Unigas P72 Series Installation, Use And Maintenance Manual

P60-P65

P72-P73A

Gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

M03956CR 1

2

/2009

TABLE OF CONTENTS

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

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

Burner model identification ............................................................................................................................................................. 5

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

Country and usefulness gas categories .......................................................................................................................................... 6

Overall dimensions ......................................................................................................................................................................... 7

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

MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 12

Packing ......................................................................................................................................................................................... 12

Fitting the burner to the boiler ....................................................................................................................................................... 12

Matching the burner to the boiler .................................................................................................................................................. 12

Gas train connections ................................................................................................................................................................... 13

Assembling the gas grain .............................................................................................................................................................. 14

Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) ......................................................................... 16

Pressure adjusting range .............................................................................................................................................................. 16

Gas Proving System VPS504 ....................................................................................................................................................... 17

Electrical connections ................................................................................................................................................................... 18

Rotation of fan motor .................................................................................................................................................................... 19

ADJUSTMENTS ........................................................................................................................................................................... 20

Combustion head gas pressure curves depending on the flow rate ............................................................................................. 20

Measuring the gas pressure in the combustion head ................................................................................................................... 20

Gas pressure in combustion head vs. gas flow rate curves .......................................................................................................... 21

Adjusting air and gas flow rates .................................................................................................................................................... 22

Startup Output ............................................................................................................................................................................... 22

Adjustments - brief description ...................................................................................................................................................... 22

Adjusting procedure ...................................................................................................................................................................... 22

Progressive burners ...................................................................................................................................................................... 26

Fully modulating burners ............................................................................................................................................................... 27

Calibration of air and gas pressure switches ................................................................................................................................ 27

Calibration of air pressure switch .................................................................................................................................................. 27

Calibration of low gas pressure switch .......................................................................................................................................... 27

Adjusting the high gas pressure switch (when provided) .............................................................................................................. 27

PART II: OPERATION ............................................................................................................................................. 28

OPERATION................................................................................................................................................................................. 29

PART III: MAINTENANCE....................................................................................................................................... 31

ROUTINE MAINTENANCE ........................................................................................................................................................... 31

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 ............................................................................................. 31

Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group) ............................................ 32

Gas filter maintenance .................................................................................................................................................................. 32

Removing the combustion head ................................................................................................................................................... 32

Adjusting the electrodes ................................................................................................................................................................ 33

Replacing the electrodes .............................................................................................................................................................. 34

Checking the detection current ..................................................................................................................................................... 34

Seasonal stop ............................................................................................................................................................................... 35

Burner disposal ............................................................................................................................................................................. 35

TROUBLESHOOTING .................................................................................................................................................................. 36

SPARE PARTS............................................................................................................................................................................. 37

BURNER EXPLODED VIEW ......................................................................................................................................................... 38

WIRING DIAGRAMS .................................................................................................................................................................... 42

APPENDIX

2

WARNINGS

THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE

USER.

INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO-

DUCT 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 integrity.

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 cutout 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 harmless.

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, therefore, 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 combustion 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 instructions 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 permitted 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 compliance 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 inspect 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 designed 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


Directive 2006/95/EC on low voltage ;





- 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


Directive 2006/95/EC on low voltage ;



-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.



Gas - Light oil burners


- Directive 90/396/CEE Gas Appliances;




-UNI EN 676 Gas Burners






Gas - Heavy oil burners


- Directive 90/396/CEE - Gas Appliances;




-UNI EN 676 (Gas Burners;






4

C.I.B. UNIGAS - M03956CR

PART I: INSTALLATION MANUAL

Burner model identification

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

Type P72 Model M-. AB. S. *. A. 0. 50

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

(1) BURNER TYPE

(2) FUEL

P72

M - Natural gas

(3) OPERATION

Available versions

(4) BLAST TUBE

AB - Double stage

PR - Progressive MD - Fully modulating

S - standard

L - Extended

(5) DESTINATION COUNTRY

* - see data plate

(6) BURNER VERSION

A - Standard

(7) EQUIPMENT

Available version

0 = 2 valves

1 = 2 valves + gas proving system

7 = 2 valves + high gas pressure switch

8 = 2 valves + gas proving system + high gas pressure switch

(8)GAS CONNECTION

40 = Rp1 1/2 50 = Rp2

65 = DN65 80 = DN80

Specifications

BURNER TYPE

Output

Fuel

Category

Gas flow rate

Gas pressure

Electric supply

Total power consumption

Fan motor

Protection

Weight

Operation

Valves size/Gas connection

Operating temperature

Storage TemperatureStorage

Temperature

Working service* min. - max. kW min.-max. Stm 3 /h min.-max. mbar kW kW kg

°C

°C

P60 M-...0.40

160 - 523

17 - 56

55

1"

1/2

/ Rp1

1/2

P60 M-...0.50

P60 M-...0.65

P65 M-....50

P65 M-....65

160 - 800 160 - 800

Natural gas

17 - 84.7

see next paragraph

17 - 84.7

28.6 - 103

(see Note 2)

230V 3~ / 400V 3N ~ 50Hz

1.6

1.1

55

IP40

70 80

Double stage - Progressive - Fully modulating

2" / Rp2 2"

1/2

/ DN65

-10 ÷ +50

2" / Rp2

270 - 970

2

1.5

28.6 - 103

95

2"

1/2

/ DN65

-20 ÷ +60

Intermittent

Note1:

Note2:

All gas flow rates are referred to Stm

3

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

(net calorific value H i

= 34.02 MJ/Stm

3

)

Maximum gas pressure = 360mbar (with Rp1"1/2 - 2" and Dungs MBDLE/MBC valves)

= 500mbar (with DN65/80 and Siemens VGD / Dungs MBCvalves)

Minimum gas pressure = see gas curves.

*

NOTE ON THE WORKING SERVICE: the control box automatically stops after 24h of continuous working. The control box immediately starts up, automatically.

5

BURNER TYPE

Output

Fuel

Category

Gas flow rate

Gas pressure

Electric supply


Fan motor

Protection

Weight

Operation



Storage TemperatureStorage

Temperature

Working service* min. - max. kW min.-max. Stm 3 / min.-max. mbar kW kW kg

°C

°C


BURNER TYPE

Output

Fuel

Category

Gas flow rate

Gas pressure

Electric supply


Fan motor

Protection

Weight

Operation



Storage TemperatureStorage Temperature

Working service* min. - max. kW min.-max. Stm 3 /h min.-max. mbar kW kW kg

°C

°C

P72

M-...0.50

85

2"/Rp2

P72

M-...0.65

300 - 1.200

P72

M-...0.80

P72

M-...1.50

P72

M-...1.65

300 - 1650

Natural gas see next paragraph

32 - 127 32 - 174.6

(see Note 2)

230V 3~ / 400V 3N ~ 50Hz

2.7

2.2

IP40

105 115 85 105

Double stages - Progressive - Fully modulating

2"

1/2

/ DN65 3” / DN80

-10 ÷ +50

2" / Rp2 2"

1/2

/ DN65

-20 ÷ +60

Intermittent

P72

M-...1.80

115

3” / DN80

P73A M-...1.50

P73A M-...1.65

320 - 2300

Natural gas see next paragraph

34 - 243

(see Note 2)

P73A M-...1.80

230V 3~ / 400V 3N ~ 50Hz

3.5

3

90

IP40

110 120

2" / Rp2

Double stages - Progressive - Fully modulating

2"

1/2

/ DN65

-10 ÷ +50

3” / DN80

-20 ÷ +60

Intermittent

Note1:

All gas flow rates are referred to Stm

3

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

(net calorific value H i

= 34.02 MJ/Stm

3

)

Note2: Maximum gas pressure = 360mbar (with Rp1"1/2 - 2" and Dungs MBDLE/MBC valves)

= 500mbar (with DN65/80 and Siemens VGD / Dungs MBCvalves)

Minimum gas pressure = see gas curves.

*

NOTE ON THE WORKING SERVICE: the 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

LU

BE

NL

ES

PL

-

-

DE -

FR -

GR

-

-

-

-

-

SE

-

-

-

-

-

FI

-

-

-

-

-

IE

-

-

-

-

-

HU

-

-

-

-

-

IS

-

-

-

-

-

NO

-

-

-

-

-

CZ

-

-

-

-

-

DK

-

-

-

-

-

-

-

-

-

-

COUNTRY

GB IT

-

-

-

-

-

PT

-

-

-

-

-

CY

-

-

-

-

-

EE

-

-

-

-

-

LV

-

-

-

-

-

SI

-

-

-

-

-

MT

-

-

-

-

-

SK

-

-

-

-

-

BG

-

-

-

-

-

LT

-

-

-

-

-

RO

-

-

-

-

-

TR

-

-

-

-

-

CH

-

-

-

-

-

6

Overall dimensions (mm)

Burner: P60

BB

CC AA

K

P

N

H

M

O

Recommended boiler drilling template and burner flange U

E

D

F B

R S

Q

C

A

P60 PR - 0.40

P60 MD - 0.40

P60 AB - 0.40

P60 PR - 0.50

P60 MD - 0.50

P60 AB - 0.50

P60 PR - 0.65

P60 MD - 0.65

P60 AB - 0.65

DN A(S*) A(L*) AA B(S*) B(L*) BB C CC D E F G H J K L M N O P Q R S U

40 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 439 112 327 444

40 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 439 112 327 444

40 1009 1099 99 343 433 314 666 298 812 500 312 184 204 210 240 344 M10 269 190 190 439 112 327 444

V**

-

-

-

W Y Z

464 162 120

464 162 120

464 162 120

50 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 447 112 335 444

50 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 447 112 335 444 -

464 162 120

464 162 120

50 1009 1099 99 343 433 314 666 298 812 500 312 184 204 210 240 344 M10 269 190 190 447 112 335 444 464 162 120

65 1079 1169 99 343 433 314 736 298 997 685 312 184 204 250 240 420 M10 269 190 190 515 112 403 540 313 540 162 120

65 1079 1169 99 343 433 314 736 298 997 685 312 184 204 250 240 420 M10 269 190 190 515 112 403 540 313 540 162 120

65 1009 1099 99 343 433 314 666 298 997 685 312 184 204 250 240 420 M10 269 190 190 515 112 403 540 313 540 162 120

*S = measure referred to burner fitted with standard blast tube

*L = measure referred to burner fitted with extended blast tube

**V measure stands for the gas filter when not built-in the gas valves (VGD or MBC valves from DN65 on).

Note: the gas proving system is an option.

Burners: P65 - P72 - P73A

K

M

N

H

P

O min.

O max.

Recommended boiler drilling jig and burner flange

P65 PR - 0.50

P65 PR - 1.50

P65 AB - 0.50

P65 AB - 1.50

P65 MD - 0.50

P65 MD - 1.50

P65 PR - 0.65

P65 PR - 1.65

P65 AB - 0.65

P65 AB - 1.65

P65 MD - 0.65

P65 MD - 1.65

DN A(S*) A(L*) AA B(S*) B(L*) BB

50

50 1129 1219 130 326 416 373 803 316 1026 694 332 184 228 208 300 376 M10 330 216

50 1129 1219 130 326 416 373 733 316 900 568 332 184 228 208 300 376 M10 330 216

50 1129 1219 130 326 416 373 733 316 1026 694 332 184 228 208 300 376 M10 330 216

50 1129 1219 130 326 416 373 803 316 900 568 332 184 228 208 300 376 M10 330 216

50

65

65

65

65

65

65

1129 1219 130

1129 1219 130

1129 1219 130

1129 1219 130

1129 1219 130

1129 1219 130

1129 1219 130

1129 1219 130

326 416

326 416

326 416

326 416

326 416

326 416

326 416

326 416

373

373

373

373

373

373

373

373

C CC D

803 316 900

803 316 1026 694

803 316 998

733 316 998

803 316 998

E

568

666

803 316 1104 772

666

733 316 1104 772

666

803 316 1104 772

F

332

332

332

332

332

332

332

332

G

184

184

184

184

184

184

184

184



**V measure stands for the gas filter when not built-in the gas valves (VGD or MBC valves from DN65 on).

Note: the gas proving system is an option.

H

228

228

228

228

228

228

228

228

J

208

208

273

273

273

273

273

273

K

300

300

300

300

300

300

300

300

L

376

376

393

393

393

393

393

393

M

M10

M10

M10

M10

M10

M10

M10

M10

N

330

330

330

330

330

330

330

330

Omin Omax P

216

216

216

216

216

216

216

216

250 233

Q

465

R

130

S

335

U

465

V**

-

W

531

Y

162

Z

155

250 233 465 130 335 465 531 162 155

250 233 465 130 335 465 531 162 155

250 233 465 130 335 465 531 162 155

250 233 465 130 335 465 531 162 155

250

250

250

250

250

250

250

233

233

233

233

233

233

233

465

533

533

533

533

533

533

130

130

130

130

130

130

130

335

403

403

403

403

403

403

465

533

533

533

533

533

533

-

313

313

313

313

313

313

531

548

548

548

548

548

548

162

162

162

162

162

162

162

155

155

155

155

155

155

155

P72 PR - 0.50

P72 PR - 1.50

P72 AB - 0.50

P72 AB - 1.50

P72 MD - 0.50

P72 MD - 1.50

P72 PR - 0.65

P72 PR - 1.65

P72 AB - 0.65

P72 AB - 1.65

P72 MD - 0.65

P72 MD - 1.65

P72 PR - 0.80

P72 PR - 1.80

P72 AB - 0.80

P72 AB - 1.80

P72 MD - 0.80

P72 MD - 1.80

DN A(S*) A(L*) AA B(S*) B(L*) BB

50 1188 1298 130 385 495 373 803 316 900 568 332 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 212 155

50 1188 1298 130 385 495 373 803 316 1026 694 332 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 212 155

50 1118 1228 130 385 495 373 733 316 900 568 332 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 212 155

50 1118 1228 130 385 495 373 733 316 1026 694 332 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 212 155

50 1188 1298 130 385 495 373 803 316 900 568 332 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 212 155

50 1188 1298 130 385 495 373 803 316 1026 694 332 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 212 155

65 1188 1298 130 385 495 373 803 316 998 666 332 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 212 155

65 1188 1298 130 385 495 373 803 316 1104 772 332 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 212 155

65 1118 1228 130 385 495 373 733 316 998 666 332 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 212 155

65 1118 1228 130 385 495 373 733 316 1104 772 332 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 212 155

65 1188 1298 130 385 495 373 803 316 998 666 332 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 212 155

65 1188 1298 130 385 495 373 803 316 1104 772 332 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 212 155

80 1188 1298 130 385 495 373 803 316 998 666 332 234 264 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 212 155

80 1188 1298 130 385 495 373 803 316 1106 774 332 234 264 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 212 155

80 1118 1228 130 385 495 373 733 316 998 666 332 234 264 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 212 155

80

80

80

1118

1188

1188

1228

1298

1298

130

130

130

385

385

385

495

495

495



**

373

373

373

C

733

803

803

CC

316

316

316

D

1106

998

1106

E

774

666

774

F

332

332

332

G

234

234

234

H

264

264

264

J

275

275

275

K

300

300

300

L M N Omin Omax P

407 M10 330

407 M10 330

407 M10 330

216

216

216

250

250

250

233

233

233

Q

574

574

574

R

130

130

130

S

444

444

444

U V**

565 344

565 344

565 344

W Y(*S) Y(*L)

562

562

562

198

198

198

212

212

212

Z

155

155

155

P73A PR - 1.50

P73A AB - 1.50

P73A MD - 1.50

P73A PR - 1.65

P73A AB - 1.65

P73A MD - 1.65

P73A PR - 1.80

P73A AB - 1.80

P73A MD - 1.80

DN A AA B BB C CC D E F G H J K L M N Omin Omax P

50 1303 130 500 373 803 316 1026 694 332 234 264 208 300 376 M10 330 216 250 233

Q

465

R

130

S

335

U

519

V x

50 1233 130 500 373 733 316 1026 694 332 234 264 208 300 376 M10 330 216

50 1303 130 500 373 803 316 1026 694 332 234 264 208 300 376 M10 330 216

250

250

233

233

465

465

130

130

335

335

519

519 x x

65 1303 130 500 373 803 316 1104 772 332 234 264 275 300 393 M10 330 216

65 1233 130 500 373 733 316 1104 772 332 234 264 275 300 393 M10 330 216

65 1303 130 500 373 803 316 1104 772 332 234 264 275 300 393 M10 330 216

80 1303 130 500 373 803 316 1106 774 332 234 264 275 300 407 M10 330 216

80 1233 130 500 373 733 316 1106 774 332 234 264 275 300 407 M10 330 216

80 1303 130 500 373 803 316 1106 774 332 234 264 275 300 407 M10 330 216

250

250

250

250

250

250

233

233

233

233

233

233

533

533

533

574

574

574

130

130

130

130

130

130

403

403

403

444

444

444

565

565

565

565

565

565

313

313

313

344

344

344

W

531

531

531

548

548

548

562

562

562

Y

212

212

212

212

212

212

212

212

212

Z

155

155

155

155

155

155

155

155

155


Performance curves

P60 M.xx.x.IT.A.0.40

8

7

6

5

4

-1

-2

1

0

3

2

100 200 300 400 500 600 kW

P60 M.xx.x.IT.A.0.50 - 65

8

7

6

5

4

3

2

-1

-2

1

0

100 200 300 400 500 600 700 800 900 kW

P65

6

5

4

3

2

1

0

9

8

7

200 300 400 500 600 700 800 900 1000 kW

P72M-...0.xx

14

12

10

8

6

4

2

0

-2

0 200 400 600 800 1000 1200 1400 kW

P72 M-...1.xx

P73A

14

12

10

8

6

0

-2

4

2

0 200 400 600 800 1000 1200 1400 1600 1800 kW

12

10

8

6

4

2

0

250 500 750 1000 1250 1500 1750 2000 2250 2500 kW

To get the input in kcal/h, multiply value in kW by 860.

Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C.

NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine. On this diagram the maximum output point is usually reached by adjsuting the combustion head to its “MAX” position (see paragraph “Adjusting the combustion head”); the minimum output point is reached setting the combustion head to its “MIN” position. During the first ignition, the combustion head is set in order to find a compromise between the burner output and the generator specifications, that is why the minimum output may be different from the Performance curve minimum.

10


Pressure in the network - gas flow rate curves

P60 M-...0.40

25

20

15

10

5

0

10 20 30 40 50

P60 M-.0.50 - M-...0.65

25

20

15

10

5

60 70 80

Gas rate Stm

3

/h

0

10 20 30 40 50

Rp 2" (50)

DN65

60 70 80 90

Gas rate Stm

3

/h

40

30

20

10

0

20

P65 M-...50-65

30

25

20

15

10

5

DN65

0

20 30 40 50 60 70 80 90 100 110 120

Gas rate Stm

3

/h

P72 M-...0.xx

40 60 80

P72 M-...1.xx

Rp 2" (50)

80

70

60

50

100

DN65

40

30

DN80

120 140

Gas rate Stm

3

/h

20

10

0

25 50 75

P73A M-...1.xx

125

100

75

50

25

0

0 50 100 150

Rp 2" (50)

200

DN65

DN80

250

Gas rate Stm

3

/h

100 125

Rp 2" (50)

DN65

DN80

150 175 200

Gas rate Stm

3

/h

Caution: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis (pressure value in the combustion chamber is not included). To know the minimum pressure at the gas train inlet, necessary to get the requested gas rate, add the pressure value in the combustion chamber to the value read on the y-axis.

11


MOUNTINGS AND CONNECTIONS

Packing

Burners are despatched in cardboard packages whose dimensions are: z z

P60: 1200mm x 670mm x 540mm (L x P x H).

P65 - P72 - P73A: 1280mm x 850mm x 760mm (L x P x H).

Packing cases of this type are affected by humidity; the maximum number of cases to be stacked is shown outside the packing.The following are placed in each packing case.

z z burner with gas train; gasket to be inserted between the burner and the boiler; z envelope containing this manual

To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials.

Fitting the burner to the boiler

To install the burner into the boiler, proceed as follows:

1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)

2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;

3 place the 4 stud bolts (5) on boiler’s door, according to the burner’s drilling template described on paragraph “Overall dimensions”;

4 fasten the 4 stud bolts;

5 place the gasket on the burner flange;

6 install the burner into the boiler;

7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture.

8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate insulating material (ceramic fibre cord or refractory cement).

Keys

1 Burner

2 Fixing nut

3 Washer

4 Sealing gasket

5 Stud bolt

7 Blast tube

The burner is designed to work positioned according to the picture below. For different installations, please contact the Technical

Department.

SIDE UP

SIDE

DOWN

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 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.

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

12

C.I.B. UNIGAS - M03956CR 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. 4 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat input in kW.

Fig. 4

Gas train connections

The next figures show the gas train components wich are included in the delivery and those wich must be fitted by the customer. The diagram complies with regulations in force.

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.

Rp1 1/2 - Rp2: Gas train with valves group MB-DLE (2 valves + gas filter + pressure governor + pressure switch) + leakage control

VPS504

INSTALLER

4 9

MANUFACTURER

4 5

1

2 7 8

3

Rp2 - DN65 - DN80: Gas train with valves group VGD with built-in gas pressure governor + gas proving system VPS504

INSTALLER

4

MANUFACTURER

4 5

1

2 6 7 8

10

3

Rp2: Gas train with valves group MBC (2 valves + gas filter + pressure governor) + VPS504 gas proving system

4

MANUFACTURER

18 4 5

INSTALLER

1

2 7 8

3

13


DN65 - DN80: Gas train with valves group MBC (2 valves + pressure governor) + VPS504 gas proving system

MANUFACTURER INSTALLER

4 19 4 5

1

2 6 7 8

3

Key

1 Burner

2 Butterfly valve

3 Gas proving system (option)

4 Maximum gas pressure switch (option*)

5 Minimum gas pressure switch

6 Gas filter

7 Bellow joint

8 Manual valve

9 MB-DLE Valves group

10 VGD Valves group

18 Valves group MBC (2”, provided with filter)

19 Valves group MBC (an external filter must be installed)

*

Note: the high gas pressure switch can be mounted either upstream the gas valve or downstream the gas valves but upstream the butterfly gas valve.

Assembling the gas grain

gas supply network

”direction” arrows for installation

1E

3

1D 2

1C 4

1B

5

1A

Keys

1A..1E Gasket

2 Gas filter

3 Gas valves group

4 Bellows unitt

5 Manual valve

Fig. 5 - Example of gas train

To mount the gas train, proceed as follows:

1-a)in case of threaded joints: use proper seals according to the gas used;

1-b)in case of flanged joints: place a gasket (no. 1A..1E - Fig. 5) between the elements

2) fasten all the items by means of screws, according to the next diagrams, observing the mounting direction for each item.

NOTE: the bellow joint, the manual valve and the gaskets are not part of the standard supply.

ATTENTION: once the gas train is mounted according to the diagram (Fig. 5), the gas proving test mus be performed, according to the procedure set by the laws in force.

ATTENTION: it is recommended to mount filter and gas valves to avoid that extraneous material drops inside the valves, during maintenance and cleaning operation of the filters (both the filters outside the valves group and the ones built-in the gas valves).

14


The procedures of installation fo the gas valves are showed in the next paragraphs, according to the gas train used: z z threaded gas trains with Multibloc Dungs MB-DLE or MBC..SE 1200 or Siemens VGD20..

flanged gas trains with Multibloc Dungs MBC..SE 1900-3100-5000 or Siemens VGD40..

2

MULTIBLOC DUNGS MB-DLE 415..420

Mounting

1. Loosen screws A and B do not unscrew (Fig. 6 - Fig. 7).

2. unscrew screws C and D (Fig. 6 - Fig. 7).

3. Remove MultiBloc between the threaded flanges (Fig. 7).

4. After mounting, perform leakage and functional tests.

C

D

A

A

B

B

C

D

Fig. 6 Fig. 7 Fig. 8

MULTIBLOC DUNGS MBC300-700-1200SE (Threaded valves group)

Mounting

1. Mount flange onto tube lines. Use appropriate sealing agent (see Fig. 10)

2. Insert MBC...SE. Note position of O rings (see Fig. 11).

3. Tighten screws A – H

4. After installation, perform leakage and functional test.

5. Disassembly in reverse order

MOUNTING

POSITIONS

OPTION

PLQ['1

%U

Ó

£

S

%U

'1

"

#

$

%

MOUNTING POSITIONS

Fig. 9

Fig. 11

Fig. 10

'

&

)

(

15


MULTIBLOCDUNGS MBC1900-3100-5000SE (Flanged valves group )

Mounting

1. Insert setscrews A

2. Insert seals

3. Insert setscrews B

4. Tighten setscrews A + B.

Ensure correct seating of the seal!

6. After installation, perform leakage and functional test.

7. Disassembly in reverse order.

Mounting positions OPTION njo/!6!y!EO

EO

21

2

10 = pulse lines

22

"

"

#

#

Fig. 12

#

#

"

"

Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor)

Mounting z z z z z z z z

When mounting the VGD.. double gas valve, two flanges are required (as for VGD20.. model, the flanges are threaded); to prevent cuttings from falling inside the valve, first fit the flanges to the piping and then clean the associated parts; install the valve; the direction of gas flow must be in accordance with the direction of the arrow on the valve body; ensure that the bolts on the flanges are properly tightened; ensure that the connections with all components are tight; make certain that the O-rings and gaskets between the flanges and the double gas valve are fitted.

Connect the reference gas pipe ( TP in figure), to the gas pressure nipples placed on the gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size .

Leave the blowhole free ( SA in figure). Should the spring fitted not permit satisfactory regulation, ask one of our service centres for a suitable replacement.

Caution: the SKP2 diaphragm D must be vertical (see Fig. 15).

WARNING: removing the four screws BS causes the device to be unserviceable!

BS

BS

SKP1.

SKP2.

BS

BS

SA TP

D

SIEMENS VGD..MOUNTING

POSITIONS

7631z05/0101

Fig. 16

Fig. 13

Fig. 14 Fig. 15

Pressure adjusting range

The pressure adjusting range, downstream the gas valves group, changes according to the spring provided with the valve group.

16

1


1

2

2

DUNGS MBC..SE

Keys

1 spring

2 cap

DUNGS MBC valves:

Performance range (mbar)

Spring colour

4 - 20

-

Siemens SKP actuator

20 - 40 red

40 - 80 black

80 - 150 green

Siemens VGD valves with SKP actuator :

Performance range (mbar)

Spring colour

0 - 22 neutral

15 - 120 yellow

100 - 250 red

Gas Proving System VPS504

The VPS504 check the operation of the seal of the gas shut off valves. This check, carried out as soon as the boiler thermostat gives a start signal to the burner, creates, by means of the diaphragm pump inside it, a pressure in the test space of 20 mbar higher than the supply pressure. To install the DUNGS VPS504 gas proving system on the MD-DLE valves group, proceed as follows:

1 turn off gas supply.;

2 Switch off power supply.

3 remove the Multibloc screw plugs (Fig. 17-A);

4 iInsert sealing rings (10,5 x 2,25) into VPS 504 (Fig. 17-B - Fig. 18)

5 Torque screws 3, 4, 5, 6 (M4 x16) Fig. 18-C

Only use screws with metric thread on reassembly (modification, repair).

6 On completion of work, perform a leak and functional test.

LC

LB

C

B

Fig. 17

A

PA

Fig. 18

When wishing to monitor the test, install a pressure gauge ranged to that of the pressure supply point PA (Fig. 18). If the test cycle is satisfactory, after a few seconds the consent light LC (yellow) comes on. In the opposite case the lockout light LB (red) comes on. To restart it is necessary to reset the appliance by pressing the illuminated pushbutton LB .

17


Once the train is installed, connect the gas valves group and pressure switches plugs.

ATTENTION: once the gas train is mounted according to the diagrams shown in the previous pages, the gas proving test mus be performed, according to the procedure set by the laws in force.

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.

WARNING: The burner is provided with a jumper between terminals 6 and 7; in the event of connecting the high/ low flame thermostat remove this jumper before connecting the thermostat.

IMPORTANT: while connecting electric supply wires to burner’s teminal block be sure that ground wire should be longer than phase and neutral ones.

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.

z z

Remove the cover of the burner electrical board.

Execute the electrical connections to the supply terminal board as shown in Fig. 21, check the direction of the fan motor (see related paragraph) and refit the panel cover.

Wiring diagram keys on page 42.

Note on elecrtical supply

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

Key

C - Capacitor (22nF/250V)

LME - Siemens control box

R - Resistor (1Mohm)

RC466890660 - RC Siemens filter

Fig. 19

18


Fig. 21 - Power supply terminal block

Thermocouple

Current signal

Terminal block for connections on printed circuit

Voltage signal

Pressure probe

Fig. 22

Fig. 20 - Probes connection scheme for modulating burners

Rotation of fan motor

Once the electrical connection of the burner is executed, remember to check the rotation of the fan motor. The motor should rotate according to the “arrow” symbol on the body. In the event of wrong rotation, reverse the three-phase supply and check again the rotation of the motor.

CAUTION: check the motor thermal cut-out adjustment

NOTE: the burners are supplied for three-phase 400V supply, and in the case of three-phase 230V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay.

19


ADJUSTMENTS

Combustion head gas pressure curves depending on the 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 properly adjusted (percentage of residual O

2

in the flues as shown in the “Recommended combustion values” table and CO in the standard limits). During this stage, the combustion head, the gas butterfly valve and the actuator are at the maximum opening. Refer to Fig. 23, 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.

1

2

4

3

Fig. 23

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 combustion chamber’s pressure outlet (Fig. 23-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig. 23-3). 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 find out the burner’s output in Stm

3

/h (quoted on the x axis) from the pressure measured in the combustion head (quoted on the y axis). The data obtained must be considered when adjusting the gas flow rate.

NOTE: THE PRESSURE-RATE CURVES ARE GIVEN AS INFORMATION ONLY; FOR A PROPER SETTING OF THE GAS RATE,

PLEASE REFER TO THE GAS METER READING.

20


Gas pressure in combustion head vs. gas flow rate curves

5

4

3

2

1

0

15

P60 M-...0.40

6

20 25 30 35 40 45

P60 M-.0.50 - M-...0.65

50 55 60

Gas rate Stm

3

/h

9

8

7

6

5

4

3

2

1

0

15 25 35 45 55 65 75 85 95

Gas rate Stm

3

/h

P65

10

7

6

5

9

8

4

3

2

20 30 40 50 60 70 80 90 100 110

Gas rate Stm

3

/h

P72 M-...0.xx

8

6

4

2

P72 M-...1.xx

12

10

8

6

4

2

0

30 40 50 60 70 80 90 100 110 120 130

Gas rate Stm

3

/h

P73A M-...1.xx

35

0

30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Gas rate Stm

3

/h

30

25

20

15

10

5

0

0 50 100 150 200 250

Gas rate Stm 3 /h

21


Adjusting 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 INVALIDATE!

Startup Output

The start-up heat output shall not exceed 1/3 the operating maximum output. The minimum gas flow rate must be set in order to reach an output value lower than 1/3 the nominal output.

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

Fuel

Natural gas

Recommended combustion parameters

Recommended (%) CO

2

9 ÷ 10

Recommended (%) O

2

3 ÷ 4.8

Adjustments - brief description

z 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 z

Check that the combustion parameters are in the suggested limits.

Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a differential pressure gauge, as described on par. “Measuring the gas pressure in the combustion head” on page 20.

z Then, adjust the combustion values corresponding to the points between maximum and minimum (progressive -fully modulating burners only): set the shape of the adjusting cam foil. The adjusting cam sets the air/gas ratio in those points, regulating the opening-closing of the air damper.

z .Set, now, the low flame output, acting on the low flame microswitch of the actuator in order to avoid the low flame output increasing too much or that the flues temperature gets too low to cause condensation in the chimney.

To change the burner setting during the testing in the plant, follows the next procedure, according to the model provided.

Adjusting procedure

The burner is factory-set with the combustion head at the position that refers to the "MAX" output. The maximum output setting refers to the “fully-ahead” position of the combustion head. As for “fully-ahead” position, it means that the head is towards the boiler, “fullybackward” position means that the head is towards the operator. As far as the reduced output operation, progressively move the combusiton head towards the “MIN” position, rotating clockwise the VRT screw (see picture below). The ID index shows how much the combustion head moved.

P60 - P65 - P72

MAX

ID

VRT

22

MIN


P73A

CAUTION: perform these adjustments once the burner is turned off and cooled.

The burner is factory-set wih the adjusting plate holes fully open, and the combustion head at its MAX position, so it is fit to work at the maximum output.

To adjust the gas flow, partially close the holes, as follows:

1 loosen the three V screws that fix the adjusting plate D ;

2 insert a screwdriver on the adjusting plate notches and let it move CW/CCW as to open/close the holes;

3 once the adjustmet is performed, fasten the V screws.

V

D open holes closed holes

To let the burner operate at a lower output, loose the VB screw and move progressively back the combustion head towards the MIN position, by turning clockwise the VRT ring nut. Fasten VB screw when the adjustment is accomplished.

VB

VRT

Attention!

Change the combustion head position only if necessary. If so, repeat the air and gas adjustments described above.

DUNGS MB-DLE gas valves group: Before starting the burner up, adjust the valves group slow opening: to set the slow opening remove cover T , reverse it upside down and use it as a toolto rotate screw VR . Decrease the ignition flow rate by screwing, increase it by unscrewing. Do not use a screwdriver on the screw VR !

Note: the screw VSB must be removed only in case of replacemente of the coil (see picture on page 24).

On the DUNGS MBC..SE gas valves group, set the pressure regulator to 1/3 of its stroke, using a 2.5 allen key.

1

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Pressure setting

1 Turn the burner on by means of its main switch A : if the burner locks (LED B on in the control panel) press the RESET button ( C ) on the control panel (Fig. 25). See chapter “Operation” for further details.

2 check the fan motor rotation (see “Rotation of fan motor” on page 19)

3 Start the burner up by means of the thermostat series and wait unitl the pre-purge phase comes to end and that burner starts up;

4 the burner starts up in the low flame stage: drive the burner to high flame stage, by means of the “high/low flame” thermostat TAB .

5 adjust the burner combustion values in the high flame stage as described in the following steps.

6 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;

7 acting on the pressure governor of the valves group, adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler/utilisation:

23


- Multibloc MB-DLE: 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. 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.

- Siemens VGD valves group: remove cap T and act on the VR adjusting screw to increase or decrease the pressure and consequently the gas rate; screwind VR the rate increases, unscrewing it decreases (see next figure).

- Dungs MBC..SE valves group: act on its pressure governor to increase or decrease the pressure and consequently the gas rate.

C VS T(VR) VSB

T

VR

1

#S

VB

RP

Dungs Multibloc MB-DLE

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Dungs MBC..SE

Siemens VGD..

Pressure governor is factory-set. The setting values must be locally adapted to machine conditions. Important! Follow the instructions carefully!

8 .To adjust the air flow rate in the high flame stage , loose the RA nut and screw VRA as to get the desired air flow rate: moving the rod T towards the air damper shaft, the air damper opens and consequently the air flow rate increases, moving it far from the shaft the air damper closes and the air flow rate decreases.

Note: once the procedure is perfomed, be sure that the blocking nut RA is fasten.

VRA

TR

RA

VRA

Go on adjusting the burner according to the model (double-stage, progressive, fully-modulating).

24


Double-stage burners

9 drive the burner to the low flame stage by means of the TAB thermostat;

10 In order to change the gas flow rate slacken the nuts DB (Fig. 24) and adjust the opening angle of the gas butterfly valve by rotating the rod TG (clockwise rotation increases gas flow, anticlockwise rotation decreases it). The slot on the butterfly valve shaft shows the opening degree of the valve regardingthe horizontal axis (Fig. 24).

NOTE: At the end of settings, make sure the locking screws RA and DB are fully tightened.

TG DB

Fig. 24

11 Now adjust the pressure switches (see page 27).

12 If it is necessary to change the burner output in the low flame stage, move the low flame cam: the low flame position matches the ignition position. As far as burners fitted with Dungs MBC gas valves, the low flame cam does not match the ignition cam position, that is why it must be set at about 30° more than the ignition cam.

13 Turn the burner off and then start it up again. If the adjustment is not correct, repeat the previous steps.

Berger STA6 B 3.41 (high-low flame burners) Siemens SQN72.2A4Axx (high-low flame burners)

MV

ST2

ST1

ST0

IV

III

II

I

AUTO/MAN

For DUNGS MB-DLE / Siemens VGD gas valves

High flame position (set to 90°)

Low flame and ignition position

Stand-by position (set to 0°)

Not used

Actuator camsBerger

STA

ST2

ST1

ST0

MV

Siemens SQN72

I (red)

III (orange)

II (blue)

IV (black)

For DUNGS MBCgas valves



Ignition

Low flame position


STA

ST2

ST0

ST1

MV

Siemens SQN72

I (red)

III (orange)

II (blue)

IV (black)

Berger STA12: a key is provided to move the cams.

Siemens SQN72: a key is provided to move cams I and IV, the other cams can be moved by means of screws.

On the BERGER STA12B3.41 actuator, the manual air damper control is not provided. On the Siemens actuator the AUTO/MAN mode is provided (see picture).

25


Progressive burners

Once the procedure till step 8 described on paragraph “Adjusting procedure” on page 22, is accomplished, go on as follows:

9 set the low flame cam matching the high flame cam;

10 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position;

The manual air damper control is not provided on these actuators. The adjustments must be carried out acting manually on the cams.

Berger STA12B3.41 (progressive and fully modulating burners) Siemens SQN72.4A4Axx (progressive and fully modulating burners)

MV

ST2

ST1

ST0

IV

III

II

I

AUTO/MAN

For DUNGS MB-DLE / Siemens VGD gas valves


Low flame and ignition position


Not used


STA

ST2

ST1

ST0

MV

Siemens SQN72

I ( red )

III ( orange )

II ( blue )

IV ( black )

For DUNGS MBCgas valves



Ignition

Low flame position


STA

ST2

ST0

ST1

MV

Siemens SQN72

I ( red )

III ( orange )

II ( blue )

IV ( black )

IBerger STA12: a key is provided to move the cams.

Siemens SQN72: a key is provided to move cams I and IV, the other cams can be moved by means of screws.

On the BERGER STA12B3.41 actuator, the manual air damper control is not provided. On the Siemens actuator the AUTO/MAN mode is provided (see picture).

11 move the low flame cam to the minimum to move the actuator towards the low flame until the two bearings find the adjusting screw that refers to the lower position: screw V to increase the rate, unscrew to decrease.

12 Move again the low flame cam towards the minimum to meet the next screw on the adjusting cam and repeat the previous step; go on this way as to reach the desired low flame point.

13 Now adjust the pressure switches (see page 27).

SV

SV

V

Gas butterfly valve clo s ed

SC

ID

VF

Gas butterfly valve open

14 If it is necessary to change the burner output in the low flame stage, move the low flame cam: the low flame position matches the ignition position. As far as burners fitted with Dungs MBC gas valves, the low flame cam does not match the ignition cam position, that is why it must be set at about 30° more than the ignition cam.

15 Turn the burner off and then start it up again. If the adjustment is not correct, repeat the previous steps.

26


Fully modulating burners

Once the procedure till step 8 described on paragraph “Adjusting procedure” on page 22 is accomplished, go on as follows:

To adjust the air rate in low flame and in the intermediate points, proceed as follows.

9 Keep pushed for 5 seconds the EXIT button on the modulator (Fig. 42); when the LED with the hand symbol lights up, press the arrow button, driving the actuator to the maximum opening position progressively;

10 stop its stroke when it meets each screw V : adjust the air rate by adjusting the V screw that matches each bearing.

11 Push the EXIT button to quit the manual mode.

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.

VR

Calibration of air pressure switch

z z

To calibrate the air pressure switch, proceed as follows: z z

Remove the transparent plastic cap.

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%.

Repeat the ignition cycle of the burner and check it runs properly.

Refit the transparent plastic cover on the pressure switch.

Calibration of low gas pressure switch

z z z z z z

As for the gas pressure switch calibration, proceed as follows: z Be sure that the filter is clean.

Remove the transparent plastic cap.

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.

Check that the burner is operating correctly.

Clockwise turn the pressure switch adjusting ring nut (as to increase the pressure value) until the burner stops.

Slowly fully open the manual cutoff valve.

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 according to its mounting position:

1 remove the pressure switch plastic cover;

2 if the maximum pressure switch is mounted upstreaam the gas valves: measure the gas pressure in the network, when flame is off; by means of the adjusting ring nut VR , set the value read, increased by the 30%.

3 if the maximum pressure switch is mounted downstream the “gas governor-gas valves” group and upstream the butterfly valve: light the burner, adjust it according to the procedure in the previous paragrph. Then, measure the gas pressure at the operating flow rate, downstream the “gas governor-gas valves” group and upstream the butterfly valve; by means of the adjusting ring nut

VR , set the value read on step 2, increased by the 30%;

4 replace the plastic cover.

27


PART II: OPERATION

LIMITATIONS OF USE

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CON-

NECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSI-

DERED 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 AUTHORI-

SED 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.

28


OPERATION

.ATTENTION: BEFORE STARTING THE BURNER UP, BE SURE THAT THE MANUAL CUTOFF VALVES ARE OPEN

AND CHECK THAT THE PRESSURE VALUE UPSTREAM THE GAS TRAIN MATCHES THE VALUE ON PARAGRAPH

“TECHNICAL SPECIFICATIONS”). CHECK THAT THE MAINS SWITCH IS CLOSED. CAREFULLY READ THE “WAR-

NINGS” CHAPTER.

z z z z

Turn to the ON position the mains switch A on the burner front panel.

Check the flame control box is not in the lockout position (light B on), if necessary reset it by means of the pushbutton C (reset);

Check that the control thermostats or pressure switches enable the burner to operate.

Check the gas supply pressure is sufficient (light D on), if necessary, adjust the pressure switches.

Only burners provided with the gas proving system: the check cycle of the gas proving system starts; the end of this check is signalled by the light of the lamp on the device. When the valves check is finished, the startup cycle of the burner begins. In the case of a leak in a valve, the gas proving system locks and the lamp E lights. To reset the device press the device pushbutton.

VPS504

LC

LB z The startup cycle begins, the actuator drives the air damper to the maximum opening position, the fan motor starts and the pre-purgue phase begins. During the pre-purgue phase, the complete opening of the air damper is signalled by the lamp F on the frontal panel of the electrical board.

z At the end of the pre-purgue phase, the air damper goes to the ignition position, the ignition transformer turns on (signalled by the lamp H) and few seconds later the solenoid valves EV1 and EV2 are energized (lights I and L on the front panel).

z Few seconds after the opening of the valves, the ignition transformer turns off and the lamp H turns off subsequently:

Double-stage burners: the burner is on in low flame stage (light G is on); some seconds later, the high flame operation begins and the burner switches automatically to high flame (light F is on) or remains in low flame operation, accordign to the plant requests.

Progressive and fully modulating burners - few seconds after the gas valve opening, the ignition transformer is de-energized. The burner is in low flame operation and some seconds later, the two-stages operation begins; the burner increases or decreases its output, directly driven by the external thermostat (progressive version) or by the modulator (P in Fig. 25, fully modulating burners only).

29

C


Fig. 25 - Frontal panel on the electrical board

B

F G H

M

P

I L D

E

Q

A

Keys

M

P

Q

G

H

I

L

A

B

C

D

E

F

Main switch on-off

Lockout indicator light

Reset pushbutton for flame control box

Gas pressure switch consent indicator light

Gas proving system lockout indicator light (only on burners with gas proving system)

High flame operation indicator light (or air damper open during pre-purgue phase)

Low flame operation indicator light

Ignition tranformer operation indicator light

Valve in operation indicator light for EV2

Valve in operation indicator light for EV1

Indicator light for fan motor overload tripped (only three-phase burners); to reset the overload tripped, the electrical board must be opened).

Modulator (fitted only on fully modulating burners)

Operation manual selector: 0) stop - 1) high flame - 2) low flame - 3) automatic

30


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 z z z z

Clean and examine the gas filter cartridge, if necessary replace it (see next paragraphs).

Remove, chack and clean the combustion head (see Fig. 30)

Check the ignition electrode, clean, adjust and, if necessary, replace (see page 34)

Check the detection electrode, clean, adjust and, if necessary, replace; in case of doubt, check the detection circuit following the diagram in Fig. 36 and Fig. 37, after turning the burner back into operation.

Clean and grease leverages and rotating parts.

ATTENTION: when servicing, if it was necessary to disassemble the gas train parts, remember to execute the gas proving test, once the gas train is reassembled, according to the procedure imposed by the law in force.

z z

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2”

z Check the filter at least once a year!

Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 26-Fig. 27)

∆ p> 10 mbar.

Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 26-Fig. 27) 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 ÷ 6 (Fig. 28).

3 Change filter insert.

4 Re-insert filter housing, screw in screws 1 ÷ 6 without using any force and fasten.

5 Perform leakage and functional test, p max.

= 360 mbar.

6 Pay attention that dirt does not fall inside the valve.

0

1

0 2

3 p e

4 p a

5 p

Br

6

1

5

1

5

0 3 p e

Fig. 27

4 p a

5 p

Br

4 2 3 3 2 4

Fig. 26

E

D

A

B

Fig. 28

C

31


Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group)

Inspect the filter at least once a year.

z Change the filter, if pressure value between pressure connections 1 and 2 is greather than 10 mbar.

z Change the filter, if pressure value between pressure connections 1 and 2 is twice as high compared to the last inspection.

1. Interrupt gas supply: close ball valve

2. Remove screws 1-2

3. Replace the filter insert 3

4. Screw in screws 1-2 without use force to fasten.

Fig. 29

5. Perform leakage and funcion test.

6. Pay attention that dirt does not fall inside the valve.

Space requirements for fitting filter, A: from 150 to 230 mm.

Gas filter maintenance

ATTENTION: Before opening the filter, close the manual cutoff valve downstream the filter and bleed the gas; check that inside the filter there is no pressurised gas.

To clean or remove the filter, proceed as follows:

1 remove the cap unscrewing the fixing screws (A);

2 remove the filtering cartridge (B), clean it using water and soap, blow it with compressed air(or replace it, if necessary)

3 replace the cartridge in its proper position taking care to place it inbetween the guides as not to hamper the cap replacement;

4 be sure to replace the “O” ring into its place (C) and replace the cover fastening by the proper screws (A).

A B C

Removing the combustion head

Type P60 z Remove cover C.

z z

Unscrew the two screws S holding in position the washer and then unscrew VRT to free the threaded rod AR.

Unscrew the screws V holding in position the manifold G and pull out the complete group as shown in figure.

Note: for the subsequent assembly carry out the above described operations in the reverse order, checking the correct position of the OR ring.

AR

OR

VRT

V

S

G C

Fig. 30

32


AR V G

Type P65 / P72 / P73A z Remove the lid C.

z Unscrew the screws V holding in position the manifold G and pull out the complete group as shown in figure.

Note: for the subsequent assembly carry out the above described operations in the reverse order, checking the correct position of the OR ring.

VRT

OR

C

Fig. 31

To remove the combustion head, pull it out. Once removed, check that the air and gas holes are not obstructed. Clean the combustion head by means of compressed air or scrape off the scale using a metallic brush.

Adjusting the electrodes

Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion head.

ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boiler operation would be compromised. Check the electrodes position after any intervention on the combustion head.

-

Electrodes position settings (P60 / P65 / P72)

Detection electrode

Earth electrode

Ignition electrode

Fig. 32

Electrodes position settings

-

P73A

Fig. 33

33


Replacing the electrodes

ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head.

P60 / P65 / P72

VB

P73A

VB

Fig. 34

Fig. 35

Checking the detection current

To measure the detection signals refer to the diagrams in Fig. 36 and Fig. 37. If the signal is less than the indicated value, check the position of the detection electrode, the electrical contacts and if necessary replace the detection electrode.

Control box

Siemens LME21-22

Minimum detection signal

3 µA

Connector

TERMINAL BOARD

MC

27

SCALE µA DC

Fig. 36

34

Test point on burners fitted with printed circuit


To check the detection current, remove the jumper between terminals and connect the microamperemeter (see Fig. 37).

Fig. 37

Seasonal stop

To stop the burner in the seasonal stop, proceed as follows:

1 turn the burner’s main switch to 0 (Off position)

2 disconnect the power mains

3 close the fuel cock of the supply line

Burner disposal

In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”.

35

TROUBLESHOOTING

TROUBLE

CAUSE

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 z z z z z z z z z z z z z z z z z

BUTTERFLY VALVE BAD SETTING

DEFECTIVE GAS GOVERNOR

GAS VALVE DEFECTIVE

BAD CONNECTION OR DEFECTIVE HIGH/LOW FLAME

THERMOSTAT OR PRESSURE SWITCH (IF PROVIDED) z z z

WRONG SETTING SERVO CONTROL CAM

UV PROBE DIRTY OR DEFECTIVE (IF PROVIDED) l

PHASE-NEUTRAL INVERTED

PHASE-PHASE SUPPLY OR PRESENCE OF VOLTAGE ON

THE NEUTRAL CONDUCTOR(*) l

= with any control box; s

= with only LGB2../LMG2../LME11/LME2..

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

z z z z z

l l s s z l z l

z z z l z z z


SPARE PARTS

DESCRIPTION

CONTROL BOX - SIEMENS LME

IGNITION ELECTRODE

GROUND ELECTRODE

DETECTION ELECTRODE

GAS FILTER - DN65

GAS FILTER - DN80

GASKET

FAN WHEEL

AIR PRESSURE SWITCH

GAS PRESSURE SWITCH - DUNGS GW50 A5

GAS PRESSURE SWITCH - DUNGS GW150 A5

IGNITION TRANSFORMER

MOTOR

GAS PROVING SYSTEM (option)

VALVE GROUP - Rp11/2 - DUNGS MB-DLE415

VALVE GROUP - Rp2 - DUNGS MB-DLE420

VALVE GROUP - DN65 - SIEMENS VGD40

VALVE GROUP - DN80 - SIEMENS VGD40

ACTUATOR SKP15

ACTUATOR SKP25

ACTUATOR (double stage) - BERGER STA

ACTUATOR (progressive and fully-modulating) - BERGER STA

ACTUATOR (double stage) - SIEMENS SQN72

ACTUATOR (progressive and fully-modulating) - SIEMENS SQN72

BURNER MODULATOR (Only Fully-mod. burners)

COMBUSTION HEAD

BLAST TUBE S*

BLAST TUBE L*

AIR PRESSURE SWITCH ASS.Y

COMBUSTION HEAD ASS.Y(S*)

COMBUSTION HEAD ASS.Y(L*)

IGNITION CABLE

DETECTION CABLE

PRINTED CIRCUIT BOARD

P60 P65 P72 P73A

2190172

-

2190181

2190183

2480042

2480053

24800A3

24800A4

2570112

3060078

3091060

3091061

3500104

3501805

3501805

6050108

6050205

6100550

2020468

2080202

2080234

2080102

2090117

-

2110013

2150044

2020468

2080202

2080234

2080102

2090117

2090118

2110033

2150038

2020468

2080207

2080107

2080234

2090117

2090118

2110033

2150038

2020468

2080278

2080114

-

2090117

2090118

2110033

2150068

2160065

2160076

2160077

2170128

2160065

2160076

2160077

2170128

2160065

2160076

2160077

2170128

2160065

2160076

2160077

2170128

218025501 218020301 218021101 218025601

2191604 2191604 2191604 2191604

21903L3

21903L4

-

21903L4

-

21903L4

-

21903L4

2190172

2190169

2190181

2190183

2480042

2480053

24800A3

24800A4

2570112

30600C2

30910E9

30910E0

3500104

3501806

3501806

6050108

6050205

6100550

2190172

2190169

2190181

2190183

2480042

2480053

24800A3

24800A4

2570112

3060080

3091092

30910C3

3500104

3501807

3501808

6050108

6050205

6100550

2190172

2190169

2190181

2190183

2480042

2480053

24800A3

24800A4

2570112

30600L9

-

30910M5

3500104

-

-

6050108

6050205

6100550

L* = extended blast tube - S* = standard blast tube

NOTE: it is recommended to mention the burner ID number on the spare parts request form.

37

BURNER EXPLODED VIEW

P60 - P65 - P72

Pos.

Description

8

9

6

7

3

4

4.1

5

2.3

2.4

2.5

2.6

1.1

1.2

2.1

2.2

FAN

MOTOR

VALVE GROUP

THREADED PIPE

ELBOW

M/F REDUCTION

VALVE GROUP FLANGE

GAS PROVING SYSTEM

AIR INLET

HOUSING

COVER

GASKET

AIR PRESSURE SWITCH PIPE

PLEXYGLASS

BLAST TUBE

AIR PRESSURE SWITCH

10.1

10.2

OR RING

BUTTERFLY VALVE

10.3

GAS MANIFOLDC

11.1.1

COMPLETE MOUNTED LEVERAGE

11.1.2

BIG HEXAG. VARYING SECTOR

11.1.3

ACTUATOR

11.1.4

ACTUATOR CONNECTOR

11.1.5

PREMOUNTED BRACKET

11.2.1

AIR ADJUSTING CAM REGULATING NUT

11.2.2

AIR ADJUSTING CAM SCREW

11.2.3

AIR ADJUSTING CAM REGULATING SCREW

Pos.

11.14

11.15

12

13.1

13.2

13.3

14.1

14.2

14.3

14.4

15

11.6

11.7

11.8

11.9

11.10

11.11

11.12

11.13

11.2.4

11.2.5

11.2.6

11.2.7

11.2.8

11.3

11.4

11.5

Description

TRANSMISSION AIR ADJUSTING CAM

CONNECTING ROD

ROD

JOINT

ROD JOINT

INDEX PLATE

INNER AIR DAMPER

INDEX BUSH

BUSH

BOX

DAMPER PIVOT

BUTTERFLY TRANSMISSION PIVOT

ACTUATOR PIVOT

CONNECTING ROD

ROD

ROD

JOINT

ROD JOINT

PREMOUNTED HEAD ADJUSTING SCREWS

WIRED FRONT PANEL

M BOARD’S ELECTRICAL PANEL

M PANEL’S COVER

DETECTION ELECTRODE

IGNITION ELECTRODE

GROUNDED ELECTRODE

COMBUSTION HEAD

BLACK/GREEN CONNECTOR

P73A

8

9

10

5

6

6.1

7

4.4.2

4.4.3

4.4.4

4.4.5

2.4

2.5

3.1

3.2

4.1

4.2

4.3

4.4.1

1

2.1

2.2.1

2.2.2

2.2.3

2.2.4

2.2.5

2.3

Position Description Position Description

BLAST TUBE

HEAD

11

12.1.1

COMPLETE SINGLE ELECTRODE 12.1.2

ADJUSTING BUSH 12.1.3

GUN-HEAD FRONTSIDE HOLDER 12.1.4

GUN-HEAD HOLDER 12.1.5

FALSE LANCE

DETECTION ELECTRODE

RING NUT

GAS MANIFOLD

FAN

MOTOR

GAS FILTER

BUTTERFLY VALVE FANGE

PIPE

PRESSURE SWITCH

VALVE

ACTUATOR SKP15

ACTUATOR SKP25

GAS PROVING SYSTEM VPS

AIR INLET

HOUSING

COVER

GASKET

AIR PRESSURE SWITCH PIPE

PLEXYGLASS

GAS BUTTERFLY VALVE

12.4

12.5

12.6

12.7

12.8

12.9

12.10

12.11

12.12

13.1

13.2

13.3

14

12.2.1

12.2.2

12.2.3

12.2.4

12.2.5

12.2.6

12.2.7

12.3

AIR PRESSURE SWITCH

COMPLETE MOUNTED LEVERAGE

BIG HEXAG. VARYING SECTOR

ACTUATOR

PREMOUNTED BRACKET

AIR ADJUSTING CAM REGULATING NUT

AIR ADJUSTINGCAM REGULATING SCREW

TRANSMISSION AIR ADJUSTING CAM

CONNECTING ROD

TENSION ROD

JOINT

JOINT FOR ROD

INNER AIR DAMPER

INNER AIR DAMPER

BOX

ACTUATOR PIVOT

ACTUATOR PIVOT

CONNECTING ROD

ROD

TENSION ROD

JOINT

JOINT FOR ROD

WIRED FRONT PANEL

M BOARD’S ELECTRICAL PANEL

M PANEL’S COVER

BLACK/GREEN CONNECTOR

WIRING DIAGRAMS

ATTENTION:

1 - Power supply: 400V 50Hz 3N a.c.three-phase and 230V 50Hz 1N a.c. monophase

2 - Don’t reverse phase and neutral

3 - Ensure the burner is properly earthed

Burners provided with Dungs MBC valves: diagram SE18-164

Burners provided with Dungs MB-DLE or Siemens VGD valves: diagram SE18-165

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.

Comparative table

LGB Series

---

LGB 21.33

LGB 22.33

LMG Series

LMG 25.33

LMG 21.33

LMG 22.33

LME Series

LME 11.33

LME 21.33

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:

LED red LED

Y yellow LED

 ........

green LED

 ...

Steady on

Off

During startup, status indication takes place according to the table:

Status

Waiting time tw, other waiting states

Ignition phase, ignition controlled

Operation, flame ok

Operation, flame not ok

Extraneous light on burner startup

Undervoltage

Color code

 .....................................

z z z z z z

 ......................................

S S S S S z S z S z S z S z S

Color

Off

Flashing yellow

Green

Flashing green

Green - red

Yellow - red

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 nominal load air volumes when using the LME22.... The diagrams show the socalled 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

The burner stops and the control device is ready for a new startup.

Fault, alarm

Error code output

(refer to “Error code table”)

S .....................................

S S S S

Red

Flashing red

LME11 control sequence

SB / R

W / GP

AL

A

M

Z

BV1

LP

FS

EK2 tw t10 t1

B t3 t3n

TSA

B´ t4

C


D

12

10

3

1

8

7

4

6 11

SB / R

W / GP

AL

A

M

Z

BV1

(LR) BV2

LP

FS tw t10 t1 t3

B t3n

B´ t4

C D

12

10

3

7

4

5

6 11

1

7101d05/0206


A

SB / R

W / GP

AL

I

LK

SA

BV1

(LR) BV2

LP

FS

EK2

M

Z tw t11 t10 t1 t12 t3

B t3n

TSA

B´ t4

C D

12

10

7101d02/0606

9

4

3

7

5

6 11

1

8

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

LME11 connection diagram

NT

P C control

EK

RESET

R / W

12

T

2

GP

K1

K2/1

10

AL

3

K2/2

7

K3

4

M Z

BV1

5

FSV

9 6

LP p a

11 8

ION

1

EK

STB

L

N

H

Si


NT P C control

EK

RESET

7101 24 /0606

R / W

12 2

T

K1

K2/1

10

GP

AL

3

K2/2

7

K3

4

K4

5

M Z BV1 BV2

FSV

9 6

LP pa

11 8

ION

1

EK

STB

L

N

H

Si


NT

P C control

EK

RESET

R / W

12 2

T

GP

K1

K2/1

10

AL

FSV

3

K2/2

7

K3

4

K4

5

M Z

BV1 BV2

9 6

LP pa

11 8

ION

1

SA

EK

Nur LME23...

12 2 br bl

1 sw

QRC

STB

H

Si

L

N

Connection diagram

AL Error message (alarm)

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

Z

Limit thermostat /pressure switch

Ignition transformer

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 program 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 prevention 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.

2 blinks **

3 blinks ***

4 blinks ****

5 blinks *****

6 blinks *****

7 blinks *******

8 ÷ 9 blinks

10 blinks **********

14 blinks ************** (only for LME4x)

CONTROL BOX LOCKED

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 z

Press the lockout reset button for more than 3 seconds to activate the visual diagnostics.

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”:

ERROR CODE TABLE

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:

- LP is faulty

- Loss of air pressure signal after t10

- LPis welded in normal position.

- Extraneous light when burner starts up.

- LP is working position.

Free.

Loss of flame during operation

- Faulty or soiled fuel valves

- Faulty or soiled flame detector

- Inadequate adjustement of burner

Free

Faulty output contacts

Attention: “lockout” remote signal (terminal no. 10) not enabled

- Wiring error

- Anomalous voltage on ouput terminals

- Other faults

- CPI contact (gas valve microswitch) not closed.

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.

Condensation, formation of ice and ingress of water are not permitted!

TECHNICAL CHARACTERISTICS

Mains voltage

Frequency

Power consumption

120V AC +10% / -15%

230V AC +10% / -15%

50 ... 60 Hz +/- 6%

12VA

External primary fuse max. 10 A (slow) input current at terminal 12 max. 5 A

Detection cable length

Detection cable length

Thermostat cable length and other terminals max. 3m (for electrode)

max. 20 m (laid separately, for QRA probe)

Reset cable length max. 20 m (posato separatamente)

Term. 8 & 10 cable length max. 20 m

max. 3 m

Safety class

Index of protection

Operating conditions

Storage conditions

Weight

I

IP40 (to be ensured during mounting)

-20... +60 °C, < 95% UR

-20... +60 °C, < 95% UR

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: [email protected]

Note: Specifications and and data subject to change. Errors and omissions excepted.

Unigas P72 Series Installation, Use And Maintenance Manual

Gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

TABLE OF CONTENTS

Burner model identification

Specifications

Country and usefulness gas categories

Overall dimensions (mm)

Performance curves

Pressure in the network - gas flow rate curves

Packing

Fitting the burner to the boiler

Matching the burner to the boiler

Gas train connections

Assembling the gas grain

Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor)

Pressure adjusting range

Gas Proving System VPS504

LC

LB

C

B

A

PA

Electrical connections

Note on elecrtical supply

Rotation of fan motor

Combustion head gas pressure curves depending on the flow rate

Measuring the gas pressure in the combustion head

Gas pressure in combustion head vs. gas flow rate curves

Adjusting air and gas flow rates

Startup Output

Adjustments - brief description

Adjusting procedure

Double-stage burners

Progressive burners

Calibration of air and gas pressure switches

Calibration of air pressure switch

Calibration of low gas pressure switch

Adjusting the high gas pressure switch (when provided)

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2”

Inspection and replacement of the MULTIBLOC DUNGS MBC..SE filter (Threaded valves group)

Gas filter maintenance

Removing the combustion head

Adjusting the electrodes

Replacing the electrodes

Checking the detection current

Seasonal stop

Burner disposal

TROUBLESHOOTING

BURNER EXPLODED VIEW

P73A

WIRING DIAGRAMS

Key Features

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