4 pins plug (double-stage burners);

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.

Connectors identification

Burner power supply connector HIGH/LOW flame connector

Single stage burner connector Double-stage burner connectors

7-pins connector 7-pins and 4-pins connectors

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

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

WARNING: the burner is fitted with a bridge between terminals T6 and T8 on CN2-TAB connector (external side link, male connector); remove this bridge before thermostat connection.

C.I.B. UNIGAS - M039135CG

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

C.I.B. UNIGAS - M039135CG

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 complies 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!

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.

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. 4, 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 as shown in the “Recommended combustion values” table and CO in the stan-

Fig. 4

Key

1 Generator 2 Pressure outlet on the combustion chamber 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 generator’s pressure outlet (Fig. 4-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig. 4-3). 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 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.

C.I.B. UNIGAS - M039135CG

Plugs for pressure measurement

To measure the pressure in the combustion chamber, as far as the IDEA series, a pressure plug is provided upstream the burner’s blast tube.

Single-stage models Double-stage models

Pressure in combustion head - gas rate curves

Natural gas Burners

NG70 M-..

Gas pressure in

combustion head

1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6, 5 7 7,5 8

NG90 M-..

Gas pressure in

combustion head

22,5 33,5 44,5 55,5 66,5 77,588,5 99,5

Gas rate Stm3/h

Gas rate Stm

NGX70 M-..

20 18 16 14 12 10

8 6 4 2 0

2345678

Gas rate Stm3/h

L.P.G. Burners

LG70 L-..

Gas pressure in

combustion head

0,5 1 1,5 2 2,5 3

Gas rate Stm

LG90 L-..

0,5 1 1,5 2 2,5 3 3,5

Gas rate Stm3/h

C.I.B. UNIGAS - M039135CG

Adjusting the air and gas flow rates

WARNING: NEVER LOOSE THE SEALED SCREWS! OTHERWISE, THE DEVICE WARRANTY WILL BE IMMEDIATELY INVALIDATE!

To perform the adjustments, unscrew the fixing screws and remove the burner cover.

NOTE: the combustion analysis must be performed with the burner cover fitted!

Startup Output

The start-up heat output shall not exceed 120 kW (single stage burners) or 1/3 of nominal 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 (see “Measuring the gas pressure in the combustion head” on page 17).

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

Recommended combustion parameters

Fuel

Recommended (%) CO

Recommended (%) O2

Natural gas 9 ÷ 10 3 ÷ 4.8

LPG 11 ÷ 12 2.8 ÷ 4.3

Adjusting procedure

z Check the phase and neutral position. z Check the proper earthening. z (Double-stage burners) Adjust the air and gas flow rates at the maximum output (“high flame”) first, by means of the air damper and

the valves group pressure stabiliser 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. “Measuring the gas pressure in the combustion head” on page 17.

z (Double-stage burners) Set, now, the low flame output, acting on the low flame actuator microswitch 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.

C.I.B. UNIGAS - M039135CG

Adjusting the combustion head

The burner is adjusted in the factory with the combustion head in the position that refers to the "MAX" output. The maximum output setting refers to the “fully-ahead” position of the combustion head, as far as standard models (Fig. 6), and to “fully-backward” position for low NOx burners (Fig. 7). 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. To remove the combsution head, please refer to par. “Removing and cleaning the combustion head” on pag. 53. As far as the reduced output operation, progressively move the combusiton head towards the “MIN” position, rotating clockwise the VRT screw (Fig. 5). The ID index shows how much the combustion head moved.

VRT

Fig. 5 Fig. 6 - Head in “fully-ahead position”

Fig. 7 - Head in “fully-backward po-

sition”

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;

To change the burner setting during the testing in the plant, follows the next procedure.

Adjustements for

single-stage burners

1 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 control panel.

ATTENTION: if the ignition pahse fails, during the first start-up, increase the gas flow rate according to the precedure quoted below.

2 acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values

requested from the boiler/utilisation:

Pressure controller is provisionally factory-set. The setting values must be locally adapted to machine conditions.

Important: Follow the instructions of the burner manufacturer!





99



Fig. 8 -DUNGS MBC 65-DLE

Keys A. measuring noozle P2 (Fig. 9) before valve D

C. startup valve (no. 10 in Fig. 9) D. maximum flow rate valve(no. 9 in Fig. 9)

Fig. 9

B. pressure regulator

The compact DUNGS gas Multibloc is made of built-in filter, valves, governor and pressure switch.

z Setting the startup gas flow rate

To adjust the gas flow rate at the startup, proceed as follows:

- slacken screw A (Fig. 8) in measuring nozzle. Connect pressure gauge.







C.I.B. UNIGAS - M039135CG

- Set to the minimum the pressure regulator by turning adjustment screw B (Fig. 8) anticlockwise .

- Turn the burner on.

- Adjust the flame during the startup phase by means of the bypass C (see Fig. 8 n. 10). Turning clockwise the gas flow decreases,

turning counterclockwise the gas flow increases. Do not exceed in the start flow, otherwise the stabiliser B (Fig. 8) will be inefficacious.

- Go on adjusting the gas flow rate (unscrewing C) until hte flame lights up. Then do not act on C anymore and see next paragraph.

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 gas flow rate.

z 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.

z Adjusting the maximum flow rate valve

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

The air flow rate can be adjusted by means of the V screw. The air damper position is shown on the graduated indes I, where “0” referes to the totally closed postion.

Fig. 10

Double-stage burners

1 Before starting the burner up, set the slow opening. To set the slow 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!Note: the screw VSB must be removed only in case of replacemente of the coil.

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 control panel..

ATTENTION: in case of start-up failure, increase the gas flow rate according to the procedure quoted below.

3 the burner lights in low flame stage; 4 drive the burner to high flame stage, by means fo the thermostat TAB. 5 acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values

requested by the boiler/utilisation: the pressure governor 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. 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.

T(VR)

VSB

6 To adjust the air flow rate, slacken the nut RA (see picture) and move the lever VRA through the slot

increase or decrease the air rate, until the desired rate is obtained; lock then the nut

7 Drive the burner to the low flame operation, by the TAB boiler thermostat.To eventually change the gas flow rate, slacken the

screw V1 (see picture below) and set the opening angle of the buttefly valve rotating the round plate C (turn clockwise to decrease the gas rate or counterclockwise to increase it). The index S shows the opening angle of the butterfly valve.

Dungs Multibloc MB-DLE

Fig. 11

in this position.

as shown in

see picture

, to

C.I.B. UNIGAS - M039135CG

MIN

MAX

Fig. 12

8 If it was necessary to change the low flame burner output, act on the actuator related cam. Then, check the gas flow rate and

repeat from step 7.

As for the setting, refer to this correspondence table. On this actuator, the manual control of the air damper is not provided; the setting of the cams is carried out working with a screwdriver on the VS screw placed internally to the cam.

III

High flame position (set to 90°) I

Low flame and ignition position IV

Stand-by position (set to 0°)

Not used III

Fig. 13

VRA

Fig. 14

BERGER

STA4.5B0.37/

C.I.B. UNIGAS - M039135CG

Calibration of 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 air pressure switch (double-stage, progressive and fully-modulating)

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 low 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 operating at the maximum output, test the gas pressure on the pressure 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: 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.

Adjusting the high gas pressure switch (when provided)

To calibrate the high pressure switch, proceed as follows:

z remove the plastic cover; z measure the gas pressure in the network, when flame is off; z by means of the adjusting ring nut VR, set the value read on step 2, increased by the 30%; z replace the plastic cover.

C.I.B. UNIGAS - M039135CG

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.

Fig. 15

C.I.B. UNIGAS - M039135CG

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 maintenance at the end 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 Check and clean the filter inside the gas valves group (see next paragraph); z remove, check and clean the combustion head (see page 26); z check the ignition and detection electrodes; clean and adjust and, if necessary, replace them (see page 27); z in case of doubt, check the detection circuit once the burner has started up, referring to the diagram on page 27. z Check and grease of sliding and rotating parts.

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. 16-Fig. 17)is ∆p > 10 mbar.

Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 16-Fig. 17) 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. 18

3 p

4 p

5 p

➞

Fig. 17

4 p

5 p

Fig. 16

Fig. 18

C.I.B. UNIGAS - M039135CG

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 Fig. 20 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 figure).

Fig. 19

Fig. 20

BEP

Removing the combustion head и замена электродов

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.

CAUTION: during the assembling phase, before tightening screws V1, V2, V3, mount and tighten screws S1 and S2.

C.I.B. UNIGAS - M039135CG

Correct electrodes positioning

To guarantee a proper ignition, the measures shown in the following pictures must be observed. Ensure the VE locking screw of the electrodes group is tight before refitting the burner.

z Standard burner

z Low NOx burners

190

2÷3

Checking the detection current

If the burner locks, perform the following inpesctions. To measure the detection signals refer to the diagrams in the next 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.

Connector

Control box Minimum detection signal

Flame

Detection electrode

µA DC SCALE

Siemens LME11 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”.

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

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(*)

z zz

zz z z z zz z z z zz z  zzzz

zzzz z

l = with any control box; s = with only LGB2../LMG2../LME11/LME2..

(*) In such cases, insert the circuit SIEMENS “RC466890660” (See chapter “Electrical connections”)

CONTINUE WITH PRE-

PURGE

TROUBLE

DOESN’T START AND

LOCK-OUT

DOESN’T START AND

REPEATS THE CYCLE

STARTS AND REPEATS

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 - M039135CG

z z

zz zz zzz z z

zz

lll

ll l

s s

C.I.B. UNIGAS - M039135CG

SPARE PARTS

Desription Code

NG/LG70 NG/LG90 NGX70

COVER

CONTROL BOX (single-stage regulation)

CONTROL BOX (double stage, progressive and fully modulating)

DETECTION ELECTRODE

IGNITION ELECTRODE 2080268

GASKET 2110055

FAN WHEEL

GAS PRESSURE SWITCH

IGNITION TRANSFORMER

MOTOR

VALVE GROUP DUNGS MBC-65-DLE Rp1/2 21903K2 VALVE GROUP DUNGS MB-DLE405 Rp1/2 2190339 VALVE GROUP DUNGS MB-DLE407 Rp3/4 2190340

GAS PROVING SYSTEM (option)

ACTUATOR (double-stage burners) 2480057

BLAST TUBE S (*)

BLAST TUBE L (*)

30900H8 30900K0 30910M1

30900H9 30900K1 30910M2

STANDARD COMBUSTION HEAD ASS.Y (GAS) 3501836 3501836 -

EXTENDED COMBUSTION HEAD ASS.Y (GAS) 3501837 3501837 -

STANDARD COMBUSTION HEAD ASS.Y (L.P.G.) 3501845 3501845 -

EXTENDED COMBUSTION HEAD ASS.Y (L.P.G.) 3501846 3501846 -

STANDARD COMBUSTION HEAD ASS.Y (NOx)

EXTENDED COMBUSTION HEAD ASS.Y (NOx )

- - 3501851

- - 3501852 IGNITION CABLE S (*) 6050122 IGNITION CABLE L (*) 6050154 DETECTION CABLE 6050216

PCB

1011805

LGB: 2020443 LME: 2020466

LGB: 2020430 LME: 2020468

2080112

2150061

2160076

2170138

2180713

2191604

6100545

(*) S = fitted with standard blast tube L = fitted with extended blast tube

BURNER EXPLODED VIEW

ITEM DESCRIPTION ITEM DESCRIPTION

1 BLAST TUBE FLANGE 7.15.3 BRACKET

2.1 AIR INTAKE 7.16.1 SPACER

2.2 FAIRLEAD 7.16.2 BUSH

2.3 BURNER HOUSING 7.16.3 BRACKET

2.4 SPACER 7.16.4 ACTUATOR

3 GASKET 7.17.1 TRANSFORMER

4 PLASTIC CAP 7.17.2 BRACKET

5 PLASTIC CAP 7.17.3 JUNCTION BOX

6 BLAST TUBE 8.1 RUBBER FAIRLEAD

7.1 FAIRLEAD 8.2 FLANGE

7.2 AIR DAMPER ASS.Y 8.3 BUTTERFLY VALVE INDEX ASS.Y

7.3 FAN WHEEL 8.4 INSPECTION GLASS

7.4 PRESSURE SWITCH 8.5 BUTTERFLY VALVE

7.5 MOTOR 8.6 COMBUSTION HEAD

7.6 AIR DAMPER INDEX ASS.Y 8.7 SCREW

7.7 PIN 8.8 NUT

7.8 MOTOR PLATE 9.1 ELBOW

7.9 ROD 9.2 NIPPLE

7.10 AIR LOUVER CAM 9.3 PRESSURE SWITCH

7.11 ROD 9.4 GAS VALVE GROUP WITH GOVERNOR

7.12 JOINT 9.5 CONNECTOR

7.13 AIR PRESSURE SWITCH BRACKET 9.6 CONNECTOR

7.14 WASHER 10.1 COVER

7.15.1 CONTROL BOX 10.2 RUBBER PUSHBUTTON

7.15.2 CONTROL BOX SOCKET 10.3 COVER FIXING SCREW

C.I.B. UNIGAS - M039135CG

WIRING DIAGRAMS

Wiring Diagrams 01-319/5 - 01-324/2 - Complete key Single-stage burners

CO Time counter ER Flame detection electrode EV1 Network side gas solenoid valve (or valves group) EV2 Burner side gas solenoid valve (or valves group) FFuse IL Line switch LPhase LB Flame lockout signalling lamp LF Borner operation lamp LGB (*) / LMG / LME SIEMENS control box MA Burner power supply terminal board MV Fan motor N Neutral PA Air pressure switch PG Minimum gas pressure switch ST Thermostats or pressure switches group TA Ignition transformer TS Safety thermostat/pressure switch on boiler VM41 BRAHMA control box VPS DUNGS gas proving system (optional)

NOTE: Bridge terminals 7 and 9 only if SIEMENS LGB21.33 is used

WARNING:

1 - Power supply 230V 50/60Hz 1N a.c. 2 - Don’t reverse phase with neutral 3 - Be sure the burner is properly hearted

C.I.B. UNIGAS - M039135CG

Wiring Diagrams 18-070/1 - Complete key Double-stage burners

C1 Time counter, low flame C2 Time counter, high flame DMG972 SATRONIC monitor box (alternative) ER Flame detection electrode EV1,2 Gas electro-valves (or valves group) FU3 Fuses IL Main switch LAF1 Burner in high flame indicator light LAF Burner in high flame indicator light LB Indicator light for burner lock-out LBF1 Burner in high flame indicator light LBF Burner in high flame indicator light LGB22/LMG22/LME22 SIEMENS control box MV Fan motor PA Air pressure switch PG Minimum gas pressure switch STA4.5B0.37/63N30L BERGER actuator ST Thermostats or pressure switches serie TA Ignition transformer TAB High-low flame thermostat or pressure switch (if fitted remove the connection between terminals T6 and T8) TS Safety thermostat or pressure switch on boiler VPS504 DUNGS gas proving system (optional)

ACTUATOR CAMS

BERGER

STA4.5B0.37

I high flame

II stand by

IV low flame

III Not used

C.I.B. UNIGAS - M039135CG

WARNING:

1 - Power supply 230V 50/60Hz 1N a.c. 2 - Don’t reverse phase with neutral 3 - Be sure the burner is properly hearted

APPENDIX



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

SB / R

/ GP

BV1

EK2

t10

LME21 control sequence

SB / R W / GP

BV1

(LR) BV2

t10

LME22 control sequence

B´

t3n

TSA

t3n

B´ C

7101d05/0206

SB / R W / GP

BV1

LR) BV2

EK2

t10

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

t11 Programmed opening time for actuator SA t12 Programmed closing time for actuator SA

t3n

TSA

B´ C

7101d02/0606

LME11 connection diagram

Connection diagram

K2/1

R / W

STB

L N

LME21 connection diagram

AL Error message (alarm)

C control

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

FSV

ION

K2/2

BV1

C control

RESET

K2/1

R / W

STB

L N

H Si

LME22 connection diagram

K2/1

R / W

K2/2

FSV

ION

FSV

ION

Nur LME23...

QRC

RESET

BV1

C control

BV2

STB

L N

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.

Unigas NG70 M-.AB 15, NG70 M-.TN 10, NG90 M-.AB 10, NG90 M-.AB 15, NG70 M-.TN 15 Technical Manual Of Installation, Use And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual