CIB UNIGAS IDEA NG400 Manual Of Installation - Use - Maintenance

LG/NG/NGX280

LG/NG/NGX350

LG/NG/NGX400

IDEA Series

Gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

M039132CD Rev. 3

.1

01/2010

TABLE OF CONTENTS

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

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

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

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

Checking the proper gas train size ................................................................................................................................................ 6

BURNER FEATURES ..................................................................................................................................................................... 7

Burner model identification ............................................................................................................................................................. 7

Technical specifications .................................................................................................................................................................. 7

Country and usefulness gas categories ........................................................................................................................................ 11

Performance Curves ..................................................................................................................................................................... 12

Pressure in the network - gas flow rate curves ............................................................................................................................ 14

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

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

Pressure in the combustion head vs. gas flow rate curves ........................................................................................................... 18

Overall dimensions ....................................................................................................................................................................... 20

MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 22

Packing ......................................................................................................................................................................................... 22

Fitting the burner to the boiler ....................................................................................................................................................... 22

Matching the burner to the boiler .................................................................................................................................................. 22

How to modify the blast tube length .............................................................................................................................................. 23

Gas Train Reversal ....................................................................................................................................................................... 24

GAS TRAIN CONNECTIONS ....................................................................................................................................................... 25

.ELECTRICAL CONNECTIONS ................................................................................................................................................... 27

Connectors wiring diagrams 2 ......................................................................................................................................................... 8

Power supply without neutral ........................................................................................................................................................ 30

SETTING GAS AND AIR FLOW RATE ........................................................................................................................................ 30

Startup Output ............................................................................................................................................................................... 30

Adjustments - brief description ...................................................................................................................................................... 30

Adjustment procedure ................................................................................................................................................................... 31

Fully modulating burners ............................................................................................................................................................... 33

Gas Proving System VPS504 (Option) ......................................................................................................................................... 33

Calibration of air and gas pressure switches ................................................................................................................................ 34

Calibration of air pressure switch (only for single stage burners) ................................................................................................. 34

Calibration of air pressure switch (double-stage, progressive and fully-modulating).................................................................... 34

Calibration of low gas pressure switch .......................................................................................................................................... 35

Adjusting the high gas pressure switch (when provided) .............................................................................................................. 35

PART II: OPERATION ............................................................................................................................................. 36

OPERATION ................................................................................................................................................................................. 37

PART III: MAINTENANCE....................................................................................................................................... 38

ROUTINE MAINTENANCE ........................................................................................................................................................... 38

Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................. 38

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 ............................................................................................. 39

Removing and cleaning the combustion head .............................................................................................................................. 40

Checking the detection current ..................................................................................................................................................... 40

Adjusting the electrodes position ................................................................................................................................................. 41

Seasonal stop ............................................................................................................................................................................... 41

Burner disposal ............................................................................................................................................................................. 41

TROUBLESHOOTING .................................................................................................................................................................. 42

SPARE PARTS ............................................................................................................................................................................. 43

BURNER EXPLODED VIEWS ...................................................................................................................................................... 44

ELECTRICAL WIRING DIAGRAMS

(see related document)

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 - M039132CD

PART I: INSTALLATION

GENERAL FEATURES

These burners are characterised by high performaces and width in the performance curves, when the pressure in the combustion chamber is high. They are also characterised for other important functional features: there are plugs which can be easily connected to the boiler and to the detecting probes, a pressure plug in the combustion chamber, all mechanical components are mounted on a plate which can be quickly taken off for maintenance. The head is adjustable through a graduated screw. The gas train can be mounted either on the right side or on the left side.

1 2

3

4

5

14

13

6

7

8

12 11 10 9

Fig. 1

1 Control panel with startup switch

2 Gas train

3 Gas filter

4 Gas valves group

5 Gas proving system

6 Adjusting cam (double-stage, progressive and fully-modulating burners)

7 Servocontrol (double-stage, progressive and fully-modulating burners)

8 Cover

9 Control box

10 Air pressure switch

11 Fan motor

12 Combustion head (inside)

13 Flange

14 Blast tube

The gas coming from the supply line, passes through the valves group provided with filter and stabiliser. This one forces the pressure in the utilisation limits. In the double-stage , progressive and fully- modulating burners, the electric servocontrol (7), that moves proportionally the air damper and the gas butterfly valve, uses an adjusting cam with variable shape. This one allows the optimisation of the gas flue values, as to get an efficient combustion. The combustion head positioning determines the burner’s output. The combustion head

(1) determines the energetic quality and the geometry of the flame. Fuel and comburent are routed into separated ways as far as the zone of flame generation (combustion chamber). The air (comburent) and fuel (gas, gas oil, heavy oil) are forced into the combustion chamber.

The control panel, placed on the burner’s front side, shows each operating stage.

5


How to interpret the burner’s “Performance curve”

To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed: z furnace input, in kW or kcal/h (kW = kcal/h / 860); z backpressure (data are available on the boiler’s ID plate or in the user’s manual).

Example:

Furnace input: kW 600

Backpressure: mbar 4

In the “Performance curve” diagram (Fig. 3), draw a vertical line matching the furnace input value and an horizontal line matching the backpressure value. The burner is suitable if the intersection point A is inside the performance curve.

Campo di lavoro bruciatori

Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65

6

5

4

8

7

3

2

1

0

-1

100 200

A

700 800 300 400 500

Potenza kW

600

Fig. 2

900

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

Checking the proper gas train size

To check the proper gas train size, it is necessary to the available gas pressure value upstream the burner’s gas valve. Then subtract the backpressure. The result is called p gas.

Draw a vertical line matching the furnace input value (600kW, in the example), quoted on the x-axis, as far as intercepitng the network pressure curve, according to the installed gas train (DN65, in the example). From the interception point, draw an horizontal line as far as matching, on the y-axis, the value of pressure necessary to get the requested furnace input. This value must be lower or equal to the p gas value, calculated before.

25

20

15

10

5

0

100

Tipo / Type P60

M-...50 (Multibloc DUNGS MB-DLE 420 B01)

M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)

200 300

Rp 2" (50)

400 500 600

Potenza / Output (kW)

700

DN65

800 900

Fig. 3


6


BURNER FEATURES

Burner model identification

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

Type NG400 Model M-. PR. S. * A. 0. 50

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

(1) BURNER TYPE

NG - Natural gas burner

LG - L.P.G. burner

NGX - Low NOx burners

(2) FUEL

(3) OPERATION

(Available versions)

(4) BLAST TUBE

(5) DESTINATION COUNTRY

M - Natural gas L - LPG

TN - Single stage AB - Double stage

PR - Progressive MD - Fully modulating

S - standard L - long M - modular

* see data plate

(6) BURNER VERSION

(7) EQUIPMENT

(8) GAS CONNECTION

A - Standard

0 = 2 gas valves

1= 2 Gas valves + gas proving system (optional)

25 = Rp1 32 = Rp11/4 40 = Rp11/2 50 = Rp2

Technical specifications

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply

Total power consumption

Electric motor

Protection

Approx. weight

Valves size / Gas connection

Operation

Operating temperature

Storage Temperature

Working service* min.- max. kW min.- max. (Stm

3

/h) min.- max. mbar kW kW kg

°C

°C

NG280

M-.TN....0.25

NG280

M-.TN....0.32

Natural gas

(see next paragraph)

10 – 32

NG280

M-.TN.....0.40

95 - 300

LG280

L-.TN....0.20

1” / Rp1 1”¼/ Rp 1 ¼

(Note2) - 360

230V - 50Hz

0,55

0,25

IP40

47

1” ½ / Rp 1 ½ 3/4”/ Rp3/4

Single stage

-10 ÷ +50

-20 ÷ +60

Intermittent

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas Pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

Working service*

LG280

L-.TN....0.25

L.P.G.

I

3B/P

3,7 – 11,5

1”/ Rp1 min.- max. kW min.- max. (Stm 3 /h) min.- max. mbar kW kW kg

°C

°C

NG280

M-.xx...0.25

NG280

M-.xx...0.32

NG280

M-.xx...0.40

65 - 300

LG280

L-.xx...0.20

Natural gas

1” / Rp 1


7 – 32

(Note2) - 360

230V - 50Hz

0,55

0,25

IP40

1” ¼ / Rp 1 ¼ 1” ½ / Rp 1” ½

47

1” / Rp1

Progressive - Fully modulating

-10 ÷ +50

-20 ÷ +60

Intermittent

LG280

L-.xx...0.25

L.P.G.

I

3B/P

2,5 – 11,5

1” / Rp1

LG280

L-.TN....0.32

1”

1/4

/ Rp 1

1/4

LG280

L-.xx...0.32

1”

1/4

/ Rp 1

1/4

7

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

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

°C

°C


NG350

M-.TN....0.25

NG350

M-.TN....0.32

NG350

M-.TN.....0.40

115 - 330

LG350

L-.TN....0.25

Natural gas

1” / Rp 1


12 – 35

(Note2) - 360

230V - 50Hz

0,67

0,37

IP40

1” ¼ / Rp 1 ¼ 1” ½ / Rp 1 ½

47

1” / Rp1

Single stage

-10 ÷ +50

-20 ÷ +60

Intermittent

LG350

L-.TN....0.32

L.P.G.

I

3B/P

4 – 13

LG350

L-.TN.....0.40

1”

1/4

/ Rp 1

1/4

1”

1/2

/ Rp 1

1/2

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

Working service*

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature


°C

°C

NG350

M-.xx...0.25

8.5 – 35

NG350

M-.xx...0.32

80 - 330

Natural gas

NG350

M-.xx...0.40

LG350

L-.xx...0.25


8.5 – 35 8.5 – 35

I

3B/P

3 – 13

(Note2) - 360

230V - 50Hz

0,67

0,37

IP40

1” / Rp 1

47

1” ¼ / Rp 1 ¼ 1” ½ / Rp 1 ½ 1” / Rp1


-10 ÷ +50

-20 ÷ +60

Intermittent

LG350

L-.xx...0.32

85 - 330

L.P.G.

I

3B/P

3 – 13

LG350

L-.xx...0.40

I

3B/P

3 – 13

1”

1/4

/ Rp 1

1/4

1”

1/2

/ Rp 1

1/2 min.- max. kW min.- max. (Stm 3 /h) min.- max. mbar kW kW kg

°C

°C

NG400

M-.TN....0.25

1” / Rp 1

NG400

M-.TN....0.32

185 - 420

NG400

M-.TN.....0.40

Natural gas


20 - 44.5

(Note2) - 360

230V - 50Hz

0,

67

0,

37

IP40

47

1” ¼ / Rp 1 ¼ 1” ½

Single-stage

/ Rp 1 ½

-10 ÷ +50

-20 ÷ +60

Intermittent

NG400

M-.TN.....0.50

2” / Rp 2

8


BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

Working service* min.- max. kW min.- max. (Stm kW kW kg

°C

°C

3 /h) min.- max. mbar

NG400

M-.xx...0.25

1” / Rp 1

NG400

M-.xx...0.32

115 - 420

NG400

M-.xx...0.40

Natural gas


12 - 44.5

(Note2) - 360

230V - 50Hz

0, 67

0,

37

IP40

47

1” ¼ / Rp 1 ¼ 1” ½ / Rp 1”


½

-10 ÷ +50

-20 ÷ +60

Intermittent

NG400

M-.xx...0.50

2” / Rp 2

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

Working service*

Note1:

Note2: min.- max. kW min.- max. (Stm min.- max. mbar kW kW kg

°C

°C

3 /h)

LG400

L-.xx...0.25

1” / Rp 1

LG400

L-.xx...0.32

105 - 420

L.P.G.

1” ¼ / Rp 1 ¼

I

3B/P

4 - 16

-10 ÷ +50

-20 ÷ +60

Intermittent

LG400

L-.xx...0.40

(Note2) - 360

230V - 50Hz

0, 67

0,

37

IP40

47

1”

½ /

Rp 1”


½

LG400

L-.xx...0.50

2” / Rp 2

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 ); for L.P.G. (net calorific value H i

= 93.5 MJ/Stm 3 )

Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC valves)

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.

9

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

Working service*

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

Working service*


Low NOx burners Technical specifications

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas Pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature


°C

°C

NGX280

M-.TN...0.25

1” / Rp1 min.- max. kW min.- max. (Stm 3 /h) min.- max. mbar kW kW kg

°C

°C min.- max. kW min.- max. min.max.(Stm 3 /h) min.- max. mbar kW kW kg

°C

°C

NGX280

M-.TN...0.32

93 - 190

Natural gas


9,8 - 20

(Note2) - 360

230V - 50Hz

0,55

0,25

IP40

47

1”

1/4

/ Rp 1

1/4

Single-stage

-10 ÷ +50

-20 ÷ +60

Intermittent

NGX280

M-.TN...0.40

1”

1/2

/ Rp 1

1/2

NGX280

M-.xx...0.25

1” / Rp1

NGX280

M-.xx...0.32

60 - 190

Natural gas


6,4 - 20

(Note2) - 360

230V - 50Hz

0,55

0,25

IP40

47

1”

1/4

/ Rp 1

1/4


-10 ÷ +50

-20 ÷ +60

Intermittent

NGX280

M-.xx...0.40

1”

1/2

/ Rp 1

1/2

NGX350

M-.xx...0.25

1” / Rp1

NGX350

M-.xx...0.32

65 - 260

Natural gas


7 - 27.5

NGX350

M-.xx...0.40

(Note2) - 360

230V - 50Hz

0,67

0,37

IP40

47

1”

1/4

/ Rp 1

1/4


-10 ÷ +50

-20 ÷ +60

Intermittent

1”

1/2

/ Rp 1

1/2

10

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply


Electric motor

Protection

Approx. weight


Operation


Storage Temperature

Working service*


NGX400

M-.xx...0.25

min.- max. kW min.- max. (Stm 3 /h) min.- max. mbar kW kW kg

°C

°C

1” / Rp 1

NGX400

M-.xx...0.32

NGX400

M-.xx...0.40

90 - 350

Natural gas


9.5 - 37

(Note2) - 360

230V - 50Hz

0, 67

0,

37

IP40

47

1” ¼ / Rp 1 ¼ 1” ½ / Rp 1” ½


-10 ÷ +50

-20 ÷ +60

Intermittent

NGX400

M-.xx...0.50

2” / Rp 2

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 ); for L.P.G. (net calorific value

H i

=

93.5 MJ/Stm 3 )

Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC valves)

Minimum gas pressure = see gas curves for network gas pressure.

* 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

ES

PL

BE -

NL -

DE -

FR -

GR

-

-

-

-

-

SE

-

-

-

-

-

FI

-

-

-

-

-

IE

-

-

-

-

-

HU

-

-

-

-

-

IS

-

-

-

-

-

NO

-

-

-

-

-

CZ

-

-

-

-

-

DK

-

-

-

-

-

GB

-

-

-

-

-

COUNTRY

IT

-

-

-

-

-

PT

-

-

-

-

-

CY

-

-

-

-

-

EE

-

-

-

-

-

LV

-

-

-

-

-

SI

-

-

-

-

-

MT

-

-

-

-

-

SK

-

-

-

-

-

BG

-

-

-

-

-

LT

-

-

-

-

-

RO

-

-

-

-

-

TR

-

-

-

-

-

CH

-

-

-

-

-

11


Performance Curves

z Gas burners

7

6

5

9

8

4

3

2

1

0

150

NG280 Single stage

6

5

4

3

2

1

0

-1

50 100 150 200 250 300 350


7

4

3

6

5

2

1

0

100 150 200


200 250

NG280 Duoble stage

7

6

5

4

3

0

-1

2

1

50 100 150 kW

NG350 Progressive

6

4

2

200 250 300 350 kW

250

300

300

350

350

400

0

400

50 100 150 200 250 300 350 400 kW

NG400 Progressive kW

450 kW

9

8

7

6

5

4

3

2

1

0

100 150 200 250 300 350 400 450 kW z L.P.G. Burners

LG280 Single stage

6

5

4

3

2

1

0

-1

80 120 160 200 240 280

LG280 Duoble stage

6

3

2

1

0

5

4

320 kW

-1

60 100 140 180 220 260 300 kW

12


7

6

5

4

3

2

1

0

100 150 200

7

6

5

4

3


9

8

2

1

0

150 200 250 300

250 300

350 400

350


LG350 Progressive

6

4

2

400 kW

0

50 100 150

LG400 Progressive

8

6

200 250 300 350 kW kW

4

2

450 500 kW kW

0

50 100 150 200 250 300 350 400 450 kW kW z Low NOx burners

NGX280 Progressive

6

5

4

3

2

1

0

-1

80 120


7

6

5

4

3

2

1

0

50 100 150

160

200

200

250

NGX280 Duoble stage

4

3

2

1

0

6

5

-1

40 80 kW kW


120

7

6

5

9

8

4

3

2

1

0

50 100 150 200 300 kW kW

250

160

300

200 kW kW

350 400 kW kW


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.

13

Pressure in the network - gas flow rate curves

z Gas burners

NG280 M-.TN...

100


NG280 M-.xx...

100

Rp ½" (15)

80

80

60 60

40

Rp ¾" (20)

40

20

0

5 10 15 20 25 30

Rp 1" (25)

Rp 1"¼ (32)

35 40

Gas rate Stm 3 /h

20

0

5 10 15

NG350 M-.TN...

100

80

60

40

20

0

10 15 20 25 30

NG350 M-.PR/MD...

100

Rp ½" (15)

80

60

Rp ¾" (20)

Rp 1" (25)

Rp 1"¼ (32)

Rp 1"½ (40)

35 40 45

Gas rate Stm 3 /h

40

20

0

5 10 15 20

20

25

25

30

Rp ½" (15)

Rp ¾" (20)

Rp 1" (25)

Rp 1"¼ (32)

30 35 40

Gas rate Stm 3 /h

Rp ½ " (15)

Rp ¾ " (20)

Rp 1" (25)

Rp 1" ¼ (32)

Rp 1" ½ (40)

35 40 45

Gas rate Stm 3 /h

NG400 M-.TN..15-20-25

140

120

100

80

60

40

20

0

15 20 25 30

NG400 M-.PR/MD...15-20-25

140

120

100

80

60

40

20

0

10 15 20 25 30 35

Rp ½" (15)

35

40

40

Rp ¾" (20)

NG400 M-.TN..32-40-50

18

16

14

12

10

8

Rp 1" (25)

6

4

2

45 50

0

15 20 25 30

Gas rate Stm

3

/h

NG400 M-.PR/MD...32-40-50

18

Rp ½" (15)

16

14

Rp ¾" (20)

Rp 1" (25)

45 50 55

Gas rate Stm 3 /h

12

10

8

6

4

2

0

10 15 20 25 30

35

Rp 1"¼ (32)

35 40

Rp 1"½ (40)

Rp 2" (50)

40 45 50

Gas rate Stm

3

/h

Rp 1"¼ (32)

Rp 1"½ (40)

Rp 2" (50)

45 50 55

Gas rate Stm 3 /h

14

C.I.B. UNIGAS - M039132CD z L.P.G. Burners

LG280 L-.TN...

50

40

30

20

10

0

3 5

LG350 L-.TN...

60

50

40

30

20

10

0

4 6

LG400 L-.TN...

70

60

50

40

30

20

10

0

6 8 10

7

8

Rp ½" (15)

Rp ¾" (20)

Rp 1" (25)

Rp 1" ¼ (32)

LG280 L-.xx...

50

40

30

20

10

12

9

10

14

11

0

13 15

Gas rate Stm 3 /h

2 4

LG350 L-.PR/MD....

60

Rp ½" (15)

50

6

Rp ¾" (20)

Rp 1" (25)

Rp 1"¼ (32)

40

30

20

10

12

0

14

Gas rate Stm

3

/h

2 4 6

LG400 L-.PR/MD....

Rp ½" (15)

Rp ¾" (20)

Rp 1" (25)

Rp 1"¼ (32)

Rp 1"½ (40)

16 18

Gas rate Stm

3

/h

70

60

50

40

30

20

10

0

2 4 6 8

8

8

10

10

Rp ½" (15)

Rp ¾" (20)

Rp 1" (25)

Rp 1"¼ (32)

12 14

Gas rate Stm 3 /h

Rp ½" (15)

Rp ¾1" (20)

Rp 1" (25)

Rp 1"¼ (32)

12 14 16

Gas rate Stm

3

/h

Rp ½" (15)

Rp ¾" (20)

Rp 1" (25)

Rp 1"¼ (32)

Rp 1"½ (40)

10 12 14 16 18 20

Gas rate Stm

3

/h

15

C.I.B. UNIGAS - M039132CD z Low NOx burners

NGX280 M-.TN..

30

25

20

15

10

5

0

8 10 12 14 16 18 20

R p ¾" ( 2 0 )

R p 1" ( 2 5 )

NGX280 M-.xx..

30

25

20

R p 1"¼ ( 3 2 )

R p 1"½ ( 4 0 )

22 24 26

Gas rate Stm

3

/h

15

10

5

0

4

R p ¾" ( 2 0 )

R p 1" ( 2 5 )

R p 1"¼ ( 3 2 )

R p 1"½ ( 4 0 )

6 8 10 12 14 16 18 20 22 24 26

Gas rate Stm

3

/h


8 0

7 0

6 0

5 0

4 0

3 0

2 0

1 0

0

5 1 0 1 5

R p ½ " (1 5 )

R p ¾ " (2 0 )

R p 1 " (2 5 )

R p 1 "¼ (3 2 )

R p 1 "½ (4 0 )

NGX400 M-...15-20-25

100

80

60

40

20

0

5 10 15 20 25

2 0

30

2 5

35

3 0 3 5

Gas rate Stm 3 /h

NGX400 M-...32-40-50

16

Rp ½ " (15)

14

12

Rp ¾ " (20)

Rp 1" (25)

10

8

6

4

2

40 45 50

Gas rate Stm

3

/h

0

5 10 15 20 25 30

R p 1"¼ (32)

R p 1"½ (40)

R p 2" (5 0)

35 40 45 50

Gas rate Stm

3

/h

16


Combustion head pressure curves vs. the gas flow rate

Curves are referred to pressure= 0mbar in the combustion head!

The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner in the combustion stage (percentage of residual O

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 servocontrol are at the maximum opening. Refer to

, 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

3

4

Fig. 4

Key

1 Generator

2 Pressure outlet on the combustion chamber

3 Gas pressure outlet on the butterfly valve

4 Differential pressure gauge

Measuring the gas pressure in the combustion head

In order to measure the pressure in the combustion head, insert the pressure gauge probes: one into the generator’s pressure outlet (-

2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (-3). On the basis of the measured differential pressure, it is possible to get the maximum flow rate: in the pressure - rate curves (showed on the next paragraph), it is easy to get the burner output in kW or Stm3/h (quoted on the x axis) from the pressure measured in the combustion head (quoted on the y axis).

NOTE: THE PRESSURE-RATE CURVES ARE APPROXIMATE; FOR A PROPER SETTING OF THE GAS RATE, PLEASE REFER

TO THE GAS METER READING.

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

Pressure plug in combustion chamber Fan air pressure plug

Fig. 5

17


Pressure in the combustion head vs. gas flow rate curves

z nNatural gas burners

NG280

16

10

8

6

4

14

12

2

0

6 10 14 18 22

NG350

26 30 34

Gas rate Stm 3 /h

NG400

12

10

8

6

4

2

0

5 10 15 20 25 30 35 40

Gas rate Stm 3 /h

5

4

3

2

1

0

10

9

8

7

6

15 z L.P.G. Burners

LG280

18

16

14

12

10

8

6

4

2

0

2 3 4 5 6 7 8 9

LG350

25

10 11 12 13

Gas rate Stm 3 /h

LG400

20

20

15

15

10

10

5

5

0

2 4 6 8 10 12 14

Gas rate Stm 3 /h

0

4 6

20

8

25

10

30

12

35 40 45

Gas rate Stm 3 /h

14 16 18

Gas rate Stm 3 /h

18

C.I.B. UNIGAS - M039132CD z Low NOx burners

NGX280

6

4

2

0

4

14

12

10

8

6 8 10 12 14 16 18 20

Gas rate Stm 3 /h

NGX350

18

16

14

12

10

8

6

4

2

0

6 8

NGX400

10 12 14 16 18 20 22 30

5

4

3

2

1

0

10

9

8

7

6

5 24 26 28

Gas rate Stm 3 /h

10 15 20 25 30 35 40

Gas rate Stm 3 /h

19

Overall dimensions (mm)

z Standard burners

Y

Recommended boiler drilling template and burner flange

NG/LG280

NG/LG350

NG/LG400

A(S*) A(L)* B(S*) B(L)* C F G H J K1 K2 M

733 878 163 308 570 396 117 137 348 215 223 M10

748 878 178 308 570 396 125 164 348 215 223 M10

768 898 198 328 570 396 144 164 348 215 223 M10

N

219

219

219

Omin Omax P

131

131

131

179 155

Q

541

R

366

S

175

T

128

X

491

Y

130

179 155 541 366 175 89 491 144

179 155 541 366 175 89 491 144

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

L = measure referred to burners fitted with extended blast tube

Valves group dimensions according to gas train size.

D ± 5 mm (*)

Rp 1 Rp 1 ¼ Rp 1” ½ Rp 2

NG/LG280 596 596 726

NG/LG350 596 596 726

NG/LG400 596 596 726

(*) If PGMAX (maximum pressure switch) is supplied, add 60mm to "D" and "E"

726

726

726

E ± 5 mm (*)

Rp 1 Rp 1 ¼ Rp 1” ½ Rp 2

200 200 330 330

200

200

200

200

330

330

330

330

W

Rp 1 Rp 1 ¼ Rp 1” ½ Rp 2

508 508 517 567

508

508

508

508

517

517

567

567

Low NOx Burner

Recommended boiler drilling template and burner flange

NGX280

NGX350

NGX400

A(S*) A(L)* B(S*) B(L)* C F G H J K1 K2 M

733 878 163 308 570 396 114 137 348 215 223 M10

748 878 178 308 570 396 137 164 348 215 223 M10

768 898 198 328 570 396 156 176 348 215 223 M10

N

219

219

219

Omin Omax P

131

131

131

179 155

Q

541

R

366

S

175

T

128

X

491

Y

130

179 155 541 366 175 89 491 144

179 155 541 366 175 89 491 156

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

L = measure referred to burners fitted with extended blast tube

Valves group dimensions according to gas train size.

NGX280

NGX350

NGX400

Rp 1

596

596

596

D ± 5 mm (*)

Rp 1 ¼ Rp 1” ½ Rp 2

596 726 726

596

596

726

726

726

726

(*) If PGMAX (maximum pressure switch) is supplied, add 60mm to "D" and "E"

Rp 1

200

200

200

E± 5 mm (*)

Rp 1 ¼ Rp 1” ½ Rp 2

200 330 330

200

200

330

330

330

330

Rp 1

508

508

508

W

Rp 1 ¼ Rp 1” ½ Rp 2

508 517 567

508

508

517

517

567

567


MOUNTINGS AND CONNECTIONS

Packing

1

1

The burners are despatched in cardboard packages whose dimensions are: 800mm x 540mm x 480mm (L x P x H)

Packing cases of this type are affected by humidity; the maximum number of cases to be stacked is indicated outside the packing.

The following are placed in each packing case.

Burner with gas train; gasket to be inserted between the burner and the boiler;

1 envelope containing tis manual

When disposing of the burner packing and if the packing is scrapped follow the procedures laid down in the current legislation regarding the disposal of materials.

Fitting the burner to the boiler

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

1 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

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 spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).

Key a) Heat output in kW b) Lenght of the flame tube in meters c) Flame tube firing intensity in MW/m 3 d) Combustion chamber diameter (m)

Fig. 6 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat input in kW.

Fig. 6

22


How to modify the blast tube length (NG/LG350-NG/LG400)

To modify blast tube length please read the following instructions.

1 Remove combustion head (See “Removing the combustion head” - Part III of this user’s guide).

2 Remove the flanged piece T by removing the 4 socket head screws VTF (Fig. 15).

3 Remove the 4 screws which hold the blast tube to the flanged piece (Fig. 17).

4 Extract the blast tube from the flanged piece and assemble it in the other way round as shown in pictures Fig. 19 and . Now fasten the two pieces using the same screws.

5 Assemble the whole piece to the burner by caring attention to the indication in picture Fig. 25.

T

VTF

Fig. 7

Fig. 9 - Short blast tube

Fig. 8

Fig. 10 - Long blast tube

Fig. 11

Fig. 12

If you modify the blast tube length you have to modify also the combustion head length by reading the following instructions.

1 Remove the screws V1 and V2 as shown in Fig. 27.

2 Lower the terminal part of the combustion head, by moving it with a slight circular movement, until the holes will match (Fig. 29) and tight the screw shown in Fig. 31.

3 Adjust cables length by pulling them very slightly paying particular attention not to disconnect the ionisation cable to the electrode.

4 Fix the combustion head again (See “Removing the combustion head”).

23


V2

V1

Fig. 13 Fig. 15

Fig. 14

Gas Train Reversal

The gas train can be fit either on the left and on the right. Follow these instruction.

.

1 Remove the plastic hook G to release the rod T (Fig. 16) .

2 Take the screws V1 , V2 , V3 , V4 , VT1 and VT2 off (Fig. 16).

3 Take the ignition cable CA off of the transformer .

4 Disconnect the connector CR from the printed cirduit (Fig. 17).

5 Take off the flange and the combustion head together (Fig. 19).

6 Take the gas pipe TR off and put it in the new position fixing the screws VT1 and VT2VT1 VT2 (Fig. 18).

LOCKED

UNLOCKED

V1 V2

S1 VT1

G

G

TR

V4

T

V3

Fig. 16

CR

S2

VT2

VT1

CA

G

Fig. 17

F

VT2

TR

Fig. 18

V

Fig. 19

Fig. 20

24


7 Unscrew the V , rotate the head of 180 ° along its axis as shown inL Fig. 19), until the hole F is found. Fit the screw again(Fig. 19 -

Fig. 20).

8 Insert again the flange and the combustion head together

9 Rotate the disc D following the instructions below

.

10 Take off the screw VF .

11 Rotate the disc D for 180 ° and then fit the screw VF ( Fig. 21).

D D

TR

VF

Fig. 21: Standard position Fig. 22: New position

12 Reconnect CR and CA .

13 Retighten the screws V1 , V2 , V3 , V4 , VT1 e VT2

14 Place again the rod T into its own position and fasten it by the platic hook G .

GAS TRAIN CONNECTIONS

This paragraph shows the gas train components which are included in the delivery and those which must be fitted by the customer. The diagram complies with regulations in force

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.

Gas train with valves group MB-DLE (2 valves + gas filter + pressure governor) + VPS504 gas proving system

4 9

MANUFACTURER

4 5

INSTALLER

1

2 7 8

3

Key

*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.

1 Burner

2 Butterfly valve

3 Gas proving system (option)

4 Low gas pressure switch

5 High gas pressure switch (option)

7 Bellow joint

8 Manual cutoff valve

9 Dungs MB-DLE valves groupTo mount the gas train, proceed as follows:

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

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 cock and the gaskets are not part of the standard supply.

The procedures of installation fo the gas valves are showed in the next paragraph.

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

25


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).

MULTIBLOC DUNGS MB-DLE 405..412

Mounting

1. Mount flange onto tube lines: use appropriate sealing agent (see );

2. insert MB-DLE: note position of O rings (see );

3. tighten screws A, B, C and D ( - ), accordind to the mounting positions ();

4. after installation, perform leakage and functional test;

5. disassembly in reverse order.

MOUNTING POSITIONS

A B

C D

Fig. 23 Fig. 24

MULTIBLOC DUNGS MB-DLE 415..420

Mounting

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

2. unscrew screws C and D ( - ).

3. Remove MultiBloc between the threaded flanges ().

4. After mounting, perform leakage and functional tests.

Fig. 25 Fig. 26

MOUNTING POSITIONS

C

D

A

A

B

B

C

D

Fig. 27 Fig. 28 Fig. 29 Fig. 30

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

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

26


.

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 ADE-

QUATE FOR CONNECTION TO THE MAINS.

ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be sure that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the “Electrical connections” section.

WARNING: if the cable that connects the thermostats and the control box should be longer than 3 meters, insert a sectioning relay following the attached electrical wiring diagram.

To execute the electrical connections, proceed as follows:

1 find the pulg or the plugs, according to the model, that comes out from the burnrer: z 7 pins plug for the power supply (for all models); z 4 pins plug (for AB - double stage, PR-progressive, MD - fully-modulating); z 3-pins plug (only for NG/NGX400);

2 execute the electrical connections to the plugs, according to hte burner model (see next paragraph);

3 once all the connections are accomplished, check the fan motor direction (sse next paragraphs)

;

4 now the burner is ready to start up.

The burner is fitted with a bridge between terminals T6 and T8 on the 4-poles plug-TAB (external side link, male connector); if the TAB high/low flame thermostat must be connected, remove the bridge between terminals, before connecting the thermostat.

IMPORTANT: before operating the burner, be sure all connectors are linked as shown in the diagrams.

Connectors identification

Burner power supply connector

(Fig. 34 - Fig. 36 - Fig. 38)

Probe connection connector ( fully modulating burners , Fig. 40)

HIGH/LOW flame connector ( progressive burners , Fig.

36)

Fig. 31

Fig. 32

Fan motor connector (NG/NGX400 only )

(Fig. 35 - Fig. 39)

Fig. 33

27

Connectors wiring diagrams

z Single stage burner’s connectors:


Fig. 34 - 7-pins connector z Progressive burners’ connectors:

Fig. 35 - Electric motor’s 3-pins connector

NG/LG/NGX400

Fig. 36 - 7-pin and 4-pin connectors

Key

C1

C2

FU1

FU3

IL

IM

KM1

LAF

LB

LOW FLAME TIME METER

HIGH FLAME TIME METER

FAN MOTOR LINE FUSE

LINE FUSE

BURNER LINE SWITCH

FAN MOTOR LINE SWITCH

FAN MOTOR CONTACTOR

BURNER IN HIGH FLAME INDICATOR LIGHT

INDICATOR LIGHT FOR BURNER LOCK-OUT

Fig. 37Electric motor’s 3-pin connector for

NG/LG/NGX400

LBF

MV

ST

TAB

BURNER IN LOW FLAME SIGNALLING LAMP

FAN MOTOR

THERMOSTATS O PRESSURE SWITCHES SERIE

HIGH LOW FLAME THERMOSTAT/PRESSURE SWITCH

TS SAFETY THERMOSTAT/PRESSURE SWITCH

CONN-MOTORE FAN MOTOR CONNECTOR

CONN-LINEA BURNER POWER SUPPLY CONNNECTOR

CONN-TAB HIGH-LOW FLAME CONNECTOR

($) IF "TAB" USED REMOVE THE BRIDGE BETWEEN TERMINALS

T6-T8

28

z Fully-modulating burners’ connectors:


Fig. 38 - 7-pin connector

Fig. 40

-

Probes connection

Fig. 39 - Electric motor’s 3-pin connector for

NG/LG/NGXG400

Key

C1

FU1

FU3

FU4

LOW FLAME TIME METER

LINE FUSE FOR FAN MOTOR

LINE FUSE

AUXILIARY FUSE

IL

IM

BURNER LINE SWITCH

FAN MOTOR LINE SWITCH

KM1 FAN MOTOR REMOTE CONTACTOR

LANDIS RWF40 MODULATION REGULATOR

LB

LBF

BURNER LOCKOUT SIGNALLING LAMP

BURNER IN LOW FLAME SIGNALLING LAMP

MV FAN MOTOR

SD-0÷10V

SD-0/4÷20mA

VOLTAGE SIGNAL

CURENT SIGNAL

SD-PRESS

SMA

PRESSURE PROBE

MAN/AUTO SELECTOR

SMF

ST

TS

OPERATION SELECTOR MIN-0-MAX

PRESSURE SWITCHES OR THERMOSTATS SERIE

SAFETY THERMOSTAT/PRESSURE SWITCH

29


Power supply without neutral

If the power supply to the burner is 230V phase-phase (without the neutral wire), with the Siemens LGB2..., LMG2... or LME.. flame control device, between the terminal 2 on the board and the earth terminal, an RC Siemens RC466890660 filter must be inserted.

Key

C - Capacitor (22nF/250V)

R - Resistor (1Mohm)

(***) RC466890660 - RC Siemens filter

(Code: 2531003)

R

C

SIEMENS

Fig. 41

SETTING GAS AND AIR FLOW RATE

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!

4

5

1

Keys

1 Valve group

2 Cover

3 Gas proving system

4 Control panel

5 Blast tube

3

2

Fig. 42

To perform the adjustments, unscrew the fixing screws and remove the burner’s cover (see Fig. 86-2)

Startup Output

The start-up heat output shall not exceed 120 kW (single stage burners) or 1/3 of nominal output (double-stage, progressive or fully modulating burners). In order to comply with these requirements, burners are provided with butterfly valve and/or slow-opening safety valve. On double-stage, progressive or modulating burners, the low flame ouptut must be higher than the minimum ouptut quoted in the performance curve (page 32).

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

Fuel

Natural gas

LPG

Adjustments - brief description

Recommended combustion parameters

Recommended (%) CO

2

9 ÷ 10

11 ÷ 12

Recommended (%) O

2

3 ÷ 4.8

2.8 ÷ 4.3

30


Adjust the air and gas flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respectively.

z Check that the combustion parameters are in the suggested limits.

z Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a differential pressure gauge, as described on par. “Measuring the gas pressure in the combustion head” on page 17. z Then, adjust the combustion values corresponding to the points between maximum and minimum: set the shape of the adjusting cam foil. The adjusting cam sets the air/gas ratio in those points, regulating the opening-closing of the throttle gas valve.

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

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

Adjustment procedure

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

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.

1 remove the burner cover

2 startup the burner by turning its main switch A to on: if the burner locks (LED B on in the control panel) press the RESET button ( C ) on the control panel (Fig. 36).

C VS T(VR)

RP

VSB

The burner is adjusted in the factory with the combustion head in the position that refers to the "MAX" output. The maximum output setting refers to the “fully-ahead” position of the combustion head, as far as standard models (Fig. 90), and to “fully-backward” position for low NOx burners (Fig. 92). As for “fully-ahead” position, it means that the head is placed

VB inside the boiler, “fully-backward” 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 (Fig. 88). The ID index shows how much the combustion head moved.

ID

VRT

Fig. 43

Fig. 44 - Head in “fully-ahead position” Fig. 45 - Head in “fully-backward position”

3 once the combustion head is adjusted, remove the actuator cover and set it to the ignition position, (ignition position= 0° on the air damper index ID );

4 (Progressive/Fully-modulating burners) Before starting the burner up, drive the high flame actuator microswitch matching the low flame one (in order to let the burner operates at the lowest output) to safely achieve the high flame stage.

31


As for the setting, refer to this correspondence table.

Berger STA4.5B0.37/63N30L (LG/NG/NGX280) - Berger STA13B0.36/83N30L

(LG/NG/NGX350-400)

I

II

III

IV

IV

III

II

I

VS

Siemens SQN72

AUTO/MAN

High flame position (set to 90°)

Low flame and ignition position

Stand-by position (set to 0°)

Not used

BERGER STA

I

IV

II

III

Siemens SQN72

I (red)

III (orange)

II (blue)

IV (black) z Berger STA12: On this actuator, the manual control of the air damper is not provided; the setting of the cams is carried out working with a screwdriver on the VS screw placed internally to the cam.. .

z Siemens SQN72: a key is provided to move cams I and IV, the other cams can be moved by means of screws. On the Siemens actuator the AUTO/MAN mode is provided (see picture).

5 go on adjusting air and gas flow rates: check, continuosly, the flue gas analisys, as to avoid combustion with little air; dose the air according to the gas flow rate change following the steps quoted below;

6 drive the burner to high flame stage, by means fo the thermostat TAB (except single-stage burners) .

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

- Multibloc MB-DLE: The pressure governor is adjusted by operating the screw VS located under the cover C . By screwing down the pressure is increased and by unscrewing it is reduced.

The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns. By unscrewing the regulator RP the valve opens, screwing the valve closes. 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.

C VS T(VR)

RP

VSB

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

To adjust the air flow rate , proceed as follows, according to the burner operation (singlestage, double-stage, prograssive or fully-modulating).

VB z Adjustements for single-stage burners

8 loosen VR screw (see picture)

9 move the ID index towards + or -, in order to increase or decrease the air flow-rate, according to the required combustion values;

10 fasten the VR screw again.

ID

ID

VR

VR

LG/NG/NGX280 LG/NG/NGX350-400 z Adjustements for double-stage - burners mod.

LG/NG/NGX280

The comburent air adjustment must be performed by means of the actuator. The actuator rotation must be equal to 90° (next paragraph). The air damper opening in the high flame stage is imposed by the adjusting cam (see picture).

11 To adjust the air flow rate, slacken the nut RA (see picture) and move the lever VRA through the slot as shown in see picture, to increase or decrease the air rate, until the desired rate is obtained; lock then the nut RA in this position.

12 Drive the burner to the low flame operation, by the TAB boiler thermostat.

To eventually change the gas flow rate, set at step 6, slacken the screw V1 (see picture) and set the opening angle of the buttefly valve

32

C.I.B. UNIGAS - M039132CD rotating the round plate C by means of the screw V3 (turn clockwise to decrease the gas rate or counterclockwise to increase it). The index S shows the opening angle of the butterfly valve

.

VRA

MIN

V2

MAX

V1

C

V3

RA

Note: If it should be necessary to adjust the rating of the burner in low flame operation, once all the adjustments are accomplished, act on the related cam of the actuator (see next paragraph). Then, check the gas rate and, eventually, repeat step 11.

z progressive or fully-modulating burners

13 still in the high flame operation and with the actuator on its 90° position, find the V screw on the adjusting cam SV (see next picture), matching with the bearings that move along the foil and related to the servocontrol position.

14 unscrew the V srew to increase the air folw rate, unscrew to decrease it

15 once the maximum flow rate is fixed, shortcircuit for a while, the thermostat TAB T6 and T7 terminals (see pag. 45). As far as the fully-modulating models, see next paragraph. The actuator will move towards the low flame position; then remove the bridge;

16 then adjust the screw V related to that position;

17 shortcircuit, again for a while, the TAB T6 and T7 terminals and repeat from point 5;

18 repeat all these instructions for all the actuator stroke, in order to define the foil shape.

Note: If it should be necessary to adjust the rating of the burner in low flame, work on the corresponding cam of the actuator. After this operation, check the gas rate and verify the combustion values. In case of lack or excess of air, work on the screws V of the adjusting cam (see next picture) matching the setting point of the air rate in low flame; unscrew to increase the air rate or screw to decrease it.

V

SC

SV

DOUBLE-STAGE-PROGRESSIVE-FULLY-MODULATING

Fully modulating burners

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

1 Keep pushed for 5 seconds the EXIT button on the modulator (Fig. 102); when the LED with the hand symbol lights up, push the arrow button, driving the actuator to the maximum opening position progressively;

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

3 Push the EXIT button to quit the manual mode.

Gas Proving System VPS504 (Option)

The VPS504 check the operation of the seal of the gas shut off valves. This check, carried out as soon as the boiler thermostat gives a start signal to the burner, creates, by means of the diaphragm pump inside it, a pressure in the test space of 20 mbar higher than the supply pressure.

To install the DUNGS VPS504 gas proving system on the MD-DLE valves group, proceed as follows:

1 turn off gas supply.;

2 Switch off power supply.

3 remove the Multibloc’s screw plugs (Fig. 94-A);

4 iInsert sealing rings (10,5 x 2,25) into VPS 504 (Fig. 96-B, Fig. 94-B)

5 Torque screws 3, 4, 5, 6 (M4 x16) Fig. 94-C

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

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

33


LC

LB

C

B

Fig. 46

A PA

Fig. 47

When wishing to monitor the test, install a pressure gauge ranged to that of the pressure supply point PA (Fig. 96). 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 .

Calibration of air and gas pressure switches

The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of the control box unlock pushbutton, placed on the burner control panel.

The gas pressure switches check the pressure to avoid the burner operate when the pressure value is not in the requested pressure range.

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

z z

Calibration is carried out as follows: z z z

Remove the transparent plastic cap.

Once air and gas setting have been accomplished, startup the burner.

While the burner is operating, rotate slowly and clockwise the adjusting ring nut VR on the scale of the pressure switch and set it again to a value reduced by the 15%.

, until the burner locks; read the pressure value

Repeat the start-up cycle and check the burner runs properly.

Refit the transparent plastic cover on the pressure switch.

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

z z

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


Once air and gas setting have been accomplished, startup the burner.

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.


34


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.


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.


Adjusting the high gas pressure switch (when provided)

z z z

To calibrate the high pressure switch, proceed as follows: z remove the plastic cover; measure the gas pressure in the network, when flame is off; by means of the adjusting ring nut replace the plastic cover.

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

Fig. 48

VR

35


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.

36


OPERATION

E G

B

H

A

V1 M C I L D

V2

Fig. 49 - Burner’s control panel

Fig. 50 - Burner modulator

Key - Fig. 49

E

G

I

H

A

B

C

D

L

M

Mains switch ON - OFF

Lockout signaling lamp

Reset button for flame control device (optional)

Minimum gas pressure switch consent signaling lamp

High flame operation signaling lamp (or air damper opening during pre-purge stage)

Low flame operation signaling lamp

Ignition transformer in operation signaling light

EV2 opening signaling lamp

EV1 opening signaling lamp

Fuse z z z z

Set to ON position the mains switch A on the burner electrical board front panel.

Check the flame control device is not in the lockout position (LED B on), if necessary reset it by means of the pushbutton C (reset), pushing for more than 0.5 seconds but less than 3 seconds;

Verify that the control thermostats or pressure switches give the consent to operate to the burner.

Check the gas supply pressure is sufficient (LED D on).

Only burners provided with gas proving system: the check cycle of the leakage control device starts; the completion of this check is signalled by the light of the lamp on the device. When the valves check is finished, the start up cycle of the burner begins. In the case of a leak in a valve, the leakage control device locks and its red lamp lights.

To reset the device operate on the device pushbutton.

All burners z When the startup cycle begins, the servocontrol 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 LED E 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 comes on (signalled by the

LED H) and 3 seconds later the solenoid valves EV1 and EV2 are energized (LEDs L and I on the front panel).

z 3 seconds after the opening of the valves, the ignition transformer comes off and the lamp H turns off; subsequently:

Single stage burners: the burner is on at the maximum power; the LEDs E and G are on;

High-low flame burners: the burner is on in low flame (LED G is on); 8 seconds later the high flame operation begins and the burner switches automatically to high flame (LED E is on) or remains in low flame operation, depending on the plant needs.

Modulating burners: they are provided with the Siemens RWF40 modulator , placed on the burner side. As for the modulator operationm see the related manual.

37


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

Clean and examining the gas filter cartdrige, if necessary replace it (Fig. 104 on).

Removal, examination and cleaning of the combustion head.

Check the ignition and detection electrodes, clean and adjust if necessary (see Fig. 126). In case of doubr, check the detection current according to the schemes in Fig. 124.

z Cleaning and greasing of sliding and rotating parts.

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

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

z z z

Check the filter at least once a year!

Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 104-Fig. 106)is

Δ p > 10 mbar.

Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 104-Fig. 106) is twice as high compared to the last check.

You can change the filter without removing the fitting.

1 Interrupt the gas supply closing the on-off valve.

2 Remove screws 1 ÷ 4 using the Allen key n. 3 and remove filter cover 5 in Fig. 108.

3 Remove the filter 6 and replace with a new one.

4 Replace filter cover 5 and tighten screws 1 ÷ 4 without using any force and fasten.

5 Perform leakage and functional test, p max.

= 360 mbar.

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

6

➞

5 3 4

2

1

0

➞

4 3 5

6

0 2

3 p e

4 p a

1

0

1

3 p e

Fig. 52

4 p a

5 p

Br

6

5 p

Br

Fig. 51

Fig. 53

38


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

z z

Check the filter at least once a year!

Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 110-Fig. 112)

Δ p> 10 mbar.

z Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 110-Fig. 112) 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. 114).

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 p e

4 p a p

Br

6

5 1

5

1

0 3 p e

Fig. 55

4 p a

5 p

Br

4 2 3 3 2 4

Fig. 54

E

D

A

B

Fig. 56

C

39

Removing and cleaning the combustion head


1 By means of the plastic hook G , unlock the rod T (Fig. 116) which drives the butterfly valve (Fig. 116 and Fig. 118), to disconnect it from its seat.

2 Remove the screws V1 , V2 , V3 , V4 and the screws S1 and S2 (Fig. 116).

3 Disconnect the ignition cable CA from the ignition transformer (Fig. 120).

4 Disconnect the connector CR (Fig. 122).

CAUTION: during the assembling phase, before tightening screws V1, V2, V3, V4, mount and tighten screws S1 and S2.

To remove the head, the operator must pull it towards himself. Once the combustione head is removed, check that the air and gas holes are not obstructed (Fig. 122 - H ). Clean the combustion head by a compressed air blow or, in case of scale, scrape it off by a scratchbrush.

G

V1 V2

S1 VT1 LOCKED

G

TR

G

V4

T

V3

S2 VT2

UNLOCKED

Fig. 57

Fig. 58

H

CA

CR

Fig. 60

Fig. 59

Checking the detection current

If the burner locks, execute the following inpesctions. To measure the detection signals refer to the diagrams in Fig. 124 . If the signal is less than the value shown, check the position of the detection electrode, the electrical contacts and if necessary replace the detection electrode.

Connector 2

Fig. 61

Control box

Siemens LME21-22

Minimum detection signal

3 µA Flame

Detection electrode

µA DC SCALE

40


Adjusting the electrodes position

ATTENTION: avoid the ignition and detection electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boiler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. The gap between the ignition electrode and the ground is 4÷5 mm .

Ground

Ignition electrode

Detection electrode detection electrode

Fig. 62

Seasonal stop

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

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

2 disconnect the power mains

3 close the fuel valve 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”.

41

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

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 z z

DETECTION ELECTRODE BAD POSITION

BUTTERFLY VALVE BAD SETTING

DEFECTIVE GAS GOVERNOR

GAS VALVE DEFECTIVE z z z

BAD CONNECTION OR DEFECTIVE HIGH/LOW FLAME

THERMOSTAT OR PRESSURE SWITCH (IF PROVIDED)

WRONG SETTING SERVO CONTROL CAM

UV PROBE DIRTY OR DEFECTIVE (IF PROVIDED) 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

Desription

COVER

CONTROL BOX (one-stage regulation)

CONTROL BOX (double stage, progressive and fully modulating)

DETECTION ELECTRODE

IGNITION ELECTRODE

GASKET

AIR PRESSURE SWITCH

GAS PRESSURE SWITCH

IGNITION TRANSFORMER MOD. COFI

IGNITION TRANSFORMER MOD. DANFOSS

MOTOR

VALVE GROUP Rp1

VALVE GROUP Rp1 1/4

VALVE GROUP Rp1 1/2

VALVE GROUP Rp2

GAS PROVING SYSTEM (option)

ACTUATOR (double stage, progressive and fully-modulating)

COMBUSTION HEAD (GAS)

COMBUSTION HEAD (L.P.G.)

BLAST TUBE S*

BLAST TUBE L*

COMBUSTION HEAD (GAS)

COMBUSTION HEAD (L.P.G.)

IGNITION CABLE

DETECTION CABLE

PRINTED CIRCUIT BOARD

LG/NG280

Code

LG/NG350 LG/NG400

1011803 1011803 1011803

LME: 2020467 LME: 2020467 LME: 2020467

LME: 2020468 LME: 2020468 LME: 2020468

2080108 2080108 2080108

2080218

2110059

2080218

2110059

2080218

2110059

2160053

2160077

2170138

2170232

2180717

2190341

2190342

21903L3

2160053

2160077

2170138

2170232

2180714

2190341

2190342

21903L3

2160053

2160077

2170138

2170232

218071

4

2190341

-

2191604

2480057

30600P9

30600Q3

30900L0

30900L1

3501842

-

2191604

2480074

30600H3

30600H7

30900G3

30900G3**

3501841

2190342

21903L3

21903L4

2191604

2480074

30600H2

30600H6

30900G3

-

6050153

6050214

6100546

3501844

6050153

6050214

6100541

30900G3**

3501842

3501843

6050153

6050214

6100541

Spare parts for Low NOx Burners only

Desription

COMBUSTION HEAD (NOx)

BLAST TUBE S*

BLAST TUBE L*

NGX280

30600Q7

30910P5

30910Q2

Code

NGX350

30600H9

30910L6

30910L6**

NGX400

30600H8

30910L6

30910L6**

*S:standard

L: extended

** To modify the blast tube’s length, see chapter “How to modify blast tube length

”

.

43


BURNER EXPLODED VIEW NG280

Position

7

8

1

3

10

11

37.2

37.3

37.4

37.5

37.6

37.7

38

41

25

26

27

30

34

35

36

37.1

20

21

22

23

16

17

18

19

12

13

14

15.1

15.2

15.3

15.4

15.5

42.1

42.12

42.13

42.17.1

42.17.2

42.17.3

42.17.5

43

44

Description

VALVE GROUP

COVER FIXING SCREW

FIXING BRACKET - LEFT SIDE

FIXING BRACKET - RIGHT SIDE

COVER

4-WAYS FAIRLEAD

2-WAYS FAIRLEAD

FAIRLEAD

FASTENER

GAS PRESSURE INTAKE

HOUSING

FLANGED COUPLING

MOTOR’S PLATE

WASHER

GASKET

AIR DAMPER INDEX

EXTENSION SCREW

FAN

GAS PRESSURE SWITCH

MOTOR

VALVE GROUP FLANGE

GAS PROVING SYSTEM

AIR FLAP

AIR DAMPER CRANK (progressive and fully modulating only)

FIXING ROD

PANEL ASSEMBLY

GREY/GREEN TERMINAL

BLACK/GREEN TERMINAL

BLOCKING PLATE

COMPONENTS BRACKET

ELECTRONIC BOARD

ACTUATOR (double stage, progressive and fully modulating only)

AIR PRESSURE SWITCH

CONTROL BOX BOARD

CONTROL BOX

GAS TRANSFORMER

BOX ASSEMBLY

BLAST TUBE

BUTTERFLY MANIFOLD

INGNITION CABLE

DETECTION CABLE

INGNITION ELECTRODE

DETECTION ELECTRODE

GROUNDED CABLE

COMBUSTION HEAD

GAS PIPE

OR RING

44


45


BURNER EXPLODED VIEW NG350-400

Position

29.2

29.3

30

31.1

31.2

31.3.1

31.3.2

31.4

32.1

32.2

32.3

32.4.1

32.4.2

32.4.3

32.5

32.6

33

34

35

36

19

20

21

22

15.5

16

17

18

12

13

14

15.1

15.2

15.3

15.4

23

24

25

26

27

28

29.1

7

8

5

6

3

4

1

2

9

10

11

Description

VALVE GROUP

WASHER

COVER FIXING SCREW

AIR DAMPER ASSEMBLY

BOX ASSEMBLY

BOARD’S SUPPORTING BRACKET

FIXING BRACKET - LEFT SIDE

FIXING BRACKET - RIGHT SIDE

BLAST TUBE

COVER

4-WAYS FAIRLEAD

2-WAYS FAIRLEAD

FAIRLEAD

FASTENER

GAS PRESSURE INTAKE

HOUSING

FLANGED COUPLING

MOTOR’S PLATE

WASHER

GASKET

AIR DAMPER INDEX

EXTENSION SCREW

FAN

GAS PRESSURE SWITCH

MOTOR

VALVE GROUP FLANGE

GAS PROVING SYSTEM

OR RING

AIR FLAP

AIR DAMPER CRANK (progressive and fully modulating only)

FIXING ROD

GAS PIPE

GAS TRANSFORMER

SMALL ADJUSTING CAM

ACTUATOR (double stage, progressive and fully modulating only)

PANEL ASSEMBLY

CONTROL BOX BRACKET

AIR PRESSURE SWITCH

CONTROL BOX

CONTROL BOX BOARD

CONTACTOR

BUTTERFLY MANIFOLD

HEAD EXTENSION ASSEMBLY

BUTTERFLY ASSEMBLY

COMBUSTION HEAD

DETECTION ELECTRODE

INGNITION ELECTRODE

INGNITION CABLE

DETECTION CABLE

ELECTRONIC BOARD

GREY/GREEN TERMINAL

BLACK/GREEN TERMINAL

BLOCKING PLATE

46


47

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:

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.

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

Fault, alarm

Error code output

(refer to “Error code table”)

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

S S S S

Color

Off

Flashing yellow

Green

Flashing green

Green - red

Yellow - red

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

M

Z

SA

BV1

(LR) BV2

LP

FS

EK2 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 5

M Z

BV1

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

T

2

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.

CIB UNIGAS IDEA NG400 Manual Of Installation - Use - Maintenance

IDEA Series

Gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

Burner model identification

Technical specifications

Low NOx burners Technical specifications

Country and usefulness gas categories

Performance Curves

Pressure in the network - gas flow rate curves

Combustion head pressure curves vs. the gas flow rate

Measuring the gas pressure in the combustion head

Pressure in the combustion head vs. gas flow rate curves

Overall dimensions (mm)

Packing

Fitting the burner to the boiler

Matching the burner to the boiler

How to modify the blast tube length (NG/LG350-NG/LG400)

Gas Train Reversal

Connectors wiring diagrams

Power supply without neutral

Startup Output

Adjustments - brief description

Adjustment procedure

LG/NG/NGX280

Fully modulating burners

Calibration of air and gas pressure switches

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

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

Calibration of low gas pressure switch

Adjusting the high gas pressure switch (when provided)

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

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

Removing and cleaning the combustion head

Checking the detection current

Adjusting the electrodes position

Seasonal stop

Burner disposal

TROUBLESHOOTING

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Table of contents