PART I - INSTALLATION .......................................................................................................................................... 5
Country and usefulness gas categories .......................................................................................................................................... 7
Pressure in the network / gas flow rate curves ........................................................................................................................... 11
MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 13
Fitting the burner to the boiler ....................................................................................................................................................... 13
Matching the burner to the boiler................................................................................................................................................... 13
Installing the gas train ................................................................................................................................................................... 14
Power supply without neutral ........................................................................................................................................................ 16
ADJUSTING THE AIR AND GAS FLOW RATES ......................................................................................................................... 17
Combustion head pressure curves vs. the gas flow rate .............................................................................................................. 17
Measuring the gas pressure in the combustion head ................................................................................................................... 17
Plugs for pressure measurement .................................................................................................................................................. 18
Pressure in combustion head - gas rate curves ............................................................................................................................ 18
Adjusting the air and gas flow rates .............................................................................................................................................. 19
Adjusting the combustion head ..................................................................................................................................................... 20
Adjustements for single-stage burners ......................................................................................................................................... 20
Calibration of air and gas pressure switches ................................................................................................................................ 23
Calibration of air pressure switch (only for single stage burners) ................................................................................................. 23
Calibration of air pressure switch (double-stage, progressive and fully-modulating) .................................................................... 23
Calibration of low gas pressure switch .......................................................................................................................................... 23
Adjusting the high gas pressure switch (when provided) .............................................................................................................. 23
PART II: OPERATION ............................................................................................................................................. 24
PART III: MAINTENANCE ....................................................................................................................................... 25
Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................ 25
Removing the combustion head ................................................................................................................................................... 26
Checking the detection current ..................................................................................................................................................... 27
SPARE PARTS ........................................................................................................................................................................... 29
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
zThe equipment must be installed in compliance with the regulations
in force, following the manufacturer’s instructions, by qualified personnel.
zQualified 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.
zImproper installation may cause injury to people and animals, or
damage to property, for which the manufacturer cannot be held liable.
zRemove 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.
zBefore 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.
zMake sure that inlet or exhaust grilles are unobstructed.
zIn 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.
zWhen a decision is made to discontinue the use of the equipment,
those parts likely to constitute sources of danger shall be made har-
mless.
zIn 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.
zFor all the units that have been modified or have options fitted then
original accessory equipment only shall be used.
zThis 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
zThe 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.
zOnly burners designed according to the regulations in force should
be used.
zThis burner should be employed exclusively for the use for which it
was designed.
zBefore connecting the burner, make sure that the unit rating is the
same as delivery mains (electricity, gas oil, or other fuel).
zObserve caution with hot burner components. These are, usually,
near to the flame and the fuel pre-heating system, they become hot
during the unit operation and will remain hot for some time after the
burner has stopped.
When the decision is made to discontinue the use of the burner, the user
shall have qualified personnel carry out the following operations:
aRemove 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
zMake sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.
zBefore the burner is started and, thereafter, at least once a year,
have qualified personnel perform the following operations:
aset the burner fuel flow rate depending on the heat input of the
appliance;
bset 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;
ccheck 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;
dmake sure that control and safety devices are operating properly;
emake sure that exhaust ducts intended to discharge the products of
combustion are operating properly;
fon completion of setting and adjustment operations, make sure that
all mechanical locking devices of controls have been duly tightened;
gmake sure that a copy of the burner use and maintenance instruc-
tions is available in the boiler room.
zIn 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.
zThe 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
zFor safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.
zIt 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.
zQualified 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.
zNo adaptors, multiple outlet sockets and/or extension cables are per-
mitted to connect the unit to the electric mains.
zAn omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.
zThe 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;
zThe 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
zThe 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.
zBefore 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.
zBefore the burner is commissioned, qualified personnel should ins-
pect the following:
athe fuel supply system, for proper sealing;
bthe fuel flow rate, to make sure that it has been set based on the
firing rate required of the burner;
cthe burner firing system, to make sure that it is supplied for the desi-
gned fuel type;
dthe fuel supply pressure, to make sure that it is included in the range
shown on the rating plate;
ethe 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.
zWhen 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:
athe gas delivery line and train are in compliance with the regulations
and provisions in force;
ball gas connections are tight;
cthe 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.
zDo not use gas pipes to earth electrical equipment.
zNever leave the burner connected when not in use. Always shut the
gas valve off.
zIn 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
ado not operate electric switches, the telephone, or any other item
likely to generate sparks;
bimmediately open doors and windows to create an air flow to purge
the room;
cclose the gas valves;
dcontact qualified personnel.
zDo 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/CEE on electromagnetic compatibility
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
Heavy oil burners
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
Gas - Light oil 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.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Gas - Heavy oil 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.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
4
C.I.B. UNIGAS - M039135CG
PART I - INSTALLATION
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type NG90 Model M-. AB. S. .* A. 0. 15
(1) (2) (3) (4) (5) (6) (7) (8)
NG - Natural gas burner
(1) BURNER TYPE
(2) FUELM - Natural gas L - LPG
(3) OPERATION
(4) BLAST TUBES - standard L - extended
(5) DESTINATION COUNTRY* - see data plate
(6) BURNER VERSIONA - Standard
(7) EQUIPMENT
(8) GAS CONNECTION
LG - L.P.G. burner
NGX - Natural gas Low NOx burners
TN - Single stage AB - Double stage
0 = 2 gas valves
1= 2 Gas valves + gas proving system (option)
10= 3/8” = Rp1/2 15= 1/2” = Rp1/2 20= 3/4” = Rp3/4
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.
Pressure in the network / gas flow rate curves
L.P.G. Burners
NG70 M-.TN...
35
30
25
20
15
10
5
GAS PRESSURE mbar
0
2345 6789
NG90 M-.TN...
50
45
40
35
30
25
20
15
10
5
GAS PRESSURE mbar
0
45678910
L.P.G. Burners
LG70 L-.TN...
14
12
10
8
6
4
2
GAS PRESSURE mbar
0
11,5 22,53
Rp ½" (10)
Rp ½" (15)
Gas rate Stm3/h
Rp ½" (10)
Rp ½" (15)
Rp ¾" (20)
Gas rate Stm3/h
Rp ½" (10)
Rp ½" (15)
Gas rate Stm3/h
NG70 M-.AB...
32
28
24
20
16
12
8
4
0
1234 56 78
Rp ½" (10)
NG90 M-.AB...
45
40
Rp ½" (10)
35
30
25
20
15
10
5
0
234567 8910
LG70 L-.AB...
12
10
8
6
4
2
0
0,511,522,53
Rp ½" (10)
kW
Rp ½" (15)
Gas rate Stm3/h
Rp ½" (15)
Rp ¾" (20)
Gas rate Stm3/h
Rp ½" (15)
Gas rate Stm3/h
11
C.I.B. UNIGAS - M039135CG
,
,
,
,
)
)
LG90 L-.TN...
18
16
14
12
10
8
6
4
GAS PRESSURE mbar
2
11,522,533,54
Low NOx burners
NGX70 M-.TN...
26
24
22
20
18
16
14
12
10
8
GAS PRESSURE mbar
6
45678
Rp ½" (10)
Rp ½" (15
Rp ½" (15)
Gas rate Stm3/h
Rp ¾" (20
Gas rate Stm3/h
LG90 L-.AB...
18
16
14
12
10
8
6
4
2
0
51
0
52
Rp ½" (10)
Rp ½" (15)
53
Gas rate Stm3/h
NGX70 M-.AB...
26
24
22
20
18
16
14
12
10
8
6
4
2
0
23456 78
Rp ½" (15)
Rp ¾" (20)
Gas rate Stm3/h
5
12
C.I.B. UNIGAS - M039135CG
MOUNTINGS AND CONNECTIONS
Packing
.The burners are despatched in cardboard packages whose dimensions are: 400mm x 300mm x 520mm (L x P x H)
Packing cases of this type are affected by humidity; the maximum number of cases to be stacked is indicated outside the packing.
The following are placed in each packing case.
1Burner with gas train;
1gasket to be inserted between the burner and the boiler;
1envelope 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:
1on the boiler’s door hole, fix the 4 stud bolts according to the drilling template showed on paragraph “Overall dimensions”
2fix the flange of the burner to the boiler;
3install the burner into the boiler;
4according to the reference showed on Fig. 2, fix the flange to the boiler’s stud bolts D, without completely fastening;
5loosen the VS screws in order to let the blast tube move back and forth;
6install the burner making the blast tube move into the flange as to reach the right position according to the boiler/utilisation
7fasten the VS screws:
8tighten the 4 stud blolts D completely;
9seal the space between the blast tube and the refractory lining with appropriate insulating material (ceramic fibre cord or refractory
cement).
D
VSD
Fig. 1Fig. 2
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 suitably-
sized
13
C.I.B. UNIGAS - M039135CG
spacer to move the burner backwards or to design a blast tube tha suites the utilisation (please, contact the manifacturer).
Key
a) Heat output in kW
b) Lenght of the flame tube in meters
c) Flame tube firing intensity in MW/m
3
d) Combustion chamber diameter (m)
Fig. 3 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.
Fig. 3
Installing the gas train
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.
The following diagram 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.
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.
14
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