Unigas NG280, NG350, NG400, NGX280, NGX350 Instructions For Installation, Use And Maintenance Manual

BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES -

ГОРЕЛКИ

Microprocessor-controlled

gas burners

MANUAL OF INSTALLATION - USE - MAINTENANCE

NG280 - NG350 - NG400

NGX280 - NGX350 - NGX400

LG280 - LG350 - LG400

M039233CA Rel. 0.1 09/2010

TABLE OF CONTENTS

WARNINGS ................................................................................................................................................................ 3

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

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

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

BURNER FEATURES ..................................................................................................................................................................... 7

Burner model identification ............................................................................................................................................................. 7

Technical specifications .................................................................................................................................................................. 7

Low NOx burners Technical specifications ..................................................................................................................................... 9

Country and usefulness gas categories ........................................................................................................................................ 10

Performance Curves ..................................................................................................................................................................... 11

Pressure in the network - gas flow rate curves ............................................................................................................................ 13

Combustion head pressure curves vs. the gas flow rate .............................................................................................................. 15

Measuring the gas pressure in the combustion head ................................................................................................................... 15

Pressure in the combustion head vs. gas flow rate curves ........................................................................................................... 16

Overall dimensions ....................................................................................................................................................................... 18

MOUNTINGS AND CONNECTIONS ............................................................................................................................................ 20

Packing ......................................................................................................................................................................................... 20

Fitting the burner to the boiler ....................................................................................................................................................... 20

Matching the burner to the boiler .................................................................................................................................................. 20

How to modify the blast tube length .............................................................................................................................................. 21

Gas Train Reversal ....................................................................................................................................................................... 22

GAS TRAIN CONNECTIONS ....................................................................................................................................................... 24

.ELECTRICAL CONNECTIONS ................................................................................................................................................... 26

Connectors wiring diagrams ......................................................................................................................................................... 27

User interface ................................................................................................................................................................................ 29

Setting menu ................................................................................................................................................................................. 30

PHASE LIST ................................................................................................................................................................................. 31

Entering the Parameter levels ....................................................................................................................................................... 31

Info level ........................................................................................................................................................................................ 32

Service level .................................................................................................................................................................................. 34

SETTING GAS AND AIR FLOW RATE ........................................................................................................................................ 36

Startup Output ............................................................................................................................................................................... 36

Adjustments - brief description ...................................................................................................................................................... 36

Adjusting procedure ...................................................................................................................................................................... 37

Adjusting the combustion head ..................................................................................................................................................... 38

Fully modulating burners ............................................................................................................................................................... 38

ibratio

Cal

Calibration of air pressure switch .................................................................................................................................................. 39

Calibration of low gas pressure switch .......................................................................................................................................... 39

Adjusting the maximum gas pressure switch (when provided) ..................................................................................................... 39

PGCP Gas leakage pressure switch (witn Siemens LDU burner control/Siemens LMV Burner Management System) ............. 39

n of air and gas pressure switches ................................................................................................................................ 39

PART II: OPERATION ............................................................................................................................................. 40

OPERATION................................................................................................................................................................................. 40

PART III: MAINTENANCE ....................................................................................................................................... 42

ROUTINE MAINTENANCE ........................................................................................................................................................... 42

Removing the filter in the MULTIBLOC DUNGS MB-DLE 405..412 ............................................................................................. 42

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 ............................................................................................. 43

Adjusting the electrodes position .................................................................................................................................................. 45

Checking the detection current ..................................................................................................................................................... 45

Extraneous lightExtraneous light .................................................................................................................................................. 45

Seasonal stop ............................................................................................................................................................................... 45

Burner disposal ............................................................................................................................................................................. 45

BURNER EXPLODED VIEW ........................................................................................................................................................ 46

SPARE PARTS ............................................................................................................................................................................. 48

ELECTRICAL WIRING DIAGRAMS ............................................................................................................................................. 49

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

 The equipment must be installed in compliance with the regulations

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

 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.

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

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

 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.

 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.

 Make sure that inlet or exhaust grilles are unobstructed.
 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.
 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.
 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.
 For all the units that have been modified or have options fitted then

original accessory equipment only shall be used.
 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

 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.
 Only burners designed according to the regulations in force should

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

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

same as delivery mains (electricity, gas oil, or other fuel).
 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

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

valve and remove the control handwheels from their spindles.

Special warnings

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

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

 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.
 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.
 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

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

as required by current safety regulations.
 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.
 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.
 No adaptors, multiple outlet sockets and/or extension cables are per-

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

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

few basic rules, for example:

the hand-opera

ted shut-off

- 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;

 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

 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.

 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.

 Before the burner is commissioned, qualified personnel should

inspect 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.
 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.

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

gas valve off.
 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.
 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 2009/142/EC - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC 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/EC on electromagnetic compatibility

Harmonised standards

-CEI EN 60335
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/EC 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 2009/142/EC - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC 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 2009/142/EC - Gas Appliances;

- Directive 2006/95/EC on low voltage;

- Directive 2004/108/EC 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

-1(Household and similar electrical appliances - Safety.

:

Heavy oil burners

Gas - Light oil burners

Gas - Heavy oil burners

4

GENERAL FEATURES

PART I: INSTALLATION

3

4

1

2

5

6

The control system is made of the Siemens LMV central unit that performs all the burner control functions and of the Siemens AZL local
programming unit that interfaces the system with the user.

Fig. 1

Keys

1 Burner
2 AZL2..
3 Air actuator
4 Fuel actuator
5LMV2..
6 Output modulatore (only for fully-modulating models)
The burner shown is indicative.

The gas coming from the supply line, passes through the valves group provided with filter and governor. This one forces the pressure in
the utilisation limits. In the double-stage , progressive and fully- modulating burners, the electric actuator, that moves proportionally the
air damper and the gas butterfly valve, is controlled by the LMV2 Burner Management System (BMS). This one allows the optimisation
of the gas flue values, as to get an efficient combustion. The combustion head positioning determines the burner’s 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

How to interpret the burner’s “Performance curve”

Campo di lavoro bruciatori

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

-1

0

1

2

3

4

5

6

7

8

100 200 300 400 500 600 700 800 900

Pote nza kW

Contropressione in camera di

combustione mbar

A

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

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

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

Example:
Furnace input: kW 600
Backpressure: mbar 4
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.

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 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

BURNER FEATURES

Burner model identification

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

Type NG400 Model M-. PR. S. * A. 0. 50. EA

(1) (2) (3) (4) (5) (6) (7) (8) (9)

NG - Natural gas burners

(1) BURNER TYPE

LG - L.P.G. burners
NGX - Low NOx burners

(2) FUEL

M - Natural gas L - LPG

(3) PR - Progressive MD - Fully modulating
(4) BLAST TUBE S - standard L - extended M - modular

(5) DESTINATION COUNTRY

(6) BURNER VERSION

(7) EQUIPMENT

(8) GAS CONNECTION

(9) GAS CONNECTION

* see data plate

A - Standard

0 = 2 gas valves
1= 2 Gas valves + gas proving system)

15 = Rp1/2 20 = Rp3/4 25 = Rp1 32 = Rp1

EA = micro-processor controlled burner (LMV2x)

EB = micro-processor controlled burner (LMV3x)

¼ 40 = Rp1 ½ 50 = Rp2

Technical specifications

BURNER TYPE

Output min.- max. kW

Fuel

Category

Gas rate

Gas Pressure min.- max. mbar

Power supply

Total power consumption kW

Electric motor kW

Protection

Valves size

Operation

Operating temperature °C

Storage Temperature °C

Working service*

Output

Fuel

Category

Gas rate

Gas pressure

Power supply

Total power consumption

Electric motor

Protection

Valves size

Operation

Operating temperature

Storage Temperature

Working service *

/ Gas connection

BURNER TYPE

/ Gas connection

min.- max. (Stm

min.- max. kW 80 - 330 85 - 330

min.- max. (Stm

min.- max. mbar (Note2)

kW 0,67

kW 0,37

°C -10 ÷ +50

°C -20 ÷ +60

NG280

M-.xx...x.25

3

/h)

1” / Rp 1

NG350

M-.xx...x.25

(see next paragraphsee next paragraph)

3

8.5 – 35 8.5 – 35 8.5 – 35 3 – 13 3 – 13 3 – 13

/h)

1” / Rp 1

NG280

M-.xx...x.32

Natural gas L.P.G.

(see next paragraph)

7 – 32 2,5 – 11,5

1” ¼ / Rp 1

NG350

M-.xx...x.32

Natural gas L.P.G.

1” ¼ / Rp 1

NG280

M-.xx...x.40

230V - 50Hz

¼

1” ½ / Rp 1” ½ 1” / Rp1 1” / Rp1

Progressive - Fully modulating

-10 ÷ +50

-20 ÷ +60

Intermittent

NG350

M-.xx...x.40

230V - 50Hz

¼

1” ½ / Rp 1½ 1” / Rp1

Progressive - Fully modulating

Intermittent

L-.xx...x.20

65 - 300

(Note2)

0,55

0,25

IP40

IP40

LG280

LG350

L-.xx...x.25

I

3B/P

L-.xx...x.25

1”

LG280

I

3B/P

LG350

L-.xx...x.32

I

3B/P

/ Rp 1

1/4

L-.xx...x.32

1”

1/4

L-.xx...x.40

1/41”1/2

LG280

/ Rp 1

LG350

I

3B/P

/ Rp 1

1/4

1/2

7

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply

Total power consumption

Electric motor

Protection

Valves size

/ Gas connection

Operation

Operating temperature

Storage Temperature

Working service *

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply

Total power consumption

Electric motor

Protection

Valves size

/ Gas connection

Operation

Operating temperature

Storage Temperature

Working service *

NG400

M-.xx...x.25

NG400

M-.xx...x.32

min.- max. kW 115 - 420

Natural gas

(see next paragraph)

min.- max. (Stm

3

/h)

12 - 44.5

min.- max. mbar (Note2)

230V - 50Hz

kW 0,67/0,75

kW 0,37/0,45

IP40

1” / Rp 1

1” ¼ / Rp 1

¼

Progressive - Fully modulating

°C -10 ÷ +50

°C -20 ÷ +60

Intermittent

LG400

L-.xx...x.25

LG400

L-.xx...x.32

min.- max. kW 105 - 420

L.P.G.

min.- max. (Stm

3

/h)

4 - 16

min.- max. mbar (Note2)

230V - 50Hz

kW 0,67/0,75

kW 0,37/0,45

1” / Rp 1

1” ¼ / Rp 1

¼

Progressive - Fully modulating

°C -10 ÷ +50

°C -20 ÷ +60

Intermittent

NG400

M-.xx...x.40

1” ½ / Rp 1” ½ 2” / Rp 2

LG400

L-.xx...x.40

I

3B/P

IP40

1” ½ / Rp 1” ½ 2” / Rp 2

NG400

M-.xx...x.50

LG400

L-.xx...x.50

Note1:

All gas flow rates are referred to Stm

calorific value H

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

i

3

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

Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC 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 Technical specifications

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply

Total power consumption

Electric motor

Protection

Valves size

/ Gas connection

Operation

NOx emissions

Operating temperature

Storage Temperature

Working service *

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply

Total power consumption

Electric motor

Protection

Valves size

/ Gas connection

Operation

NOx emissions

Operating temperature

Storage Temperature

Working service *

NGX280

M-.xx...x.25

NGX280

M-.xx...x.32

min.- max. kW 60 - 190

Natural gas

(see next paragraph)

min.- max. (Stm

3

/h)

6,4 - 20

min.- max. mbar (Note2)

230V - 50Hz

kW 0,55

kW 0,25

IP40

/ Rp 1

1” / Rp1

1”

1/4

Progressive - Fully modulating

Class 3 - EN676/2008

°C -10 ÷ +50

°C -20 ÷ +60

Intermitent

NGX350

M-.xx...x.25

NGX350

M-.xx...x.32

min.- max. kW 65 - 260

Natural gas

(see next paragraph)

min.- max. min.-

max.(Stm

3

/h)

7 - 27.5

min.- max. mbar (Note2)

230V - 50Hz

kW 0,67

kW 0,37

IP40

/ Rp 1

1” / Rp1

1”

1/4

Progressive - Fully modulating

Class 3 - EN676/2008

°C -10 ÷ +50

°C -20 ÷ +60

Intermitent

NGX280

M-.xx...x.40

1”

1/4

1/4

/ Rp 1

1/2

NGX350

M-.xx...x.40

1”

/ Rp 1

1/2

1/2

1/2

Note1:

All gas flow rates are referred to Stm

calorific value H

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

i

3

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

Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC 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.

9

BURNER TYPE

Output

Fuel

Category

Gas rate

Gas pressure

Power supply

Total power consumption

Electric motor

Protection

Valves size

Operation

NOx emissions

Operating temperature

Storage Temperature

Working serivce *

/ Gas connection

NGX400

M-.xx...x.25

NGX400

M-.xx...x.32

min.- max. kW 90 - 350

Natural gas

(see next paragraph)

min.- max. (Stm

3

/h)

9.5 - 37

min.- max. mbar (Note2)

230V - 50Hz

kW 0,67/0,75

kW 0,37/0,45

IP40

1” / Rp 1

1” ¼ / Rp 1

¼

Progressive - Fully modulating

Class 3 - EN676/2008

°C -10 ÷ +50

°C -20 ÷ +60

Intermittent

NGX400

M-.xx...x.40

NGX400

M-.xx...x.50

1” ½ / Rp 1” ½ 2” / Rp 2

Note1:

All gas flow rates are referred to Stm

calorific value H

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

i

3

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

Note2: Maximum gas pressure = 360mbar (with Dungs MBDLE/MBC 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 G SE FI IE HU IS N CZ DK GB IT PT CY EE LV SI MT SK BG LT R TR CH

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

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

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

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

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

COUNTRY

10

Performance Curves

0

1

2

3

4

5

6

7

50 100 150 200 250 300 350

0

2

4

6

50 100 150 200 250 300 350 400

0

1

2

3

4

5

6

7

8

9

100 150 200 250 300 350 400 450

0

1

2

3

4

5

6

7

50 100 150 200 250 300 350

0

2

4

6

50 100 150 200 250 300 350

0

2

4

6

8

50 100 150 200 250 300 350 400 450

 Gas burners

BACK PRESSURE IN

BACK PRESSURE IN

NG280

COMBUSTION CHAMBER mbar

NG400

COMBUSTION CHAMBER mbar

kW

kW

NG350

kW

L.P.G. Burners



LG280

BACK PRESSURE IN

CCOMBUSTION CHAMBER mbar

LG400

LG350

kW

kW

BACK PRESSURE IN

CCOMBUSTION CHAMBER mbar

kW

11

 Low NOx burners

0

1

2

3

4

5

6

40 80 120 160 200

0

1

2

3

4

5

6

7

50 100 150 200 250 300

0

1

2

3

4

5

6

7

8

9

50 100 150 200 250 300 350 400

NGX280

BACK PRESSURE IN

CCOMBUSTION CHAMBER mbar

NGX350

kW

NGX400

BACK PRESSURE IN

CCOMBUSTION CHAMBER mbar

kW

kW

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.

12

Pressure in the network - gas flow rate curves

0

20

40

60

80

10 0

5 10 152025303540

Rp 1" (25)

Rp 1"¼ (32)

Rp ¾" (20)

Rp ½" (15)

0

20

40

60

80

100

5 1015202530354045

Rp 1" (25)

Rp 1"½ (40)

Rp 1"¼ (32)

Rp ½" (15)

Rp ¾" (20)

0

2

4

6

8

10

12

14

16

18

10 15 20 25 30 35 40 45 50 55

Rp 1"¼ (32)

Rp 1"½ (40)

Rp 2" (50)

0

10

20

30

40

50

2468101214

Rp 1"¼ (32)

)

0

10

20

30

40

50

60

2 4 6 8 10 12 14 16

Rp 1"¼ (32)

Rp 1" (25)

Rp ¾1" (20)

Rp ½" (15)

0

10

20

30

40

50

60

70

2 4 6 8 10 12 14 16 18 20

Rp 1"½ (40)

Rp 1" (25)

Rp 1"¼ (32)

Rp ½" (15)

Rp ¾" (20)

 Gas burners

NG280 M-.AB...

GAS PRESSURE mbar

NG350 M-.PR/MD...

Gas rate Stm3/h

NG400 M-.PR/MD...32-40-50

GAS PRESSURE mbar



L.P.G. Burners

LG280 L-.AB...

Gas rate Stm3/h

Gas rate Stm3/h

LG350 L-.PR....

Rp ½" (15)

Rp ¾" (20

Rp 1" (25)

GAS PRESSURE mbar

LG400 L-.PR/MD....

GAS PRESSURE mbar

Caution: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis (pressure value in
the combustion chamber is not included). To know the minimum pressure at the gas train inlet, necessary to get the reque­sted gas rate, add the pressure value in the combustion chamber to the value read on the y-axis.

Gas rate Stm3/h

Gas rate Stm3/h

Gas rate Stm3/h

13

Low NOx burners

0

5

10

15

20

25

30

4 6 8 101214161820222426

Rp 1"¼ (32)

Rp 1"½ (40)

Rp 1" (25)

Rp ¾" (20)

0

10

20

30

40

50

60

70

80

5 101520253035

Rp 1" (25)

Rp 1"½ (40)

Rp 1"¼ (32)

Rp ¾" (20)

Rp ½" (15)

0

20

40

60

80

100

5 101520253035404550

Rp 1" (25)

Rp ½" (15)

Rp ¾" (20)

0

2

4

6

8

10

12

14

16

5 101520253035404550

Rp 1"¼ (32)

Rp 1"½ (40)

Rp 2" (50)



NGX280

GAS PRESSURE mbar

NGX350

Gas rate Stm3/h

Gas rate Stm3/h

NGX400 M-...15-20-25

NGX400 M-...32-40-50

GAS PRESSURE mbar

Gas rate Stm3/h

Gas rate Stm3/h

Caution: the gas rate value is quoted on the x-axis, the related network pressure is quoted on the y-axis (pressure value in
the combustion chamber is not included). To know the minimum pressure at the gas train inlet, necessary to get the reque­sted gas rate, add the pressure value in the combustion chamber to the value read on the y-axis.

14

Combustion head pressure curves vs. the gas flow rate

2

4

3

1

Fan air pressure plug

Pressure plug in combustion chamber

Fig. 5

Curves are referred to pressure= 0mbar in the combustion head!

The curves referred to the gas pressure in the combustion head, depending on the gas flow rate, are referred to the burner in the com­bustion stage (percentage of residual O
dard limits). During this stage, the combustion head, the gas butterfly valve and the servocontrol are at the maximum opening. Refer to
Fig. 4, showing the correct way to measure the gas pressure, considering the values of pressure in combustion chamber, surveyed by
means of the pressure gauge or taken from the boiler’s Technical specifications.

in the flues as shown in the “Recommended combustion values” table and CO in the stan-

2

Fig. 4

Key

1 Generator
2 Pressure outlet on the combustion chamber
3 Gas pressure outlet on the butterfly valve
4 Differential pressure gauge

Measuring the gas pressure in the combustion head

In order to measure the pressure in the combustion head, insert the pressure gauge probes: one into the generator’s pressure outlet
(Fig. 4-2) to get the pressure in the combustion chamber and the other one into the butterfly valve’s pressure outlet of the burner (Fig.
4-3). On the basis of the measured differential pressure, it is possible to get the maximum flow rate: in the pressure - rate curves (sho­wed on the next paragraph), it is easy to get the burner output in kW or Stm3/h (quoted on the x axis) from the pressure measured in
the combustion head (quoted on the y axis).

NOTE: THE PRESSURE-RATE CURVES ARE APPROXIMATE; FOR A PROPER SETTING OF THE GAS RATE, PLEASE REFER
TO THE GAS METER READING.

To measure the pressure in the combustion chamber, as far as the IDEA series, a pressure plug is provided upstream the burner’s
blast tube.

15

Pressure in the combustion head vs. gas flow rate curves

0

2

4

6

8

10

12

14

16

610141822263034

0

2

4

6

8

10

12

5 10152025303540

0

1

2

3

4

5

6

7

8

9

10 15 20 25 30 35 40 45

0

2

4

6

8

10

12

14

16

18

2345678910111213

0

5

10

15

20

25

2468101214

0

5

10

15

20

4 6 8 1012141618

 Natural gas burners

NG280

combustion head

Gas backpressure in

Gas rate Stm3/h

NG350

NG400

combustion head

Gas backpressure in

 L.P.G. Burners

LG280

combustion head

Gas backpressure in

LG350

Gas rate Stm

3

Gas rate Stm3/h

/h

LG400

Gas rate Stm3/h

combustion head

Gas backpressure in

Gas rate Stm3/h

Gas rate Stm3/h

16

Low NOx burners

0

2

4

6

8

10

12

14

468101214161820

0

2

4

6

8

10

12

14

16

18

6 8 10 12 14 16 18 20 22 24 26 28 30

0

1

2

3

4

5

6

7

8

9

10

5 10152025303540



NGX280

combustion head

Gas backpressure in

Gas rate Stm3/h

combustion head

Gas backpressure in

NGX350

Gas rate Stm

NGX400

3

/h

Gas rate Stm3/h

17

Overall dimensions (mm)

z Standard burners

18

DN A(S*) A(L*) B(S*) B(L*) C D ±5mm E ±5mm F G H Y K1 K2 L M N Omin Omax P Q R S T W X

NG280 M-..PR..Ex
NG280 M-..PR..Ex
NG280 M-..PR..Ex

NG280 M-..PR..Ex
NG280 M-..MD..Ex
NG280 M-..MD..Ex
NG280 M-..MD..Ex
NG280 M-..MD..Ex

NG350 M-..PR..Ex
NG350 M-..PR..Ex
NG350 M-..PR..Ex
NG350 M-..PR..Ex
NG350 M-..MD..Ex
NG350 M-..MD..Ex
NG350 M-..MD..Ex
NG350 M-..MD..Ex

0.25 (1") 733 878 163 308 570 596 200 396 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.32 (1"1/4) 733 878 163 308 570 596 200 396 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.40 (1"1/2) 733 878 163 308 570 726 330 396 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 517 491

0.50 (2") 733 878 163 308 570 726 330 396 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 567 491

0.25 (1") 733 878 163 308 570 668 200 468 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.32 (1"1/4) 733 878 163 308 570 668 200 468 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.40 (1"1/2) 733 878 163 308 570 798 330 468 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 517 491

0.50 (2") 733 878 163 308 570 798 330 468 113 164 108 215 223 348 M10 219 131 179 155 459 366 93 128 567 491

DN A(S*)A(L*)B(S*)B(L*) C D ±5mmE ±5mm F G H Y K1 K2 L M N OminOmax P Q R S T W X

0.25 (1") 748 878 178 308 570 596 200 396125164144215223348M10219 131 179 1554593669389508491

0.32 (1"1/4) 748 878 178 308 570 596 200 396125164144215223348M10219 131 179 1554593669389508491

0.40 (1"1/2) 748 878 178 308 570 726 330 396125164144215223348M10219 131 179 1554593669389517491

0.50 (2") 748 878 178 308 570 726 330 396125164144215223348M10219 131 179 1554593669389567491

0.25 (1") 748 878 178 308 570 668 200 468125164144215223348M10219 131 179 1554593669389508491

0.32 (1"1/4) 748 878 178 308 570 668 200 468125164144215223348M10219 131 179 1554593669389508491

0.40 (1"1/2) 748 878 178 308 570 798 330 468125164144215223348M10219 131 179 1554593669389517491

0.50 (2") 748 878 178 308 570 798 330 468125164144215223348M10219 131 179 1554593669389567491

When PGMAX (maximum pressure switch) is supplied, add 60mm to "D" and "E"

Boiler recommended drilling template and burner

flange

NG400 M-..PR..Ex
NG400 M-..PR..Ex
NG400 M-..PR..Ex
NG400 M-..PR..Ex
NG400 M-..MD..Ex
NG400 M-..MD..Ex
NG400 M-..MD..Ex
NG400 M-..MD..Ex

NGX280 M-..PR..Ex
NGX280 M-..PR..Ex
NGX280 M-..PR..Ex
NGX280 M-..PR..Ex
NGX280 M-..MD..Ex
NGX280 M-..MD..Ex
NGX280 M-..MD..Ex
NGX280 M-..MD..Ex

NGX350 M-..PR..Ex

19

NGX350 M-..PR..Ex
NGX350 M-..PR..Ex
NGX350 M-..PR..Ex
NGX350 M-..MD..Ex
NGX350 M-..MD..Ex
NGX350 M-..MD..Ex
NGX350 M-..MD..Ex

DN A(S*)A(L*)B(S*)B(L*) C D ±5mmE ±5mm F G H Y K1 K2 L M N OminOmax P Q R S T W X

0.25 (1") 768 898 198 328 570 596 200 396144164144215223348M10219 131 179 1554593669389508496

0.32 (1"1/4) 768 898 198 328 570 596 200 396144164144215223348M10219 131 179 1554593669389508496

0.40 (1"1/2) 768 898 198 328 570 726 330 396144164144215223348M10219 131 179 1554593669389517496

0.50 (2") 768 898 198 328 570 726 330 396144164144215223348M10219 131 179 1554593669389567496

0.25 (1") 768 898 198 328 570 668 200 468144164144215223348M10219 131 179 1554593669389508496

0.32 (1"1/4) 768 898 198 328 570 668 200 468144164144215223348M10219 131 179 1554593669389508496

0.40 (1"1/2) 768 898 198 328 570 798 330 468144164144215223348M10219 131 179 1554593669389517496

0.50 (2") 768 898 198 328 570 798 330 468144164144215223348M10219 131 179 1554593669389567496

DN A(S*) A(L*) B(S*) B(L*) C D ±5mm E ±5mm F G H Y K1 K2 L M N Omin Omax P Q R S T W X

0.25 (1") 733 878 163 308 570 596 200 396 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.32 (1"1/4) 733 878 163 308 570 596 200 396 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.40 (1"1/2) 733 878 163 308 570 726 330 396 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 517 491

0.50 (2") 733 878 163 308 570 726 330 396 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 567 491

0.25 (1") 733 878 163 308 570 668 200 468 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.32 (1"1/4) 733 878 163 308 570 668 200 468 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 508 491

0.40 (1"1/2) 733 878 163 308 570 798 330 468 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 517 491

0.50 (2") 733 878 163 308 570 798 330 468 117 137 108 215 223 348 M10 219 131 179 155 459 366 93 128 567 491

DN A(S*)A(L*)B(S*)B(L*) C D ±5mmE ±5mm F G H Y K1 K2 L M N OminOmax P Q R S T W X

0.25 (1") 748 878 178 308 570 596 200 396131164144215223348M10219 131 179 1554593669389508491

0.32 (1"1/4) 748 878 178 308 570 596 200 396131164144215223348M10219 131 179 1554593669389508491

0.40 (1"1/2) 748 878 178 308 570 726 330 396131164144215223348M10219 131 179 1554593669389517491

0.50 (2") 748 878 178 308 570 726 330 396131164144215223348M10219 131 179 1554593669389567491

0.25 (1") 748 878 178 308 570 668 200 468131164144215223348M10219 131 179 1554593669389508491

0.32 (1"1/4) 748 878 178 308 570 668 200 468131164144215223348M10219 131 179 1554593669389508491

0.40 (1"1/2) 748 878 178 308 570 798 330 468131164144215223348M10219 131 179 1554593669389517491

0.50 (2") 748 878 178 308 570 798 330 468131164144215223348M10219 131 179 1554593669389567491

DN A(S*)A(L*)B(S*)B(L*) C D ±5mmE ±5mm F G H Y J K1 K2 L M N OminOmax P Q R S T W X

NGX400 M-..PR..Ex
NGX400 M-..PR..Ex
NGX400 M-..PR..Ex
NGX400 M-..PR..Ex
NGX400 M-..MD..Ex
NGX400 M-..MD..Ex
NGX400 M-..MD..Ex
NGX400 M-..MD..Ex

* S = standard blast tube
L = long blast tube

0.25 (1") 768 898 198 328 570 596 200 396156176156-215223348M10219 131 179 1554593669389508496

0.32 (1"1/4) 768 898 198 328 570 596 200 396156176156-215223348M10219 131 179 1554593669389508496

0.40 (1"1/2) 768 898 198 328 570 726 330 396156176156-215223348M10219 131 179 1554593669389517496

0.50 (2") 768 898 198 328 570 726 330 396156176156-215223348M10219 131 179 1554593669389567496

0.25 (1") 768 898 198 328 570 668 200 468156176156-215223348M10219 131 179 1554593669389508496

0.32 (1"1/4) 768 898 198 328 570 668 200 468156176156-215223348M10219 131 179 1554593669389508496

0.40 (1"1/2) 768 898 198 328 570 798 330 468156176156-215223348M10219 131 179 1554593669389517496

0.50 (2") 768 898 198 328 570 798 330 468156176156-215223348M10219 131 179 1554593669389567496

When PGMAX (maximum pressure switch) is supplied, add 60mm to "D" and "E"

MOUNTINGS AND CONNECTIONS

Packing

The burners are despatched in cardboard packages whose dimensions are: 795mm x 490mm x 550mm (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.

 Burner with gas train;
 gasket to be inserted between the burner and the boiler;
 envelope containing tis 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 perform the installation, proceed as follows:
1 place the 4 stud bolts on the hole of the boiler’s door, according to the burner’s

drilling plate described on paragraph “Overall dimensions”;
2 place the gasket on the burner’s flange;
3 install the burner into the boiler;
4 fix the burner to the stud bolts, by means of the fixing nuts, according to Fig. 6.
5 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).

Key

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

Fig. 6

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:

 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.

 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) Length of the flame tube in meters

c) Flame tube firing intensity in MW/m

3

d) Combustion chamber diameter (m)

Fig. 7 - Firing intensity, diameter and lenght of the test flame tube as a function of the heat
input in kW.

sized

Fig. 7

20

How to modify the blast tube length (NG/LG350-NG/LG400)

T

VTF

To modify blast tube length please read the following instructions.
1 Remove combustion head (See “Removing the combustion head” - Part III of this user’s guide).
2 Remove the flanged piece T by removing the 4 socket head screws VTF (Fig. 8).
3 Remove the 4 screws which hold the blast tube to the flanged piece (Fig. 9).
4 Extract the blast tube from the flanged piece and assemble it in the other way round as shown in pictures Fig. 10 and Fig. 11. Now

fasten the two pieces using the same screws.
5 Assemble the whole piece to the burner by caring attention to the indication in picture Fig. 13.

Fig. 8

Fig. 10 - Short blast tube

Fig. 11 - Long blast tube

Fig. 9

Fig. 12

Fig. 13

If you modify the blast tube length you have to modify also the combustion head length by reading the following instructions.
1 Remove the screws V1 and V2 as shown in Fig. 14.
2 Lower the terminal part of the combustion head, by moving it with a slight circular movement, until the holes will match (Fig. 15)

and tight the screw shown in Fig. 16.
3 Adjust cables length by pulling them very slightly paying particular attention not to disconnect the ionisation cable to the electrode.
4 Fix the combustion head again (See “Removing the combustion head”).

21

Fig. 14

V2

V1

V1

V2

V3

V4

S1

S2

T

VT1

VT2

TR

G

CA

CR

LOCKED

UNLOCKED

G

G

VT2

VT1

TR

Fig. 15

Gas Train Reversal

The gas train can be fit either on the left and on the right. Follow these instruction..
1 Remove the plastic hook G to release the rod T (Fig. 17) .
2 Take the screws V1, V2, V3, V4, VT1 and VT2 off (Fig. 17).
3 Take the ignition cable CA off of the transformer .
4 Disconnect the connector CR from the printed cirduit (Fig. 18).
5 Take off the flange and the combustion head together (Fig. 20).
6 Take the gas pipe TR off and put it in the new position fixing the screws VT1 and VT2 (Fig. 19).

Fig. 16

Fig. 17

Fig. 18

Fig. 19

22

Fig. 20

F

V

D

VF

TR

D

Fig. 21

7 Unscrew the V, rotate the head of 180 ° along its axis as shown in Fig. 20), until the hole F is found. Fit the screw again (Fig. 20 -

Fig. 21).
8 Insert again the flange and the combustion head together
9 Rotate the disc D following the instructions below.
10 Take off the screw VF.
11 Rotate the disc D for 180 ° and then fit the screw VF (Fig. 22).

Fig. 22: Standard position Fig. 23: New position

12 Reconnect CR and CA.
13 Retighten the screws V1, V2, V3, V4, VT1 e VT2.
14 Place again the rod T into its own position and fasten it by the plastic hook G.

23

GAS TRAIN CONNECTIONS

1

2

5

78

9

4

16

4

MANUFACTURER INSTALLER

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
4 High gas pressure switch (option*)
5 Low gas pressure switch
7 Bellows unit
8 Manual cutoff valve
9 Dungs MB-DLE valves group
16 Gas leakage pressure switch

* Note: the maximum gas pressure switch can be mounted either upstream or downstream the gas valve but upstream the butterfly
gas valve (see item no.4 in the scheme above).

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 cock 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).

24

MULTIBLOC DUNGS MB-DLE 405..412

A

B

DC

MOUNTING POSITIONS

A

B

C

D

C

B

D

A

MOUNTING POSITIONS

Mounting

1. Mount flange onto tube lines: use appropriate sealing agent (see Fig. 30);

2. insert MB-DLE: note position of O rings (see Fig. 30);

3. tighten screws A, B, C and D (Fig. 28 - Fig. 29), accordind to the mounting positions (Fig. 31);

4. after installation, perform leakage and functional test;

5. disassembly in reverse order.

Fig. 24 Fig. 25 Fig. 26 Fig. 27

MULTIBLOC DUNGS MB-DLE 415..420

Mounting

1. Loosen screws A and B do not unscrew (Fig. 28 - Fig. 29).

2. unscrew screws C and D (Fig. 28 - Fig. 29).

3. Remove MultiBloc between the threaded flanges (Fig. 29).

4. After mounting, perform leakage and functional tests.

Fig. 28 Fig. 29 Fig. 30 Fig. 31

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

25

.ELECTRICAL CONNECTIONS

RESPECT THE BASIC SAFETY RULES. MAKE SURE OF THE CONNECTION TO THE EARTHING SYSTEM. DO NOT

REVERSE THE PHASE AND NEUTRAL CONNECTIONS. FIT A DIFFERENTIAL THERMAL MAGNET SWITCH ADE-

QUATE FOR CONNECTION TO THE MAINS.

ATTENTION: before executing the electrical connections, pay attention to turn the plant’s switch to OFF and be sure
that the burner’s main switch is in 0 position (OFF) too. Read carefully the chapter “WARNINGS”, and the “Electrical
connections” section.

WARNING: if the cable that connects the thermostats and the control box should be longer than 3 meters, insert a
sectioning relay following the attached electrical wiring diagram.

To execute the electrical connections, proceed as follows:
1 find the pulg or the plugs, according to the model, that comes out from the burnrer:

7 pins plug for the power supply (for all models);

4 pins plug;

3-pins plug (only for NG/NGX400);

2 execute the electrical connections to the plugs, according to hte burner model (see next paragraph);
3 once all the connections are accomplished, check the fan motor direction (sse next paragraphs);
4 now the burner is ready to start up.

The burner is fitted with a bridge between terminals T6 and T8 on the 4-poles plug-TAB (external side link, male con­nector); if the TAB high/low flame thermostat must be connected, remove the bridge between terminals, before con­necting the thermostat.

IMPORTANT: before operating the burner, be sure all connectors are linked as shown in the diagrams.

Connectors identification

Burner power supply connector

(Fig. 35 - Fig. 37 - Fig. 39)

Probe connection connector

(fully modulating burners, Fig. 41)

Fig. 32

HIGH/LOW flame connector(Fig. 37)

Fig. 33

Fan motor connector (NG/NGX400 only)
(Fig. 36 - Fig. 38 - Fig. 40)

Fig. 34

26

Connectors wiring diagrams

Fig. 35 - 7-pins connector

 Progressive burners’ connectors:

Fig. 37 - 7-pin and 4-pin connectors

Key

C1 LOW FLAME TIME METER
C2 HIGH FLAME TIME METER
FU1 FAN MOTOR LINE FUSE
FU3 LINE FUSE
IL BURNER LINE SWITCH
IM FAN MOTOR LINE SWITCH
KM1 FAN MOTOR CONTACTOR
LAF BURNER IN HIGH FLAME INDICATOR LIGHT
LB INDICATOR LIGHT FOR BURNER LOCK-OUT

Fig. 36 - Electric motor’s 3-pins connector

NG/LG/NGX400

Fig. 38Electric motor’s 3-pin connector for

NG/LG/NGX400

LBF BURNER IN LOW FLAME SIGNALLING LAMP
MV FAN MOTOR
ST THERMOSTATS O PRESSURE SWITCHES SERIE
TAB HIGH LOW FLAME THERMOSTAT/PRESSURE SWITCH
TS SAFETY THERMOSTAT/PRESSURE SWITCH
CONN-MOTORE FAN MOTOR CONNECTOR
CONN-LINEA BURNER POWER SUPPLY CONNNECTOR
CONN-TAB HIGH-LOW FLAME CONNECTOR

($) IF "TAB" USED REMOVE THE BRIDGE BETWEEN TERMINALS

T6-T8

27



Fully-modulating burners’ connectors:

Fig. 39 - 7-pin connector

Fig. 40 - Electric motor’s 3-pin connector for

NG/LG/NGXG400

Key

C1 LOW FLAME TIME METER
FU1 LINE FUSE FOR FAN MOTOR
FU3 LINE FUSE
FU4 AUXILIARY FUSE
IL BURNER LINE SWITCH
IM FAN MOTOR LINE SWITCH
KM1 FAN MOTOR REMOTE CONTACTOR
LANDIS RWF40 MODULATION REGULATOR

Fig. 41 - Probes connectiion

LB BURNER LOCKOUT SIGNALLING LAMP
LBF BURNER IN LOW FLAME SIGNALLING LAMP
MV FAN MOTOR
SD-0÷10V VOLTAGE SIGNAL

SD-0/4÷20mA CURENT SIGNAL
SD-PRESS PRESSURE PROBE
SMA MAN/AUTO SELECTOR

SMF OPERATION SELECTOR MIN-0-MAX
ST PRESSURE SWITCHES OR THERMOSTATS SERIE
TS SAFETY THERMOSTAT/PRESSURE SWITCH

28

User interface

Bild 1/0707

P

V

hmin

s%

VSD

ESC

nfo

AF

The AZL2x.. display is shown below:
The keys functions are the following:

Key F

Used to adjust the “fuel” actuator position (Fuel): :
While pressing the F key, the “fuel” actuator position can be changed by means of the + and - keys.

Key A

Used to adjust the “air” actuator position (Air):
While pressing the A key, the “air” actuator position can be changed by means of the + and - keys.

Key F + A

While pressing the two keys contemporarly, the code message will appear: by entering the proper
password it is possible to access the Service mode.

Info and Enter keys

Used for Info and Service menues
Used as Enter key in the setting modes
Used as Reset key in the burner operation mode
Used to enter a lower level menu

-Key -

Used to decrease a a value
Used to enter Info and Serivce during the curve adjustments

+Key +

Used to increase a a value
Used to enter Info and Serivce during the curve adjustments

Keys (+ & - )= ESC

By pressing + and - at the same time, the ESCAPE function is perfomed:
to erase a entered value
to enter a lower level menu

29

The display will show these data:

P

Vh

mi n

s%

Lock+unlock codes

Flame

Open valves

Fan motor energised

Oil pre-heater energised

Ignition transformers energised

Plant heat request

Parametere setting mode

Info mode

Service mode

Closing actuator

Opening actuator

Unit measure

The display will show these data:

Setting menu

The setting menu is divided into different blocks:

Bloc. Descrizione Description Password

100 Informazioni generali General OEM / Service / Info

200 Controllo bruciatore Burner control OEM / Service

400 Curve rapporto Ratio curves OEM / Service

500 Controllo rapporto Ratio control OEM / Service

600 Servocomandi Actuators OEM / Service

700 Storico errori Error history OEM / Service / Info

900 Dati di processo Process data OEM / Service / Info

The accesses to the various blocks are allowed by passwords. Passwords are divided into three levels:

 User level (info): no password needed
 Service level (Service)
 Manifacturer level (OEM)

30

PHASES LIST

During operation, the following program phases are shown. The meaning for each phase is quoted in the table below

Phase Funzione Function

Ph00 Fase blocco Lockout phase

Ph01 Fase di sicurezza Safety phase

Ph10 t10 = tempo raggiungimento posizione riposo t10 = home run

Ph12 Pausa Standby (stationary)

Ph22

Ph24 Verso posizione preventilazione Traveling to the prepurge position

Ph30 t1 = tempo preventilazione t1 = prepurge time

Ph36 Verso posizione accensione Traveling to the ignition position

Ph38 t3 = tempo preaccensione t3 = preignition time

Ph40

Ph42

Ph44 t44 = intervallo 1 t44 = interval 1

Ph50 TSA2 = secondo tempo sicurezza TSA2 = 2nd safety time

Ph52 t52 = intervallo2 t52 = interval 2

Ph60 Funzionamento 1 (stazionario) Operation 1 (stationary)

Ph62

Ph70 t13 = tempo postcombustione t13 = afterburn time

Ph72 Verso posizione postcombustione Traveling to the postpurge position

Ph74 t8 = tempo postventilazione t8 = postpurge time

Ph80 t80 = tempo evacuazione controllo tenuta valvole t80 = valve proving test evacuation time

Ph81

Ph82 t82 = test perdita, test riempimento t82 = leakage test filling test, filling

Ph83 t80 = tempo perdita pressione gas, test pressione

Ph90 Tempo attesa “mancanza gas” Gas shortage waiting time

t22 = tempo di salita ventilatore (motore ventilatore = ON,
valvola intercettazione di sicurezza = ON)

TSA1 = primo tempo sicurezza (trasformatore accen­sione ON)

TSA1 = primo tempo sicurezza (trasformatore accen­sione OFF)

t62 = massimo tempo bassa fiamma (funzionamento 2, in
preparazione per spegnimento, verso bassa fiamma)

t80 = tempo perdita pressione atmosferica, prova atmo­sferica

t22 = fan ramp up time (fan motor = ON,
safety shutoff valve = ON)

TSA1= 1st safety time (ignition transformer
ON)

TSA1 = 1st safety time (ignition transformer
OFF)

t42 = preignition time OFF

t62 = max. time low-fire (operation 2, prepa­ring for shutdown, traveling to low-fire)

t81 = leakage time test time atmospheric
pressure, atmospheric test

t83 = leakage test time gas pressure, pres
sure test

Entering the Parameter levels

By means of a proper use of the keys, it is possible to enter the various level parameters, as shown in the following flow chart:

31

The burner and consequently the LMV2x.. are factory set; the air and fuel curves as set as well.

Info level

To enter the Info level, proceed as follows:
1 in any menu position, press keys + and - at the same time, then the program will start again: the display will show OFF.

2 until the display will show InFo, Press the enter (InFo) key

3 then il will show the first code (167) flashing, on the right side it will show the data entered. By pressing + or - it is possible to scroll

(up or down) the parameter list.
4 If a dot-line is shown on the right, there is no enough room for complete visualisation: press enter again the data will be completely

shown for 1 to 3 seconds. By pressing enter or + and- at the same time, the system will exit the parameter visualisation and go

back to the flashing number.

32

The Info level shows some basic parameters as:

Parameter Description

167 Cubic meters of fule (resettable)

162 Operating hours (resettable)

163 Device operating hours

164 Burners start-ups (resettable)

166 Total number of start-ups

113 Burner number (i.e. serial number)

107 Software version

102 Software date

103 Device serial number

104 Parameter set preassignment: Customer code

105 Parameter set preassignment: Version

143 Free

5 Example: choose parameter 102 to show the date

the display shows parameter 102 flashing on the left and characters ._._ on the right.
6 press InFo for 1-3 seconds: the date will appear
7 press InFo to go back to parameter “102”
8 by pressing + / -, it is possible to scroll up/down the parameter list (see table above), or, by pressing ESC or InFo for more seconds,

the display will show
9 Once the last parameter is accessed (143) by pressing + , the End message will flash.

10 Press InFo

for more than three seconds or for more than three seconds orto return to the normal display.

33

If a message like the one below is shown during operation,

it means that the burner is locked out and the Errore code is shown (in the example “error code:4”); this message is alternating with
another message

Diagnostic code (in the example “diagnostic code:3”). Record the codes and find out the fault in the Error table.
To perform the reset, press InFo for one second:

The unit displays an event which does not lead to shutdown.
The display shows current error code c: alternating with diagnostic code d:

.
Press InFo to return to the display of phases.
Example: Error code 111 / diagnostic code 0

To reset, press InFo for a second. Record the codes and check the Error List to find the type of faults.

Service level

To enter the Service mode, press InFo until the display will show:

The service level shows all the information about flame intensity, actuators position, number and lock codes:

34

Parameter Description

954 Flame intensity

121 % output, if set = automatic operation

922 Actuators position, 00=combustibile; 01= aria

161 Lock-outs number

701..725 Lock-outs History (see chapter 23 in the LMV2x manual)

1 the first parameter will be “954”: the percentage of flame is shown on the right. By pressinf + or - it is possible to scroll up/down the

parameter list.
2 Once the last parameter is accessed (143) by pressing + , the End message will blink.

3Press InFo

for more than three seconds or for more than three seconds orto return to the normal display.

For further nformation, see tha LMV2 related manual.

35

SETTING GAS AND AIR FLOW RATE

3

1

4

2

ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open and check that the pres­sure upstream the gas train complies the value quoted on paragraph “Technical specifications”. Be sure that the
mains switch is closed.

.ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation
of carbon monoxide); if this should happen, make the gas decrease slowly until the normal combustion values are achieved.

WARNING: NEVER LOOSE THE SEALED SCREWS! OTHERWISE, THE DEVICE WARRANTY WILL BE IMMEDIA­TELY INVALIDATE!

Keys

1 Valve group
2Cover
3 Control panel
4Blast tube

Fig. 42

To perform the adjustments, unscrew the fixing screws and remove the burner’s cover (see Fig. 42-2)

Startup Output

The start-up heat output shall not exceed 120 kW (single stage burners) or 1/3 of nominal output (double-stage, progressive or fully
modulating burners). In order to comply with these requirements, burners are provided with butterfly valve and/or slow-opening safety
valve. On double-stage, progressive or modulating burners, the low flame ouptut must be higher than the minimum ouptut quoted in the
performance curve (page 11).

IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:

Recommended combustion parameters

Fuel

Natural gas 9 ÷ 10 3 ÷ 4.8

LPG 11 ÷ 12 2.8 ÷ 4.3

Recommended (%) CO

Recommended (%) O2

2

Adjustments - brief description

 Check that the combustion parameters are in the suggested limits.

 Check the flow rate measuring it on the counter or, if it was not possible, verifying the combustion head pressure by means of a dif-

ferential pressure gauge, as described on par. “Measuring the gas pressure in the combustion head” on page 15.

 Then, adjust the combustion by settin the “air/gas ratio” curvepoints (see the LMV2x attached manual).
 Set, now, the low flame output, in order to avoid the low flame output increasing too much or that the flues temperature gets too low

to cause condensation in the chimney.

36

Adjusting procedure

C

VS

T(VR)

RP

VB

VSB

C

VS

T(VR)

RP

VB

VSB

Dungs Multibloc MB-DLE

To change the burner setting during the testing in the plant, follows the next procedure, according to the burner operation.

DUNGS MB-DLE gas valves group: Before starting the burner up, adjust the valves group slow opening: to set the slow opening
remove cover T, reverse it upside down and use it as a toolto rotate screw VR. Decrease the ignition flow rate by screwing, increase it
by unscrewing. Do not use a screwdriver on the screw VR!

Note: the screw VSB must be removed only in case of replacemente of the coil (see picture).

.
Go on adjusting air and gas flow rates: check, continuosly, the flue gas analisys, as to avoid combustion with little air; dose the air

according to the gas flow rate change following the steps quoted below;
acting on the pressure stabiliser of the valves group, adjust the gas flow rate in the high flame stage as to meet the values requested

from the boiler/utilisation:

- Multibloc MB-DLE: the valve is adjusted by means of the RP regulator after slackening the locking screw VB by a number of
turns. By unscrewing the regulator RP the valve opens, screwing the valve closes. The pressure stabilizer is adjusted by operating
the screw VS located under the cover C. By screwing down the pressure is increased and by unscrewing it is reduced. Note: the
screw VSB must be removed only in case of replacemente of the coil.

Pressure stabiliser is factory-set. The setting values must be locally adapted to machine conditions. Important! Follow the instruc­tions carefully!
Now adjust the pressure switches (see next par.).

37

Adjusting the combustion head

VRT

Fig. 43

ID

The burner is adjusted in the factory with the combustion head in the position that refers to the "MAX" output. The maximum output set­ting refers to the “fully-ahead” position of the combustion head, as far as standard models (Fig. 44), and to “fully-backward” position for
low NOx burners (Fig. 45). As for “fully-ahead” position, it means that the head is placed inside the boiler, “fully-backward” position
means that the head is towards the operator. As far as the reduced output operation, progressively move the combusiton head
towards the “MIN” position, rotating clockwise the VRT screw (Fig. 43). The ID index shows how much the combustion head moved.

Fig. 44 - Head in “fully-ahead position”

Fig. 45 - Head in “fully-backward position”

Fully modulating burners

To adjust the fully-modulating burners, use the CMF switch on the burner control panel (see next picture), instead of the TAB thermo­stat as described on the previous paragraphs about the progressive burners. Go on adjusting the burner as described before, paying
attention to use the CMF switch intead of TAB.

The CMF position sets the oprating stages: to drive the burner to the high-flame stage, set CMF=1; to drive it to the low-flame stage, set
CMF=2.

To move the adjusting cam set CMF=1 or 2 and then CMF=0.

CMF = 0 stop at the current position
CMF = 1 high flame operation
CMF = 2 low flame operation
CMF = 3 automatic operation

As for the RWF setting, please refer to the related documentation.

38

Calibration of air and gas pressure switches

The air pressure switch locks the control box if the air pressure is not the one requested. If it happens, unlock the burner by means of
the control box unlock pushbutton, placed on the burner control panel.

The gas pressure switches check the pressure to avoid the burner operate when the pressure value is not in the requested pressure
range.

Calibration of air pressure switch

To calibrate the air pressure switch, proceed as follows:

 Remove the transparent plastic cap.
 Once air and gas setting have been accomplished, startup the burner.
 During the pre-purge phase o the operation, turn slowly the adjusting ring nut VR in the clockwise direction until the burner lockout,

then read the value on the pressure switch scale and set it to a value reduced by 15%.

 Repeat the ignition cycle of the burner and check it runs properly.
 Refit the transparent plastic cover on the pressure switch.

Calibration of low gas pressure switch

As for the gas pressure switch calibration, proceed as follows:

 Remove the transparent plastic cap.
 While the burner is operating at the maximum output, test the gas pressure on the low gas pressure switch port.
 Slowly close the manual shut-off valve (placed upstream the pressure switch, see gas train installation diagram), until the measu-

red pressure is reduced by 50%. Pay attention that the CO value in the flue gas does not increase.

 Check that the burner is operating correctly.
 Screw down the pressure switch adjusting ring nut until the burner lockout.
 Fully open the manual shut-off valve.
 Refit the transparent plastic cover on the pressure switch.

Adjusting the maximum gas pressure switch (when provided)

To calibrate the maximum pressure switch, proceed as follows according to its mounting position:
1 remove the pressure switch plastic cover;
2 if the maximum pressure switch is mounted upstreaam the gas valves: measure the gas pressure in the network, when flame is off;

by means of the adjusting ring nut VR, set the value read, increased by the 30%.

3 if the maximum pressure switch is mounted downstream the “gas governor-gas valves” group and upstream the butterfly valve:

light the burner, adjust it according to the procedure in the previous paragrph. Then, measure the gas pressure at the operating
flow rate, downstream the “gas governor-gas valves” group and upstream the butterfly valve; by means of the adjusting ring nut
VR, set the value read on step 2, increased by the 30%;

4 replace the plastic cover.

PGCP Gas leakage pressure switch (witn Siemens LDU burner control/Siemens LMV Burner Management
System)

 remove the pressure switch plastic cover;
 adjust the PGCP pressure switch to the same value set for the minimum gas pressure switch;
 replace the plastic cover.

39

LIMITATIONS OF USE

PART II: OPERATION

M

C

I

L

D

B

H

G

E

A

V2

V1

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CONNEC­TED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSIDE­RED IMPROPER AND THEREFORE DANGEROUS.

THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO
QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORI­SED BY THE COMPANY MANUFACTURING THE BURNER.

A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND
SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF
THE BURNER.

THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION
OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN
PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER).

NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.

OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO
FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON.

IN CASE OF A BURNER SHUT-DOWN, RESET 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.

WARNING: DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR (COUPLING
FLANGE) CAN BECOME VERY HOT, AVOID TOUCHING THEM SO AS NOT TO GET BURNT.

OPERATION

Fig. 46 - Burner’s control panel Fig. 47 - Burner modulator

Key - Fig. 46

A Mains switch ON - OFF
B Lockout signaling lamp
C AZL user interface
D Minimum gas pressure switch consent signaling lamp
E High flame operation signaling lamp (or air damper opening during pre-purge stage)
G Low flame operation signaling lamp
H Ignition transformer in operation signaling light
I EV2 opening signaling lamp
L EV1 opening signaling lamp
MFuse

40

OPERATION

ATTENTION: BEFORE STARTING THE BURNER UP, BE SURE THAT THE MANUAL CUTOFF VALVES ARE OPEN
AND CHECK THAT THE PRESSURE VALUE UPSTREAM THE GAS TRAIN MATCHES THE VALUE ON PARAGRAPH
“TECHNICAL SPECIFICATIONS”). CHECK THAT THE MAINS SWITCH IS CLOSED. CAREFULLY READ THE “WAR­NINGS” CHAPTER.

 Set to On the A main switch on the burner front panel.
 Check that tha control box is not in lockout position (lamp B On), eventually unlock it by pressing the Enter/InFo key on the AZL

display (for further information on LMV2/AZL, please refer to the relatoed manual).

 Check the thermostat/pressure swicthes series enables the burner to operate.
 Check that the gas pressure is sufficient (if not the display AZL2.. will show a warning message).
 At the beginning of startup cycle, the actuator drives the air damper to its maximum opening position, then the fan motor starts up:

the pre-purging phase starts. During pre-puerging, the air damper complete opening is signalled by the lamp F on the front panel.

 At the end of pre-purging, the air damper is driven to ignition position, the ignition transfomer is energised (signalled by lamp H on

the front panel) and, few seconds later, the EV1 and EV2 gas valves are open (lamp L and I on the front panel).

Few seconds later, after the gas valve opening, then the ignition transformeris de-energised (lamp H tunrs to off). The burner is now
operating in low flame, later on the tow-stage operation begins and the burner increases or decreases the output directly controlled by
the external thermostat (in the progressive version) ro by the output controller (P in the next picutre, only for fully-modulating burners).

41

At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry

PART III: MAINTENANCE

➞

1
0

5

3

4

53

4

6

6

➞

2

1

3
p

e

0

4
p

a

5
p

Br

03

p

e

4
p

a

61

5
p

Br

2

out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6
months.

WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND
THE FUEL MANAUL CUTOFF VALVES CLOSED!

ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL.

ROUTINE MAINTENANCE

 Clean and examining the gas filter cartdrige, if necessary replace it (Fig. 48 on).
 Removal, examination and cleaning of the combustion head.
 Check the ignition and detection electrodes, clean and adjust if necessary (see Fig. 55). In case of doubr, check the detection cur-

rent according to the schemes in Fig. 59.

 Cleaning and greasing of sliding and rotating parts.

ATTENTIONwhen servicing, if it was necessary to disassemble the gas train parts, remember to execute the gas proving test,

once the gas train is reassembled, according to the procedure imposed by the law in force.

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

 Check the filter at least once a year!
 Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 48-Fig. 49)is Dp > 10 mbar.



Change the filter if the pressure difference between pressure connection 1 and 3 (Fig. 48-Fig. 49) is twice as high compared to the last

check.
You can change the filter without removing the fitting.
1 Interrupt the gas supply closing the on-off valve.

2 Remove screws 1 ÷ 4 using the Allen key n. 3 and remove filter cover 5 in
3 Remove the filter 6 and replace with a new one.
4 Replace filter cover 5 and tighten screws 1 ÷ 4 without using any force and fasten.
5 Perform leakage and functional test, p

= 360 mbar.

max.

6 Pay attention that dirt does not fall inside the valve.

Fig. 50

.

Fig. 49

Fig. 48

Fig. 50

42

Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2”

2

3

4

2

3

4

1

5

5

0

1

3
p

e

0

4
p

a

5
p

Br

03

p

e

4
p

a

61

5
p

Br

2

B

A

C

D

E

 Check the filter at least once a year!
 Change the filter if the pressure difference between pressure connection 1 and 2 (



Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 51-Fig. 52) is twice as high compared to the last

check.
You can change the filter without removing the fitting.
1 Interrupt the gas supply closing the on-off valve.

2 Remove screws 1 ÷ 6 (

Fig. 53

).
3 Change filter insert.
4 Re-insert filter housing, screw in screws 1 ÷ 6 without using any force and fasten.
5 Perform leakage and functional test, p

= 360 mbar.

max.

6 Pay attention that dirt does not fall inside the valve.

Fig. 51-Fig. 52

) Dp> 10 mbar.

Fig. 51

Fig. 53

Fig. 52

43

Removing and cleaning the combustion head

V1 V2

V3

V4

S1

S2

T

VT1

VT2

TR

G

LOCKED

UNLOCKED

G

G

CA

CR

H

1 By means of the plastic hook G, unlock the rod T (Fig. 54) which drives the butterfly valve (Fig. 54 and Fig. 55), to disconnect it

from its seat.
2 Remove the screws V1, V2, V3, V4 and the screws S1 and S2 (Fig. 54).
3 Disconnect the ignition cable CA from the ignition transformer (Fig. 56).
4 Disconnect the connector CR (Fig. 57).

CAUTION: during the assembling phase, before tightening screws V1, V2, V3, V4, mount and tighten screws S1 and S2.
To remove the head, the operator must pull it towards himself. Once the combustione head is removed, check that the air and gas

holes are not obstructed
scratchbrush.

(Fig. 57 - H)

. Clean the combustion head by a compressed air blow or, in case of scale, scrape it off by a

Fig. 54

Fig. 56

Fig. 55

Fig. 57

44

Adjusting the electrodes position

Detection electrode

Ignition electrode

Ground

detection electrode

Protective earth PE

Ionization probe (ION)

QRB.../ QRC... signal voltage

QRB... GND

1

2

3

4

5

L

X10-05

QRA... (-)

QRA... (+)

1

2

X10-06

+

ATTENTION: avoid the ignition and detection electrodes to get in touch with metallic parts (blast tube, head, etc.), otherwise the boi­ler’s operation would be compromised. Check the electrodes position after any intervention on the combustion head. The gap between
the ignition electrode and the ground is 4÷5 mm.

Fig. 58

Checking the detection current

To measure the detection signals refer to the diagrams in the picture below. If the signal is less than the indicated value, check the
position of the detection electrode, the electrical contacts and if necessary replace the detection electrode.

Control box

Minimum

detection signal

Siemens LMV2 4 µA (value on display:30%)

Fig. 59

Error code Diagnostic code Cause

93 3

Sensore short-circuit

Permissible length of flame detector cable (laid separately): 3 m (core-earth 100 pF / m).

Extraneous lightExtraneous light

Extraneous light during standby (phase 12) leads to start prevention, followed by a restart.
Extraneous light during the prepurge phase leads to immediate lockout.
If extraneous light occurs during the shutdown phase, the system switches to the safety phase.
One repetition is permitted. This means that if the error occurs again the next time the system is shut down, the unit initiates lockout.

Seasonal stop

To stop the burner in the seasonal stop, proceed as follows:
1 turn the burner main switch to 0 (Off position)
2 disconnect the power mains
3 close the fuel valve of the supply line

Burner disposal

In case of disposal, follow the instructions according to the laws in force in your country about the “Disposal of materials”.

45

BURNER EXPLODED VIEW

46

POS. DESCRIPTION POS. DESCRIPTION

1 COVER 24.5 O RING

2 FAIRLEAD 24.6 PIN

3 FAIRLEAD 24.7 BUSH

4 FAIRLEAD 24.8 INDEX LABEL

5 FAIRLEAD 24.9 INDEX

6.1 BURNER HOUSING 25.1 GAS MANIFOLD

6.2 MOTOR SUPPORT PLATE 25.2 HEAD EXTENSION

6.3 FLANGED PIPE 25.3.1 DETECTION ELECTRODE

7 GENERATOR GASKET 25.3.2 IGNITION ELECTRODE

8 THREADED GAS PIPE 25.3.3 COMBUSTION HEAD

9 FAN WHEEL 25.4 IGNITION CABLE

10 GAS PRESSURE 25.5 DETECTION CABLE

11 MOTOR 26 CONNECTOR

12 GAS VALVES GROUP WITH GOVERNOR 27 CONNECTOR

13 FLANGE 28.1 IGNITION TRANSFORMER

47

14 PLUG 28.2 AIR PRESSURE SWITCH

15 O RING 28.3 BRACKET

16 AIR FLAP 28.4 CONTACTOR

17 COVER FIXING SCREW 28.5 CONTROL BOX

18 AIR INTAKE 29.1 ACTUATOR BRACKET

19 AIR INTAKE 29.2 ACTUATOR

20 BRACKET 29.3 ADJUSTING BUSH

21 BRACKET 30.1 FRONT CONTROL PANEL

22 GAS MANIFOLD 30.2 BOARD

23 BLAST TUBE 30.3 LIGHT

24.1 ACTUATOR 30.4 FUSE

24.2 FLANGE 30.5 SWITCH

24.3 BUTTERFLY GAS VALVE 30.6 LIGHT

24.4 COUPLING 30.7 CONTROL PANEL

SPARE PARTS

Desription Code

LG/NG280 LG/NG350 LG/NG400

COVER 1011803 1011803 1011803
BURNER MANAGEMENT SYSTEM - SIEMENS LMV2.. 2020474 2020474 2020474
BURNER MANAGEMENT SYSTEM - SIEMENS LMV3.. 2020477 2020477 2020477
USER INTERFACE/DISPLAY - SIEMENS AZL2.. 2022115 2022115 2022115
DETECTION ELECTRODE 2080108 2080108 2080108
INGNITION ELECTRODE 2080218 2080218 2080218
GASKET 2110059 2110059 2110059
AIR PRESSURE SWITCH 2160053 2160053 2160053
GAS PRESSURE SWITCH 2160077 2160077 2160077
IGNITION TRANSFORMER MOD. COFI 2170138 2170138 2170138
IGNITION TRANSFORMER MOD. DANFOSS 2170232 2170232 2170232
MOTOR 2180717 2180714 2180712
VALVE GROUP Rp1 2190341 2190341 2190341
VALVE GROUP Rp1 1/4 2190342 2190342 2190342
VALVE GROUP Rp1 1/2 21903L3 21903L3 21903L3
ACTUATOR - SIEMENS SQN14 2480096 2480096 2480096
ACTUATOR - SIEMENS RWF 2570112 2570112 2570112
COMBUSTION HEAD (GAS) mod. NG 30600P9 30600H3 30600H2
COMBUSTION HEAD (L.P.G.) mod. LG 30600Q3 30600H7 30600H6
BLAST TUBE S* 30900L0 30900G3 30900F9
BLAST TUBE L* 30900L1 30900G3** 30900F9**
COMBUSTION HEAD (GAS) mod. NG 3501842 3501841 3501842
COMBUSTION HEAD (L.P.G.) mod. LG - 3501844 3501843
INGNITION CABLE 6050153 6050153 6050153
DETECTION CABLE 6050214 6050214 6050214

Spare parts for Low NOx Burners only

Desription Code

NGX280 NGX350 NGX400

COMBUSTION HEAD (NOx) 30600Q7 30600H9 30600H8
BLAST TUBE S* 30910P5 30910L6 30910L7

*S:standard

L: long

** To modify the blast tube’s length, see chapter “How to modify blast tube length”.

NOTE: it is recommended to mention the burner ID number on the spare parts request form.

48

ELECTRICAL WIRING DIAGRAMS

See the attached wiring diagrams.

Wiring diagram SE04-755 - Progressive burners

Wiring diagram SE04-753 - Fully-modulating burners

49

Note: Specifications and and data subject to change. Errors and omissions excepted.

C.I.B. UNIGAS S.p.A.

Via L.Galvani, 9 - 35011 Campodarsego (PD) - ITALY

Tel. [phone] - Fax [phone]

web site: www.cibunigas.it - e-mail: [e-mail]