Unigas IDEA Series, IDEA LG550, IDEA NG550, IDEA NGX550 Manual Of Installation - Use - Maintenance

IDEA Series

Gas burners

LG550

NG550

NGX550

MANUAL OF INSTALLATION - USE - MAINTENANCE

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

M039119CE Rel. 4.1 06/2010

TABLE OF CONTENTS

WARNINGS ............................................................................................................................................................... 5

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

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

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

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

BURNERS SPECIFICATIONS ....................................................................................................................................................... 7

Matching the burner to the boiler .................................................................................................................................................... 7

Specifications .................................................................................................................................................................................. 8

Country and usefulness gas categories .......................................................................................................................................... 9

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

Overall dimensions ....................................................................................................................................................................... 12

MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 14

Packing ......................................................................................................................................................................................... 14

Fitting the burner to the boiler ....................................................................................................................................................... 14

GAS TRAIN CONNECTIONS ....................................................................................................................................................... 15

Gas Proving System VPS504 (Option) ......................................................................................................................................... 16

ELECTRICAL CONNECTIONS .................................................................................................................................................... 17

Power supply without neutral ........................................................................................................................................................ 19

Combustion head pressure curves vs. the gas flow rate .............................................................................................................. 20

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

Plugs for pressure measurement .................................................................................................................................................. 20

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

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

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

Adjustment procedure ................................................................................................................................................................... 22

Fully modulating burners ............................................................................................................................................................... 24

Calibration of air and gas pressure switches ................................................................................................................................ 24

Calibration of air pressure switch (only for single stage burners) ................................................................................................. 24

Calibration of air pressure switch (double-stage, progressive and fully-modulating) .................................................................... 24

Calibration of minimum gas pressure switch ................................................................................................................................ 25

Adjusting the high gas pressure switch (when provided) .............................................................................................................. 25

PART II: OPERATION ............................................................................................................................................. 26

Burner control panel ...................................................................................................................................................................... 27

OPERATION ................................................................................................................................................................................. 28

PART III: MAINTENANCE ....................................................................................................................................... 29

ROUTINE OPERATIONS ............................................................................................................................................................. 29

Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................ 29

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 ............................................................................................. 30

Removing and cleaning the combustion head .............................................................................................................................. 30

Replacing the electrodes .............................................................................................................................................................. 32

Electrodes position setting ............................................................................................................................................................ 32

Checking the ionisation current ..................................................................................................................................................... 33

Seasonal stop ............................................................................................................................................................................... 33

TROUBLESHOOTING .................................................................................................................................................................. 34

SPARE PARTS ............................................................................................................................................................................. 35

BURNER EXPLODED VIEW ........................................................................................................................................................ 36

ELECTRICAL WIRING DIAGRAMS ............................................................................................................................................. 38

APPENDIX

2

WARNINGS

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

INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO­DUCT INSTALLATION AND MAINTENANCE.

THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION
OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.

CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.

1) GENERAL INTRODUCTION

z The equipment must be installed in compliance with the regulations

in force, following the manufacturer’s instructions, by qualified per­sonnel.

z Qualified personnel means those having technical knowledge in the

field of components for civil or industrial heating systems, sanitary
hot water generation and particularly service centres authorised by
the manufacturer.

z Improper installation may cause injury to people and animals, or

damage to property, for which the manufacturer cannot be held lia­ble.

z Remove all packaging material and inspect the equipment for inte-

grity.
In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devices, plastic

bags, foamed polystyrene, etc), should not be left within the reach of chil­dren, as they may prove harmful.

z Before any cleaning or servicing operation, disconnect the unit from

the mains by turning the master switch OFF, and/or through the cut-

out devices that are provided.

z Make sure that inlet or exhaust grilles are unobstructed.
z In case of breakdown and/or defective unit operation, disconnect the

unit. Make no attempt to repair the unit or take any direct action.
Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly authorised

by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair the unit’s
safety.
To ensure equipment efficiency and proper operation, it is essential that
maintenance operations are performed by qualified personnel at regular

intervals, following the manufacturer’s instructions.
z When a decision is made to discontinue the use of the equipment,

those parts likely to constitute sources of danger shall be made har-

mless.
z In case the equipment is to be sold or transferred to another user, or

in case the original user should move and leave the unit behind,

make sure that these instructions accompany the equipment at all

times so that they can be consulted by the new owner and/or the

installer.
z For all the units that have been modified or have options fitted then

original accessory equipment only shall be used.
z This unit shall be employed exclusively for the use for which it is

meant. Any other use shall be considered as improper and, there-

fore, dangerous.
The manufacturer shall not be held liable, by agreement or otherwise, for
damages resulting from improper installation, use and failure to comply

with the instructions supplied by the manufacturer.

2) SPECIAL INSTRUCTIONS FOR BURNERS

z The burner should be installed in a suitable room, with ventilation

openings complying with the requirements of the regulations in force,

and sufficient for good combustion.
z Only burners designed according to the regulations in force should

be used.
z This burner should be employed exclusively for the use for which it

was designed.
z Before connecting the burner, make sure that the unit rating is the

same as delivery mains (electricity, gas oil,
z Observe caution with hot burner components. These are, usually,

near to the flame and the fuel pre-heating system, they become hot

during the unit operation and will remain hot for some time after the

burner has stopped.
When the decision is made to discontinue the use of the burner, the user

or other fuel).

shall have qualified personnel carry out the following operations:
a Remove the power supply by disconnecting the power cord from the

mains.

b) Disconnect the fuel supply by means of the hand-operated shut-off

valve and remove the control handwheels from their spindles.

Special warnings

z Make sure that the burner has, on installation, been firmly secured to

the appliance, so that the flame is generated inside the appliance
firebox.

z Before the burner is started and, thereafter, at least once a year,

have qualified personnel perform the following operations:

a set the burner fuel flow rate depending on the heat input of the

appliance;

b set the flow rate of the combustion-supporting air to obtain a combu-

stion efficiency level at least equal to the lower level required by the
regulations in force;

c check the unit operation for proper combustion, to avoid any harmful

or polluting unburnt gases in excess of the limits permitted by the

regulations in force;
d make sure that control and safety devices are operating properly;
e make sure that exhaust ducts intended to discharge the products of

combustion are operating properly;
f on completion of setting and adjustment operations, make sure that

all mechanical locking devices of controls have been duly tightened;
g make sure that a copy of the burner use and maintenance instruc-

tions is available in the boiler room.
z In case of a burner shut-down, reser the control box by means of the

RESET pushbutton. If a second shut-down takes place, call the

Technical Service, without trying to RESET further.
z The unit shall be operated and serviced by qualified personnel only,

in compliance with the regulations in force.

3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED

3a) ELECTRICAL CONNECTION

z For safety reasons the unit must be efficiently earthed and installed

as required by current safety regulations.
z It is vital that all saftey requirements are met. In case of any doubt,

ask for an accurate inspection of electrics by qualified personnel,

since the manufacturer cannot be held liable for damages that may

be caused by failure to correctly earth the equipment.
z Qualified personnel must inspect the system to make sure that it is

adequate to take the maximum power used by the equipment shown

on the equipment rating plate. In particular, make sure that the

system cable cross section is adequate for the power absorbed by

the unit.
z No adaptors, multiple outlet sockets and/or extension cables are per-

mitted to connect the unit to the electric mains.
z An omnipolar switch shall be provided for connection to mains, as

required by the current safety regulations.
z The use of any power-operated component implies observance of a

few basic rules, for example:

- do not touch the unit with wet or damp parts of the body and/or with

bare feet;

- do not pull electric cables;

- do not leave the equipment exposed to weather (rain, sun, etc.)

unless expressly required to do so;

- do not allow children or inexperienced persons to use equipment;

z The unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact qualified
personnel to replace.
When the unit is out of use for some time the electric switch supplying all
the power-driven components in the system (i.e. pumps, burner, etc.)
should be switched off.

3

3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS

GENERAL

z The burner shall be installed by qualified personnel and in com-

pliance with regulations and provisions in force; wrong installation
can cause injuries to people and animals, or damage to property, for
which the manufacturer cannot be held liable.

z Before installation, it is recommended that all the fuel supply system

pipes be carefully cleaned inside, to remove foreign matter that might
impair the burner operation.

z Before the burner is commissioned, qualified personnel should ins-

pect the following:
a the fuel supply system, for proper sealing;
b the fuel flow rate, to make sure that it has been set based on the

firing rate required of the burner;
c the burner firing system, to make sure that it is supplied for the desi-

gned fuel type;
d the fuel supply pressure, to make sure that it is included in the range

shown on the rating plate;
e the fuel supply system, to make sure that the system dimensions are

adequate to the burner firing rate, and that the system is equipped

with all the safety and control devices required by the regulations in

force.
z When the burner is to remain idle for some time, the fuel supply tap

or taps should be closed.

SPECIAL INSTRUCTIONS FOR USING GAS

Have qualified personnel inspect the installation to ensure that:
a the gas delivery line and train are in compliance with the regulations

and provisions in force;
b all gas connections are tight;
c the boiler room ventilation openings are such that they ensure the air

supply flow required by the current regulations, and in any case are

sufficient for proper combustion.

z Do not use gas pipes to earth electrical equipment.
z Never leave the burner connected when not in use. Always shut the

gas valve off.
z In case of prolonged absence of the user, the main gas delivery

valve to the burner should be shut off.

Precautions if you can smell gas

a do not operate electric switches, the telephone, or any other item

likely to generate sparks;
b immediately open doors and windows to create an air flow to purge

the room;
c close the gas valves;
d contact qualified personnel.
z Do not obstruct the ventilation openings of the room where gas

appliances are installed, to avoid dangerous conditions such as the

development of toxic or explosive mixtures.

DIRECTIVES AND STANDARDS

Gas burners

European directives:

- Directive 90/396/CEE - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/CEE on electromagnetic compatibility

Harmonised standards :

-UNI EN 676 (Gas Burners;

-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;

- EN 50165 (Electrical equipment of non-electric appliances for house­hold and similar purposes. Safety requirements.

Light oil burners

European directives:

- Directive 2006/95/EC on low voltage;

-

Directive 2004/108/

Harmonised standards :

-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;

- EN 50165 (Electrical equipment of non-electric appliances for house­hold and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

European directives:

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/CEE on electromagnetic compatibility

Harmonised standards :

-CEI EN 60335-1 Household and similar electrical appliances - SafetyPart
1: General requirements;

- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

European directives:

- Directive 90/396/CEE Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/CEE on electromagnetic compatibility

Harmonised standards :

-UNI EN 676 Gas Burners

-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;

- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

European directives:

- Directive 90/396/CEE - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/CEE on electromagnetic compatibility

Harmonised standards :

-UNI EN 676 (Gas Burners;

-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;

- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.

National standards :

-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

CEE on electromagnetic compatibility

Heavy oil burners

Gas - Light oil burners

Gas - Heavy oil burners

4

C.I.B. UNIGAS - M039119CE

PART I: INSTALLATION

1

3

4

2

6

5

7

10

11

8

14

13

9

15

12

GENERAL FEATURES

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

Fig. 1
1 Control panel with startup switch
2 Combustion head (inside)
3 Gas valves group
4 Gas proving system
5 Cover
6 Adjusting cam (double-stage, progressive and fully-modulating burners)
7 Actuator (double-stage, progressive and fully-modulating burners)
8 Control box
9 Air pressure switch
10 Fan motor
11 Burner plate
12 Air intake
13 Printed board circuit (PCB)
14 Flange
15 Blast tube

The gas coming from the supply line, passes through the valves group provided with filter and stabiliser. This one forces the pressure in
the utilisation limits. In the double-stage , progressive and fully- modulating burners, the electric actuator (7), that moves proportionally
the air damper and the gas butterfly valve, uses an adjusting cam with variable shape. This one allows the optimisation of the gas flue
values, as to get an efficient combustion. The combustion head (2) positioning determines the burner output. Fuel and comburent are
routed into separated ways as far as the zone of flame generation (combustion chamber). The air (comburent) and fuel (gas, gas oil,
heavy oil) are forced into the combustion chamber.

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

5

C.I.B. UNIGAS - M039119CE

Tipo / Type P6 0
M-...50 (Multibloc DUNGS MB-DLE 420 B01)
M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)

0

5

10

15

20

25

100 200 300 400 500 600 700 800 900

Potenza / Output (kW)

Minima pressione gas in

rete / Minimum inlet gas

pressure (mbar)

Rp 2" (50)

DN65

How to interpret the burner “Performance curve”

To check if the burner is suitable for the boiler to which it must be installled, the following parameters are needed:

z furnace input, in kW or kcal/h (kW = kcal/h / 860);
z backpressure (data are available on the boiler ID plate or in the user’s manual).

Example:
Furnace input: 600kW
Backpressure: 4mbar
In the “Performance curve” diagram (Fig. 2), draw a vertical line matching the furnace input value and an horizontal line matching the

backpressure value. The burner is suitable if the intersection point A is inside the performance curve.

Camp o di l avoro bruci at o ri

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

8
7
6
5
4
3
2
1

combustione mbar

0

Contropressione in camera di

-1
100 200 300 400 500 600 700 800 900

A

Pote nza kW

Fig. 2

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

Checking the proper gas train size

To check the proper gas train size, it is necessary to know the available gas pressure value upstream the burner’s gas valve. Then
subtract the backpressure. The result is called pgas. Draw a vertical line matching the furnace input value (600kW, in the example),
quoted on the x-axis, as far as intercepitng the network pressure curve, according to the installed gas train (DN65, in the example).
From the interception point, draw an horizontal line as far as matching, on the y-axis, the value of pressure necessary to get the reque­sted furnace input. This value must be lower or equal to the p

gas value, calculated before.

Fig. 3

6

C.I.B. UNIGAS - M039119CE

BURNERS SPECIFICATIONS

Burner model identification

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

Type NG550 Model M-. PR. S. .* A. 0. 50

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

(1) BURNER TYPE

(2) FUEL

(3) OPERATION

(4) BLAST TUBE S - standard L - extended

(5) DESTINATION COUNTRY see data plate

(6) BURNER VERSION

(7) EQUIPMENT

(8) GAS CONNECTION 25 = Rp1 32 = Rp1”

NG - Natural gas burner
LG - L.P.G. burner
NGX - Low NOx burners

M - Natural gas
L - LPG

TN - Single stage AB - Double stage

PR - Progressive MD - Fully modulating

A - Standard

0 = 2 gas valves
1= 2 Gas valves + gas proving system (option)
7 = 2 gas valves + maximum gas pressure switch
8= 2 Gas valves + gas proving system (option) + maximum gas pressure switch

1/4 40 = Rp1”1/2 50 = Rp2

Matching the burner to the boiler

The burners described in this manual have been tested with combustion chambers that comply with EN676 regulation and whose
dimensions are described in the diagram . In case the burner must be coupled with boilers with a combustion chamber smaller in dia­meter or shorter than those described in the diagram, please contact the supplier, to verify that a correct matching is possible, with res­pect of the application involved. To correctly match the burner to the boiler verify the necessary input and the pressure in combustion
chamber are included in the burner performance curve; otherwise the choice of the burner must be revised consulting the burner manu­facturer. To choose the blast tube lenght follow the instructions of the boiler manufacturer. In absence of these consider the following:

z Cast-iron boilers, three pass flue boilers (with the first pass in the rear part): the blast tube must protrude no more than 100 mm into

the combustion chamber.

z Pressurised boilers with flame reversal: in this case the blast tube must penetrate at least 50 - 100 mm into combustion chamber in

respect to the tube bundle plate.

The length of the blast tubes does not always allow this requirement to be met, and thus it may be necessary to use a suitably­spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).

Key

a) Heat output in kW
b) Lenght of the flame tube in meters
c) Flame tube firing intensity in MW/m

3

d) Combustion chamber diameter (m)

Fig. 4 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.

Fig. 4

sized

7

Specifications

C.I.B. UNIGAS - M039119CE

BURNERS

Output min. - max kW

Fuel

NG550

M-.TN..0.25

NG550

M-.TN..0.32

NG550

M-.TN..0.40

NG550

M-.TN..0.50

LG550

L-.TN..0.25

245 - 570

Natural gas L.P.G.

Gas category (see next paragraph)

Gas rate

min.- max Stm

3

/h

26 - 60 9.4 - 22

Gas pressure min. - max. mbar (see Note 2)

Power supply

Total power consumption kW

Electric motor) kW

Protection

Approx. weight kg

Valves size / Gas connection

Operation

Operating temperature °C

Storage Temperature °C

Working service*

BURNERS

Output min. - max kW

Fuel

1”

/ Rp 1 1”

NG550

M-.xx..0.25

/Rp 1

1/4

NG550

M-.xx...0.32

1/41”1/2

NG550

M-.xx...0.40

/Rp 1

1/2

Natural gas L.P.G.

230V - 50Hz

2”/ Rp 2

Single stage

-10 ÷ +50

-20 ÷ +60

Internittent

NG550

M-.xx...0.50

160 - 570

0.92

0.62

IP40

55

1”

LG550

L-.xx..0.25

Gas category (see next paragraph)

Gas rate

min.- max Stm

3

/h

17 - 60 6.2 - 22

Gas pressure min. - max. mbar (see Note 2)

Power supply

Total power consumption kW

Electric motor kW

Protection

Approx. weight kg

Valves size / Gas connection

Operation

Operating temperature °C

Storage Temperature °C

Working service*

1”

/ Rp 1 1”

1/4

/Rp 1

/ Rp 1

1/41”1/2

1/2

Double stage - Progressive - Fully-modulating

230V - 50Hz

2” / Rp 2

-10 ÷ +50

-20 ÷ +60

Internittent

0.92

0.62

IP40

55

1”

/ Rp 1 1”

/ Rp 1 1”

LG550

L-.TN..0.32

/Rp 1

1/4

LG550

L-.xx...0.32

/ Rp 1

1/4

L-.TN..0.40

I

3B/P

1/41”1/2

L-.xx...0.40

I

3B/P

1/41”1/2

LG550

/Rp 1

LG550

/ Rp 1

LG550

L-.TN...0.50

2”/ Rp 2

1/2

LG550

L-.xx...0.50

2” / Rp 2

1/2

Note1:

All gas flow rates are referred to Stm

(nett calorific value H

= 34.02 MJ/Stm3); for L.P.G. (nett calorific value Hi = 93.5 MJ/Stm3)

i

3

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

Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE valves)

Minimum gas pressure = see gas curves.

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

8

Low NOx burners

C.I.B. UNIGAS - M039119CE

BURNERS

Output min. - max kW

Fuel

NGX550

M-.xx...0.25

NGX550

M-.xx...0.32

132 - 490

Natural gas

NGX550

M-.xx...0.40

NGX550

M-.xx...0.50

Gas category (see next paragraph)

Gas rate

min.- max Stm

3

/h

14 - 52

Gas pressure min. - max. mbar (see Note 2)

/ Rp 1

230V - 50Hz

0.92

0.62

IP40

55

1/4

1”

-10 ÷ +50

-20 ÷ +60

Internittent

1/2

/ Rp 1

1/2

2” / Rp 2

Power supply

Total power consumption kW

Electric motor kW

Protection

Approx. weight kg

Valves size / Gas connection

Operation

Operating temperature °C

Storage Temperature °C

Working service*

Note1:

All gas flow rates are referred to Stm

(nett calorific value H

= 34.02 MJ/Stm3); for L.P.G. (nett calorific value Hi = 93.5 MJ/Stm3)

i

1”

/ Rp 1 1”

1/4

Double stage - Progressive - Fully-modulating

3

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

Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE valves)

Minimum gas pressure = see gas curves.

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

Country and usefulness gas categories

GAS

CATEGORY

I

2H

I

2E

I

2E( R ) B

I

2L

I

2ELL

I

2Er

AT ES GR SE FI IE HU IS NO CZ DK GB IT PT CY EE LV SI MT SK BG LT RO TR CH

LUPL-----------------------

BE------------------------

NL------------------------

DE------------------------

FR------------------------

COUNTRY

9

Performance curves

0

1

2

3

4

5

6

7

8

9

10

200 250 300 350 400 450 500 550 600 650

-1

0

1

2

3

4

5

6

7

8

9

100 150 200 250 300 350 400 450 500 550 600 650

0

1

2

3

4

5

6

7

8

9

100 200 300 400 500

C.I.B. UNIGAS - M039119CE

NG550 - LG550 Single stage

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

NGX550 Low NOx burner

NG550 - LG550 Double-stage/Progressive

kW

kW

BACK PRESSURE IN

COMBUSTION CHAMBER mbar

kW

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

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

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

10

Pressure in the network/gas rate curves

0

10

20

30

40

50

60

70

20 30 40 50 60 70

Rp 1"¼ (32)

Rp 1"½ (40)

R p 2" (50)

Rp 1" (25)

0

10

20

30

40

50

60

70

15 25 35 45 55 65 75

Rp 1"½ ( 40)

Rp 2" (50)

10

30

50

70

90

110

8 1012141618202224 26

Rp 1" (25)

2

6

10

14

18

22

26

30

8 101214161820222426

Rp 1"¼ (32)

)

Rp 2" (50)

0

20

40

60

80

100

6 8 10 12 14 16 18 20 22 24

Rp 1" (25)

0

5

10

15

20

25

30

5 1015202530

Rp 1"¼ (32)

Rp 2" (50)

Rp 1"½ (40)

0

10

20

30

40

50

60

10 20 30 40 50 60

Rp 1"¼ ( 32)

)

)

)

z Natural gas burners

NG550 Single stage

GAS PRESSURE mbar

C.I.B. UNIGAS - M039119CE

NG550 Double-stage/Progressive

Rp 1"

Rp 1"¼

L.P.G. Burners

z

LG550 L-TN..25 Single stage

GAS PRESSURE mbar

LG550 L-PR.. Double-stage/Progressive

Gas rate Stm3/h

Gas rate Stm3/h

Gas rate Stm3/h

LG550 L-TN..32/40/50 Single stage

Rp 1"½ (40

Gas rate Stm3/h

LG550 L-PR.. Double-stage/Progressive

GAS PRESSURE mbar

z

Low NOx burners

NGX550 Double-stage/Progressive

GAS PRESSURE mbar

Gas rate Stm3/h

Rp 1" (25

Rp 1"½ (40

Rp 2" (50

Gas rate Stm3/h

11

Gas rate Stm3/h

Overall dimensions (mm)

z Standard burners

12

C.I.B. UNIGAS - M039119CE

Recommended boiler drilling jig and burner flange

DN A(S*) A(L*) B(S*) B(L*) C

D

±5mm

E

±5mm

F G H J K L M N Omin Omax P Q R S T W X Y

NG/LG550 25/32 843 943 253 353 590 671 245 426 165 178 384 241 384 M10 247 157 192 174 552 377 175 69 543 533 155

NG/LG550 40 843 943 253 353 590 744 318 426 165 178 384 241 384 M10 247 157 192 174 552 377 175 69 553 533 155

NG/LG550 50 843 943 253 353 590 744 318 426 165 178 384 241 384 M10 247 157 192 174 552 377 175 69 603 533 155

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

Low NOx BurnerLow NOx burners

C.I.B. UNIGAS - M039119CE

13

DN A(S*) A(L*) B(S*) B(L*) C

NGX550 25/32 874 974 253 353 590 671 245 426 176 198 384 241 384 M10 247 157 192 174 552 377 175 69 543 533 168

NGX550 40 874 974 253 353 590 744 318 426 176 198 384 241 384 M10 247 157 192 174 552 377 175 69 553 533 168

NGX550 50 874 974 253 353 590 744 318 426 176 198 384 241 384 M10 247 157 192 174 552 377 175 69 603 533 168

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

D

±5mm

E

±5mm

Recommended boiler drilling jig and burner flangeRecommended boiler

drilling jig and burner flange

F G H J K L M N Omin Omax P Q R S T W X Y

C.I.B. UNIGAS - M039119CE

Keys

1 Burner
2 Fixing nut
3 Washer
4 Sealing gasket
5 Stud bolt
7Blast tube

SIDE UP

SIDE

DOWN

MOUNTINGS AND CONNECTIONS

Packing

urners are despatched in cardboard packages whose dimensions are: 1030mm x 530mm x 570mm (L x P x H)
Packing cases of this type are affected by humidity; the maximum number of cases to be stacked is showed outside the packing.
The following are placed in each packing case.
1 Burner with gas train;
1 gasket to be inserted between the burner and the boiler;
1 envelope containing this manual
When disposing of the burner packing and if the packing is scrapped follow the procedures laid down in the current legislation regarding

the disposal of materials.

Fitting the burner to the boiler

To install the burner into the boiler, proceed as follows:
1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)
2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;
3 place the 4 stud bolts (5) on boiler’s door, according to the burner’s drilling template described on paragraph “Overall dimensions”;
4 fasten the 4 stud bolts;
5 place the gasket on the burner flange;
6 install the burner into the boiler;
7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture.
8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate

insulating material (ceramic fibre cord or refractory cement).

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

14

C.I.B. UNIGAS - M039119CE

1

2

3

4

5

78

9

4

MANUFACTURER INSTALLER

GAS TRAIN CONNECTIONS

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

ATTENTION: BEFORE EXECUTING THE CONNECTIONS TO THE GAS PIPE NETWORK, BE SURE THAT THE
MANUAL CUTOFF VALVES ARE CLOSED. READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING
OF THIS MANUAL.

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

Key

1 Burner
2 Butterfly valve
3 Gas proving system (option)
4 Low gas pressure switch
5 High gas pressure switch (option)
7 Bellow joint
8 Manual cutoff valve
9 MB-DLE valve group
*Note: the high gas pressure switch can be mounted either upstream the gas valve or downstream the gas valves but upstream the but-

terfly gas valve.
To mount the gas train, proceed as follows:

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

2) fasten all the items by means of screws, according to the next diagrams, observing the mounting direction for each item.
NOTE: the bellow joint, the manual valve and the gaskets are not part of the standard supply.

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

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

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

MULTIBLOC DUNGS MB-DLE 405..412
Mounting

1. Mount flange onto tube lines: use appropriate sealing agent (see Fig. 7);

2. insert MB-DLE: note position of O rings (see Fig. 7);

3. tighten screws A, B, C and D (Fig. 5 - Fig. 6), accordind to the mounting positions (Fig. 8);

4. after installation, perform leakage and functional test;

5. disassembly in reverse order.

15

C.I.B. UNIGAS - M039119CE

A

B

DC

MOUNTING POSITIONS

A

B

C

D

C

B

D

A

MOUNTING POSITIONS

Fig. 5 Fig. 6 Fig. 7 Fig. 8

MULTIBLOC DUNGS MB-DLE 415..420

Mounting

1. Loosen screws A and B do not unscrew (Fig. 5 - Fig. 6).

2. unscrew screws C and D (Fig. 5 - Fig. 6).

3. Remove MultiBloc between the threaded flanges (Fig. 6).

4. After mounting, perform leakage and functional tests.

Fig. 9 Fig. 10 Fig. 11 Fig. 12

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

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

Gas Proving System VPS504 (Option)

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

To install the DUNGS VPS504 gas proving system on the MD-DLE valves group, proceed as follows:
1 turn off gas supply.;
2 Switch off power supply.
3 remove the Multibloc’s screw plugs (Fig. 13-A);
4 iInsert sealing rings (10,5 x 2,25) into VPS 504 (Fig. 14-B, Fig. 13-B)
5 Torque screws 3, 4, 5, 6 (M4 x16) Fig. 13-C

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

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

16