CIB UNIGAS IDEA Series Manual Of Installation - Use - Maintenance
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CIB UNIGAS IDEA Series Manual Of Installation - Use - Maintenance

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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

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  • Page 1 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...

  • Page 2: Table Of Contents

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

  • Page 3: Warnings

    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.
  • Page 4 DIRECTIVES AND STANDARDS 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS Gas burners GENERAL European directives: The burner shall be installed by qualified personnel and in com- - Directive 90/396/CEE - Gas Appliances; pliance with regulations and provisions in force; wrong installation Directive 2006/95/EC on low voltage;...

  • Page 5: Part I: Installation

    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.

  • Page 6: How To Interpret The Burner's "Performance Curve

    C.I.B. UNIGAS - M039132CD 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: furnace input, in kW or kcal/h (kW = kcal/h / 860); backpressure (data are available on the boiler’s ID plate or in the user’s manual).

  • Page 7: Burner Features

    C.I.B. UNIGAS - M039132CD BURNER FEATURES Burner model identification Burners are identified by burner type and model. Burner model identification is described as follows. Type NG400 Model NG - Natural gas burner LG - L.P.G. burner (1) BURNER TYPE NGX - Low NOx burners M - Natural gas L - LPG (2) FUEL...
  • Page 8 C.I.B. UNIGAS - M039132CD NG350 NG350 NG350 LG350 LG350 LG350 BURNER TYPE M-.TN..0.25 M-.TN..0.32 M-.TN..0.40 L-.TN..0.25 L-.TN..0.32 L-.TN..0.40 115 - 330 Output min.- max. kW Natural gas L.P.G. Fuel Category (see next paragraph) 3B/P 12 – 35 4 – 13 Gas rate min.- max.
  • Page 9 C.I.B. UNIGAS - M039132CD NG400 NG400 NG400 NG400 BURNER TYPE M-.xx...0.25 M-.xx...0.32 M-.xx...0.40 M-.xx...0.50 115 - 420 Output min.- max. kW Natural gas Fuel Category (see next paragraph) 12 - 44.5 Gas rate min.- max. (Stm (Note2) - 360 Gas pressure min.- max.
  • Page 10 C.I.B. UNIGAS - M039132CD Low NOx burners Technical specifications NGX280 NGX280 NGX280 BURNER TYPE M-.TN...0.25 M-.TN...0.32 M-.TN...0.40 Output min.- max. kW 93 - 190 Natural gas Fuel Category (see next paragraph) 9,8 - 20 Gas rate min.- max. (Stm Gas Pressure min.- max.

  • Page 11: Country And Usefulness Gas Categories

    C.I.B. UNIGAS - M039132CD NGX400 NGX400 NGX400 NGX400 BURNER TYPE M-.xx...0.25 M-.xx...0.32 M-.xx...0.40 M-.xx...0.50 Output min.- max. kW 90 - 350 Natural gas Fuel Category (see next paragraph) Gas rate min.- max. (Stm 9.5 - 37 Gas pressure min.- max. mbar (Note2) - 360 230V - 50Hz Power supply...

  • Page 12: Performance Curves

    C.I.B. UNIGAS - M039132CD Performance Curves Gas burners NG280 Single stage NG280 Duoble stage NG350 Single stage NG350 Progressive NG400 Single stage NG400 Progressive L.P.G. Burners LG280 Single stage LG280 Duoble stage...
  • Page 13 C.I.B. UNIGAS - M039132CD LG350 Single stage LG350 Progressive LG400 Single stage LG400 Progressive Low NOx burners NGX280 Progressive NGX280 Duoble stage NGX350 Progressive NGX400 Progressive Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C. NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine.

  • Page 14: Pressure In The Network - Gas Flow Rate Curves

    C.I.B. UNIGAS - M039132CD Pressure in the network - gas flow rate curves Gas burners NG280 M-.TN... NG280 M-.xx... 1 00 1 00 Rp ½" (1 5) Rp ½" (1 5) Rp ¾" (20) Rp ¾" (20) Rp 1 " (25) Rp 1 "...
  • Page 15 C.I.B. UNIGAS - M039132CD L.P.G. Burners LG280 L-.TN... LG280 L-.xx... Rp ½" (15) Rp ½" (1 5) Rp ¾" (20) Rp ¾" (20) Rp 1" (25) Rp 1 " (25) Rp 1 "¼ (32) Rp 1" ¼ (32) Gas rate Stm Gas rate Stm LG350 L-.TN...
  • Page 16 C.I.B. UNIGAS - M039132CD Low NOx burners NGX280 M-.TN.. NGX280 M-.xx.. R p ¾" ( 2 0 ) R p ¾" ( 2 0 ) R p 1" ( 2 5 ) R p 1" ( 2 5 ) R p 1"¼ ( 3 2 ) R p 1"¼...

  • Page 17: Combustion Head Pressure Curves Vs. The Gas Flow Rate

    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.

  • Page 18: Pressure In The Combustion Head Vs. Gas Flow Rate Curves

    C.I.B. UNIGAS - M039132CD Pressure in the combustion head vs. gas flow rate curves nNatural gas burners NG280 Gas rate Stm NG350 NG400 Gas rate Stm Gas rate Stm L.P.G. Burners LG280 Gas rate Stm LG350 LG400 Gas rate Stm Gas rate Stm...
  • Page 19 C.I.B. UNIGAS - M039132CD Low NOx burners NGX280 Gas rate Stm NGX350 NGX400 Gas rate Stm Gas rate Stm...

  • Page 20: Overall Dimensions

    Overall dimensions (mm) Standard burners Recommended boiler drilling template and burner flange A(S*) A(L)* B(S*) B(L)* Omin Omax NG/LG280 NG/LG350 NG/LG400 * 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.
  • Page 21 Low NOx Burner Recommended boiler drilling template and burner flange A(S*) A(L)* B(S*) B(L)* Omin Omax NGX280 NGX350 NGX400 * 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.

  • Page 22: Mountings And Connections

    C.I.B. UNIGAS - M039132CD MOUNTINGS AND CONNECTIONS Packing 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.

  • Page 23: How To Modify The Blast Tube Length

    C.I.B. UNIGAS - M039132CD How to modify the blast tube length (NG/LG350-NG/LG400) To modify blast tube length please read the following instructions. Remove combustion head (See “Removing the combustion head” - Part III of this user’s guide). Remove the flanged piece T by removing the 4 socket head screws VTF (Fig. 15). Remove the 4 screws which hold the blast tube to the flanged piece (Fig.

  • Page 24: Gas Train Reversal

    C.I.B. UNIGAS - M039132CD 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.. Remove the plastic hook G to release the rod T (Fig. 16) . Take the screws V1, V2, V3, V4, VT1 and VT2 off (Fig.

  • Page 25: Gas Train Connections

    C.I.B. UNIGAS - M039132CD 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). Insert again the flange and the combustion head together Rotate the disc D following the instructions below.
  • Page 26 C.I.B. UNIGAS - M039132CD 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).

  • Page 27: Electrical Connections

    C.I.B. UNIGAS - M039132CD 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.

  • Page 28: Connectors Wiring Diagrams 2

    C.I.B. UNIGAS - M039132CD Connectors wiring diagrams Single stage burner’s connectors: Fig. 34 - 7-pins connector Fig. 35 - Electric motor’s 3-pins connector NG/LG/NGX400 Progressive burners’ connectors: Fig. 36 - 7-pin and 4-pin connectors Fig. 37Electric motor’s 3-pin connector for NG/LG/NGX400 BURNER IN LOW FLAME SIGNALLING LAMP LOW FLAME TIME METER...
  • Page 29 C.I.B. UNIGAS - M039132CD 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 BURNER LOCKOUT SIGNALLING LAMP BURNER IN LOW FLAME SIGNALLING LAMP FAN MOTOR LOW FLAME TIME METER SD-0÷10V VOLTAGE SIGNAL LINE FUSE FOR FAN MOTOR...

  • Page 30: Power Supply Without Neutral

    C.I.B. UNIGAS - M039132CD 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. C - Capacitor (22nF/250V) R - Resistor (1Mohm) (***) RC466890660 - RC Siemens filter...

  • Page 31: Adjustment Procedure

    C.I.B. UNIGAS - M039132CD Adjust the air and gas flow rates at the maximum output (“high flame”) first, by means of the air damper and the adjusting cam respec- tively. Check that the combustion parameters are in the suggested limits. Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a dif- ferential pressure gauge, as described on par.
  • Page 32 C.I.B. UNIGAS - M039132CD As for the setting, refer to this correspondence table. Berger STA4.5B0.37/63N30L (LG/NG/NGX280) - Berger STA13B0.36/83N30L Siemens SQN72 (LG/NG/NGX350-400) AUTO/MAN BERGER STA Siemens SQN72 I (red) High flame position (set to 90°) III (orange) Low flame and ignition position Stand-by position (set to 0°) II (blue) IV (black)

  • Page 33: Fully Modulating Burners

    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. 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).

  • Page 34: Calibration Of Air And Gas Pressure Switches

    C.I.B. UNIGAS - M039132CD Fig. 46 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.

  • Page 35: Calibration Of Low Gas Pressure Switch

    C.I.B. UNIGAS - M039132CD Calibration of low gas pressure switch As for the gas pressure switch calibration, proceed as follows: Be sure that the filter is clean. Remove the transparent plastic cap. While the burner is operating at the maximum output, test the gas pressure on the pres- sure port of the minimum gas pressure switch.

  • Page 36: Part Ii: Operation

    C.I.B. UNIGAS - M039132CD 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.

  • Page 37: Operation

    C.I.B. UNIGAS - M039132CD OPERATION Fig. 49 - Burner’s control panel Fig. 50 - Burner modulator Key - Fig. 49 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...

  • Page 38: Part Iii: Maintenance

    C.I.B. UNIGAS - M039132CD 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.

  • Page 39: Removing The Filter In Themultibloc Dungs Mb-Dle 415 - 420

    C.I.B. UNIGAS - M039132CD Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2” 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) Δp> 10 mbar. Change the filter if the pressure difference between pressure connection 1 and 2 (Fig.

  • Page 40: Removing And Cleaning The Combustion Head

    C.I.B. UNIGAS - M039132CD Removing and cleaning the combustion head 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. Remove the screws V1, V2, V3, V4 and the screws S1 and S2 (Fig. 116). Disconnect the ignition cable CA from the ignition transformer (Fig.

  • Page 41: Adjusting The Electrodes Position

    C.I.B. UNIGAS - M039132CD 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.

  • Page 42: Troubleshooting

    TROUBLESHOOTING TROUBLE CAUSE MAIN SWITCH OPEN LACK OF GAS MAXIMUM GAS PRESSURE SWITCH DEFECTIVE (IF PROVIDED) THERMOSTATS/PRESSURE SWITCHES DEFECTIVE OVERLOAD TRIPPED INTERVENTION AUXILIARIES FUSE INTERRUPTED CONTROL BOX FAULTY DEFECTIVE SERVOCONTROL (IF PROVIDED) AIR PRESSURE SWITCH FAULT OR BAD SETTING MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIRTY IGNITION TRANSFORMER FAULT IGNITION ELECTRODES BAD POSITION...

  • Page 43: Spare Parts

    C.I.B. UNIGAS - M039132CD SPARE PARTS Desription Code LG/NG280 LG/NG350 LG/NG400 COVER 1011803 1011803 1011803 CONTROL BOX (one-stage regulation) LME: 2020467 LME: 2020467 LME: 2020467 CONTROL BOX (double stage, progressive and fully modulating) LME: 2020468 LME: 2020468 LME: 2020468 DETECTION ELECTRODE 2080108 2080108 2080108...

  • Page 44: Burner Exploded Views

    C.I.B. UNIGAS - M039132CD BURNER EXPLODED VIEW NG280 Position Description VALVE GROUP COVER FIXING SCREW FIXING BRACKET - LEFT SIDE FIXING BRACKET - RIGHT SIDE COVER 4-WAYS FAIRLEAD 2-WAYS FAIRLEAD FAIRLEAD FASTENER 15.1 GAS PRESSURE INTAKE 15.2 HOUSING 15.3 FLANGED COUPLING 15.4 MOTOR’S PLATE 15.5...
  • Page 45 C.I.B. UNIGAS - M039132CD...
  • Page 46 C.I.B. UNIGAS - M039132CD BURNER EXPLODED VIEW NG350-400 Position 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 15.1...
  • Page 47 C.I.B. UNIGAS - M039132CD...

  • Page 48: Appendix

    APPENDIX SIEMENS LME11/21/22 CONTROL BOX The series of equipment LME.. is used for the starup and supervisione of START-UP PROGRAM 1- or 2- stage gas burners. The series LME.. is interchangeable with the series LGB.. and LMG.., all diagrams and accessories are interchangea- As far as the startup program, see its time diagram: ble.
  • Page 49 LME11 control sequence LME21 control sequence B´ B´ SB / R SB / R W / GP W / GP (LR) BV2 7101d05/0206 Control sequence Waiting time LME22 control sequence Purge time B´ TSA Ignition safety time SB / R W / GP Preignition time Postignition time...
  • Page 50 LME11 connection diagram Connection diagram Error message (alarm) Fuel valve C control RESET EK2 Remote lockout reset button Flame signal Gas pressure switch Air pressure switch Load controller K2/1 K2/2 Fan motor Control thermostat/pressurestat R / W Safety limit thermostat Limit thermostat /pressure switch Ignition transformer 7101 24 /0606...
  • Page 51 CONTROL PROGRAM IN THE EVENT OF FAULT CONTROL BOX LOCKED If a fault occurs, all outputs will immediately be deactivated (in less In the event of lockout, the LME.. remains locked and the red signal lamp than 1s). (LED) will light up.The burner control can immediately be reset. This state After an interruption of power, a restart will be made with the full pro- is also mantained in the case fo mains failure.
  • Page 52 C.I.B. UNIGAS S.p.A. Via L.Galvani, 9 - 35011 Campodarsego (PD) - ITALY Tel. +39 049 9200944 - Fax +39 049 9200945/9201269 web site: www.cibunigas.it - e-mail: cibunigas@cibunigas.it Note: Specifications and and data subject to change. Errors and omissions excepted.

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