PROCESS BURNERS

INSTALLATION, COMMISSIONING
AND MAINTENANCE MANUAL

The information contained in this manual is advisory and in general terms only and does not
constitute a legal liability on Lanemark Combustion Engineering Ltd.

Lanemark Combustion Engineering Ltd reserves the right to supply equipment to their latest
specification.

FD Mk VI SERIES GAS BURNER SYSTEM J52940

CUSTOMER : PLANET DRYERS LTD

END USER :

BURNERS : FD5GAP Rated 220kW

FD BURNER MANUAL CONTENTS

SECTION DESCRIPTION PAGE

0 Index 1
0 Index 2
0 Burner data plates 3
0 Certificates 4

1 GENERAL DESIGN 1
1 Brief burner specification 2
1 Shipping contents 2
1 Construction standards 2
1 Installation 2
1 General design considerations 3
1 Oven and furnace application 3
1 FDC (GA) General arrangement drawing with dimensions 4

1 FDC (GA) Burner air pressure pipe connections 5

1 Temperature control 6
1 Flue system 6
1 Ventilation systems 6
1 Protection of burner systems 6
1 Electrical supply 7
1 Gas supply general 7
1 Gas supply – natural gas 7
1 Gas supply – propane gas 7
1 Fig 3 Flame length against burner output 8

2 COMBUSTION TUBE DESIGN 1

2 Combustion tube design 2
2 Oven mounting hole 2
2 Fig 1 Design combustion tubes 3

3 CONTROL PANEL DESIGN 1

3 Control panel 2
3 Interface wiring diagram 2
3 Panel internal wiring diagram 2
3 Fig 1 FD “ E “ Control panel 3
Fig 2 FD “ C “ Control panel
3 Electrical interface and control panel internal wiring diagram 5

4 TEMPERATURE AND OTHER CONTROLS DESIGN 1

4 Temperature control 2
4 Wiring / setting / programming temperature controllers 2
4 Temperature sensors 2
4 Wiring / setting / programming other controls 2
4 Data sheets on controls and sensors ( only included if supplied with the Job) 3

5 SPEED CONTROL (INVERTER) MODULATION DESIGN 1

5 Schematic Diagram 2
5 VCV Modulating Valve operation 3
5 Setting Parameters 4
5 Data sheets on dampers and controls 5→

Contents Page 1
FD BURNER MANUAL CONTENTS

SECTION DESCRIPTION PAGE

6 GAS TRAIN DESIGN 1

6 Gas trains 2
6 Wiring gas trains 2
6 Drawings of gas trains 2
6 Setting / adjusting gas valves 2
6 Gas train drawing 3
6 Gas valve data sheets 4

7 INSTALLATION 1
7 Fitting the flame & combustion tube/ fitting the burner/ making the gas connection 2
7 Making the gas connection/high low controls 3
7 Modulating temperature control / over temperature protection/ burner fitting diagram 4
7 FD Burner installation check list 5/6

COMMISSIONING 1
8 Precommissioning control panel / fan / gas 2
8 Dry run of burner 3
8 Commissioning combustion 4
8 Fig 1 Natural gas pressure against output graph 6
Fig 2 Propane gas pressure against output graph
Fig 3 Natural gas pressure against output graph ( for FD5 only below 300,000 Btu/h )
8 Fig 3 Air differential pressure against burner output graph 7
8 Commissioning report form 8

9 MAINTENANCE 1
9 Cleaning and maintenance 2
9 Cleaning burner head / fan gas train / controls 2
9 Fig 1 Burner head and electrodes 3

10 FAULT FINDING 1
10 Fault finding general 2
10 Fault finding temperature control 2
10 Fault finding gas valves 2
10 Fault finding burner programmer 3

11 COMPONENT REPLACEMENT 1
11 Replacing probes / burner head / fan impeller / valve coils / 2
11 Replacing gas valves / burner programmer / transformer / mod.motor / 3 way valve / 3
air pressure switch

12 SPECIAL FEATURES 1
12 Data sheets / instructions ( only included if supplied with a Job) 2

13 RECOMMENDED SPARES 1
13 Recommended spares list ( only included if supplied with a Job) 2

14 HEALTH AND SAFETY 1

14 Health and safety data sheet 2

15 NOTES 1
15 Notes 2

Contents Page 2
FD BURNER MANUAL DATA PLATES

If this manual was sent out with an actual burner ( or several burners built to the same specification ) a
duplicate Burner Data Plate will be shown on this page. This will give the actual burner :-

Serial Numbers
Gas Type ( Natural or Propane )
Electrical and Gas Train Specification
Burner Head Pressure Setting
Fan Motor Supply Voltage Required

Data Plates Page 3

SERIAL NO. J52940 - 1
MODEL FD5GAN SERIAL NO. J52940 - 1
FUEL TYPE NATURAL GAS MODEL FD5GAN
HEAT INPUT 220 kW FUEL TYPE NATURAL GAS
BURNER HEAD PRESSURE 7.3 mbar HEAT INPUT 220 kW
MANUFACTURED 10/19 BURNER HEAD PRESSURE 7.3 mbar
MANUFACTURED 10/19
SUPPLY GAS TEMP 15 °C SUPPLY AIR TEMP. 15 °C
MAXIMUM HEAT INPUT 220 kW MINIMUM HEAT INPUT 9 kW

GROSS CALORFIC VALUE 39.911 MJ/Nm3 NET CALORIFIC VALUE 35.9 MJ/Nm3

MAXIMUM INLET PRESSURE 100 mbar MINIMUM INLET PRESSURE 20 mbar

GAS VALVE TRAIN TYPE KROMSCHRODER VCV1 DRAWING NO. 56905
ELECTRICAL WIRING DIAGRAM NO. 62126 & 62127

CONTROL SUPPLY 110 V 1 PH 50 Hz FLC 3 A

FAN SUPPLY 400 V 3 PH 50 Hz
FAN POWER & FLC 1.10 kW 2.2 A

SERIAL NO. J52940 - 1

MODEL FD5GAN
SUPPLY VOLTAGE 110 V
MANUFACTURED 10/19
SERIAL NO. J52940 - 1
MODEL FD5GAP SERIAL NO. J52940 - 1
FUEL TYPE PROPANE MODEL FD5GAP
HEAT INPUT 220 kW FUEL TYPE PROPANE
BURNER HEAD PRESSURE 10.1 mbar HEAT INPUT 220 kW
MANUFACTURED 10/19 BURNER HEAD PRESSURE 10.1 mbar
MANUFACTURED 10/19
SUPPLY GAS TEMP 15 °C SUPPLY AIR TEMP. 15 °C
MAXIMUM HEAT INPUT 220 kW MINIMUM HEAT INPUT 9 kW

GROSS CALORFIC VALUE 99.102 MJ/Nm3 NET CALORIFIC VALUE 91.2 MJ/Nm3

MAXIMUM INLET PRESSURE 100 mbar MINIMUM INLET PRESSURE 35 mbar

GAS VALVE TRAIN TYPE KROMSCHRODER VCV1 DRAWING NO. 56905
ELECTRICAL WIRING DIAGRAM NO. 62126 & 62127

CONTROL SUPPLY 110 V 1 PH 50 Hz FLC 3 A

FAN SUPPLY 400 V 3 PH 50 Hz
FAN POWER & FLC 1.10 kW 2.2 A

SERIAL NO. J52940 - 1

MODEL FD5GAP
SUPPLY VOLTAGE 110 V
MANUFACTURED 10/19
FD BURNER MANUAL CERTIFICATES

If this manual was sent out with an actual burner a copy of the :-

 Declaration Of Incorporation For Partly Completed Machinery..

 Declaration Of Conformity To Order.
 Test Certificates.
 Calibration Certificates.
 Certificates for equipment supplied by Lanemark Combustion Engineering Ltd but not manufactured by
Lanemark.

will be included after this page if specifically requested by the Customer’s order.

Certificates Page 4
 Declaration of Conformity
QAF 06-34
(In accordance with Machinery Directive 2006/42/EC)

Reference/ Serial No. J52940

Issued by: Lanemark Combustion Engineering Limited

Object of Declaration: FD5GAP Rated 220kW

Customers Name: PLANET DRYERS LTD

Purchase Order/ Reference: SB501

The object of the declaration described above have been inspected and tested in
accordance with the conditions and requirements of the purchase order and unless
otherwise stated conform in all respects to the specifications(s) drawings relevant thereto
and is in conformity with the requirements of the following documents:
2014/30/EC Electromagnetic Compatibility Directive.
ISO 9001: 2015 Quality Management System – Requirements.
BS EN 746-2: 2010 Industrial Thermoprocessing Equipment, Safety requirements for
combustion and fuel handling systems.
2014/35/EC Low Voltage Directive (LVD).
BS EN 60204-1:2006 Safety of Machinery. Electrical equipment of machines General
requirements.

Additional Information: If applicable (i.e. Applicable concessions, Raw materials, Cast

numbers/Test results/Batch numbers.

Signed for and behalf of:

Lanemark Combustion Engineering Limited

Name/function: J. Foster/ Director. Name/function: P. Collier/ Managing Director

Date of Issue: 01/02/2021

Place of Issue: As address below

Registered Address: Lanemark House, Whitacre Road, Nuneaton,

Warwickshire, UK, CV11 6BW
Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166
E-mail: info@lanemark.com Web site: http://www.lanemark.com
Company Registration No. 05471903 VAT No. GB 185 5272 84
Place of Registration: England & Wales
Directors: P.R. Collier, J.S. Foster, A.E. Thompson Reg. No. 567424
 Declaration of Incorporation for Partly Completed Machinery
QAF 06-35
(In accordance with The Machinery Directive 2006/42/EC)

Reference/ Serial No. J52940

Object of Declaration: FD5GAP Rated 220kW

Customers Name: PLANET DRYERS LTD

Purchase Order/ Reference: SB501

LANEMARK COMBUSTION ENGINEERING LIMITED

Hereby declares that the object of declaration identified above is in accordance with the
relevant safety and health requirements of the EC Council Directive on Machinery.
It must be installed and commissioned in accordance with our customer installation and
maintenance instructions.
We further declare that the equipment identified above as the object is intended to be
incorporated into other equipment/machines to constitute machinery.
Our product must not be put into service until the assembled machinery has been
declared in conformity with the provisions of the Machinery Directive 2006/42/EC.

Additional Information: If applicable:

Signed for and behalf of:

Lanemark Combustion Engineering Limited

Name/ function: Managing Director Name/ function: Director

Date of Issue: 01/02/2021

Place of Issue: As address below

Registered Address: Lanemark House, Whitacre Road, Nuneaton,

Warwickshire, UK, CV11 6BW
Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166
E-mail: info@lanemark.com Web site: http://www.lanemark.com
Company Registration No. 05471903 VAT No. GB 185 5272 84
Place of Registration: England & Wales
Directors: P.R. Collier, J.S. Foster, A.E. Thompson Reg. No. 567424
FD BURNER MANUAL SECTION 1 GENERAL DESIGN

SECTION 1 GENERAL DESIGN

Section 1 Page 1
FD BURNER MANUAL
BRIEF BURNER SPECIFICATION
The FD range of burners are forced draught
burners designed for industrial process air heating
requirements.
Short flame lengths, exceptional flame stability and
accurate turndown as low as 9 kW (30,000 Btu/h)
are achieved by the unique Lanemark cone design
combustion head.
Two configurations are available:-
FD ‘C’ where the controls are all mounted inside a
steel control panel.
FD ‘C G-A’ where the controls are all mounted
inside a steel control panel. Including a Variable
Speed Drive for Gas & Air ratio control.
For both configurations the combustion air fan, gas
train and controls are all prefitted and prewired.
The burners can be supplied as on/off, high/low,
high/low/ultra low, modulating gas only or
modulating air and gas to suit the process
requirements.
The controls include the gas burner sequence
controller, on/off switch, differential air pressure
switch, ignition transformer and two off 3-way air
valves. These air valves are fitted so that the burner
can be used on applications where the recirculation
or exhaust fans can run continuously without
interfering with the operation of the air pressure
switch.
The burners can be supplied with 230V or 110V
controls and the combustion fans can have 400V 3
phase or 230V single phase motors. The electrical
protection rating is IP54 which is suitable for most
commercial applications but higher ratings are
available to order.
The burner’s combustion air fan is generally
designed to run continuously when the oven is in
use or alternatively it can it can be energised from
the burner’s controller to run only when the burner is
required to run.
The fan motor electrical supply is made via an
isolator, contactor and motor overload normally
provided by others in the main site motor control
panel. Alternatively Lanemark can supply and fit
these components. A fan motor isolation switch is
fitted inside the burner control panel as standard.
The burner is painted blue and is suitable for
mounting directly onto the side of the oven or for
down firing as required.
Section 1
SECTION 1 GENERAL DESIGN
The gas train inlet position must be specified at the
time of ordering but can be configured to suit most
installations.
If the burner is to run for more than 24 hours
without being switched off then the burner must be
equipped with a control box certified for continuous
running to comply with European combustion
equipment standards.
These burners are generally built to the customers’
specification and may incorporate many variations
and features to suit the particular application. If this
manual was sent out with an actual burner then a
duplicate copy of the burners Data Plates will be
shown in the front of this manual giving the principal
information and the manual will be specific to that
burner project.
SHIPPING CONTENTS
The burner is shipped in a single heavy duty
cardboard box with an infill of expanded foam. The
gas train on larger models may be packed in a
transport only position or supplied loose in the box.
The control pack on larger models may also be
supplied loose in the box.
CONSTRUCTION STANDARDS
The burners are generally constructed in
accordance with:-
 EN676: Automatic Forced Draught Burners
For Gaseous Fuels.
 EN 746 Part 1: Common Safety
Requirements for Industrial
Thermoprocessing Equipment.
 EN 746 Part 2: Safety Requirements for
Combustion and Fuel Handling Systems of
Industrial Thermoprocessing Equipment.
As these burners are intended to be incorporated
into another machine or system they are supplied
with a Declaration of Incorporation For Partly
Completed Machinery as required by the Machinery
Directive 2006/42/EC.
INSTALLATION
It is UK Law that these burners are installed,
commissioned and maintained by competent
persons only e.g. GAS SAFE & ACS registered
installers only. For other countries they must be
installed and commissioned in accordance with
local regulations.
Page 2
FD BURNER MANUAL SECTION 1 GENERAL DESIGN

If the burner is mounted on the outside face of an

GENERAL DESIGN CONSIDERATIONS oven and there is typically 150 mm of internal
insulation then consideration should be given to the
position of the flame as it expands into the
The burner must be installed in accordance with the
combustion chamber through the burner port hole.
following regulations:-
The neck of the burner port should be protected
from flame impingement by fitting a combustion
I.E.E Regulations (BS7671)
tube or similar. See Fig 1 Section 2.
Local Gas Service Area Recommendations
BS5440 Part 1 Specification for Installation of Flues
The length of the flame is contained in this manual
BS2915 Specification for Bursting Discs and
for various outputs and typical combustion chamber
Bursting Disc Devices
minimum diameters are:-
BS5440 Part 2 Specification for Installation of
Ventilation for Gas Appliances
FD5 350 mm. FD10 500 mm.
BS6644 Installation of Gas Fired Boilers between
FD15 600 mm. FD20 750 mm.
60kW and 2MW
British Gas IM/30 Code of Practice for Gas Fired
The burner flame is generally quite stable under
Process Plant
most firing conditions but if the flame is subject to a
British Gas IM/11 Flues for Commercial and
cross flow of air (or combustion products) at or in
Industrial Gas Fired Boilers and Air Heaters
excess of velocities of 6 m/s (20 ft/sec) then a
British Gas IM/12 Use of Gas in High Temperature
combustion tube should be fitted. This tube shields
Plant
and stabilises the flame and can recirculate some of
British Gas IM/18 Use of Gas in Low Temperature
the ovens cooler gas back around the base of the
Plant
combustion tube.
LPGA COP9 LPG Air Plant
LPGA COP17 Purging LPG Vessels and Systems
A drawing of standard length combustion tubes is
IGE/UP/1 Soundness Testing and Purging Of
contained in this manual and they are available as
Industrial and Commercial Gas Installations
an optional accessory from Lanemark Combustion
IGE/UP/4 Commissioning Of Gas Fired Plant on
Engineering Ltd. See Fig 1 Section 2.
Industrial and Commercial Premises
IGE/UP/2 Gas Installation Pipe work, Boosters and
For higher velocities or temperatures the Technical
Compressors on Industrial and Commercial
Department of Lanemark would be pleased to
Premises
advise on the application and special heads and
Health and Safety Executive HS (g) 16 Evaporating
combustion tubes made from high temperature
and Other Ovens
alloys can generally be designed to protect the
DETR Good Practice Guide Selecting and
combustion head and maintain flame stability.
Specifying New Paint Plant and Stoving Ovens
The low fire (also start gas rate) of the burner
For some applications the discharge of flue gas into
cannot exceed 30% of the full high setting to comply
the atmosphere may be controlled and it is the
with standards. The maximum low fire rate is
responsibility of the owner to obtain permission from
restricted to 74 kW (250,000 Btu/h) on all burners
Local or National Government Departments as
and the minimum is typically 15 kW (50,000 Btu/h)
required.
depending on burner type etc. Should a higher low
fire rate be required then a pilot stage / low fire /
high fire burner should be specified.
OVEN AND FURNACE APPLICATION
For down firing applications the burners own
The burners are suitable for firing into ovens, combustion air fan should be wired to run
furnaces and after burners with a pressure of continuously and overrun once the oven has been
between:- switched off, to prevent hot air from back flowing
out of the burner.
- 5.0 mBar
For very contaminated environments inlet air filters
+ 0mBar can be supplied and fitted to the combustion fans
air inlet or adapter flanges so that clean air can be
and process temperatures of up to 500 C. ducted in from outside.
The standard burner flame tube projects 100 mm The oven should be fitted with a suitable Bursting
from the burner mounting flange. Disc or Explosion Relief Panel and if the burner is
being fitted to an existing oven the original
equipment manufacturer should be consulted to
check the suitability of the application.

Section 1 Page 3
 8 7 6 5 4 3 2 1
1. The High and Low air pressure solenoid valves (items 4) are connected electrically to the burner fan connection in the flame safety sequence of the control unit.
2. Under burner 'stand by' conditions the valves (4) are not energised and so the pressure switch (5) vents to atmosphere via the top port of the three way air solenoid valves. The
pressure switch is therefore kept in the 'no air' position even if the burner air fan has been energised from another electrical source.
F F
3. When the burner receives a start signal the sequence can start because the pressure switch proves 'no air' supply.
4. The air solenoid valves (4) are then energised from the control unit and air passes through to the pressure switch that then proves air supply in the correct sequence and the internal
contact is closed.
5. Once the burner is operating correctly, 5
the differential air pressure is monitored by 2
1
the Air Pressure Switch. If the pressure falls FRONT VIEW
below the level set at the commissioning 3
of the burner, the Pressure Switch contact
will break (open) and the Control Unit will go
4 + -
E E
to lockout, closing both the air solenoid valves
ready for the sequence to begin again. 2 1

E
VIEW ON VCV GAS BLOCK 2 1
D D

Psa

Psc

4
C C
12 11 10
Psa shown top right is the connection
for the high air control line.
Psc shown centre bottom is the connection
for the low air control line. 6 PLAN VIEW
4 5

7
PARTS LIST
B ITEM DESCRIPTION B
1 BACKPLATE ASSEMBLY
2 LOW AIR PRESSURE TEST POINT

92005
3 HIGH AIR PRESSURE TEST POINT
4 3 WAY AIR VALVE
5 DIFFERENTIAL AIR PRESSURE SWITCH

DRAWING No:
6 BURNER HEAD
7 LOW AIR PRESSURE SENSING PIPE PROJECTION
DIMENSIONS ARE IN 9 DRAWN BY:
Do Not This is a
8 GAS PRESSURE TEST POINT mm AND DEGREES
AJS 1st angle drawing

L ANEMAR
K
8 Scale Print
9 VCV GAS VALVE ASSEMBLY TOLERANCE AS STATED
OR
7 DATE: TITLE:

10 HIGH AIR PRESSURE Psa CONNECTION 6 COMBUSTION ENGINEERING 20/01/2010 FD GAS/AIR MODULATING BURNER
DRAWING SCALE 5 CHECKED BY: AIR PRESSURE PIPE CONNECTIONS
A 11 LOW AIR PRESSURE Psc CONNECTION WHITACRE ROAD, NUNEATON, WARWICKSHIRE, CV11 6BW
AJL A
12 OUTLET PRESSURE Pd TEST POINT (1:2.5) 4
3 Psa, Psc and Pd were labelled PL, PF and PG respectively 14/02/2017 AJS
Tel: +44 (0)2476 352000 Fax: +44 (0)2476 341166
E-Mail: info@lanemark.com Website: www.lanemark.com
DATE: PROJECT No:

PAPER SIZE 2 STEEL BUNDY REPLACES PLASTIC ON BACKPLATE: EXTRA FITTINGS 02/10/2011 AJS THIS DRAWING IS THE COPYRIGHT OF
14/02/2017
'LANEMARK COMBUSTION ENGINEERING Ltd'
A2 1 FIRST 20/01/2010 AJS ISSUE: DRAWING No: SHEET 1 OF 1
ISSUE DESCRIPTION DATE BY
AND MUST NOT BE COPIED OR RE-ISSUED
WITHOUT PERMISSION.
03 92005
8 7 6 5 4 3 2 1
FD BURNER MANUAL
TEMPERATURE CONTROL
If Lanemark supplied temperature controls with a
burner details of these will be contained in the section
of this manual Temperature Controls. This section
also gives additional detail on specifying, installing
and commissioning these controls.
If this manual was sent out with an actual burner the
specific wiring diagram will be contained in the section
of the manual Control Panels and this will show
electrical interconnections for temperature controls.
The burner can be supplied to operate depending on
the specification ordered as :-
1. On / off at fixed air.
2. Or High / low at fixed air.
3. Or High / low with 2 stage air.
4. Or Modulating gas at fixed air.
5. Or Modulating gas and modulating air.
to suit the application requirements.
It is anticipated that the burner will be run continuously
in low ( start gas ) fire which can be as set as low as
15 kW ( 50,000 Btu/h ) depending on model size.
The maximum low ( pilot ) stage is limited to 30% of
the main flame by European Standards and is
restricted by the pilot gas valve to 74 kW ( 250,000
Btu/h ). For higher values of low fire a start gas stage /
low fire / high fire burner should be specified.
The burner will usually be commissioned such that low
fire is not sufficient to maintain the oven temperature.
Then the main high flame will be brought in
intermittently to maintain the set point or the burner
flame will modulate upwards.
It is anticipated that a digital electronic temperature
controller will be supplied either by Lanemark as an
optional accessory or by the installer.
This controller should have a set point and an
additional alarm stage with fixed differentials for
high/low burners. Modulating burners will require a
suitable controller that can provide the required control
signal. These controllers will typically have full 3 term
P.I.D control and Autotune to suit the characteristics
of the application.
It is unlikely that simple mechanical thermostats will
be suitable for controlling oven temperature because
of the speed of response needed.
It is recommended that consideration be given to
fitting a second totally independent temperature
control device. This may be necessary if it is critical
that the process being heated is never allowed to go
over temperature. This will act as a High Temperature
Trip Thermostat ( Policeman Thermostat ).
Section 1
SECTION 1 GENERAL DESIGN
Once its set point has been exceeded the burner is
held off until manual intervention occurs to reset it.
FLUE SYSTEMS
The oven or furnace must be fitted with a suitable
exhaust discharging the burner’s products of
combustion outside the building in a down draught
free area. If this is not possible the oven/furnace
manufacturer or Lanemark Combustion Engineering
Ltd should be consulted.
For some installations Local and National Government
Departments should be contacted for approval to
discharge flue gas and this is the responsibility of the
owner.
VENTILATION SYSTEMS
The burner should only be installed in a production
area with sufficient natural or mechanical ventilation to
ensure that there is adequate fresh air for complete
combustion and adequate extract to maintain an
acceptable working environment.
The burner should not be installed in an area where
there is a high degree of powered mechanical extract
but only natural ventilation inlet air. With such a
combination the mechanical extract system may
starve the burner of combustion air.
For suggested values for natural and mechanical
ventilation see BS6644.
Where the air supply quality cannot be ensured
consideration should be given to ducting fresh air in
from outside.
PROTECTION OF BURNER SYSTEMS
The burner control panel and the gas train are
manufactured to IP54 with regard to their protection
against water and dust. This standard is sufficient for
most commercial applications.
In food hygiene areas where “ washing down “ takes
place or in areas of excessive condensation the
burner’s controls and gas train must be protected from
the ingress of water or detergent.
If the air is very contaminated with chemicals or dust
then the burner should have its air for combustion
vented in from a source of fresh clean air.
Lanemark can supply equipment to higher IP
standards, equipment manufactured from stainless
steel for food preparation areas and with connections
for fresh air ducts.
Page 6
FD BURNER MANUAL
ELECTRICAL SUPPLY
The burner is available with:-
230V 1 Phase 50 Hz or 110V 1 Phase 50 Hz
controls and gas trains as given on the Burner Data
Plate (a duplicate is shown in the front of this manual).
The single phase 230V or 110V control panel supply
should be made into the control panel through a M20
cable gland from a suitable isolator and fused supply.
The cable should be run in cable of sizes suitable for the
panel load of 250 VA. All cable should be suitable for a
service temperature of 60 degrees centigrade.
THIS BURNER MUST BE EARTHED
The burner’s combustion air fan is built into the burner
assembly. This will be 400V 3 phase or 230V single
phase as specified. The fan motor power and the full
load current will be contained on the Data Plate a copy of
which is in the front of this manual if this manual was
sent out with a burner.
The fan should have an independent isolator, motor
protection device, contactor with an auxiliary contact
provided by others. Alternatively Lanemark would be
pleased to supply this as an optional extra.
The fan can run continuously from the main plant control
panel. The burner must only run when the fan is running
and stop immediately if the fan motors overload trips. An
auxiliary contact on the motor overload should be
interlocked to the burners own control panel. See the
wiring diagram details.
Alternatively the fans motor contactor can be energised
from the burners own control panel as shown in the
wiring diagram.
All electrical installations should be in accordance with
I.E.E Regulations (BS7671).
Output signals are available from the burners control
panel, at 230V AC or 110V AC as appropriate for burner
ON HIGH / ON LOW / AT LOCKOUT.
Time switches and ON/OFF switches should be
connected as shown in the wiring diagram and
temperature controllers as discussed later.
Main motor control panels must never backfeed into the
Lanemark control panel.
Isolating or 110V transformers must be end and not
centre tapped.
Depending on the model the burner control box may
have over/under voltage protection and will not run if the
supply voltage is incorrect.
Remote reset of control box lockout is possible by briefly
applying a 110V or 230V input reset signal or pulling the
reset terminal down to neutral as appropriate for the box
type. See the wiring diagram.
Section 1
SECTION 1 GENERAL DESIGN
This reset cable must NOT pick up any induced voltage
as it can interfere with the box. If there is a possibility of
such voltages screened cable is recommended.
GAS SUPPLY GENERAL
Before the burner is connected to a new or existing gas
supply the Local Gas Supply Service Provider must be
consulted to ensure that the gas meter and supply are of
adequate size for the load required.
The burner gas train includes an isolating ball valve and
union to allow the burner to be isolated and removed for
servicing and a coarse filter.
The pipe work final connections should be made such
that it is possible to isolate the gas supply and remove
the burner for servicing without removing any gas pipe
work. Consideration may be given to making the final
connection in an armoured flexible gas hose that
complies with current standards.
The gas supply pipe work should be designed and
installed in accordance with the standards listed
previously.
GAS SUPPLY NATURAL GAS
A stable gas supply pressure supply of:-
20 mBar ( 8 in.wg) minimum inlet pressure
100 mBar (14 in.wg) maximum inlet pressure
is required with the burner(s) running and if the supply is
a medium pressure supply, or above the maximum
required, an additional gas regulator should be installed.
Lanemark would be pleased to advise on types, sizes
etc.
GAS SUPPLY PROPANE GAS
The burner should be connected to a Propane gas
supply of sufficient capacity so that at the full burner out
put, the gas flow rate of the storage system and its
regulators is not exceeded. This burner should not be
used on Propane/Butane or Propane/Air mixtures. A
stable supply pressure of:-
35 mBar (14 in.wg) minimum inlet pressure
100 mBar (20 in.wg) maximum inlet pressure
is required with the burner(s) running. If the supply is
above the maximum required an additional gas regulator
should be installed. Low and high pressure slam shut cut
offs with vents must be fitted. Care should be taken in
the design and selection to prevent governor lockup or
nuisance trip of these. Lanemark would be pleased to
advise on types, sizes etc.
Page 7
FD BURNER MANUAL SECTION 1 GENERAL DESIGN

Fig 3 GRAPH OF FLAME LENGTH mm AGAINST BURNER OUTPUT Btu/h

Section 1 Page 8
FD BURNER MANUAL SECTION 2 COMBUSTION TUBE DESIGN

SECTION 2 COMBUSTION TUBE DESIGN

Section 2 Page 1
FD BURNER MANUAL
COMBUSTION TUBE DESIGN
The length of the flame is contained in this manual
Section 1 Fig 3 for various outputs and typical
combustion chamber minimum diameters are:-
FD5 350 mm.
FD10 500 mm.
FD15 600 mm.
FD20 750 mm.
The burner flame is generally quite stable under
most firing conditions but if the flame is subject to a
cross flow of air (or combustion products) at or
above velocities of 6 m/s (20 ft/sec) then a
combustion tube should be fitted. This tube shields
and stabilises the flame and can recirculate some
of the ovens cooler gas back around the base of
the combustion tube.
The standard lengths of these tubes are shown on
the drawing but many different lengths have been
used to suit a particular application.
Section 2
SECTION 2 COMBUSTION TUBE DESIGN
A drawing of standard length combustion tubes is
contained in this manual and they are available as
an optional accessory from Lanemark Combustion
Engineering Ltd.
The tube can also be used to protect the oven or
heat exchanger from excessive heat particularly in
the area of the mounting aperture.
These tubes are generally made from commercial
grade stainless steel but for higher temperature
applications high temperature alloy is used.
OVEN MOUNTING APERTURE
The standard oven mounting aperture, see Section
1 Fig 1 and Fig 2, must be enlarged to accept the
standard combustion tube. See the drawing
contained in this manual for details.
Page 2
FD BURNER MANUAL SECTION 2 COMBUSTION TUBE DESIGN

Fig 1 COMBUSTION TUBE DESIGN

Standard Combustion Tubes are manufactured from Stainless Steel, an alternative is available made from
high temperature alloy.

Section 2 Page 3
FD BURNER MANUAL SECTION 3 CONTROL PANEL DESIGN

SECTION 3 CONTROL PANEL DESIGN

Section 3 Page 1
FD BURNER MANUAL SECTION 3 CONTROL PANEL DESIGN

CONTROLS

All control panels are supplied mounted to the

burner within a painted steel enclosure.

If required a control cabinet including motor control,

time switch, temperature control etc. can be
supplied for remote mounting near the burner.
Occasionally burners are supplied with no controls
and these are supplied by others.

The control panels supplied by Lanemark are

generally designed to suit each individual
customer’s requirements with regard to:-

Voltage 110V / 230V

Burner programmer (Satronic/ Siemens/ Honeywell)
Temperature controller
Fan motor control
Interface to gas train
Gas train modulation control

Figure 1 shows the general layout for the FD ‘E’ and

Figure 2 shows the layout for the FD ‘C’ panels
which both contain:-

On / Off / Lockout Reset switch

Control fuse
Din Rail terminals to suit
Burner control programmer
Ignition transformer
3 way air valve
Air pressure switch
Combustion fan isolator switch

And if the application requires it:-

Temperature controller.
Modulating gas valve transformer and interface.
Time switch.
Variable Speed Drive.

PANEL INTERNAL WIRING DIAGRAM

If this manual was despatched with a burner this

manual will contain the correct Internal Wiring
Diagram in this section of the manual.

The correct drawing number is given on each

burner’s Data Plate and a duplicate Data Plate is
stuck in the front of this manual.

Section 3 Page 2
FD BURNER MANUAL SECTION 4 TEMPERATURE & OTHER CONTROLS

SECTION 4
TEMPERATURE AND OTHER CONTROLS DESIGN

Section 4 Page 1
FD BURNER MANUAL
TEMPERATURE CONTROL
The burner can be supplied to operate:-
1. On / off at fixed air.
2. High / low at fixed air.
3. High / low with 2 stage air.
4. Modulating gas at fixed air.
5. Modulating gas and modulating air.
to suit the application requirements.
It is anticipated that the burner will be run continuously
in low (start gas) fire which can be as set as low as 15
kW (approximately 50,000 Btu/h).
The maximum low (pilot) stage is limited to 30% of the
main flame by standards and is restricted by the pilot
gas valve to approximately 75 kW (250,000 Btu/h). For
higher values of low fire a pilot stage / low fire / high fire
burner should be specified.
The burner is normally commissioned with the low fire
(pilot stage) such that it is not sufficient to hold the
process temperature at the Set Point ‘SP’ and the
temperature controller brings the burner back in at high
fire to top up the temperature or modulates the gas
upwards if modulating valves are used. The low fire
(pilot start gas) should not exceed 30% of high fire to
comply with the standards to which the burner is built. If
the process temperature exceeds the Alarm
Temperature ‘AL’ then the alarm stage of the
temperature controller switches the burner from low fire
to off.
A second independent temperature controller may have
been specified at the design stage to act as Policeman
or High Limit Thermostat. Should the process
temperature exceed the Set Point and also the normal
Alarm Point (possibly because the main temperature
controller has failed), then this second thermostat will
switch the burner off and not allow automatic restart.
The temperature controllers for on/off or high/low control
are typically digital electronic controllers that are
programmed for on/off control and the P.I.D and
Autotune facility are disabled. It is unlikely that simple
mechanical thermostats will be suitable for controlling
oven temperature because of the speed of response
needed.
For processes that require accurate temperature control
a modulating gas valve or modulating burner air inlet
damper may be fitted and this will be driven by a:-
1. 0-10 V dc control signal
2. 4-20 mA control signal
3. 3 wire valve positioning signals
Lanemark normally use 24V AC modulating motors on
gas valves and the 24V AC power supply is supplied by
Lanemark if a control panel is supplied.
For 3 wire valve positioning motors (a simple 24V, 110V
or 230V feed is used to open and then to close the
modulating motor) the electronic temperature controller
must have slave relays placed between itself and the
modulating motor.
Section 4
SECTION 4 TEMPERATURE AND OTHER CONTROLS
This is to protect its internal contacts which are
generally rated at a fraction of an Amp and not able to
carry the associated in-rush current.
WIRING OF TEMPERATURE CONTROLLERS
If Lanemark supplied an electronic digital temperature
controller and built it into the control panel the wiring
diagrams contained in this manual will show this
controller.
Generally the only additional field wiring will be to
connect the temperature sensor back to the control
panel. This must be done in suitable cable and
screened.
For simple mechanical thermostats if these were
supplied by Lanemark these will require field wiring back
to the control panel and interconnecting as shown on
the Interface Wiring Diagram.
PROGRAMMING TEMPERATURE CONTROLS
If Lanemark supplied temperature controls with a burner
a Data Sheet will be contained in this section of the
manual detailing how to programme and adjust them.
TEMPERATURE SENSORS
For electronic temperature controllers Lanemark supply
Pt100 (platinum resistance) sensors to suit the controller
with an industrial style housing. The sensor has a
300mm stainless steel stem and a fixing collar with a ½”
BSP male thread.
The oven will require a ½” BSP boss adding to the wall
in a position where the sensor will detect a
representative temperature. This position must be such
that the sensor will not be damaged when work passes
through the oven or be shielded form sensing the heat
by the work pieces.
A data sheet will be included in this section of the
manual if such a sensor was supplied.
OTHER CONTROLS
When specified Lanemark can supply and build
other controls into the control panel to suit the
application. Typical additional controls are:-
1. Time clocks
2. Hours run meters
3. Fan motor controls ( overload / contactor )
This section of the manual will contain Data Sheets
on wiring, setting and programming.
Page 2
FD BURNER MANUAL SECTION 5 MODULATING GAS & AIR

SECTION 5

GAS AND AIR MODULATION.

SETTING THE VARIABLE SPEED DRIVE PARAMETERS ON THE
COMBUSTION AIR FAN.

Section 5 Page 1
 FD BURNER MANUAL SECTION 5 MODULATING GAS & AIR

INTRODUCTION

Lanemark’s standard Gas and Air Modulated Forced Draught burner, features a Kromschroder VCV series
gas valve, and an ABB ACS310 variable speed drive (VSD) to control the speed of the combustion fan motor.
Customers may select to supply a different variable speed drive themselves, in which case this chapter should
be used as a guide only and reference made to the instruction manual for the specific speed drive.

In operation the gas through the Kromschroder VCV gas valve and the speed of the fan motor
will modulate in tandem providing efficient combustion to meet the requirements of the temperature controller
for the system.

SCHEMATIC OF MODULATING AIR & GAS BURNER WITH KROMSCHRODER VCV VALVE

COMBUSTION FAN MOTOR – CONTROLLED BY VARIABLE SPEED DRIVE (VSD)

FAN
IMPELLOR

KROMSCHRODER VCV SERIES GAS/AIR RATIO VALVE

GAS IN

V = TRANSMISSION RATIO N = ZERO OFFSET

Psc = OVEN PRESSURE Psa = FAN AIR PRESSURE

IMPORTANT! THE VALVES MUST NOT BE INSTALLED UPSIDE DOWN

Section 5 MODULATING GAS/AIR VCV P2

FD BURNER MANUAL SECTION 5 MODULATING GAS / AIR

SETTING THE VARIABLE SPEED DRIVE (VSD) PARAMETERS

1. The VSD will usually be supplied with parameters pre set by Lanemark. Those parameters which
have been changed from the suppliers pre set parameters are listed and included in this section
of the manual.

2. Before firing the burner, Parameters 11-04 REF 1 Min and 11-05 REF 1 Max, which relate to the
highest and lowest firing rates of the burner, should be set as follows:

3. Identify the rated output of the burner in kW, this is shown upon the burner rating plate, a copy of
which is in the front of this manual. Refer to the `Air Differential Against Output’ chart included in
this section of the manual. Note the air DP (mbar) from the vertical scale by plotting the heat
release kW (burner output) against the relevant FD burner model.

Example: an FD5 with a rated output of 180kW has an air DP of 2.4 mbar.

The noted figure relates to the maximum output of the burner.

4. Fit a manometer onto the differential pressure test points on the burnerhead 3 & 4, refer to
drawing 92005 `FD Gas/Air Modulating Burner Air Pressure Pipe Connections’ included in this
section of the manual.

5. Using the keypad on the VSD refer to page 4 `ABB ASSISTANT CONTROL PANEL’ ensure it is
in local (LOC) mode (button 7) then scroll up and down on the keypad to show the noted
maximum output figure. Now note the frequency (Hz) from the keypad display.

6. With the manometer attached to test point 11 on the VCV gas valve (see drawing 92005 at the
end of this section) record the suction.

7. Now reconnect the manometer to the test points 3 & 4 on the burnerhead, on the VSD keypad,
scroll down to achieve 1 mbar on the manometer. Note the frequency (Hz) from the keypad
display.
Also record the pressure (mbar) on the gas valve test point 11. (This is the low fire air pressure)
Leaving the manometer in place, turn the VSD to 29.8 (Parameter 12-03) Record the manometer
reading, this is the start gas, air pressure reading.

8. The manometer may be left in position as the normal FD commissioning procedure, as Section 8
of the
manual is carried out.
It is suggested that pre commissioning settings of V = 1 & N = -1.5 are set on the VCV gas valve
(see VCV gas valve illustration page 9)
N.B. The burner will start at 29.8Hz as the keypad is in the local mode.

9. Set the start gas pressure for reliable operation.

10. The burner will run and after approximately 5-10 seconds the main valve will have opened,
indicated by the blue neon light on the VCV valve. Use the VSD keypad to scroll to the maximum
run setting previously noted. Set the maximum gas pressure on the VCV valve using adjuster `V’
Then turn down to the low set point also previously noted using adjuster `N’ as low as possible
while retaining a reliable flame.

11. Turn off the burner, check all the VSD parameters against the sheet provided. Set the parameters
11-04 & 11-05 to your noted figures.

12. These parameters which are in the Key Pad now have to be saved to the panel. Press the `menu’
button and scroll down to PAR BACKUP and select DOWNLOAD FULL SET. As a backup, within
the same sub-menu select UPLOAD TO PANEL, this ensures both the keypad and panel are set
the same.

Section 5 MODULATING GAS/AIR VCV P3

 BURNER MANUAL SECTION 5

ABB ASSISTANT CONTROL PANEL

Section 5 Page 4
FD BURNER MANUAL SECTION 5 MODULATING GAS & AIR

LANEMARK STANDARD
LANEMARK PARAMETERS
STANDARD ABB ACS310
PARAMETERS VARIABLE
ABB ACS310 SPEEDSPEED
VARIABLE DRIVE DRIVE.

Patameter Level 99 – Start-Up Data

Parameter Parameter Name Lanemark Value Unit
01 Language English
02 Applic Macro ABB Standard
05 Motor Nom Volt 400 V
06 Motor Nom Curr (FD5) 0.6 A
06 Motor Nom Curr (FD10) 0.7 A
06 Motor Nom Curr (FD15) 1.1 A
06 Motor Nom Curr (FD20) 1.3 A
07 Motor Nom Freq 50 Hz
08 Motor Nom Speed 2780 rpm
09 Motor Nom Power (FD5) 0.2 kW
09 Motor Nom Power (FD10) 0.3 kW
09 Motor Nom Power (FD15) 0.4 kW
09 Motor Nom Power (FD20) 0.6 kW
Patameter Level 10 - Start/Stop/Dir
Parameter Parameter Name Lanemark Value Unit
01 EXT1 Commands DI1
03 Direction Forward
Patameter Level 11 - Reference Select
Parameter Parameter Name Lanemark Value Unit
01 Key Pad Ref Select REF 1
03 Ref1 Select AI1
04 REF 1 Min 20 Hz
05 REF 1 Max 50 Hz
Patameter Level 12 - Constant Speeds
Parameter Parameter Name Lanemark Value Unit
01 Const. Speed Select DI 2&3 `
02 Const Speed 1 50 Hz
03 Const Speed 2 29.8 Hz
Patameter Level 13 - Analouge Inputs
Parameter Parameter Name Lanemark Value Unit
01 Minimum AI1 20 %
02 Maximum AI1 100 %
Patameter Level 14 – Relay Outputs
Parameter Parameter Name Lanemark Value Unit
01 Relay Output 1 Fault (-1)
Patameter Level 16 – System Controls
Parameter Parameter Name Lanemark Value Unit
01 Run Enable Not Sel
02 Parameter Lock Open
11 Parameter View Long View
Patameter Level 21 – Start Stop
Parameter Parameter Name Lanemark Value Unit
01 Start Function Scan Start
All other parameters are left as the factory default.

Section 5 MODULATING GAS/AIR VCV P5

 Fig 3. FD BURNER – AIR DIFFERENTIAL AGAINST OUTPUT.

Conversions: 1kW = 3,412 Btu/hr 1 m.bar = 0.4 in.w.g.

Section 5 Page 6
FD BURNER MANUAL SECTION 5 MODULATING GAS / AIR

THE VCV MODULATING GAS VALVE

The VCV modulating valve does not have a governor as seen on the VCD on / off or high / low versions of this
valve, or a slow opening adjuster. It does have a maximum throughput adjuster on the first coil called “V max “.

A by-pass valve is fitted around the VCV’s second main valve. The first main valve and the by-pass open for the
start gas rate.

The start gas rate is set by adjusting the Allen Key drive on the top of the VAS bypass valve to give a reliable
starting rate ( clockwise to reduce gas flow ).

Four terms are used: - Psc= furnace pressure and labelled “low pressure” on the burner windbox.
Psa = fan air pressure and labelled “high pressure” on the burner wind box.
V = gas to air ratio control.
N = an offset (zero offset) to correct R at low pressures.

See Page 9 of this section for the position of the N and V adjusters which are adjusted by a 2.5mm Allen key.

The two plastic pipes carry the fan air pressure (Psa) and the furnace (oven) pressure (Psc) to the valve. This is
the differential air pressure across the burner head. The gas pressure will follow the air pressure which is
determined by the Fan Motor Speed. The motor speed is set by the variable speed drive (VSD), which once the
burner has been lit, is being driven by the temperature controller.

The air/fuel ratio mechanism of the valve adjusts the gas pressure to equal the differential air pressure multiplied
by the ratio V.

For example if V = 1.2 and the differential air pressure is:-

Psa = 4.5 mbar and Psc = - 0.5 mbar then the air differential pressure is 4.5 - (- 0.5) = 5 mbar

then the gas pressure will be 5mbar x 1.2 = 6 mbar.

At low air pressures the gas pressure will not follow the air pressure exactly and N is used to add or subtract
some gas pressure (turn N adjuster + or – to add or subtract gas) by correcting the V ratio at low pressures.

These ratios are set as part of the on site commissioning process.

When commissioning FD burners on ovens or heat exchangers where it is possible to measure the products of
combustion the ratio V and the offset N can be used to achieve a CO2 ( carbon dioxide ) of 9 % ( or an
equivalent O2 oxygen of 5 % ) with a negligible carbon monoxide value e.g. 50 ppm. At the lowest outputs when
the valve has modulated down the correction N (zero correction) will help achieve the correct CO2.
At these very low outputs the valve cannot hold the air / gas ratio exactly and it may be that a slightly different
value of CO2 is achieved.

The throughput restrictor on the first valve coil should be adjusted when the burner is firing at its maximum rate
(clockwise to decrease flow) so that it just starts to restrict the gas flow.

The VCV valve must not be mounted in the upside down position.

Section 5 MODULATING GAS/AIR VCV P7

FD BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

SECTION 6 GAS TRAIN DESIGN

Section 6 Page 1
FD BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

GAS TRAINS
WIRING GAS TRAINS

Gas trains are designed by Lanemark to meet the

specific application and customer requirements
e.g.
1. Type and volume of gas
2. Voltage ( 110V or 230V )
3. Class of IP protection required
4. Destination Country
5. Special features e.g. pressure switches
6. Modulating gas valve motor requirement
7. Fine filters for some countries supplies
The gas inlet position must be specified at the
design stage e.g. ‘right hand bottom’ to suit the
application. Once a gas train is built and delivered
to this configuration it must not be modified on site
without consulting Lanemark.
Gas trains are suitable for a maximum inlet
pressure of 100 mbar / 40 in.wg and IP54 unless
specifically ordered to a different specification.
Lanemark will be pleased to advise on special
pressure requirements and supply special pressure
regulators to suit.
The gas trains on models FD5, FD10, and FD15
are normally supplied prefitted to the burner body
and fully prewired.
The gas trains on all FD20 and some special gas
trains for smaller burners are normally supplied
loose for fitting on site as they are too large to be
despatched fitted. A union is used and only has to
be remade to refit the gas train.
The gas train’s gas valves are electrically
connected back to the burners control panel.
Lanemark generally make this wiring connection
and run it in a 3 m flexible PVC conduit. It is
disconnected for transport and has to be remade
on site. The cable cores are tagged and identified
to aid reconnection.
The connections are also shown in the wiring
diagram contained in this manual if the manual was
despatched with a burner.
DRAWINGS OF GAS TRAINS
If this manual was sent out with a burner a copy of
the gas train drawing will be included in this section
of the manual. The gas train drawing number is on
the burner’s Data Plate and a copy of this Data
Plate is stuck in the front of this manual.
SETTING / ADJUSTING GAS VALVES
The gas train drawing will show the type of gas
valves used. Data sheets for the gas valves and
other gas components including modulating motors
will be contained in this section of the manual.
These data sheets will show the basic adjustments
that can be made.

The gas train electrical connections will have been

fully made for testing at Lanemark but will have
been removed for transport. The cable cores are
tagged with the terminal numbers and should be
reconnected with reference to the wiring diagram
contained in this manual if needed.

The maximum low (start gas) stage is limited to

30% of the main flame by standards and is
restricted by the pilot gas valve to approximately 75
kW (250,000 Btu/h). For higher values of low fire a
pilot stage / low fire / high fire burner should be
specified.

The minimum pilot/low fire rate is typically 15 kW

(50,000 Btu/h) depending on the burner model.

Section 6 Page 2
BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

VMV TRIM VALVE.

A Kromschroder VMV Linear Flow Valve is fitted to modulating gas and air valves to provide
additional back pressure on the VAV governor on the VCV1 and 2 gas valve assemblies.

Fitted to the outlet of the VCV gas valve it provides additional back pressure for improved control.

The Kromschroder VMV Linear Flow Gas Valve

Commissioning & Setting.

When despatched from Lanemark, the valve is left in the pre-set position as received from
Kromschroder.

If required, the VMV valve can be adjusted by turning the adjustment scrw on the bottom of the
VMV valve.

It is particularly useful when the required burnerhead pressure is low.

There is not a definitive pressure setting. It is to be determined by the commissioning engineer to

give best control of the gas/air modulation.

Section 6 Additional Page

 BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

KROMSCHRODER VCV VALVE

1” Gas Train General Layout

Main Valve
MV1
VAS125
Main Valve
MV2
VAV1

<<<<<<<<< GAS FLOW

Bypass
Valve S1
VAS1

1 ½” Gas Train General Layout

Main Valve Main Valve Note: All gas trains are supplied with a
M2 M1 Low Gas Pressure Switch as standard.
VAV2 VAS240 DG40 (5-40 mbar)

Bypass <<<<<<< GAS FLOW

Valve
S1
VAS1

Section 6 Kromschroder VCV Gas Valve

BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

KROMSCHRODER VCV VALVE

Valve Adjustment

Technical Specification

VAS Solenoid valve for VAV Constant Pressure Governor

Safe-guarding gas. for modulating burner.

Inlet Pressure PE: 10-500 mbar Inlet Pressure PE: 10-500 mbar
Outlet Pressure PG: 2.5-25 mbar

VAS The markings on the cover cap can be used for coarse adjustment of the flow rate. A 2.5mm Allen key
should be used, 1 turn is equivalent to 0.75mm valve stroke to a maximum of 5 turns.

Pd Psa

Psc

No adjustment on N = Low Fire Adjustment Psa shown top right is the connection
Actuator Cap V = Gas to Air Ratio Setting for the high air control line.
Psc shown centre bottom is the
connection for the low air control line.

Section 6 Kromschroder VCV Gas Valve

 1 2 3 4 5 6 7 8
Parts List
ITEM QTY PART NUMBER DESCRIPTION 2 1
1 1 1256906 GAS VALVE TRAIN ASSEMBLY VCV1 110V 1" - NAT GAS GAS TRAINS TO FINISH FLUSH
A A
2 1 1256907 GAS VALVE TRAIN ASSEMBLY VCV1 110V 1" - PROPANE
3 1 0015127 1" 3 WAY L-PORT
4 2 0021095 1" ST STL EXTENDED NIPPLE 100MM LONG
A1
5 3 0021113 1" M/F UNION ST STL D1
6 2 0021004 1" F/F ST STL ELBOW
7 2 N/A EXTENDED 1" BARREL NIPPLE S/S
8 6 0021145 1" x 8mm FLAMCO CLIP S/S
9 4 0071303 M10 THREADED BAR (PER METRE) (NOT PICTURED) 500mm
10 4 0021087 MUNSON RING BASE (NOT PICTURED) M10 THREADED BAR
11 6 0022026 MALE PUSHOVER FITTING
12 2 0052335 1/8" EQUAL TEE 8 8
B B1 B
E1
12 11 SUPPORT THREAD MINIMUM
PIPE CONNECTIONS
100mm

C1
F1 8 8

C C

500mm
M10 THREADED BAR 8 8

D G1 D
4 150 150 4
SUPPORT THREAD

6 7 5 7 6

M10 THREADED BAR

E TO SUIT GAS TRAIN SIZE E

ENSURE GAS VALVE TRAIN IS SUITABLY SUPPORTED

56905
GAS TRAIN SPLIT INTO SECTIONS FOR TRANSPORTATION

DRAWING No:
SUPPLY MUNSON RING BASES TO BOTTOM OF SUPPORT THREADS
PROJECTION
DIMENSIONS ARE IN 09 DRAWN BY:
Do Not This is a
mm AND DEGREES
LJM 1st angle drawing

L ANEMAR
K
08 Scale Print
TOLERANCE AS STATED
OR
07 DATE: TITLE:

06 COMBUSTION ENGINEERING 03/10/2019 DUAL GAS VALVE TRAIN ASSEMBLY

DRAWING SCALE 05 CHECKED BY: NATURAL GAS VCV1 ASSEMBLY
F 04
WHITACRE ROAD, NUNEATON, WARWICKSHIRE, CV11 6BW
JCF PROPANE VCV1 ASSEMBLY F
1:6 03
Tel: +44 (0)2476 352000 Fax: +44 (0)2476 341166
E-Mail: info@lanemark.com Website: www.lanemark.com
DATE: PROJECT No:
-
PAPER SIZE 02 ADDED PIPE CONNECTIONS VIEW, ADDED SUPPORTS AND ITEMS 22/10/2019 LJM THIS DRAWING IS THE COPYRIGHT OF
04/10/2019
'LANEMARK COMBUSTION ENGINEERING Ltd'
A2 01 FIRST 04/10/2019 LJM ISSUE: DRAWING No: SHEET 1 OF 1
ISSUE DESCRIPTION DATE BY
AND MUST NOT BE COPIED OR RE-ISSUED
WITHOUT PERMISSION.
02 56905
1 2 3 4 5 6 7 8
FD BURNER MANUAL SECTION 7 INSTALLATION

SECTION 7 INSTALLATION

Section 7 Page 1
FD BURNER MANUAL
FITTING THE COMBUSTION TUBE
For high temperature and high velocity applications
a burner combustion tube may have been supplied
as a loose item and this should first be fitted as
shown in Section 7 Fig 1 to the burner’s firing port.
Care should be taken that the annular gap around
this combustion tube does not become blocked
when mounting the burner.
FITTING THE FLAME TUBE
The Flame Tube should be fitted to the oven using
8 off studs fitted to the oven as shown in Section 1
Fig 1 and Section 7 Fig 1. The Flame Tube
mounting gasket should first be fitted to complete a
gas tight seal.
FITTING THE BURNER
The burner should be fitted to the oven using 8 off
studs fitted to the oven as shown in Section 1, Fig 1
and Fig 2. The burner mounting gasket should first
be fitted to complete a gas tight seal.
FITTING THE CONTROL PANEL
The control panel will normally be supplied prefitted
to the burner. For special applications the control
panel may have been designed and supplied loose
for remote mounting close to the burner.
In this case the control panel should be fitted within
2 m of the burner body to a cool dry surface so that
the flexible conduits reach between the two
assemblies.
Section 7
SECTION 7 INSTALLATION
FITTING THE GAS TRAIN
The gas inlet position must be specified at the
design stage e.g. “ right hand bottom “ to suit the
application. Once a gas train is built and delivered
to this configuration it must not be modified on site
without consulting Lanemark.
The gas trains on FD5, FD10, and FD15 are
normally supplied prefitted to the burner body and
fully prewired.
The gas trains on all FD20 and some special gas
trains for smaller burners are normally supplied
loose for fitting on site as they are too large to be
despatched fitted. A union is used and only has to
be remade to refit the gas train.
MAKING THE GAS CONNECTION
The gas connection should be made to the inlet
point on the gas train to the isolating ball valve
supplied.
The pipework final connection should be made in
such a way that it is possible to isolate the gas with
the ball valve provided and then to break the union
and remove the complete burner without removing
any further gas pipework. The weight of the
incoming gas pipework will require independent
support and must not be supported off the burner.
The burner must not be put into operation until the
gas supply has been purged and proved sound as
given under Design previously. The burners gas
train is suitable for an inlet pressure of 100 m.bar
maximum.
If the gas supply system is to be pressure tested the
gas train must be isolated first, as a pressure over
100 mBar will destroy the gas valves.
INSULATING THE OVEN
The burner contains many plastic parts and fittings.
These can be adversely affected by excessive heat
being radiated from hot surfaces and also general
ambient heat.
The burner should be protected from such heat
typically by insulating the oven in the area of the
burner and providing adequate ventilation. Care
should be taken not to obstruct with insulation the
burner fan air inlet which faces towards the oven.
Page 2
FD BURNER MANUAL
MAKING THE ELECTRICAL CONNECTIONS
An external wiring interface and a panel internal
wiring diagram are contained in Section 3 of this
manual.
THIS APPLIANCE MUST BE EARTHED
All wiring should be in accordance with I.E.E.
Regulations ( BS7671 ) and the requirements
contained under Design given previously.
The voltage requirements for each burner vary to
meet the end users specification. If this manual has
been sent out with an actual burner ( or series of
burners built to the same specification ) then a
Burner Data Plate duplicate label will have been
stuck inside the front cover of this manual. This
data plate will give the exact as built electrical
details for a particular burner.
The high tension ignition and flame detection
connections will have been pre-made.
The gas trains on FD5, FD10, and FD15 are
normally supplied pre-fitted to the burner body and
fully pre-wired.
The gas trains on all FD20 and some special gas
trains for smaller burners are normally supplied
loose for fitting on site as they are too large to be
despatched fitted. The gas train electrical
connections will have been fully made for testing at
Lanemark but will have been removed for transport.
The cable cores are tagged with the terminal
numbers and should be reconnected with reference
to the wiring diagram contained in this manual if
needed.
The 230V or 110V 1 Phase supply to the burners
control panel should be made through the 20 mm
cable gland from a suitable isolator and fuse as
given previously under Design. 110V supplies must
be end tapped not from centre tapped transformers.
The 230V 1 Phase or 415V 3 Phase AC 50 Hz
supply to the burner’s combustion air fan motor
should be made from a suitable isolator, motor
protection device and contactor as given under
Design earlier. The supply should be made into the
terminals U – V – W for 3 phase and U – V for 1
phase motors. These are contained in the burner’s
control panel. The actual motor terminal box will
have been prewired back to these terminals by
Lanemark.
Section 7
SECTION 7 INSTALLATION
The supply and motor protection device should be
suitable for the motor’s power and full load current.
These are given on the burner’s Data plate a copy
of which is included in the front of this manual.
The auxiliary contact on the fan motor contactor,
temperature controller and external burner lockout
reset input signal should be connected back to the
burners control panel. The lockout reset cable must
be screened and not allowed to pickup induced
voltage.
Alternatively the motor overload and contactor may
have been supplied, prefitted and prewired
( including the auxiliary contact ) by Lanemark if
specified. These parts are contained in a separate
standalone plastic enclosure. The motor’s supply
should now be made direct into this enclosure.
HIGH / LOW TEMPERATURE CONTROLS
See Section 4. For high / low burners a temperature
controller with a Set Point and an Alarm stage
should be used with a suitable sensor. The internal
contacts of the temperature controller should be
suitable to carry the burners full load of 250VA and
the in-rush current associated with valves opening
and ignition transformers delivering a spark. It is
recommended that interposing relays be used rated
at 5 Amps.
The controller should not switch quicker than 30
seconds as gas valves should not be cycled rapidly.
The temperature controller may however have been
supplied by Lanemark as an optional extra with a
suitable sensor which will require site wiring.
The temperature controller should be wired to the
control panel as shown in the wiring diagram
contained using suitably screened cable for the
sensor as necessary.
Page 3
FD BURNER MANUAL SECTION 7 INSTALLATION

MODULATING TEMPERATURE CONTROL OVER TEMPERATURE PROTECTION

For modulating gas burners the type of control

signal i.e. 0-10 V dc, 4-20 mA or 3 wire direct
control will have been determined at the design
stage.
The modulating control signal should be made into
the appropriate terminals as shown in the wiring
diagram using suitable screened cable. A negative
or 0V return is generally required by the
temperature control instrument. This should be
connected to the 24V AC neutral from the
transformer feeding the modulating motor. This will
complete the circuit.
At the design stage it may have been decided that a
second totally independent temperature controller to
act as a High Temperature Trip Thermostat
( Policeman Thermostat ) is required because of
the nature of the application. Once the overheat
temperature has been exceeded the burner is held
off until manual intervention occurs to reset this
thermostat. This thermostat should be connected
into the burners control circuit in such a way as to
isolate the electrical supply to the burner.

For 3 wire direct control of a modulating valve,

temperature controllers should have internal
contacts suitable for the in-rush current of the
modulating motor. Lanemark recommend that
interposing relays be used that are rated for 10
Amp. Generally Lanemark supply these interposing
relays. The temperature controller should have a
minimum ON and OFF switching time of 0.6
seconds to allow the modulating motor ( which has
a 30 second travel time ) to correctly interpret the
signal and move the gas ball valve accordingly.

Section 7 Page 4
FD BURNER MANUAL SECTION 7 INSTALLATION - CHECKLIST

FD BURNER INSTALLATION CHECKLIST

Before the burner is ready for commissioning the following should be checked to establish that the installation
is complete in accordance with the installation details given in the Manual.

Generally a Mechanical and Electrical Installation Drawing will have been prepared by the customer or his
installer and Lanemark would be pleased to receive copies of these drawings for comment.

The gas supply should be turned off while performing these checks and electrical connections should be made
with reference to the wiring diagram for connection numbers.

ITEM DESCRIPTION
1 The burner and flame tube must be fitted to the oven with their insulating gaskets. If a
combustion tube was also ordered this must be fitted first and a slightly larger mounting hole
will be required if such a tube is to be used.
Sufficient space should be left around the burner for access by the Service Engineer.
Typically 1000mm is required in front of the burner and 300mm to the sides, top and bottom.

2 The burner gas train may have been removed on larger models for packing and transport.
If so the installer must refit the gas train and remake the electrical connections from the
burner control panel to the gas train.
When refitting the gas train it must be replaced so that the gas flows through the gas valves
in the correct direction. There is an arrow engraved into the gas valve body to show the
correct direction of flow. A flying lead in PVC flexible conduit will be provided by Lanemark
and all the cables will have finished tails that are numbered for connection to the Lanemark
wiring diagram.

3 The gas train will have been assembled in accordance with the customers specification with
regard to the orientation of the gas train relative to the burner body.
The gas train should not be modified on site without consulting Lanemark.
4 The gas supply should be made to the burner gas inlet connection.

5 The gas supply system should be proved sound and purged and a Certificate will be required
for a new system to prove this was done.

6 The gas system should be capable of providing the specified volume of Natural Gas or
Propane (LPG) Gas.
The minimum inlet gas pressure to the burner with the burner running is 17.5 m.bar for
Natural Gas and 37.5 m.bar for Propane. The maximum inlet pressure is 100 m.bar for all
fuel gases.

7 The burners own combustion air fan electrical supply ( generally 3 phase 400V 50 Hz )
should be made to the fan motor through a contactor with a suitably sized overload usually
supplied by others via Lanemark electrical terminals U-V-W in the burner control panel.
The contactor should have an auxiliary contact to interlock with the burners own controls to
prove that the fan is running.
Lanemark may have supplied and pre-wired the overload/contactor if specifically ordered in
which case the fan motor supply is made into the contactor box.
Wiring diagrams are available for the overload/contactor arrangement.
N.B. A fan motor isolation switch is fitted in the burner control panel.

Section 7 Page 5
FD BURNER MANUAL SECTION 7 INSTALLATION – CHECKLIST

8 Generally the fans are designed to run continuously from a manual selector switch or similar
or from a main control panel supplied by others.
If the fan is to start only when required by the burner then a start signal should be connected
from the burner to the coil of the fan motor contactor.

9 The fan should be tested, the overload set and the direction of rotation checked.

10 Standard FD fans have a drain hole with a closable plastic plug. In normal conditions this
plug should be closed. For tropical or very humid conditions the plug should be in the open
position and the fan mounted with the drain hole face down.
11 The temperature control sensor(s) and oven door interlocks, oven pressure switches etc.
lug should
should be closed
be fitted and wired up. These should be wired back to their instruments or to the
burner(s) control panel.
12 The fan running interlock should be made from the fan contactor auxiliary contact to the
burners interlock connections.

13 The burners power supply and earth should be made from a local isolator with a suitable
fuse ( or MCB ) for protection. This should be rated for a 250 VA load for 110V or 230V as
specified.
14 Temperature / time switches / on/off controls etc. should be connected and tested.
Any digital instruments should be configured and the correct temperatures and times set.
If the burner is a modulating burner the 3 wire direct valve positioning, 4-20 mA or 0-10 V DC
control signal should be connected to the burner as shown in the wiring diagram and the
instrument tested to ensure the modulating valve responds to the input signal.

15 Any remote burner status signals connections e.g. burner ON, LOCKOUT and REMOTE
RESET should be wired in to the burners control panel and tested.

16 The burner body and gas train in particular contain items made of plastic. The front of the
oven and any hot structures adjacent to the burner must be insulated by the installer to
prevent heat damage to the burner.
17 If the burner is installed in a confined space the combustion air inlet and extract ventilation
systems must be installed and if fans are used they should be tested and interlocked so that
the burner cannot run unless these fans are running.
18 The oven will generally have one or more air inlet dampers and flues which may have
dampers. The oven may have a series of recirculation or air inlet or air extract fans.
It is the responsibility of the installer to commission these and not the Lanemark Service
Engineer. The products of combustion must discharge outside the building. If this is not
possible the oven manufacturer or Lanemark should be consulted.

19 The general area must be made safe for Service Engineers to work in. If burners are
installed on the top of ovens then safe ladders, scaffolding or cat walks must be provided.

20 In the UK the burner must only be put into operation and commissioned by a Service
Engineer who is ACS and GAS SAFE registered for Industrial Gas Burners. In other
countries local gas regulations must be observed.

Section 7 Page 6
FD BURNER MANUAL SECTION 8 COMMISSIONING

SECTION 8 COMMISSIONING

IN THE UK COMMISSIONING OF GAS APPLIANCES CAN ONLY BE CARRIED OUT BY SUITABLY

QUALIFIED TECHNICIANS WHO WILL BE GAS SAFE REGISTERED SPECIFICALLY TO UNDERTAKE
WORK ON INDUSTRIAL GAS BURNERS. IN OTHER COUNTRIES LOCAL REGULATIONS MUST BE
OBSERVED.

Section 8 Page 1
FD BURNER MANUAL
PRECOMMISSONING THE BURNERS
ELECTRICAL CONTROL PANEL
THIS APPLIANCE MUST BE EARTHED
These tests can only be carried out by suitably qualified
electricians.
Carry out the following electrical safety checks using a
multimeter. Do not use a P.A.T (portable appliance
tester) as high voltages generated could damage the
electronics in temperature controllers and the Burner
Controller and give a false reading.
Earth Continuity Check
1. The appliance must be disconnected from the main
supply.
2. Set the multimeter to Ohms x 1 scale and zero if
necessary.
3. Measure the resistance between the earth connection
point in the burner’s junction box and the earth
connection point from the supply panel or distribution
board.
4. If the resistance is greater than 0.1 Ohm then check
that the earth cable size is adequate and that all
connections are clean, sound and correctly made.
Short Circuit Check
1. The burner must be electrically disconnected from
the main supply and the burners own ON/OFF switch
must be ON and any temperature controllers or time
clocks interlinked should be calling.
2. Set the meter to the Ohms scale x 1 and measure the
resistance between the incoming live and neutral
terminals in the burner’s junction box. If the meter reads
zero then there is a direct short circuit and a fault that
should be rectified.
3. Set the meter to Ohms x 100 scale and measure the
resistance between the burner’s earth connection point
and the its incoming live terminal. If the resistance seen
is less than infinity then there is a fault that requires
rectifying.
Section 8
SECTION 8 COMMISSIONING
Polarity Check
Connect the burner control panel to the incoming supply
set the meter to read AC Volts by 300V scale.
If an isolating or step down transformer has been used
the secondary side must be end tapped and not centre
tapped as this can interfere with the operation of the
Burner Controller.
1. Measure the voltage between the incoming live and
neutral terminals in the burner’s junction box and it
should read typically 230V AC or 110V as appropriate.
The Satronic control box has under/over voltage
protection and will not run if the supply is incorrect.
2. Measure the voltage between the incoming neutral
and the earth connection in the burner’s electrical
junction box. The voltage should read less than 15V AC.
3. If these voltages are not seen than a neutral fault or
polarity fault may exist. If very sensitive earth leakage
trips have been fitted to the electrical installation then
some types of multi meter may cause them to trip while
attempting to measure voltages to earth.
Resistance to Earth Check
1. The burner must be electrically disconnected from
the main supply and the burners own ON/OFF switch
must be ON and any temperature controllers or time
clocks interlinked should be calling.
2. Set the meter to Ohms x 100 scale.
3. Measure the resistance between the incoming live
connection and the earth connection in the burner’s
electrical junction box. The reading should be infinity and
if there is any other reading then there is a fault which
should be isolated and rectified.
PRECOMMISSIONING THE BURNERS
ELECTRICAL 1 OR 3 PHASE FAN
1. Generally the connections will be checked in a similar
way as given previously. Look for 230V to neutral on 1
phase and 400V between phases on 3 phase motors.
2. For 3 phase motors use the manual button on the
motor contactor or similar and check the motor is rotating
in the correct direction. If not isolate and reverse two of
the phase connections.
3. For 1 and 3 phase motors set the overload or motor
protection device in accordance with maker’s instructions
and with reference to the fan motor kW rating and full
load current.
N.B. A fan isolator switch is fitted in the burner control
panel. See Fig 1. Section 3, Page 3 of this manual.
Page 2
FD BURNER MANUAL SECTION 8 COMMISSIONING

been made. If the Siemens controller locks out at

PRECOMMISSIONING GAS
The gas pipework system from the gas meter to the
burner should be sound and purged in accordance with
the standards given previously. A Test and Purging
Certificate will be available to show this was completed.
With the gas isolated at the main inlet, main gas train
outlet (and pilot line outlet isolating valve if fitted)
undertake the following checks to prove that the gas train
valves are sound and have not been damaged in transit
LET- BY TEST ON ISOLATING VALVE
1. With reference to the gas train schematic drawing fit a
manometer to the inlet pressure test nipple.
2. Open the main isolating gas cock briefly and then
close it. The gas trapped between the main isolating gas
cock and the first main valve seat should remain at
constant pressure for 2 minutes. If loss of pressure is
seen then the main valves or the pilot bypass gas valve
seats are letting by and it is faulty and must be replaced
as given later under Maintenance. Replace all test
nipples.
phase 22 (orange light) this is because the air
pressure switch is set too high. It is set to maximum
at the factory. Adjust the switch to 1 m.bar, if the
controller again locks out at this stage it is because
the pressure switch or controller has failed to see that
the fan is running. If this happens again investigate
as given later under Fault Finding.
6. The Siemens controller will continue to the ignition
stage where the orange light will start to flash and the
digital display will show phase 38. Here the start (also
low fire) gas valves will open (gas should be ON for
Test run) and the ignition spark will attempt to light
the start flame. At this stage the controller will display
a green light to show that the burner is lit.
If the Siemens Burner Controller has run to green light
then the burner is ready for commissioning. Once the
burner is running the Siemens LME7 digital display will
also show ‘Op1’ in addition to the green light

TEST RUN OF BURNER WITH LME7 SERIES

BURNER CONTROLLER

With the main inlet gas isolating cock turned off and the
burner on/off switch turned off (located on the burners
electrical control panel) complete the following checks:-

1. Ensure that the oven is put into operation with any

recirculating fans or exhaust fans running. The burner
combustion air fan should be available to run and
may have been wired back to the burner to get the
start signal or it may receive a start signal from an
independent main motor control panel.

2. Low inlet gas pressure switches are fitted to the gas

valve train; they require adequate inlet gas pressure
to operate.

3. When power is supplied to the Siemens LME7

controller should start to run. If the controller was left
at Lockout previously the reset button will illuminate
red. Press the reset button on the burner controller or
the lid of the control panel

4. The auxiliary contact from the burner’s combustion air

fan motor starter must be wired into ‘fan contactor
aux contact’ link within the burner control panel,
check this connection or put in a temporary link

5. When power is supplied to the control panel the

‘supply on’ lamp should illuminate (if fitted). When
power is supplied to the Siemens LME7 burner
controller an orange light should be illuminated on the
LED and the digital display should show burner
phase. If the fan contactor has been wired into the
burner control panel the combustion air fan will also
start at this time. The two off 3 way solenoid valves
fitted to the pipes going to the air pressure switch will
also be energised. The pressure switch will now see
the actual fan differential pressure + suction from the
oven and will not be venting to atmosphere as
previous. The controller has 14 seconds to detect
that the fan is running and the air pressure switch has

Section 8 Siemens LME7 Series Burner Controller Page 3

FD BURNER MANUAL SECTION 8 COMMISSIONING

SIEMENS LME7 SERIES OPERATION.

The lockout reset button «EK» is the key operating

element for resetting the burner control and for activating
/ deactivating the diagnostics functions.
LED
▲ Red
● Yellow
□ Green

The multicolor signal lamp (LED) in the lockout reset

button is an indicating element for visual diagnostics and
interface diagnostics. Both «EK» and LED are located
under on the side of the digital display screen.

Operation Status Indication.

Status Colour Code Colour

Waiting time ○........................ Off
Ignition phase ●○●○●○●○●○● Flashing yellow
Operation, flame ok □....................... Green
Operation, flame not ok □○□○□○□○□○ Flashing Green
External light on startup □▲□▲□▲□▲ Green-red
Undervoltage ●▲●▲●▲●▲● Yellow-red
Fault, alarm ▲...................... Red
Error code output ▲○ ▲○ ▲○ ▲○ Flashing red
Interface diagnostics ▲▲▲▲▲▲ Red flicker light

........ Steady on ▲ Red

‫ס‬ Off ● Yellow
□ Green

After lockout, the red fault signal lamp ▲ will remain on.
Diagnostics of the cause of the fault can be seen by
pressing the lockout reset button for more than 3
seconds and referring to the Error Code Table in section
10 of this manual. The error code will also be shown on
the digital display screen of the burner controller with an
actual number to represent the lockout code

Burner controller in standby mode (awaiting

start signal)

Burner in pre purge mode (Phase 21 awaiting air

pressure switch) orange LED also displayed

Burner running mode, green LED also displayed

Burner controller in lockout mode, red LED also

displayed

Section 8 Siemens LME7 Series Burner Controller Page 4

FD BURNER MANUAL
COMMISSIONING COMBUSTION
All burners are fired at works as part of the final
inspection procedure but final settings can only be
set on site to suit the application.
The following settings and checks should be made
after the precommissioning procedure has been
completed.
Note: The air pressure switch is set to maximum
prior to despatch.
If the gas pipework is not completely purged of air
the burner may lock out on the first attempts at
ignition. If lockout occurs the cause can be found by
viewing the burner controller digital display or
interpreting the lockout blink code from the Siemens
controller. The most common faults are air pressure
problem or failure to detect the start gas flame.
(refer to fault finding section 10).
The start gas flame can be adjusted to give a
reliable flame. (The position of the adjuster screw
on the start valve is shown in Section 6). To comply
with European burner standards it must not exceed
30% of the main flame rate.
To set the main flame fit a manometer to the gas
pressure set point on the burner main valve outlet
or head. From the burners Data Plate (or the
graphs in this section) obtain the gas head pressure
required to achieve the required burner output. Set
the main gas pressure through the main gas valve.
(the governor position is shown in Section 6) There
may be a protective cover over the adjuster screw.
Once the gas pressure has been correctly set for
main flame the combustion should be set. On many
ovens and processes it is not possible to measure
combustion but the following figures are typical for
high fire settings if the burner were to be installed
on an indirect heat exchanger or similar.
Natural Gas
Oxygen (O2 ) 6.0 %
Carbon dioxide ( CO2 ) 8.5 %
Carbon monoxide ( CO ) 100ppm (maximum )
Propane Gas
Oxygen ( O2 ) 6.5 %
Carbon dioxide ( CO2 ) 9.5 %
Carbon monoxide ( CO ) 100ppm (maximum )
The flue gas temperature when the system is up to
its operating temperature will depend entirely on the
characteristics of the system.
The combustion air is set by adjusting the position
of the combustion air damper blade. This is
Section 8 Siemens LME7 Series Burner Controller
SECTION 8 COMMISSIONING
normally set to fully open for most applications. If
the burner however is not being used to deliver its
full potential output there could be too much air if
the damper is set fully open. Figure 3 is a graph of
differential air pressure against burner output. It can
be used as an approximate guide to setting the
damper for other settings other than full open.
The fan fixing nuts have to be slackened off to
move the air damper blade and must always be
retightened afterwards. Once set the start gas and
main flame gas pressures should be rechecked as
the damper can have a slight influence on the gas
pressure.
SETTING THE AIR PRESSURE SWITCH
The air pressure switch should be set when the
burner is in high fire with the combustion air fan and
any other fans fitted to the oven running. And with
the air damper set.
The pressure switch should be set to typically 70%
of the measured air pressure or 1 m.bar less than
the measured air pressure. If the pressure switch is
set too close to the measured pressure then there
is a possibility that a nuisance lockout could occur.
If the pressure switch is set too low then there is the
possibility that the pressure switch would not switch
the burner off if there was a problem e.g. a partially
blocked flue.
The pressure switch should never be set to
minimum because it can stick. An air pressure
switch must never be set too low to sacrifice
safety for reliability.
1. Fit a differential manometer to the two air
pressure test points on the burner’s back plate.
2. With the burner running to the air prepurge
stage the pressure switch should be turned up
to test that the air pressure switch prevents the
burner from firing and that it locks out. If the
pressure switch cannot be turned up high
enough to cause a lockout, then hold a piece
of paper or similar over the burner’s fan air
inlet to mimic loss of air.
3. With the burner running turn off the main gas
isolating cock and check that the burner locks
out due to loss of flame signal.
4. Note: If a Low Gas Pressure Switch is fitted
and there is insufficient gas pressure to make
the switch the burner will turn off, but will not
lock out.
5. To test that the burner will lock out due to loss
of flame signal remove the plug cap from the
flame probe and run the burner until it locks
out.
6. With the burner running in main flame the inlet
gas pressure should checked to ensure it is
within specification :-
Page 5
FD BURNER MANUAL SECTION 8 COMMISSIONING

Natural Gas called to start more than 6 times an hour and

100 m.bar ( 40 in.wg ) maximum
20 m.bar ( 7.0 in.wg ) minimum and typical
Propane Gas
100 m.bar ( 40 in.wg ) maximum
35 m.bar ( 14 in.wg ) minimum and typical
should not switch from high flame to pilot / low
flame more than 60 times an hour.
Check that there is adequate ventilation for safe
combustion as given under design considerations
previously.
The owner/operator of the burner system should be
instructed in the basic operation of the burner and
its controls.

If the inlet pressure is above the maximum an
additional regulator must be fitted. If the inlet
pressure is below the minimum then the local Gas
Supply Authority should be contacted to establish
the cause. If the inlet pressure is unstable ( the
pressure may fall at times of peak demand ) then
as the burner has been commissioned relative to
the standard inlet pressures problems may well
occur during periods of low pressure.
On Propane systems overpressure cut out with
vents and under pressure cut out devices must be
fitted. The settings of these should be checked for
suitability and recorded.
FINALLY replace all pressure test points and
complete a commissioning form similar to the
sample contained in this manual.
IMPORTANT: IF FOR ANY REASON THE
COMMISSIONING HAS NOT BEEN FULLY
COMPLETED OR IF THERE IS A PROBLEM
WITH THE GAS SUPPLY , FLUE, VENTILATION
OR SAFETY CONTROLS THEN THE SYSTEM
SHOULD NOT BE LEFT CAPABLE OF BEING
RUN. THE OWNER / OPERATOR OF THE
BURNER SYSTEM SHOULD BE MADE AWARE
BEFORE LEAVING SITE.

Setting Gas Pressure Switches

If low inlet and high outlet gas pressure switches

have been fitted these should be set and their
operation checked.
A low inlet gas pressure switch will be set to 5
m.bar below the minimum inlet pressure specified
above. A high outlet gas pressure switch should
typically be set to 3 m.bar above the normal high
fire gas pressure.

The slow opening adjuster on the main gas valve ( if

fitted ) may need adjusting to slow the opening
down or a pressure pulse may occur on normal
opening and trip the pressure switch.

Modulating Motors On Gas Ball Valves

Modulating Motors On Gas Ball Valves

If a modulating motor is fitted to a ball valve the

motor end stop must be set so that when it is at its
fullest closed position, there is still sufficient gas
flow, to light reliably and sustain a stable flame. The
temperature controller should be set and the correct
response of the modulating motor to the control
signal should be checked. See the Data Sheet on
the motor that will be contained in this manual.

Final Checks

Check the operation of any mechanical or electronic

temperature controllers. Record the set points and
for electronic temperature controllers record the set-
up parameters. Generally the burner should not be

Section 8 Siemens LME7 Burner Controller Page 6

 AUTHOR: KA
CLIENT: LANEMARK JOB NO.: J36710
PO NO.: LANEMARK DRG. NO.: 98043
PROJECT NUMBER: DATE: 27/05/2015
MR NO.: REVISION: 1
CLIENT DOC. CODE:

Combustion Air Performace Curves - FD5 MK6

Natural Gas Heat Input vs. Combustion Air Differential Pressure

3.5

FD5
3.0
Combustion Air Differential Pressure (mbar.g)

2.5

2.0

1.5

1.0

0.5

0.0
0 50 100 150 200 250
220 kW
DESIGN

Natural Gas Heat Input (kW)

Author Aidan Lewis
Date 03.02.2016
Drawing Number 98054
Revision Number 1

Propane Gas FD5 Burner:

Heat Input vs Burner Head Pressure
35.00

30.00

25.00
Burner Head Pressure (mbar)

20.00

15.00 FD5

10.00

5.00

0.00
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230
Heat Input (kW)
SECTION 8: FD BURNER COMMISSIONING REPORT FORM

CUSTOMER NAME: …………………………………………………………………………………………………

SITE ADDRESS: ……………………………………………………………………………………………………….

BURNER MODEL: ……………………SERIAL No: ……………………… GAS TYPE: ……………………….

CONTROL PANEL VOLTAGE:……………V GAS TRAIN TYPE: …………………………….………………..
BURNER MOTOR POWER …………….kW VOLTAGE:……………V RUN CURRENT:………….Amp
( The above can be found on the burner data plate stuck to the burner body and also a duplicate may be stuck in the inside cover of this manual )

PRECOMMISSIONING CHECKS:

1 BURNER EARTHED:………………………………………………………………………………………….. Y / N
2 BURNER CONTROL PANEL ELECTRICAL INSTALLATION CHECKED:…..……………………….. Y / N
3 BURNER FAN MOTOR ELECTRICAL INSTALLATION CHECKED:…………………………………… Y / N
4 FAN MOTOR OVERLOAD SET ( COLD ) TO: ………………………………………………………………Amp
5 GAS INSTALLATION SOUNDNESS TESTED AND PURGED:…………………………………………. Y / N
6 BURNER GAS TRAIN SOUNDNESS TESTED:…………………………………………………………… Y / N
7 BURNER DRY RUN COMPLETED:…………………………………………………………………………. Y / N

COMMISSIONING CHECKS

1 AIR INLET DAMPER SETTING % OPEN

2 AIR PRESSURE SWITCH SETTING mBar

PILOT / LOW FIRE SETTINGS

1 BURNER HEAD PRESSURE mBar

2 COMBUSTION CHAMBER PRESSURE mBar
3 WIND BOX DIFFERENTIAL AIR PRESSURE mBar
4 FLAME SIGNAL STRENGTH
5 OXYGEN %O2
6 CARBON DIOXIDE %CO2
7 CARBON MONOXIDE %CO
8 NET FLUE GAS TEMPERATURE °C
9 PROCESS TEMPERATURE °C
10 GAS FLOW RATE m3/h

HIGH FIRE SETTINGS

1 BURNER HEAD PRESSURE mBar

2 COMBUSTION CHAMBER PRESSURE mBar
3 WIND BOX DIFFERENTIAL AIR PRESSURE mBar
4 FLAME SIGNAL ( neons on or microamps )
5 OXYGEN %O2
6 CARBON DIOXIDE %CO2
7 CARBON MONOXIDE %CO
8 NET FLUE GAS TEMPERATURE °C
9 PROCESS TEMPERATURE °C
10 GAS FLOW RATE m3/h
( It m ay not be pr ac tic al to tak e s om e of the above r eadings depending on the applic ation)

NOTES:

SIGNED: FOR: DATE:

Section 8 Page 9
FD BURNER MANUAL SECTION 9 MAINTENANCE

SECTION 9 MAINTENANCE

Section 9 Page 1
FD BURNER MANUAL
CLEANING AND MAINTENANCE
A BURNER IN THE UK MUST ALWAYS BE
COMMISSIONED BY A SUITABLY QUALIFIED
TECHNICIAN WHO HAS BEEN SPECIFICALLY GAS
SAFE & ACS REGISTERED TO DO THIS WORK. IN
OTHER COUNTRIES LOCAL REGULATIONS MUST BE
COMPLIED WITH.
Maintenance should be carried at intervals depending on
the hours run and the application of the burner. For
burners running continuously this could be up to four times
a year but never less than once a year.
CLEANING THE BURNER HEAD ASSEMBLY
1. Isolate the gas supply at the service gas cock provided
as part of the gas train. Isolate all electrical supplies to the
burner. Isolate and make safe all other fuel and electrical
supplies to the oven. Isolate the burner combustion air fan
using the isolation switch upon the terminal rail inside the
burner control panel,(see Fig 1 section 3 of this manual).
2. Remove the ignition and flame detection connections
from their probes that are part of the burner back plate.
3. Break the gas union to the burner gas train. Remove
the 8 bolts holding the burner body back plate to the
burner body.
4. It should now be possible to remove the burner head
assembly and the burner back plate with the gas train
attached.
5. If the burner is left unattended at this stage the
incoming gas pipe must be capped off. It must not be left
isolated on the gas cock alone.
6. The burner head will typically have a light covering of
dust on the cone and associated pipework. This should be
removed with a lint free rag or a soft brush and vacuumed
up if necessary. This dust should be treated with care. A
disposable mask and safety goggles should be worn to
prevent the possibility of inhaling this dust or getting any
dust in the eyes.
7. The burner electrodes should be checked for their
serviceability and generally they will be replaced yearly.
8. The electrodes should be set as shown in Fig 1.
9. Visually inspect the flame tube and combustion tube, if
fitted for heat damage.
10. Replacement of the burner head assembly is the
reverse of the above.
11. After each service visit the integrity of the gas safety
valves and the soundness of any gas pipework disturbed
must be shown to be safe, as given previously under
Precommissioning Gas. The burner settings must be
checked as given previously under Commissioning and a
written record made.
CLEANING THE FAN IMPELLER
Section 9
SECTION 9 MAINTENANCE
1. Isolate the gas supply at the service gas cock provided
as part of the gas train. Isolate the burner combustion air
fan using the isolation switch located on the terminal rail in
the burner control panel. Isolate all electrical supplies to
the burner. Isolate and make safe all other fuel and
electrical supplies to the oven.
2. If the electrical connection to the fan motor junction box
has been run in flexible conduit it may be possible to
remove the impeller and motor assembly without
disconnecting this. The electrical supply must be isolated.
If this electrical supply has been made through fixed
conduit then it will require disassembling once the supply
has been isolated.
3. Release the four screws that hold the fan impeller
mounting plate to the body of the fan scroll. Lift the
impeller assembly away from the fan scroll and with a lint
free rag or soft brush remove any dust or debris. This dust
should be treated with care. A disposable mask and safety
goggles should be worn to prevent the possibility of
inhaling this dust or getting any dust in the eyes.
4. The weight of the fan impeller and motor assembly
must not be supported on the flexible electrical conduit.
5. Replace the fan impeller assembly as the reverse of
the above.
6. If any electrical connections have been disturbed they
must be checked for correct reassembly as given
previously under Precommissioning Electrical.
GAS TRAIN AND CONTROLS
The following checks should be made annually.
1. The operation and soundness of the isolating gas
cocks on the gas train should be checked. This should be
done by pressure testing up to the seal of these ball valves
and establishing that there is no loss of pressure in a
similar way to that used for testing the main gas valve
seats.
2. The gas soundness of the gas train gas valves and
associated pipe work should be checked as given
previously under Precommissioning Gas.
3. The setting of the air pressure switch and the lockout
function of the Satronic control box to an incorrectly set
pressure switch and lack of pilot stage gas should be
rechecked. This should be done as given previously under
Commissioning Dry Run.
4. The gas train and control panel should be visually
inspected to look for obvious signs of damage or
deterioration.
COMBUSTION FAN FILTERS
1. A combustion air fan filter is available as an option
upon most FD burners. If fitted, ensure the fan is isolated,
slide the filter out from the housing and inspect. Replace
with new as required.
Page 2
FD BURNER MANUAL SECTION 9 MAINTENANCE

Fig 1 FD BURNER HEAD AND ELECTRODES

FD5 = 20mm
FD10=25mm
FD15 = 25mm
FD20 = 25mm

All Burners 50mm

Section 9 Page 3
FD BURNER MANUAL SECTION 10 FAULT FINDING

SECTION 10 FAULT FINDING

Section 10 Page 1
FD BURNER MANUAL
FAULT FINDING GENERAL - SIEMENS LME7 SERIES BURNER CONTROLLER
SYMPTOM
Burner’s Siemens controller at lockout
or not attempting to start.
Process temperature rising above the
required temperature.
Process temperature fails to reach the
required temperature.
Evidence of poor combustion
conditions e.g. sooting or smells.
FAULT FINDING TEMPERATURE CONTROLLERS
SYMPTOM
Burner runs to ignition and the
temperature controller switches the
burner off and it attempts to cycle
again.
FAULT FINDING GAS VALVES
SYMPTOM
st
1 valve or governor will not open.
nd
2 main valve not opening.
No pilot/start gas.
Section 10 SIEMENS LME7 Series Burner Controller
FAULT
Burner fault or safety interlocks
holding the burner off.
The supply voltage is above/below the
nominal supply voltage value (110 or
240V) and the Siemens controller will
not operate.
The remote burner lockout reset has
been continuously switched on.
Burner fan isolator switch is off.
Thermostat is set incorrectly.
Thermostat is not sensing a
representative process temperature.
Thermostat is not switching down to
low fire or modulating downwards.
Low fire is set too high.
Thermostat is set incorrectly.
Thermostat is holding burner in low
fire or not modulating upwards.
The burner performance has not been
matched to the process requirement.
The process conditions have been
changed since commissioning.
High fire coil has failed.
Original commissioning settings have
been altered.
Do not use equipment
FAULT
The ignition spark is interfering with
the electronics of the temperature
controller.
FAULT
High pressure gas trapped between
st nd
1 and 2 main valve seats and
st
locking up 1 valve.
The throughput restrictor has been
fully or almost fully closed. The slow
opening adjuster is set to the slowest
opening.
Coil failed.
The adjuster on the pilot / start gas
valve closed or nearly fully closed.
Pilot valve coil failed.
SECTION 10 FAULT FINDING
ACTION
Refer to the later section specifically
on burner control faults.
Correct the supply voltage.
Release the reset switch.
Check switch in burner panel is on.
Reset thermostat.
Check the actual temperature in the
area of the sensor.
Check the wiring and settings of
electronic controls and replace if
necessary.
Reduce low fire
Reset thermostat.
Check the wiring and settings of
electronic controls and replace if
necessary.
Recommission the burner.
Recommission the burner.
Replace coil.
Recommission the burner.
ACTION
Check that the ignition spark plug cap
is an original part or replacement and
suppressed with a 5 kilo ohm resistor.
ACTION
Remove test point between seats.
st
Tap valve to release 1 valve seat.
Open up by-pass valve to allow more
gas to flow.
Open up the through put restrictor and
increase the speed of lift of the slow
opening adjuster.
Replace coil.
Use the adjuster to increase the
pilot/start gas flow.
Replace coil.
Page 2
FD BURNER MANUAL SECTION 10 FAULT FINDING

FAULT FINDING BURNER CONTROLS SIEMENS LME7 BURNER CONTROLLER

The burner faults can be diagnosed by looking at the flashes on the Siemens LME7 Series Controller.

SYMPTOM FAULT ACTION

No lights on the burner controller
even when the reset button is
pressed
No power supply to the controller.
Check terminal 5 on the LME7
burner controller plug X3-04 is at
the same voltage as the inlet
supply voltage and that terminal
4 on the LME7 burner controller
plug X4-03 is a neutral.
If correct voltage is present,
replace the burner controller

Burner at Ph02 / green/red LED
flashing, burner in standby
Siemens Controller is seeing a
flame signal.
Fault on remote reset.
Controller is faulty.
Look for flame being present due
to the gas valves having failed to
close.
Check that terminal 3 on LME7
plug X2-03 is not being held at
permanent neutral which initiates
remote reset of the controller.

Faulty controller. Replace controller.

After lockout the red fault signal lamp LED within the reset button will be illuminated as will the LME7 burner
controller LED, the LME7 burner controllers digital display will also show a lockout/error diagnostics code,
Holding the reset button on the burner controller for 3 seconds will also display a flashing error code on the
burner controllers LED.

Section 10 SIEMENS LME7 Series Burner Controller Page 3

FD BURNER MANUAL
Power to the burner controller
No LED light
LME7 Burner Controller digital
display shows OFF (standby
mode).
Burner starts but locks out after
the orange light has been on for
30 seconds.
LME7 Burner Controller digital
display shows phase 21.
Burner starts but locks out after
the orange light has been on for
14 seconds.
LME7 Burner Controller digital
display shows phase 22
(fan on, air pressure switch test).
Lockout after the orange light /
phase 38 (pre purge) and when
the light is green (burner in
operation). OP1
Pilot flame established but lockout
after orange flashing light /phase
st
38/40 pre ignition and 1 safety
time.
Section 10 SIEMENS LME7
SECTION 10 FAULT FINDING
Control circuit not complete.
Air pressure switch is in the
normally open position i.e. it is
sensing air when an air flow signal
should not be present.
The air pressure switch has not
detected that the burner fan is
running and moved across to the
normally open position within 14
seconds.
Air pressure switch has returned
to the normally closed position.
Failure to detect the start gas
flame.
Check for continuity between the
terminals in the on/off control loop
between LME7 plug X5-03. 1-4
Check that any interlocks fitted in
this circuit are made.
Check the wiring to the air
pressure switch and establish if
the air pressure switch has stuck
in the normally open position
(n/o), if so replace the switch.
If the oven has its own fan the
draught from this fan may be
holding the air pressure switch at
normally open. There are 2 3 way
air valves fitted into the 2 air
sensing pipes, these should be
venting the air pressure switch to
atmosphere. Check that these 3
way valves are not fitted in the
wrong direction or have stuck in
the wrong position. Check that the
pipes are not blocked
Check that the process fan motor
is running and the contact has
made across terminals from the
normally open position of the air
pressure switch, to LME7 plug X3-
02 terminal 1
Check that the 2 3-way air valves
are being energised and not
venting the air pressure being
created to atmosphere.
Check that the air pressure switch
contacts are switching. Use a
manometer to measure the actual
differential air pressure being
created and compare this to the
pressure switch setting.
Check with a manometer the air
pressure being seen and the
operation of the switch. Check the
3 way air valves are not venting
the pressure being generated.
Check the ionisation current. It
should be a minimum of 1
microamps dc for a flame rod or
70 microamps for a U.V cell.
Check the position of the
detection probe and the
connections to it.
Check if the pilot flame is too
weak or being over aired.
If UV cell, clean the sight glass.
Replace burner controller or U.V
cell.
Page 4
FD BURNER MANUAL
Pilot flame NOT established
lockout at phase 42 safety time
(IGN off / flame check).
Lockout after green light. Phase
44 and 50.
Section 10 SIEMENS LME7
SECTION 10 FAULT FINDING
Failure to provide gas and or air.
Failure to provide an ignition spark.
Unstable pilot flame.
Weak flame signal.
Unstable main flame as main
valves open.
Weak main flame signal.
Check that the gas supply is on
and that the start gas valve is
opening and that gas pressure is
reaching the burner head.
Check that the pilot stage is not
being over aired or under gassed
and producing a mixture that will
not light.
Check the ignition probe spark
gap. Check that the probe is not
earthing and the connections are
OK. Check that the ignition
transformer is being energised via
plug X4-02 terminal 3.
Check the flame signal strength
and check for a reduction in
signal. Adjust the start gas rate or
the air damper as appropriate.
Check the position of the flame
sensing probe and the
connections.
Put a manometer on the burner
head test point. Check that the
gas pressure increased
progressively. If pressure
increases rapidly. Check the
setting and operation of the inlet
gas governor.
Check that the flame detection
probe is positioned as given in this
manual.
Page 5
FD BURNER MANUAL SECTION 10 FAULT FINDING

FAULT FINDING BURNER CONTROLS SIEMENS LME7 PROGRAMMER

The burner faults can be diagnosed by looking at the indicator light on the control box.

Section 10 SIEMENS LME7 Page 6

FD BURNER MANUAL SECTION 10 FAULT FINDING

FAULT FINDING BURNER CONTROLS SIEMENS LME7 PROGRAMMER

The burner faults can be diagnosed by looking at the digital display on the control box. The burner controller
lockout codes for PME840 are as follows:

Section 10 SIEMENS LME7 Page 7

FD BURNER MANUAL SECTION 10 FAULT FINDING

FAULT FINDING BURNER CONTROLS SIEMENS LME7 PROGRAMMER

To display the flame current when on either ION or UV QRA

This display is possible in standby mode or operating mode by pressing the + button on the LME7 see below:

This will then display the flame signal current as a percentage: see flame sense percentage reference chart
below:

Flame sense signal can also be viewed on the AZL Display units by pressing down the ‘reset’ button twice to
get to ‘service level’ once here scroll to parameter 954 ‘flame intensity’ this will then appear as a percentage

Section 10 SIEMENS LME7 Page 8

FD BURNER MANUAL SECTION 10 FAULT FINDING

FAULT FINDING BURNER CONTROLS SIEMENS LME7 PROGRAMMER

The burner phase is displayed on the digital display of the burner controller. The burner controller phase list
(state the burner controller is in) is displayed below

Section 10 SIEMENS LME7 Page 9

FD BURNER MANUAL SECTION 10 FAULT FINDING

FAULT FINDING BURNER CONTROLS SIEMENS LME7 PROGRAMMER

Input and output connection diagram for LME7 PME840

Section 10 SIEMENS LME7 Page 10

FD BURNER MANUAL SECTION 11 COMPONENT REPLACEMENT

SECTION 11 COMPONENT REPLACEMENT

Section 11 Page 1
FD BURNER MANUAL SECTION 11 COMPONENT REPLACEMENT

COMPONENT REPLACEMENT 4. Replace the fan assembly as the reverse of the

COMPONENT REPLACEMENT IN THE UK CAN ONLY
BE CARRIED OUT BY SUITABLY QUALIFIED
TECHNICIANS WHO HAVE BEEN GAS SAFE & ACS
REGISTERED TO DO THIS WORK. IN OTHER
COUNTRIES LOCAL REGULATIONS MUST BE
COMPLIED WITH.
ONLY ORIGINAL EQUIPMENT SPARES SUPPLIED BY
LANEMARK INTERNATIONAL SHOULD BE FITTED
TO THESE BURNERS TO ENSURE THE SAFE AND
CORRECT OPERATION OF THE BURNER.
above using a new gasket if necessary.
5. The electrical connections must be checked for
correct reassembly as given previously under
Precommissioning Electrical.
6. After such work the integrity of the gas safety valves
and the soundness of any gas pipework disturbed must
be shown to be safe, as given previously under
Precommissioning Gas. The burner settings must be
checked as given previously under Commissioning and a
written record made.

ISOLATE THE GAS SUPPLY AT THE SERVICE GAS
COCK PROVIDED AS PART OF THE GAS TRAIN.
ISOLATE ALL ELECTRICAL SUPPLIES TO THE
BURNER.
CONTROLS
The controls are mounted inside the control panel which
will require opening first.
IGNITION AND FLAME DETECTION PROBES
1. To replace the ignition and flame detection probe set
follow the instructions as given previously in this manual
under Maintenance – cleaning the burner head
assembly. It should be possible to release the fixing
screw and remove and inspect an electrode without
removing the burner head assembly. See the drawing
under Maintenance for the correct electrode setting.
BURNER HEAD ASSEMBLY
GAS VALVE COILS
Warning - Solenoid coils run hot in operation,
allow sufficient time to cool before removal.
1. Remove the electrical connections to the gas valve
by removing the push on plug caps or the connections to
the valve terminal blocks. Make a note of the position of
the connections to aid replacement later.
2. Remove the coil from the body of the gas valve by
releasing the fixing nut or retaining clip on the top of the
gas valve. This fixing may be located under a plastic
cover.
3. Fit a new coil as the reverse of the above. Ensure
that the replacement is the same voltage as that
removed.
4. After such work the integrity of the gas safety valves
and the soundness of any gas pipework disturbed must
be shown to be safe, as given previously under
Precommissioning Gas. The burner settings must be
checked as given previously under Commissioning and a
written record made.

1. To replace the burner head follow the instructions as

given previously in this manual under Maintenance –
cleaning the burner head assembly.

FAN IMPELLER AND MOTOR

1. The fan impeller and motor are available as individual

spares. They are not balanced and may be replaced as
individual items. Similarly an assembled spare motor,
backplate & fan impellor is available as a spare which
allows the fan casing to be left in position.

2. Remove the electrical connections to the motor

junction box and if the burner is to be left unattended
these connections must be left in a safe condition.

3. Release the four screws that hold the complete fan

assembly to the body of the fan scroll. Lift the fan
assembly away from the fan scroll noting the air dampers
approximate position.

Section 11 Page 2
FD BURNER MANUAL
GAS VALVES BODIES
1. Remove the electrical connections to the gas valves
by removing the push on plug caps or the
connections to the valve terminal blocks. Make a note
of the position of the connections to aid replacement
later.
2. Fit a temporary earth continuity connection and then
break the gas unions on the burner gas train.
3. Remove the faulty gas valve body and replace using
a new “O” Ring or replace pipework using a
proprietary gas jointing compound. Ensure that the
direction of gas flow through the gas valve is correct
by looking for the direction arrow stamped on the
casting.
4. Replace the complete gas train assembly as the
reverse of the above.
5. After such work the integrity of the gas safety valves
and the soundness of any gas pipework disturbed
must be shown to be safe, as given previously under
Precommissioning Gas. The burner settings must be
checked as given previously under Commissioning
and a written record made.
BURNER CONTROLLER
1. Release the fixing screw holding the Burner
Controller box (Satronic, Siemens, Honeywell or
similar) to its base and pull the box out.
2. Replace as the reverse of the above.
3. The burner settings must be checked as given
previously under Commissioning and a written record
made.
IGNITION TRANSFORMER
1. Release the live, neutral and earth electrical
connections from the ignition transformer.
2. Unscrew the ignition cable from the transformer.
3. Release the fixing screws and remove the ignition
transformer complete.
4. Replace as the reverse of the above. Care must be
taken that a good connection is made with the
ignition cable onto the transformer body.
5. The burner settings must be checked as given
previously under Commissioning and a written record
made.
MODULATING MOTOR
1. Remove the plastic cover over the motor and
release the electrical connections.
Note where these electrical connections go.
Section 11
SECTION 11 COMPONENT REPLACEMENT
2. The shaft of the ball valve will have an index mark.
Note the position of this mark relative to the clamp
that grips it.
3. Release the clamp and the screws holding the motor
body.
4. Turn the motor over and note how the splined shaft
is aligned relative to its indexing mark. A Data Sheet
for the motor is contained in this manual giving more
details of this. Note how the small switches on the
Printed Circuit Board are set as these determine the
direction of travel and the type of control signal
used.
5. Set the splined shaft and switches on the new motor
as per the old motor.
6. Refitting is the reverse of the above.
7. The burner settings must be checked as given
previously under Commissioning and a written
record made. In particular the bottom end stop of the
modulating motor must be set sufficiently open to
allow enough gas to pass for reliable starting of the
burner.
3-WAY AIR VALVE
1. Release the electrical plug cap from the coil of the
valve.
2. Release the retaining nut from the stem of the valve
and the coil can now be lifted away.
3. If the valve body itself is faulty the body can be
released from the plastic tubes by releasing the push
on pipe connections. A screwdriver should be used to
push the collars inwards then the pipe can be pulled
out.
4. Release the valve body if necessary by releasing the
backnut holding the valve to the backplate.
5. Replace as the reverse of the above.
6. If the 6mm plastic pipes have been disturbed care
should be taken that these have been replaced
correctly and a good air tight seal made.
7. The burner settings must be checked as given
previously under Commissioning and a written record
made.
AIR PRESSURE SWITCH
1. Remove the plastic cover over the pressure switch
and release the electrical connections and the switch
fixing screws.
2. Replace as the reverse of the above.
3. The burner settings must be checked as given
previously under Commissioning and a written record
made.
Page 3
FD MANUAL SECTION 11 COMPONENT REPLACEMENT

AIR PRESSURE SWITCH

1. Remove the plastic cover over the pressure switch

and release the electrical connections and the switch
fixing screws.

2. Replace as the reverse of the above.

3. The burner settings must be checked as given

previously under Commissioning and a written record
made.

Section 11 Page 4
FD BURNER MANUAL SECTION 12 SPECIAL FEATURES

SECTION 12 SPECIAL FEATURES

If any Special Features were designed and supplied with a burner details will be contained
in this section. This could be Data Sheets for special components and additional operating
and commissioning instructions.

Section 12 Page 1
FRM
Medium Pressure Regulator

Medium pressure regulator Type FRM

Direct acting pressure regulator with

adjustable setpoint springs and modular
mounted safety shutoff valve (SAV)

In compliance with EN 334 and EN 14382

• Inlet pressures up to 25 bar (2 500 kPa)

• High flow rate
• Stable, accurate and sensitive regulation of the outlet pressure
• Admission pressure compensation diaphragm for a high
regulation accuracy
• External impulse
• Maintenance-friendly
• Flange connection according to DN 25 - DN 50

FRM Ÿ Edition 08.20 Ÿ 270 440 1 ... 23

Table of contents FRM

Application 3

Approval 3

Technical data 4 + 5

Pressure taps 6

Nomenclature 7

Adjustment range 8

Selection of regulator springs 9
Selection of SAV springs 10

Dimensions 11 + 12

Function 13

Sectional drawing FRM/SAV 13 + 14

Device selection / flow rate tables 15 - 20

Design example 22

Contact details 23

FRM Ÿ Edition 08.20 Ÿ 270 440 2 ... 23

FRM Application Approval
Spring-loaded, pressure com- Pressure regulation of industrial gas
pensating regulator with adjusta- EC type testing certificate as per:
burners and gas heating appliances.
ble setpoint springs for regulation Also for installation in the municipal • EC-Pressure Equipment Directive
of the regulator outlet pressure. and commercial gas supply.
External impulse of the regulator
outlet pressure. Suitable for gases of gas families
1, 2, 3 and other neutral gases.

FRM Ÿ Edition 08.20 Ÿ 270 440 3 ... 23

Technical Data FRM

Spring-loaded medium pressure regulator in compliance with EN334

Type FRM 100... IS (integral strength range) / FRM 250... DS (differential strength range)

Type of gas Family 1+2+3

Nominal diameters Connecting flange PN 25 according to EN1092-1or ANSI 150 lbs (B16.5)
Flanges DN 25 40 50

Max. inlet pressure FRM 100... 10 bar (1 000 kPa) / FRM 250... 25 bar (2 500 kPa)

Outlet pressure range 30 mbar up to 4000 mbar (3-400 kPa)

Minimum differential pressure (ND) 270 mbar (27 kPa)

Minimum differential pressure (MD) 350 mbar (35 kPa)

Minimum differential pressure (HD/UHD) 500 mbar (50 kPa)

Accuracy class up to AC 5 (see adjustment range, page 3)

Lock-up pressure class up to SG 10 (see adjustment range, page 3)

Failure mode (diaphram rupture) fail-open

Materials Main body housing: cast iron GGG 50 (GJS 400-18 on request)
Diaphragm housing: steel
Diaphragms: NBR

Ambient temperature -20 °C to +60 °C

FRM Ÿ Edition 08.20 Ÿ 270 440 4 ... 23
Technical Data SAV

Safety shut-off valve in compliance with EN14382, class A

Type FRM 100... IS (integral strength range) /
FRM 250... DS (differential strength range)

Response time <2s

Lower adjustment range Wdu 10 mbar up to 3 000 mbar (1-300 kPa)

Upper adjustment range Wdo 40 mbar up to 5 000 mbar (4-500 kPa)

Materials Main body housing: cast iron GGG 50 (GJS 400-18 on request)
Diaphragm housing: aluminium
Diaphragms: NBR

FRM Ÿ Edition 08.20 Ÿ 270 440 5 ... 23

Pressure taps

1 Vent line connection of the regulator,

G1/2 ISO 228

2 External impulse line connection of the

regulator, Ermeto screw connection
GE 12- 1/2 for tubes 12 x 1.5

3 External impulse line connection of the

SAV, Ermeto screw connection
GE 12- 1/4 for tubes 12 x 1.5
1
4 Vent line connection of the SAV,
G1/4 ISO 228

FRM Ÿ Edition 08.20 Ÿ 270 440 6 ... 23

Nomenclature

Example FRM 100025 ND / SAV ND FRM 100 025 ND SAV ND

Type Spring-loaded medium pressure regulator

MOP 100 … 10 000 mbar

250 ... 25 000 mbar
Nominal diameter DN 25 025
DN 40 040
DN 50 050
Pressure range, outlet pressure ND Low pressure
MD Medium pressure
HD High pressure
UHD Ultra high pressure
Safety device SAV Integrated shut-off valve

Pressure range, trip pressure ND Low pressure

MD Medium pressure
HD High pressure
UHD Ultra high pressure
Flange type with standard PN-25
ANSI with ANSI 150 lbs

FRM Ÿ Edition 08.20 Ÿ 270 440 7 ... 23

Adjustment range

Type Connec- Ver- Accuracy Lock-up Outlet pressure Under pressure monitoring SAV Over pressure monitoring SAV
tion sion class* pressure range Wd
[AC] class* [SG] Wdu AG Wdo AG

FRM 100025 ND DN 25 ND AC 10 SG 20 30-100 mbar

FRM 100025 MD DN 25 MD AC 5/10** SG 20 90-420 mbar

FRM 100025 HD DN 25 HD AC 5 SG 10 400-1500 mbar
FRM 250025 UHD DN 25 UHD AC 5 SG 10 1000-4000 mbar
FRM 100025 ND / SAV ND DN 25 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10
FRM 100025 MD / SAV MD DN 25 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100025 HD / SAV HD DN 25 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
FRM 250025 UHD / SAV UHD DN 25 UHD AC 5 SG 10 1000-4000 mbar 150-3000 mbar AG 5 1300-5000 mbar AG 5

FRM 100040 ND DN 40 ND AC 10 SG 20 30-100 mbar

FRM 100040 MD DN 40 MD AC 5/10** SG 20 90-420 mbar
FRM 100040 HD DN 40 HD AC 5 SG 10 400-1500 mbar
FRM 250040 UHD DN 40 UHD AC 5 SG 10 1000-4000 mbar
FRM 100040 ND / SAV ND DN 40 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10
FRM 100040 MD / SAV MD DN 40 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100040 HD / SAV HD DN 40 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
FRM 250040 HD / SAV UHD DN 40 UHD AC 5 SG 10 1000-4000 150-3000 mbar Ag 5 1300-5000 mbar AG 5

FRM 100050 ND DN 50 ND AC 10 SG 20 30-100 mbar

FRM 100050 MD DN 50 MD AC 5/10** SG 20 90-420 mbar
FRM 100050 HD DN 50 HD AC 5 SG 10 400-1500 mbar
FRM 250050 UHD DN 50 UHD AC 5 SG 10 1000-4000 mbar
FRM 100050 ND / SAV ND DN 50 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10
FRM 100050 MD / SAV MD DN 50 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100050 HD / SAV HD DN 50 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
FRM 250050 UHD / SAV UHD DN 50 UHD AC 5 SG 10 1000-4000 mbar 150-3000 mbar AG 5 1300-5000 mbar AG 5
*Accuracy class / Lock-up pressure class to EN 334 **pd = 90-180 mbar: AC 10; pd= 180-420 mbar: AC 5

FRM Ÿ Edition 08.20 Ÿ 270 440 8 ... 23

Selection of regulator springs

The response pressure results Specific set range, outlet pressure Wds
from the force of the installed
adjusting spring and the weight Spring colour Order Wire diameter Length Diameter Setpoint range [mbar]
force of the movable parts. By number [mm] [mm] [mm] ND MD HD UHD
changing the setpoint spring 1, Silver 270341 5.5 300 60 30-40 90-110
it is possible to set different outlet
Green 270345 6.5 300 62 40-55 110-170
pressures.
Yellow 270346 7.0 300 63 55-80 170-240

Blue 270347 8.0 300 65 80-100 240-330

Black 270348 9.0 300 68 330-420 400-580

Purple 270349 10.0 300 69 560-850

Orange 270350 11.0 300 71 800-1200 1000-1600

1
Pink 270352 12.0 300 73 1100-1500

White 271113 13.0 300 75 1500-2500

Red 271132 14.0 300 77 1900-3300

Red/Brown 276127 14.0/8.0 300 77/46 2900-4000

FRM Ÿ Edition 08.20 Ÿ 270 440 9 ... 23

Selection of SAV springs

The response pressure results from Specific set range, underpressure Wdsu
the force of the installed adjusting
spring. The upper response pres- Spring colour Order number Wire diameter Length Diameter Setpoint range [mbar]
[mm] [mm] [mm]
sure (overpressure) is set on the ND MD HD UHD
external spring 1 of the measure- White 270353 1.2 60 10.0 10-32
ment device. The lower response Yellow 270355 1.5 55 12.3 24-40
pressure (vacuum) can be set on
Blue 270356 2.0 55 12.3 30-115 35-110
the internal spring 2. By changing
the setpoint springs, different Black 270357 2.3 55 12.3 50-250
response pressures Purple 270358 2.5 55 12.3 80-400 150-500 150-500
can be set. Orange 270359 2.8 55 12.3 300-1000 300-1000
Silver 270360 3.0 60 15.0 800-1400 800-1400
Pink 276126 3.5 60 15.0 1200-3000

1 Specific set range, overpressure Wdso

Spring colour Order number Wire diameter Length Diameter Setpoint range [mbar]
[mm] [mm] [mm]
ND MD HD UHD
Silver 270361 2.2 60 30.0 40-130
Green 270366 2.5 60 30.0 60-190 180-290
2 Red 270367 2.7 60 30.0 90-240 230-370
Yellow 270368 3.2 60 30.0 300-500
Blue 270369 3.5 60 30.0 400-800 500-1000
Black 270370 3.7 60 30.0 700-1300
Purple 270371 4.0 60 30.0 1000-1800
Orange 270372 4.5 60 30.0 1300-2500 1300-2500
Pink 270373 4.8 60 30.0 1800-3500 1800-3500
White 271115 5.0 60 30.0 2500-5000

FRM Ÿ Edition 08.20 Ÿ 270 440 10 ... 23

 Dimensions FRM

Type Order p max. DN Dimensions Weight

A
number [bar / kPa] A B C D E [kg]
FRM 100025 ND 270272 10 / 1000 25 500 184 57 492 820 38
FRM 100025 MD 270273 10 / 1000 25 380 184 57 492 820 32
FRM 100025 HD 270274 10 / 1000 25 380 184 57 502 830 36
FRM 250025 UHD 271116 25 / 2500 25 380 184 57 502 830 36
FRM 100040 ND 270278 10 / 1000 40 500 223 69 505 830 42
FRM 100040 MD 270279 10 / 1000 40 380 223 69 505 830 36
FRM 100040 HD 270280 10 / 1000 40 380 223 69 515 840 40
E
FRM 250040 UHD 271118 25 / 2500 40 380 223 69 515 840 40
D FRM 100050 ND 270284 10 / 1000 50 500 254 80 515 840 49
FRM 100050 MD 270285 10 / 1000 50 380 254 80 515 840 43
FRM 100050 HD 270286 10 / 1000 50 380 254 80 525 850 47
FRM 250050 UHD 271120 25 / 2500 50 380 254 80 525 850 47

FRM Ÿ Edition 08.20 Ÿ 270 440 11 ... 23

 Dimensions FRM with SAV

Type Order p max. DN Dimensions Weight

A number [bar / kPa] [kg]
A B C D E
FRM 100025 ND/SAV ND 270275 10 / 1000 25 500 184 232 492 1070 40
FRM 100025 MD/SAV MD 270276 10 / 1000 25 380 184 229 492 1070 34
FRM 100025 HD/SAV HD 270277 10 / 1000 25 380 184 236 502 1080 38
FRM 250025 UHD/SAV UHD 271117 25 / 2500 25 380 184 236 502 1080 38
FRM 100040 ND/SAV ND 270281 10 / 1000 40 500 223 243 505 1080 44
FRM 100040 MD/SAV MD 270282 10 / 1000 40 380 223 239 505 1080 38
E D
FRM 100040 HD/SAV HD 270283 10 / 1000 40 380 223 247 515 1090 42
FRM 250040 UHD/SAV UHD 271119 25 / 2500 40 380 223 247 515 1090 42
FRM 100050 HD/SAV ND 270287 10 / 1000 50 500 254 252 515 1090 51
FRM 100050 HD/SAV MD 270288 10 / 1000 50 380 254 248 515 1090 45
FRM 100050 HD/SAV HD 270289 10 / 1000 50 380 254 256 525 1100 49
FRM 250050 UHD/SAV UHD 271121 25 / 2500 50 380 254 256 525 1100 49

FRM Ÿ Edition 08.20 Ÿ 270 440 12 ... 23

 Sectional drawing FRM
Function Pressure regulator in open position

Mode of operation according to the force

comparison principle between the force: In case of an increase of the outlet pressure, the
• of the adjustable setpoint spring, working diaphram 6 is pushed upwards, until the
• of the defined return spring, force of the setpoint spring 8 is equal to that of the
• coming from the differential pressure on the outlet pressure.
8 The upward movement of the working diaphragm
working diaphragm and
• of the weight of the movable parts. 6 causes the lever system 4 to be pulled upwards.
In this way, the control plate 1 is then pushed
7 downwards and the valve gap is reduced.
The setting spring acts independently of the
weight of the movable parts. The outlet pres- The flow volume decreased in this way reduces
sure is set depending on the preload of the the outlet pressure until the set nominal value
6
setting spring. (outlet pressure) is reached and a balance of forc-
es at the working diaphragm 6 is established.
Information
gas carrying and impulse lines and connecting 4
lines must be resistant to thermal, chemical and
3
mechanical stresses. They must also be dura-
ble and resistant to deformation and cracks.
2 5
1 Control plate
2 Inlet pressure compensation
1 diaphragm
Any condensate from impulse lines must 3 Lower diaphragm shell
not flow into the pressure regulator. 4 Lever system
5 Impulse connection for the outlet pressure
Combustible gas and gas/air mixtures 6 Working diaphragm
must not enter the installation space of 7 Vent connection
the adjusting spring. 8 Setpoint spring

FRM Ÿ Edition 08.20 Ÿ 270 440 13 ... 23

 Sectional drawing SAV
Function Device in the closed position

1 Chamber 4 is connected to the outlet pressure via

an impulse line. The pressure being monitored
2 acts on the working diaphragm 5. The force of the
setpoint springs 7 and 8 acts as counterforce. In
case of an unbalance of forces (overpressure or
underpressure), the SAV is actuated and the gas
3 supply is blocked.
4

5
6
8 7
1 Valve disc
2 Closing spring
3 Ball catch / trigger mechanism
4 Chamber with the pressure to be monitored
5 Working diaphragm
6 Push rod
7 Setpoint spring for pdo
8 Setpoint spring for pdu
9 Protective cap
9

FRM Ÿ Edition 08.20 Ÿ 270 440 14 ... 23

 Flow rate tables
Device selection

The following flow rate tables can be used to

select the device. The maximum indicated vol- FRM 100025... DN25 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 10)
ume flow refers to the air with a standard densi- FRM ... ND MD HD
ty of 1.24 kg / m3 at a temperature of pd [bar]
15 °C. In case of different types of gases, a 0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5
conversion of the volume flow according to the pu [bar]
equation on page 18 is carried out. It is possible 0,5 186 217 229 235 192 186 173 161
to determine the maximum flow volume of the 0,75 198 266 285 297 235 240 224 223 210
corresponding regulator at the operating point
1 210 297 346 359 273 306 308 325 313 297 285
defined using pd and pu. This corresponds to the
maximum power of the regulator at which an 1,5 223 322 433 458 371 377 396 371 384 384 371 384 396
accuracy class of AC 10 is observed. 2 235 346 507 532 445 445 445 445 483 445 445 445 445 458 470
2,5 247 371 569 594 507 507 582 594 606 557 557 557 557 557 557
3 272 396 631 656 557 582 681 693 730 643 643 643 643 643 643
Design a straight stabilisation section 3,5 297 421 693 705 594 656 779 779 841 705 755 792 792 792 792
with the equal diameter.
4 309 445 755 755 631 718 866 866 940 792 891 940 940 940 940
4,5 322 470 804 804 656 767 953 965 1039 866 990 1052 1076 1076 1089
Impulse connection at a distance of > 5 x
DN. 5 334 495 841 854 681 817 1027 1052 1126 928 1064 1151 1175 1175 1237
6 346 507 866 891 718 891 1114 1175 1287 1052 1237 1336 1423 1423 1423
Maximum flow velocity in the stabilisation 7 346 520 891 940 742 977 1175 1336 1411 1163 1373 1509 1608 1608 1608
section of </= 30 m/s. 8 359 532 916 977 767 1052 1237 1398 1509 1274 1485 1658 1732 1732 1732
9 359 544 940 1015 792 1089 1287 1460 1621 1349 1596 1794 1794 1794 1794
FRM with SAV max. flow of 2.500 Nm3/h (Air).
10 371 557 965 1052 817 1138 1312 1509 1695 1411 1707 1881 1881 1881 1881

FRM Ÿ Edition 08.20 Ÿ 270 440 15 ... 23

 Flow rate tables
Device selection

FRM 100040... DN40 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 10)

FRM... ND MD HD
pd [bar]
0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5
pu [bar]
0,5 297 359 359 371 334 334 334 334
0,75 322 396 445 557 421 433 433 433 433
1 346 433 569 705 495 507 507 544 582 582 582
1,5 396 557 681 804 569 656 656 668 730 755 767 779 916
2 433 656 779 891 681 767 767 792 866 903 953 1015 1039 1039 1089
2,5 513 718 866 990 761 866 866 928 990 1039 1076 1262 1274 1274 1361
3 569 779 965 1101 829 953 953 1027 1101 1163 1163 1423 1608 1608 1608
3,5 625 829 1064 1200 885 1039 1039 1151 1225 1274 1287 1646 1757 1769 1856
4 668 866 1175 1274 934 1114 1114 1262 1361 1398 1411 1745 1905 1967 2103
4,5 705 928 1299 1361 977 1188 1188 1361 1485 1509 1522 1905 2054 2140 2351
5 755 990 1398 1460 1015 1262 1262 1448 1584 1608 1621 2066 2215 2326 2536
6 866 1114 1534 1670 1114 1386 1411 1633 1794 1794 1856 2351 2462 2660 2846
7 977 1225 1646 1831 1213 1460 1559 1794 1967 1955 2079 2623 2747 2969 3093
8 1076 1324 1745 1918 1287 1509 1670 1943 2165 2091 2252 2846 2994 3217 3279
9 1151 1411 1794 1955 1336 1547 1757 2091 2326 2215 2413 3093 3217 3403 3464
10 1175 1472 1819 2004 1373 1571 1831 2202 2475 2239 2487 3229 3403 3526 3600

FRM Ÿ Edition 08.20 Ÿ 270 440 16 ... 23

 Flow rate tables
Device selection

FRM 100050... DN50 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 10)

FRM... ND MD HD
pd [bar]
0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5
pu [bar]
0,5 198 210 285 285 260 260 260 260
0,75 247 272 334 334 371 396 396 396 396
1 272 322 408 408 483 495 507 507 544 470 470
1,5 303 371 483 483 594 656 656 693 829 582 582 656 761
2 334 408 569 569 705 779 779 866 1076 742 742 866 866 866 928
2,5 365 445 668 668 804 903 903 1015 1237 916 953 1089 1114 1114 1163
3 396 495 718 718 891 1027 1027 1138 1361 1064 1213 1287 1336 1336 1386
3,5 427 532 767 767 965 1101 1151 1274 1460 1188 1349 1485 1534 1534 1608
4 452 582 792 792 1052 1175 1250 1386 1559 1287 1485 1633 1707 1707 1881
4,5 470 631 854 854 1138 1213 1336 1485 1608 1386 1596 1782 1856 1856 2029
5 507 674 916 916 1213 1287 1411 1571 1670 1460 1670 1893 1955 2004 2153
6 582 742 990 990 1312 1398 1534 1707 1794 1596 1806 1943 2054 2202 2425
7 643 817 1064 1076 1411 1497 1646 1794 1918 1707 1905 1980 2140 2400 2673
8 705 878 1126 1151 1485 1571 1732 1881 2042 1794 1980 2017 2239 2635 2895
9 767 928 1175 1213 1547 1633 1819 1930 2165 1856 2029 2054 2314 2772 3007
10 841 977 1225 1299 1608 1707 1868 1967 2289 1893 2079 2079 2351 2895 3106

FRM Ÿ Edition 08.20 Ÿ 270 440 17 ... 23

 Flow rate tables
Device selection

FRM 250025 UHD... DN25 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 10)

FRM ... UHD

pd [bar]
1 1,5 2 3 4
pu [bar]
8 1423 1423 1485 1837 1485
10 1670 2143 1794 2220 1794
12 1918 1980 2103 2103 2165
16 2475 3215 2722 2722 2784
18 2536 2660 2846 2908 3031
20 2598 3444 2969 3093 3279
25 2846 3031 3279 3526 3836

FRM 250025 UHD... DN25 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 5)

FRM ... UHD

pd [bar]
1 1,5 2 3 4
pu [bar]
8 990 1175 1175 1531 1299
10 1361 1423 1547 1990 1670
12 1732 1794 1918 2449 2042
16 2475 3215 2722 2722 2784
18 2536 2660 2846 2908 3031
20 2598 3444 2969 3093 3279
25 2784 3751 3279 3526 3836

FRM Ÿ Edition 08.20 Ÿ 270 440 18 ... 23

 Flow rate tables
Device selection

FRM 250040 UHD... DN40 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 10)

FRM ... UHD

pd [bar]
1 1,5 2 3 4
pu [bar]
8 2660 2908 3217 4133 3464
10 3031 4210 3774 3836 3959
12 3464 3836 4269 5358 4392
16 4207 5894 5320 5320 5382
18 4578 6430 5815 5939 6125
20 4949 6965 6310 8190 6929
25 5877 6558 7424 8104 8847

FRM 250040 UHD... DN40 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 5)

FRM ... UHD

pd [bar]
1 1,5 2 3 4
pu [bar]
8 1608 1794 2042 2679 2289
10 1732 2042 2413 3138 2660
12 1856 2832 2722 2846 3031
16 2165 2722 3341 4440 3836
18 2289 3598 3526 3836 4207
20 2475 3827 3712 4145 4640
25 2846 3464 4145 6047 5630

FRM Ÿ Edition 08.20 Ÿ 270 440 19 ... 23

 Flow rate tables
Device selection

FRM 250050 UHD... DN50 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 10)

FRM ... UHD

pd [bar]
1 1,5 2 3 4
pu [bar]
8 2103 2227 2413 2784 3217
10 2413 3291 2908 4440 4269
12 2784 3031 3341 5358 5320
16 3464 3836 4269 7272 7486
18 3836 5205 4578 6186 7857
20 4269 5664 4887 6558 8290
25 5197 6736 5691 6583 4949

FRM 250050 UHD... DN50 - max. flow volume [Nm3/h] natural gas of density 0,81 kg/m3 (AC 5)

FRM ... UHD

pd [bar]
1 1,5 2 3 4
pu [bar]
8 1547 1423 1361 2067 1980
10 1547 1485 1485 1918 2413
12 1485 1914 1608 2756 2846
16 1423 1608 1856 3444 3712
18 1670 2296 2042 2969 3959
20 1980 2042 2165 3155 4207
25 2660 2598 2598 4669 4949

FRM Ÿ Edition 08.20 Ÿ 270 440 20 ... 23

Calculation of gas types

°
V = ° x f
used gas
V air
Type of gas Spec.
Wgt.
dv f

[kg/m3]

Natural gas 0.81 0.65 1.24

air density

spec. weight of the gas used City gas 0.58 0.47 1.46

f=
NDG 2.08 1.67 0.77

Air 1.24 1.00 1.00

FRM Ÿ Edition 08.20 Ÿ 270 440 21 ... 23

 Design example
Device selection

FRM 100025... DN25 - max. air flow volume (AC 10) FRM 100040... DN40 - max. air flow volume (AC 10)
FRM ... ND MD HD FRM... ND MD HD

System data pd [bar]

0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5
pd [bar]
0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5

Medium: natural gas

pu [bar] pu [bar]
0,5 150 175 185 190 155 150 140 130 0,5 240 290 290 300 270 270 270 270

Natural gas specific density: 0.81 kg/m3

0,75 160 215 230 240 190 194 181 180 170 0,75 260 320 360 450 340 350 350 350 350
1 170 240 280 290 221 247 249 263 253 240 230 1 280 350 460 570 400 410 410 440 470 470 470

Volume flow Vnatural gas system: 550 Nm3/h 1,5

2
180
190
260
280
350
410
370
430
300
360
305
360
320
360
300
360
310
390
310
360
300
360
310
360
320
360 370 380
1,5
2
320
350
450
530
550
630
650
720
460
550
530
620
530
620
540
640
590
700
610
730
620
770
630
820
740
840 840 880

Inlet pressure pu: 4 bar (400 kPa) 2,5

3
200
220
300
320
460
510
480
530
410
450
410
470
470
550
480
560
490
590
450
520
450
520
450
520
450
520
450
520
450
520
2,5
3
415
460
580
630
700
780
800
890
615
670
700
770
700
770
750
830
800
890
840
940
870
940
1020
1150
1030
1300
1030
1300
1100
1300

Outlet pressure pd: 150 mbar (15 kPa) 3,5

4
240
250
340
360
560
610
570
610
480
510
530
580
630
700
630
700
680
760
570
640
610
720
640
760
640
760
640
760
640
760
3,5
4
505
540
670
700
860
950
970
1030
715
755
840
900
840
900
930
1020
990
1100
1030
1130
1040
1140
1330
1410
1420
1540
1430
1590
1500
1700
4,5 260 380 650 650 530 620 770 780 840 700 800 850 870 870 880 4,5 570 750 1050 1100 790 960 960 1100 1200 1220 1230 1540 1660 1730 1900
5 270 400 680 690 550 660 830 850 910 750 860 930 950 950 1000 5 610 800 1130 1180 820 1020 1020 1170 1280 1300 1310 1670 1790 1880 2050
6 280 410 700 720 580 720 900 950 1040 850 1000 1080 1150 1150 1150 6 700 900 1240 1350 900 1120 1140 1320 1450 1450 1500 1900 1990 2150 2300
7 280 420 720 760 600 790 950 1080 1140 940 1110 1220 1300 1300 1300 7 790 990 1330 1480 980 1180 1260 1450 1590 1580 1680 2120 2220 2400 2500
8 290 430 740 790 620 850 1000 1130 1220 1030 1200 1340 1400 1400 1400 8 870 1070 1410 1550 1040 1220 1350 1570 1750 1690 1820 2300 2420 2600 2650
9 290 440 760 820 640 880 1040 1180 1310 1090 1290 1450 1450 1450 1450 9 930 1140 1450 1580 1080 1250 1420 1690 1880 1790 1950 2500 2600 2750 2800
10 300 450 780 850 660 920 1060 1220 1370 1140 1380 1520 1520 1520 1520 10 950 1190 1470 1620 1110 1270 1480 1780 2000 1810 2010 2610 2750 2850 2910

V° FRM DN 25= 510 m3/h air V° FRM DN 40= 755 m3/h air

Conversion V° FRM DN 25 air in V

°
FRM DN 25 natural gas
: Conversion V° FRM DN 40 air in V° FRM DN 40 natural gas:

V° FRM DN 25 natural gas= 510 m3/h * (1.24/0.81) V° FRM DN 40 natural gas= 755 m3/h * (1.24/0.81)

V° FRM DN 25 natural gas= 631 m3/h V° FRM DN 40 natural gas= 934 m3/h

V° FRM DN 25 natural gas >V° natural gas system V° FRM DN 40 natural gas >V° natural gas system

631 m3/h > 550 m3/h 934 m3/h > 550 m3/h

Since the effective operating point of the system (550 m3/h natural gas) should correspond as closely as
possible to the maximum power of the regulator, for this design example a FRM 100025 DN 25 is used.
In this way optimum regulation behaviour can be guaranteed.

FRM Ÿ Edition 08.20 Ÿ 270 440 22 ... 23

 Head of office and factory Subsidiary

Karl Dungs GmbH & Co. KG Karl Dungs Limited

Karl-Dungs-Platz 1 18, Liberty Way
D-73660 Urbach, Attleborough Fields Ind. Est.
Germany GB-Nuneaton CV11 6RZ
Phone +49 (0)7181-804-0 Großbritannien / Great Britain
Fax +49 (0)7181-804-166 Phone +44 (0)24/76 37 57 33
e-mail: info@dungs.com Fax +44 (0)24/76 34 28 52
Internet: www.dungs.com e-mail: info.gb@dungs.com
Subject to technical modification in the interest of technical progress. Internet: www.dungs.com

FRM Ÿ Edition 08.20 Ÿ 270 440 23 ... 23

FD BURNER MANUAL SECTION 13 RECOMMENDED SPARES

SECTION 13 RECOMMENDED SPARES

If this manual was sent out with a burner then the Recommended Spares list will be
contained in this section of the manual for the burner and any accessories e.g.
Temperature Controllers.

Section 13 Page 1
Job No: J52940

Status: Shipped

Part No Description

ESSENTIAL SPARES
0010032 3-WAY AIR VALVE ASSEMBLY (110V)
0010772 KROMSCHRODER GAS VALVE COIL VA1 (110V)
0010777 KROMSCHRÖDER GAS PRESSURE SWITCH DG40/VC-6W (5-40mbar)
0010778 KROMSCHRÖDER GAS VALVE COIL VBY (110V)
0012027 DUNGS AIR PRESSURE SWITCH LGW50A2 (2.5-50mbar)
0013022 MCT IGNITION TRANSFORMER (110V)
0013032 NGK IGNITION ELECTRODE CAP LB05E
0013033 NGK FLAME SENSE ELECTRODE CAP LB05F
0013041 CONTROL BOX FUSE (3.15A) 20x5mm
0013200 FINDER SINGLE RELAY (110V) 4661-8110-0054
0013201 FINDER SINGLE RELAY (230V)
0013563 FINDER DOUBLE RELAY (NARROW) (110V)
0013791 FINDER DOUBLE RELAY (NARROW) (24VDC)
0016214 FD5 MK6 IGNITION ELECTRODE
0016215 FD5 MK6 FLAME SENSE ELECTRODE
1014175 LME75 110V COMPLETE ASSY

OTHER SPARES
0010590 KROMSCHRÖDER BYPASS GAS VALVE VBY (110V)
0010860 KROMSCHRÖDER GAS VALVE VCV1 1" 110v excl. LGPS
0011115
0011124 VMF1/1 FILTER PAD SET
0014382 ABB VSD ACS310 (400V/3ph/50Hz/1.1kW)
0016200 FD5 MK6 IGNITION ELECTRODE ASSEMBLY
0016201 FD5 MK6 FLAME SENSE ELECTRODE ASSEMBLY
0016228 FD MK6 BULKHEAD ELECTRODE
1140571 FD5 FLAME TUBE ASSY 210mm
9681002 EXHAUST FAN 12/125DF BS/DIN (400V/3ph/50Hz/1.1kW)
FB81057 TX EXHAUST FAN IMPELLOR 12/125DF - (M/S)
FB81081 TX EXHAUST FAN MOTOR 12/125DF 400V/3ph/50Hz/1.1kW/WEG
FD BURNER MANUAL SECTION 14 HEALTH AND SAFETY

SECTION 14 HEALTH AND SAFETY

Section 14 Page 1
FD BURNER MANUAL SECTION 14 HEALTH AND SAFETY

C.O.S.H.H (CONTROL OF SUBSTANCES SHARP EDGES

HAZARDOUS TO HEALTH )
Any sheet metal edge that does not have a safety
The burner as delivered including packaging
edge or protective covering should be handled with
contains no chemicals or substances that represent
gloves.
a hazard to health during installation or operation if
installed in accordance with these instructions.
ELECTRICAL
GASKETS
THIS BURNER MUST BE EARTHED
The gaskets as supplied as original equipment are
The burner must only be installed and maintained
ceramic fibre with binder. They are pre-cut to shape
electrically by trained competent electricians.
and prefitted to the burner. These gaskets do not
need cutting on site.

For service work when fitting new gaskets, use GAS

gloves and protective goggles and do not allow this
material to come into contact with the skin, eyes or
inhale or ingest it.
PAINTS
In the UK this burner must only be installed and
maintained by trained technicians who are GAS
SAFE & ACS registered specifically for industrial
gas burners. In other countries local regulations
must be complied with.

During first operation there may be a faint smell but

RECYCLING
if the burner is operated in an area ventilated in
accordance with this manual this represents no
hazard. The burner is made from:

Mild and stainless steel sheet and tube.

SEALENTS
Gas tight joints are made with a proprietary gas
jointing compound and no other chemical sealants
are used. Gaskets are fixed with silicone based
adhesive.
HEALTH AND SAFETY
The following should be considered when installing,
operating or servicing this burner.
LIFTING
The weight of the burner and fan or heat exchanger
should be assessed before lifting commences. The
gas train may be removed if necessary to reduce
the weight of the burner and so aid safe lifting.
Two persons may be required to lift larger fans and
heat exchangers.
Aluminium / cast iron castings.
Copper wire and windings.
Plastic switches, terminals, controls etc.
These burners contain the minimum of welding and
they can easily be unassembled into their main
material group. Approximately 95% by weight can
be recycled.
DISPOSAL OF PACKAGING AND BURNER
The cardboard box and polyurethane packing can
be recycled or disposed of to an appropriate facility.
The burner body can be stripped down and the
materials recycled or disposed of to an appropriate
facility.
Lanemark Combustion Engineering Ltd would be
pleased to receive back by prior arrangement the
burner or its packaging for recycling.

Burners, fans and heat exchangers should not be

left unsupported.

Section 14 Page 2
FD BURNER MANUAL SECTION 15 NOTES

SECTION 15 NOTES

Section 15 Page 1
FD BURNER MANUAL SECTION 15 NOTES

NOTES

CUSTOMER NAME: ………………………………………………………………………………………………………

SITE ADDRESS: ………………………………………………………………………………………………………….

BURNER MODEL: ……………………SERIAL No: ……………………… GAS TYPE: ………………………….

CONTROL PANEL VOLTAGE:……………V GAS TRAIN TYPE: …………………………….………………..
BURNER MOTOR POWER …………….kW VOLTAGE:……………V RUN CURRENT:…………….Amp
(The above can be found on the burner data plate. Affixed to the burner body, In the burner control box and a copy in this manual)

DATE NOTES SIGNED

Section 15 Page 2
FD BURNER MANUAL

This manual is also available in PDF format. Please quote the Job Number on the front.

LANEMARK COMBUSTION ENGINEERING LTD

LANEMARK HOUSE WHITACRE RD NUNEATON ENGLAND CV11 6BW
Tel +44 (0)24 7635 2000 Fax +44 (0)24 7634 1166 e-mail info@lanemark.com Web Site http://www.lanemark.com