CIB UNIGAS E205A Manual Of Installation - Use - Maintenance

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E165A

E205A

Gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ

M039506CA 0.0 03/2022

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Summary of Contents for CIB UNIGAS E205A

Page 1 E165A E205A Gas burners MANUAL OF INSTALLATION - USE - MAINTENANCE BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ M039506CA 0.0 03/2022...
Page 2 DANGERS, WARNINGS AND NOTES OF CAUTION THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER. INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.
Page 3 3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS DIRECTIVES AND STANDARDS Gas burners GENERAL European directives  The burner shall be installed by qualified personnel and in compliance -Regulation 2016/426/UE (appliances burning gaseous fuels) with regulations and provisions in force; wrong installation can cause -2014/35/UE (Low Tension Directive) injuries to people and animals, or damage to property, for which the -2014/30/UE (Electromagnetic compatibility Directive)
Page 4 Burner data plate Type Gas - Light oil burners For the following information, please refer to Model Year European Directives the data plate: S.Number -Regulation 2016/426/UE (appliances burning gaseous fuels) burner type and burner model: must be Output  Oil Flow -2014/35/UE (Low Tension Directive) reported in any communication with the Fuel...
Page 5 PART I: SPECIFICATIONS PART I: SPECIFICATIONS BURNERS FEATURES Burner with ABS polymer (silenced) air inlet Burner with aluminium air inlet Note: the figure is indicative only. Control panel with startup switch Gas valves group Electrical panel Air intake (aluminium or ABS) Blast tube + Combustion head Flange Adjusting cam (progressive/fully modulating burners only)
Page 6 Burners are identified by burner type and model. Burner model identification is described as follows. Type E165A Model MD. SR. BURNER TYPE E165A, E205A FUEL M - Natural gas, L - LPG OPERATION (Available versions) PR - Progressive MD - Fully modulating...
Page 7 PART I: SPECIFICATIONS Technical Specifications BURNER TYPE E165A M-.. - E205A M-.. E165A L-.. E205A L-.. 340 - 2050 340 - 2050 320 - 1650 320 - 1650 Output min. - max. kW Natural gas Fuel (see next paragraph) Category...
Page 8 PART I: SPECIFICATIONS Procedure for accessing the equipment and making electrical connections Unscrew the screw as shown in Fig. 1 Lift the plate using the screws as shown in Fig. 2 Make the electrical connections...
Page 9 O min O max BURNER FLANGE BOILER RECOMMENDED (BS-BL) DRILLING TEMPLATE (AS-AL) B*: SPECIAL blast tube lengths must be agreed with Cib Unigas DN(*) AA V(**) AB - 0.40 40 1146 1256 354 AB - 0.50 50 1146 1256 354 AB - 0.65 65...
Page 10 ABS air intake version O min O max BOILER RECOMMEN- BURNER FLANGE (BS-BL) DED DRILLING TEM- (AS-AL) PLATE B*: SPECIAL blast tube lengths must be agreed with Cib Unigas DN(*) V(**) 1313 1423 1078 1313 1423 1013 E165A 1313 1423...
Page 11 PART I: SPECIFICATIONS Combustion head gas pressure curves Combustion head gas pressure depends on gas flow and combustion chamber backpressure. When backpressure is subtracted, i depends only on gas flow, provided combustion is properly adjusted, flue gases residual O2 percentage complies with “Recommended combustion values”...
Page 12 PART I: SPECIFICATIONS Performance Curves E165A E205A To get the input in kcal/h, multiply value in kW by 860. Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15° C NOTE: The performance curve is a diagram that represents the burner performance in the type approval phase or in the laboratory tests, but does not represent the regulation range of the machine.
Page 13 PART I: SPECIFICATIONS Pressure in the Network / gas flow rate curves(L-) E165A L- Gas rate Stm ATTENTION: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis (pressure value in the combustion chamber is not included). To know the minimum pressure at the gas train inlet, necessary to get the requested gas rate, add the pressure value in the combustion chamber to the value read on the y-axis.
Page 14 Pressure - rate in combustion head curves (natural gas) Curves are referred to pressure = 0 mbar in the combustion chamber! E165A M-.. E205A M-.. Pressure - rate in combustion head curves (LPG) Curves are referred to pressure = 0mbar in the combustion chamber!
Page 15 PART II: INSTALLATION PART II: INSTALLATION MOUNTING AND CONNECTING THE BURNER Transport and storage ATTENTION! The equipment must be installed in compliance with the regulations in force, following the manufac- turer’s instructions, by qualified personnel. All handling operations must be carried out with appropriate resources and qualified personnel ATTENTION: Use intact and correctly dimensioned hoisting equipment, conforms to the local regulations and health and safety regulations.
Page 16 PART II: INSTALLATION Fitting the burner to the boiler To install the burner into the boiler, proceed as follows: make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”) place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”; place the 4 stud bolts (5), according to the burner’s drilling plate described on paragraph “Overall dimensions”;...
Page 17 PART II: INSTALLATION GAS TRAIN CONNECTIONS The diagrams show the components of the gas trai included in the delivery and which must be fitted by the installer.The diagrams are in compliance with the current laws. Gas train with valves group MB-DLE (2 valves + gas filter + pressure governor) by others by burner constructor GAS INLET...
Page 18 PART II: INSTALLATION GAS TRAIN CONNECTIONS The diagrams show the components of the gas train included in the delivery and which must be fitted by the installer.The diagrams are in compliance with the current laws. Note: the figure is indicative only ”direction”...
Page 19 PART II: INSTALLATION MultiBloc MB-DLE - Assembling the gas train Note: the figure is indicative only ”direction” arrows for gas supply network installation Keys Gasket Gas filter Gas valves group Bellows unit Manual valve MULTIBLOC DUNGS Mounting Mount flange onto tube lines: use appropriate sealing agent MB-DLE 405..412 Insert MB-DLE: note position of O rings MB-DLE 415..420...
Page 20 PART II: INSTALLATION MultiBloc MBE ALLA V. FARFALLA Example of gas train MBE 501939 GAS BRUCIATORE ø185 VD-R VD-V VD-R VD-V Gas filter PGMAX PGMAX PGMI PGMIN PS pressure sensor PGCP PGCP ATTENTION: once the gas train is mounted according, the gas proving test mus be performed, according to the procedure set by the laws in force.
Page 21 PART II: INSTALLATION Mounting VD-R & PS-... ActuatorVD-V ActuatorVD-R M12 x 5 Pin The actuator VD-V does not need any adjustment (funzione ON-OFF)  The actuator VD-R It must be combined with the PS sensor (include  regolatore di pressione) VD-R + PS 1.
Page 22 PART II: INSTALLATION Siemens VGD20.. e VGD40.. Siemens VGD20.. and VGD40.. gas valves - with SKP2.. (pressure governor) - Connect the reference gas pipe (TP in figure; 8mm-external size pipe supplied loose), to the gas pressure nipples placed on the gas pipe, downstream the gas valves: gas pressure must be measured at a distance that must be at least 5 times the pipe size.
Page 23 PART II: INSTALLATION Siemens VGD SKPx5 (Auxiliary-optional micro switch) Actuator connection Valve drive End of stroke Plug connection Plug connection (only with SKPxx.xx1xx) A Valve closed Gas valveGas Filter (if provided) The gas filters remove the dust particles that are present in the gas, and prevent the elements at risk (e.g.: burner valves, counters and regulators) from becoming rapidly blocked.
Page 24 PART II: INSTALLATION ELECTRICAL CONNECTIONS WARNING! Respect the basic safety rules. make sure of the connection to the earthing system. do not reverse the phase and neutral connections. fit a differential thermal magnet switch adequate for connection to the mains. WARNING! 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 25 PART III: OPERATION PART III: OPERATION LIMITATIONS OF USE THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNEC- TED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDE- RED IMPROPER AND THEREFORE DANGEROUS.
Page 26 PART III: OPERATION Gas operation Turn to the ON position the mains switch S1 on the burner front panel.  Check the flame control box is not in the lockout position (light B1 on), if necessary reset it by means of the pushbutton S2 (reset); ...
Page 27 PART III: OPERATION WARNING! 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 fuel decrease slowly until the normal combustion values are achieved. WARNING! the combustion air excess must be adjusted according to the values in the following chart. Recommended combustion parameters Fuel Recommended (%) CO...
Page 28 PART III: OPERATION REGULATION: Multibloc MB-DLE VS T(VR) The multibloc unit is a compact unit consisting of two valves, gas pressure switch, pres- sure stabilizer and gas filter. The valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of turns.
Page 29 PART III: OPERATION Regulation VD-R whith PS Setting scale is „Not“ linear! Various sensors available. Output pressure according to sensor‘s measuring range. Increasing pressure Adjust the outlet pressure to the value specified by the burner or equipment manufacturer! Decreasing pressure While making outlet pressure adjustments, do not exceed a value that creates a hazardous condition to the burner!
Page 30 For natural gas burners, plate holes are fully opened  (E205A L-..) Center head holes gas flow regulation To adjust the gas flow, partially close the holes, as follows: loosen the three V screws that fix the adjusting plate D;...
Page 31 PART III: OPERATION closed holes opened holes The adjusting plate correct position must be regulated in the plant during the commissioning. The factory setting depends on the type of fuel for which the burner is designed: For LPG burners, plate holes are opened about 1.7mm ...
Page 32 PART III: OPERATION Adjustment procedure Turn the burner on by means of its main switch S1: if the burner locks (LED B1 on in the control panel) press the RESET button (S2) on the control panel. See chapter “Operation” for further details. check the fan motor rotation Start the burner up by means of the thermostat series and wait unitl the pre-purge phase comes to end and that burner starts up;...
Page 33 PART III: OPERATION Fig. 8 Now adjust the pressure switches.  If it is necessary to change the burner output in the low flame stage, move the low flame cam: the low flame position matches the  ignition position. As far as burners fitted with Dungs MBC gas valves, the low flame cam does not match the ignition cam position, that is why it must be set at about 30°...
Page 34 PART III: OPERATION Progressive burners Once the procedure till step 8 described on paragraph “” on page 30, is accomplished, go on as follows: set the low flame cam matching the high flame cam; 10 set the TAB thermostat to the minimum in order that the actuator moves progressively towards the low flame position;; The manual air damper control is not provided on these actuators.
Page 35 PART III: OPERATION Calibration 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 bur- ner control panel.
Page 36 PART IV: MAINTENANCE PART IV: 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 37 PART IV: MAINTENANCE MultiBloc MBE MultiBloc VD Mounting to push position 1. Position VD on VB, fig. 2+3. 2. Slide VD forward up to the stop, fig. 4. 3. Screw VD on with 2 M5 screws for each, max. 5 Nm/44 in.-lb., fig. 5/6. 4.
Page 38 ATTENTION: avoid the ignition and detection electrodes to contact metallic parts (blast tube, head, etc.), other- wise the boiler operation would be compromised. Check the electrodes position after any intervention on the combustion head. Electrodes position settings E205A Adjusting the electrodes Important Note: Check the ignition and detection electrodes after removing/adjusting the combustion head. E165A...
Page 39 PART IV: MAINTENANCE Reassemble the burner by fllowing the procedure in the reversed order. E205A E165A Checking the detection current with electrode (natural gas) To check the detection signal follow the scheme in the picture below. If the signal is less than the value indicated, check the position of the detection electrode or detector, the electrical contacts and, if necessary, replace the electrode or the detector.
Page 40 PART IV: MAINTENANCE TROUBLESHOOTNG GUIDE Gas operation * No electric power supply * Restore power supply * Main switch open * Close switch * Thermostats open * Check set points and thermostat connections * Bad thermostat set point or broken thermostat * Reset or replace the thermostat * No gas pressure * Restore gas pressure...
Page 41 SIEMENS LME11/21/22 CONTROL BOX START-UP PROGRAM The series of equipment LME.. is used for the starup and supervisione of As far as the startup program, see its time diagram: 1- or 2- stage gas burners. The series LME.. is interchangeable with the Start command (switching on) series LGB..
Page 42 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 Preignition time W / GP Postignition time...
Page 43 LME11 connection diagram Connection diagram Error message (alarm) Fuel valve PC control EK2 Remote lockout reset button RESET 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 44 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- ...
Page 45 FRONTALE QUADRO FRONT CONTROL PANEL...
Page 46 FRONTALE QUADRO FRONT CONTROL PANEL...
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 data subject to change. Errors and omissions excepted.
Page 53 LME73.000Ax + PME73.831AxBC LME73.831AxBC Service instruction manual M12921CB Rel.1.2 02/2016...
Page 54 GENERAL FEATURES LME/ is suitable for gas, light and heavy oil burners LME7 series has two devices: LME73.000 (hardware) and PME73.831AxBC (programmable unit). The LME73.831AxBC is also available: it has a built in software and it isa not programmable. LME7 is inside the control panel. If supplied, PME73.831BC is inside the LME7; The display AZL23..
Page 55 User interface : Button A - Display preset output - In lockout position: Power value to the time of fault Info and Enter button - Reset in the event of fault, changeover visual diagnostic of the cause of fault (refer to chapter Diagnostics of cause of fault ) - button - Display flame signal current 2 or phases display - In lockout position: MMI phase to the time of fault...
Page 56 List of phase display on board LME : Phase number of Function 7-segment display Standby Standby, waiting for heat demand Mains ON / test phase (e.g. detector test) Startup Yellow Safety valve ON, air pressure switch test / POC test (timeout / locking Yellow Fan motor ON / air pressure switch test / settling time Yellow...
Page 57 Operation : The lockout reset button (info button) (EK) is the key operating element for resetting the burner control and for activating / deactivating the diagnostics functions. The multicolor signal lamp (LED) is the key indicating element for visual diagnostics. Both lockout reset button (EK) and signal lamp (LED) are located in the control panel.
Page 58 Program sequence : Version 1: • Ignition load < low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 > 0 seconds)
Page 59 Program sequence : Version 2: • Ignition load > low-fire • Prepurging in high-fire • Parameter 515 = 1 (condition parameter 259.01 = 0 seconds)
Page 60 Phase Function number Lockout phase Standby, waiting for heat demand Operation, modulating operation Interval until release of load controller target (analog or 3-position step input) Under voltage Safety loop open Extraneous light on burner startup (timeout/locking after 30 seconds) Mains ON/test phase (e.g. detector test) Shutdown, actuator opens in CLOSE position (homerun) Safety valve ON, air pressure switch OFF, actuator opens in CLOSE position Part 1: Fan motor ON...
Page 61 Error code table : Red blink code of fault signal lamp (LED) Possible cause 2 x blinks No establishment of flame at the end of the safety time (TSA) - Faulty or soiled flame detector - Faulty or soiled fuel valves - Poor adjustment of burner, no fuel - Faulty ignition equipment 3 x blinks...
Page 62 Flame detection – detection electrode : Short-circuit current Max. AC 1 mA Required detector current Min. DC 2 μA, display approx. 45 % Possible detector current Max. DC 3 μA, display approx. 100 % Permissible length of detector cable (laid separately) 30 m (core-earth 100 pF/m) Measuring circuit Keys...
Page 63 Gas proving system : Valve proving is dependent on input valve proving ON / OFF (X2-02). When a leak is detected, the gas valve proving function ensures that the gas valves will not be opened and that ignition will not be switched on. Lockout will be initiated. Valve proving with separate pressure switch (P LT) Step 1: td4 –...
Page 64 Instruction, control and modify via AZL2x : The AZL2x.. display/programming unit is shown below: The keys functions are the following: Key F + A While pressing the two keys contemporarly, the code message will appear: by entering the proper password it is possible to access the Service mode. Info and Enter keys Used for Info and Service menues Used as Enter key in the setting modes...
Page 65 The display will show these data: Lock+unlock codes Flame Open valves Ignition transformers energised Fan motor energised Oil pre-heater energised Plant heat request Parameter setting mode Info mode Service mode Closing actuator Opening actuator Unit measure While pushing the button together with whatever else button, LME73 locks out; the display shows On stand-by position, appears On operation, all the phases appears with their number.
Page 66 List of phase with display AZL2x : Phase number Function Standby Standby, waiting for heat request Ph08 Power ON / test phase (e.g. detector test) Startup Ph21 Safety valve ON, air pressure switch test / POC test (timeout / locking after 5 seconds), actuator opens in low-fire position / CLOSE position Ph22 Fan motor ON or air pressure switch test / settling time...
Page 67 Error code list with operation via internal AZL : Error code Clear text Possible cause Loc 2 No establishment of flame at the - Faulty or soiled fuel valves end of the safety time (TSA) - Faulty or soiled flame detector - Poor adjustment of burner, no fuel - Faulty ignition equipment Loc 3...
Page 68 Entering the Parameter levels: y means of a proper use of the keys, it is possible to enter the various level parameters, as shown in the following flow chart :...
Page 69 Info level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
Page 70 Service level : Keep pushing the button until appears. Use + or - for scrolling the parameter list. . If on the right side a dash-dot appears, it means the display doesn't show the full description. Push again for 1 to 3 s in order to show the full description. Below the visible Info parameters: Parameter Parameter list...
Page 71 Process data Normalized speed Read only 100% 0.01 % Service Mains voltage Read only LME73.000A1: Service 175 V LME73.000A2: 350 V Flame intensity Read only 100% Service...
Page 72 Parameter level (Heating engeneering) : This level lets the engineer to modify some burner parameters. It is protect with a 4 digit password (SO level) and a 5 digit password (OEM level) Password input : push F and A buttons together until the display shows "code" and 7 underlines. The left one flashes. By move the flashing underline until it is on the desired position and push "enter".
Page 73 Repetition in the event of loss of flame during operation Edit 0 SO 0 = None 1 = None 2 = 1 x Repetition 241.00 Valve proving Edit 1 SO 0 = Off 1 = On 241.01 Valve proving Edit 0 SO 0 = During prepurge time (t1) 1 = During postpurge time (t8)
Page 74 Power setting Analog input (feedback potentiometer ASZxx.3x required) Edit 0 SO 0 = 3-position step input 1 = 0...10 V 2 = 0...135 Ω 3 = 0...20 mA 4 = 4...20 mA with lockout at I <4 mA 5 = 4...20 mA WARNING Parameter Num.
Page 76 Note: Specifications and data subject to change. Errors and omissions excepted.

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