Unigas IDEA NG280 Instructions For Installation, Use And Maintenance Manual

NG280 - NG350 - NG400
NGX280 - NGX350 - NGX400
LG280 - LG350 - LG400
Microprocessor-controlled
gas burners
MANUAL OF INSTALLATION - USE - MAINTENANCE
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
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
Calibration of air and gas pressure switches ................................................................................................................................ 39
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
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
shall have qualified personnel carry out the following operations:
a
Remove the power supply by disconnecting the power cord from the
mains.
b) Disconnect the fuel supply by means of the hand-operated shut-off
valve and remove the control handwheels from their spindles.
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 integrity.
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 cutout 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 harmless.
 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, therefore, 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.

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 combustion 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 instructions 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





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

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 permitted 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:
- 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
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.
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
GENERAL
 The burner shall be installed by qualified personnel and in compliance 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 designed 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.
Light oil burners
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 - 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
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.
Heavy oil burners
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
Gas - Light oil 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.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Gas - Heavy oil 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.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
4
PART I: INSTALLATION
GENERAL FEATURES
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.
2
6
1
3
4
5
Fig. 1
Keys
1 Burner
2 AZL2..
3 Air actuator
4 Fuel actuator
5 LMV2..
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”
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.
Campo di lavoro bruciatori
Tipo P60 Mod. M-xx.x.IT.A.0.50 - M-.xx.x.IT.A.0.65
Contropressione in camera di
combustione mbar
8
7
6
5
A
4
3
2
1
0
-1
100
200
300
400
500
600
700
800
900
Potenza kW
Fig. 2
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C.
Checking the proper gas train size
To check the proper gas train size, it is necessary to 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 pgas value, calculated before.
Tipo / Type P60
M-...50 (Multibloc DUNGS MB-DLE 420 B01)
M-...65 (Filtro / Filter DN65+ SIEMENS VGD40.065 +SKP1x+SKP2x)
Minima pressione gas in
rete / Minimum inlet gas
pressure (mbar)
25
Rp 2" (50)
20
DN65
15
10
5
0
100
200
300
400
500
600
Potenza / Output (kW)
Fig. 3
6
700
800
900
BURNER FEATURES
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Type NG400
Model
(1)
M-.
PR. S.
(2)
(3)
(1) BURNER TYPE
*
A.
0.
50.
EA
(4) (5)
(6) (7) (8)
NG - Natural gas burners
LG - L.P.G. burners
NGX - Low NOx burners
(9)
(2) FUEL
(3)
(4) BLAST TUBE
M - Natural gas
L - LPG
PR - Progressive
S - standard
MD - Fully modulating
L - extended
(5) DESTINATION COUNTRY
* see data plate
(6) BURNER VERSION
A - Standard
(7) EQUIPMENT
(8) GAS CONNECTION
(9) GAS CONNECTION
0 = 2 gas valves
1= 2 Gas valves + gas proving system)
15 = Rp1/2
20 = Rp3/4
25 = Rp1
M - modular
32 = Rp1 ¼
40 = Rp1 ½
50 = Rp2
EA = micro-processor controlled burner (LMV2x)
EB = micro-processor controlled burner (LMV3x)
Technical specifications
NG280
M-.xx...x.25
BURNER TYPE
Output
NG280
M-.xx...x.32
NG280
M-.xx...x.40
Category
Natural gas
L.P.G.
(see next paragraph)
I3B/P
7 – 32
2,5 – 11,5
min.- max. (Stm3/h)
Gas Pressure
LG280
L-.xx...x.25
LG280
L-.xx...x.32
65 - 300
min.- max. kW
Fuel
Gas rate
LG280
L-.xx...x.20
(Note2)
min.- max. mbar
230V - 50Hz
Power supply
Total power consumption
kW
0,55
Electric motor
kW
0,25
IP40
Protection
1” ¼ / Rp 1 ¼ 1” ½ / Rp 1” ½
1” / Rp 1
Valves size / Gas connection
1” / Rp1
1” / Rp1
1”1/4 / Rp 11/4
LG350
L-.xx...x.32
LG350
L-.xx...x.40
Progressive - Fully modulating
Operation
Operating temperature
°C
Storage Temperature
°C
-10 ÷ +50
-20 ÷ +60
Intermittent
Working service*
NG350
M-.xx...x.25
BURNER TYPE
Output
min.- max. kW
LG350
L-.xx...x.25
85 - 330
Natural gas
L.P.G.
I3B/P
I3B/P
I3B/P
3 – 13
3 – 13
3 – 13
(see next paragraphsee next paragraph)
Category
Gas pressure
NG350
M-.xx...x.40
80 - 330
Fuel
Gas rate
NG350
M-.xx...x.32
min.- max. (Stm3/h)
8.5 – 35
8.5 – 35
min.- max. mbar
8.5 – 35
(Note2)
230V - 50Hz
Power supply
Total power consumption
kW
Electric motor
kW
0,67
0,37
IP40
Protection
1” ¼ / Rp 1 ¼ 1” ½ / Rp 1½
1” / Rp 1
Valves size / Gas connection
1” / Rp1
Progressive - Fully modulating
Operation
Operating temperature
°C
-10 ÷ +50
Storage Temperature
°C
-20 ÷ +60
Intermittent
Working service *
7
1”1/4 / Rp 11/4 1”1/2 / Rp 11/2
NG400
M-.xx...x.25
BURNER TYPE
NG400
M-.xx...x.32
min.- max. kW
Output
NG400
M-.xx...x.40
115 - 420
Natural gas
Fuel
(see next paragraph)
Category
12 - 44.5
min.- max. (Stm3/h)
Gas rate
min.- max. mbar
Gas pressure
(Note2)
230V - 50Hz
Power supply
Total power consumption
kW
0,67/0,75
Electric motor
kW
0,37/0,45
IP40
Protection
1” / Rp 1
Valves size / Gas connection
1” ¼ / Rp 1 ¼
1” ½ / Rp 1” ½
2” / Rp 2
Progressive - Fully modulating
Operation
Operating temperature
°C
Storage Temperature
°C
-10 ÷ +50
-20 ÷ +60
Intermittent
Working service *
LG400
L-.xx...x.25
BURNER TYPE
LG400
L-.xx...x.32
min.- max. kW
Output
LG400
L-.xx...x.40
LG400
L-.xx...x.50
105 - 420
L.P.G.
Fuel
I3B/P
Category
Gas rate
Gas pressure
min.- max. (Stm3/h)
4 - 16
min.- max. mbar
(Note2)
230V - 50Hz
Power supply
Total power consumption
kW
0,67/0,75
Electric motor
kW
0,37/0,45
IP40
Protection
1” / Rp 1
Valves size / Gas connection
1” ¼ / Rp 1 ¼
1” ½ / Rp 1” ½
2” / Rp 2
Progressive - Fully modulating
Operation
Operating temperature
°C
-10 ÷ +50
Storage Temperature
°C
-20 ÷ +60
Intermittent
Working service *
Note1:
NG400
M-.xx...x.50
All gas flow rates are referred to Stm3/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (nett
calorific value Hi = 34.02 MJ/Stm3); for L.P.G. (net calorific value Hi = 93.5 MJ/Stm3)
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
NGX280
M-.xx...x.25
BURNER TYPE
NGX280
M-.xx...x.32
min.- max. kW
Output
60 - 190
Natural gas
Fuel
(see next paragraph)
Category
6,4 - 20
min.- max. (Stm /h)
3
Gas rate
min.- max. mbar
Gas pressure
(Note2)
230V - 50Hz
Power supply
Total power consumption
kW
Electric motor
kW
0,55
0,25
IP40
Protection
1”1/4 / Rp 11/4
1” / Rp1
Valves size / Gas connection
1”1/2 / Rp 11/2
Progressive - Fully modulating
Operation
Class 3 - EN676/2008
NOx emissions
Operating temperature
°C
Storage Temperature
°C
-10 ÷ +50
-20 ÷ +60
Intermitent
Working service *
NGX350
M-.xx...x.25
BURNER TYPE
NGX350
M-.xx...x.32
min.- max. kW
Output
NGX350
M-.xx...x.40
65 - 260
Natural gas
Fuel
(see next paragraph)
Category
Gas rate
min.- max. min.max.(Stm3/h)
Gas pressure
min.- max. mbar
7 - 27.5
(Note2)
230V - 50Hz
Power supply
Total power consumption
kW
Electric motor
kW
0,67
0,37
IP40
Protection
1”1/4 / Rp 11/4
1” / Rp1
Valves size / Gas connection
1”1/2 / Rp 11/2
Progressive - Fully modulating
Operation
Class 3 - EN676/2008
NOx emissions
Operating temperature
°C
-10 ÷ +50
Storage Temperature
°C
-20 ÷ +60
Intermitent
Working service *
Note1:
NGX280
M-.xx...x.40
All gas flow rates are referred to Stm3/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (net
calorific value Hi = 34.02 MJ/Stm3); for L.P.G. (net calorific value Hi = 93.5 MJ/Stm3)
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
NGX400
M-.xx...x.25
BURNER TYPE
NGX400
M-.xx...x.32
min.- max. kW
Output
NGX400
M-.xx...x.40
NGX400
M-.xx...x.50
90 - 350
Natural gas
Fuel
(see next paragraph)
Category
Gas rate
Gas pressure
min.- max. (Stm3/h)
9.5 - 37
min.- max. mbar
(Note2)
230V - 50Hz
Power supply
Total power consumption
kW
0,67/0,75
Electric motor
kW
0,37/0,45
IP40
Protection
1” ¼ / Rp 1 ¼
1” / Rp 1
Valves size / Gas connection
2” / Rp 2
Class 3 - EN676/2008
NOx emissions
Operating temperature
°C
Storage Temperature
°C
-10 ÷ +50
-20 ÷ +60
Intermittent
Working serivce *
Note1:
1” ½ / Rp 1” ½
Progressive - Fully modulating
Operation
All gas flow rates are referred to Stm3/h (1013 mbar absolute pressure, 15 °C temperature) and are valid for G20 gas (net
calorific value Hi = 34.02 MJ/Stm3); for L.P.G. (net calorific value Hi = 93.5 MJ/Stm3)
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
COUNTRY
I2H
AT ES
G
SE
FI
IE HU IS
N
CZ DK GB IT
I2E
LU PL
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
I2E( R ) B
BE
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
I2L
NL
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
I2ELL
DE
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
I2Er
FR
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
10
PT CY EE LV
SI MT SK BG LT
R
TR CH
Performance Curves

Gas burners
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
NG280
7
6
6
5
4
4
3
2
2
1
0
0
50
100
150
200
250
300
350
50
100
150
200
250
300
350
400
kW
kW
NG400
9
8
7
6
5
4
3
2
1
0
100
150
200
250
300
350
400
450
kW
BACK PRESSURE IN
CCOMBUSTION CHAMBER mbar
L.P.G. Burners
BACK PRESSURE IN
CCOMBUSTION CHAMBER mbar

NG350
LG280
LG350
7
6
6
5
4
4
3
2
2
1
0
0
50
100
150
200
250
300
50
350
LG400
8
6
4
2
0
100
150
200
250
300
350
400
150
200
250
300
350
kW
kW
50
100
450
kW
11

Low NOx burners
BACK PRESSURE IN
CCOMBUSTION CHAMBER mbar
BACK PRESSURE IN
CCOMBUSTION CHAMBER mbar
NGX280
6
5
4
3
2
1
0
40
80
120
160
200
kW
NGX350
NGX400
7
9
8
7
6
5
4
3
2
1
0
6
5
4
3
2
1
0
50
100
150
200
250
50
300
kW
100
150
200
250
300
350
400
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

Gas burners
NG280 M-.AB...
NG350 M-.PR/MD...
100
100
Rp ½ " (15)
GAS PRESSURE mbar
Rp ½" (15)
80
80
60
60
Rp ¾" (20)
40
40
Rp ¾ " (20)
Rp 1" (25)
Rp 1" (25)
20
20
Rp 1"¼ (32)
Rp 1"¼ (32)
Rp 1"½ (40)
0
5
10
15
20
25
30
35
0
40
5
10
15
20
25
30
35
40
45
Gas rate Stm3/h
3
Gas rate Stm /h
NG400 M-.PR/MD...32-40-50
18
GAS PRESSURE mbar
16
Rp 1"¼ (32)
14
12
Rp 1"½ (40)
10
Rp 2" (50)
8
6
4
2
0
10
15
20
25
30
35
40
45
50
55
Gas rate Stm3/h

L.P.G. Burners
LG280 L-.AB...
LG350 L-.PR....
50
60
GAS PRESSURE mbar
Rp ½" (15)
Rp ½" (15)
50
40
40
30
Rp ¾1" (20)
Rp ¾" (20)
30
Rp 1" (25)
Rp 1" (25)
20
20
Rp 1"¼ (32)
10
Rp 1"¼ (32)
10
0
0
2
4
6
8
10
12
2
14
3
4
6
8
10
12
14
16
Gas rate Stm3/h
Gas rate Stm /h
LG400 L-.PR/MD....
GAS PRESSURE mbar
70
Rp ½" (15)
60
50
Rp ¾" (20)
40
Rp 1" (25)
30
Rp 1"¼ (32)
20
Rp 1"½ (40)
10
0
2
4
6
8
10
12
14
16
18
20
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.
13
Low NOx burners
NGX280
NGX350
80
30
R p ½ " (1 5 )
70
R p ¾" ( 2 0 )
GAS PRESSURE mbar
25
60
50
20
R p 1" ( 2 5 )
40
15
10
R p 1"¼ ( 3 2 )
30
R p 1"½ ( 4 0 )
20
R p ¾ " (2 0 )
R p 1 " (2 5 )
R p 1 "¼ (3 2 )
R p 1 "½ (4 0 )
10
5
0
5
0
4
6
8
10
12
14
16
18
20
22
24
10
15
20
25
30
35
Gas rate Stm3/h
26
Gas rate Stm3/h
NGX400 M-...15-20-25
NGX400 M-...32-40-50
16
R p 1"¼ (32)
Rp ½" (15)
100
GAS PRESSURE mbar

14
R p 1"½ (40)
12
80
R p 2" (50)
10
Rp ¾" (20)
60
8
6
40
4
Rp 1" (25)
20
2
0
0
5
10
15
20
25
30
35
40
45
50
5
Gas rate Stm3/h
10
15
20
25
30
35
40
45
50
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
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 O2 in the flues as shown in the “Recommended combustion values” table and CO in the standard 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.
1
2
4
3
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.
Pressure plug in combustion chamber
Fan air pressure plug
Fig. 5
15
Pressure in the combustion head vs. gas flow rate curves

Natural gas burners
NG280
16
Gas backpressure in
combustion head
14
12
10
8
6
4
2
0
6
10
14
18
22
26
30
34
Gas rate Stm3/h
NG400
NG350
9
12
Gas backpressure in
combustion head
8
10
7
6
8
5
6
4
3
4
2
2
1
0
0
5
10
15
20
25
30
35
40
10
15
20
25
30
35
Gas rate Stm /h

40
45
Gas rate Stm3/h
3
L.P.G. Burners
LG280
18
Gas backpressure in
combustion head
16
14
12
10
8
6
4
2
0
2
3
4
5
6
7
8
9
10
11
12
13
Gas rate Stm3/h
LG400
LG350
Gas backpressure in
combustion head
25
20
20
15
15
10
10
5
5
0
0
2
4
6
8
10
12
14
4
Gas rate Stm /h
3
16
6
8
10
12
14
16
18
Gas rate Stm3/h

Low NOx burners
NGX280
Gas backpressure in
combustion head
14
12
10
8
6
4
2
0
4
6
8
10
12
14
16
18
20
Gas rate Stm3/h
Gas backpressure in
combustion head
NGX350
NGX400
18
10
16
9
14
8
12
7
6
10
5
8
4
6
3
4
2
2
1
0
0
6
8
10
12
14
16
18
20
22
24
26
28
30
Gas rate Stm3/h
17
5
10
15
20
25
30
35
40
Gas rate Stm3/h
Overall dimensions (mm)
z
Standard burners
Boiler recommended drilling template and burner
flange
18
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
DN
0.25 (1")
0.32 (1"1/4)
0.40 (1"1/2)
0.50 (2")
0.25 (1")
0.32 (1"1/4)
0.40 (1"1/2)
0.50 (2")
DN
A(S*)
733
733
733
733
733
733
733
733
A(L*)
878
878
878
878
878
878
878
878
B(S*)
163
163
163
163
163
163
163
163
B(L*)
308
308
308
308
308
308
308
308
A(S*) A(L*) B(S*) B(L*) C D
C D ±5mm E ±5mm
570
596
200
570
596
200
570
726
330
570
726
330
570
668
200
570
668
200
570
798
330
570
798
330
±5mmE
0.25 (1")
748 878 178 308 570
596
NG350 M-..PR..Ex
0.32 (1"1/4) 748 878 178 308 570
596
NG350 M-..PR..Ex
0.40 (1"1/2) 748 878 178 308 570
726
NG350 M-..PR..Ex
0.50 (2")
748 878 178 308 570
726
NG350 M-..PR..Ex
0.25 (1")
748 878 178 308 570
668
NG350 M-..MD..Ex
0.32 (1"1/4) 748 878 178 308 570
668
NG350 M-..MD..Ex
0.40 (1"1/2) 748 878 178 308 570
798
NG350 M-..MD..Ex
0.50 (2")
748 878 178 308 570
798
NG350 M-..MD..Ex
When PGMAX (maximum pressure switch) is supplied, add 60mm
F
396
396
396
396
468
468
468
468
G
113
113
113
113
113
113
113
113
H
164
164
164
164
164
164
164
164
Y
108
108
108
108
108
108
108
108
K1
215
215
215
215
215
215
215
215
K2
223
223
223
223
223
223
223
223
L
348
348
348
348
348
348
348
348
M
M10
M10
M10
M10
M10
M10
M10
M10
N
219
219
219
219
219
219
219
219
Omin Omax P
Q
R S T W X
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 517 491
131 179 155 459 366 93 128 567 491
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 517 491
131 179 155 459 366 93 128 567 491
±5mm F G H Y K1 K2 L M N OminOmax P Q R S T W X
200
396125164144215223348M10219 131 179 1554593669389508491
200
396125164144215223348M10219 131 179 1554593669389508491
330
396125164144215223348M10219 131 179 1554593669389517491
330
396125164144215223348M10219 131 179 1554593669389567491
200
468125164144215223348M10219 131 179 1554593669389508491
200
468125164144215223348M10219 131 179 1554593669389508491
330
468125164144215223348M10219 131 179 1554593669389517491
330
468125164144215223348M10219 131 179 1554593669389567491
to "D" and "E"
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
DN
A(S*) A(L*) B(S*) B(L*) C D
0.25 (1")
768 898 198 328 570
0.32 (1"1/4) 768 898 198 328 570
0.40 (1"1/2) 768 898 198 328 570
0.50 (2")
768 898 198 328 570
0.25 (1")
768 898 198 328 570
0.32 (1"1/4) 768 898 198 328 570
0.40 (1"1/2) 768 898 198 328 570
0.50 (2")
768 898 198 328 570
DN
0.25 (1")
0.32 (1"1/4)
0.40 (1"1/2)
0.50 (2")
0.25 (1")
0.32 (1"1/4)
0.40 (1"1/2)
0.50 (2")
A(S*)
733
733
733
733
733
733
733
733
A(L*)
878
878
878
878
878
878
878
878
B(S*)
163
163
163
163
163
163
163
163
±5mmE
596
596
726
726
668
668
798
798
B(L*)
308
308
308
308
308
308
308
308
±5mm F G H Y K1 K2 L M N OminOmax P Q R S T W X
200
396144164144215223348M10219 131 179 1554593669389508496
200
396144164144215223348M10219 131 179 1554593669389508496
330
396144164144215223348M10219 131 179 1554593669389517496
330
396144164144215223348M10219 131 179 1554593669389567496
200
468144164144215223348M10219 131 179 1554593669389508496
200
468144164144215223348M10219 131 179 1554593669389508496
330
468144164144215223348M10219 131 179 1554593669389517496
330
468144164144215223348M10219 131 179 1554593669389567496
C D ±5mm E ±5mm
570
596
200
570
596
200
570
726
330
570
726
330
570
668
200
570
668
200
570
798
330
570
798
330
F
396
396
396
396
468
468
468
468
G
117
117
117
117
117
117
117
117
H
137
137
137
137
137
137
137
137
Y
108
108
108
108
108
108
108
108
K1
215
215
215
215
215
215
215
215
K2
223
223
223
223
223
223
223
223
L
348
348
348
348
348
348
348
348
M
M10
M10
M10
M10
M10
M10
M10
M10
N
219
219
219
219
219
219
219
219
Omin Omax P
Q
R S T W X
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 517 491
131 179 155 459 366 93 128 567 491
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 508 491
131 179 155 459 366 93 128 517 491
131 179 155 459 366 93 128 567 491
19
NGX350 M-..PR..Ex
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
0.25 (1")
748 878 178 308 570
0.32 (1"1/4) 748 878 178 308 570
0.40 (1"1/2) 748 878 178 308 570
0.50 (2")
748 878 178 308 570
0.25 (1")
748 878 178 308 570
0.32 (1"1/4) 748 878 178 308 570
0.40 (1"1/2) 748 878 178 308 570
0.50 (2")
748 878 178 308 570
±5mmE
596
596
726
726
668
668
798
798
±5mm F G H Y K1 K2 L M N OminOmax P Q R S T W X
200
396131164144215223348M10219 131 179 1554593669389508491
200
396131164144215223348M10219 131 179 1554593669389508491
330
396131164144215223348M10219 131 179 1554593669389517491
330
396131164144215223348M10219 131 179 1554593669389567491
200
468131164144215223348M10219 131 179 1554593669389508491
200
468131164144215223348M10219 131 179 1554593669389508491
330
468131164144215223348M10219 131 179 1554593669389517491
330
468131164144215223348M10219 131 179 1554593669389567491
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
DN
A(S*) A(L*) B(S*) B(L*) C D
0.25 (1")
768 898 198 328 570
0.32 (1"1/4) 768 898 198 328 570
0.40 (1"1/2) 768 898 198 328 570
0.50 (2")
768 898 198 328 570
0.25 (1")
768 898 198 328 570
0.32 (1"1/4) 768 898 198 328 570
0.40 (1"1/2) 768 898 198 328 570
0.50 (2")
768 898 198 328 570
±5mmE
596
596
726
726
668
668
798
798
±5mm F G H Y J K1 K2 L M N OminOmax P Q R S T W X
200
396156176156 - 215223348M10219 131 179 1554593669389508496
200
396156176156 - 215223348M10219 131 179 1554593669389508496
330
396156176156 - 215223348M10219 131 179 1554593669389517496
330
396156176156 - 215223348M10219 131 179 1554593669389567496
200
468156176156 - 215223348M10219 131 179 1554593669389508496
200
468156176156 - 215223348M10219 131 179 1554593669389508496
330
468156176156 - 215223348M10219 131 179 1554593669389517496
330
468156176156 - 215223348M10219 131 179 1554593669389567496
* S = standard blast tube
L = long blast tube
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 suitably-sized
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) Length of the flame tube in meters
c) Flame tube firing intensity in MW/m3
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.
Fig. 7
20
How to modify the blast tube length (NG/LG350-NG/LG400)
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.
T
VTF
Fig. 9
Fig. 8
Fig. 10 - Short blast tube
Fig. 11 - Long blast tube
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
V2
V1
Fig. 14
Fig. 16
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).
LOCKED
UNLOCKED
V2
V1
S1
VT1
G
G
TR
T
V4
S2
VT2
V3
Fig. 17
CR
VT1
CA
TR
VT2
Fig. 18
Fig. 19
22
G
F
V
Fig. 21
Fig. 20
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).
D
D
TR
VF
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
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
MANUFACTURER
9
4
4
INSTALLER
5
1
2
7
8
16
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
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.
MOUNTING POSITIONS
C
A
D
B
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.
MOUNTING POSITIONS
C
A
D
B
Fig. 28
A
C
B
D
Fig. 29
Fig. 30
Once the train is installed, connect the gas valves group plug.
25
Fig. 31
.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 ADEQUATE 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

Fig. 36 - Electric motor’s 3-pins connector
NG/LG/NGX400
Progressive burners’ connectors:
Fig. 38Electric motor’s 3-pin connector for
NG/LG/NGX400
Fig. 37 - 7-pin and 4-pin connectors
Key
C1
LBF
BURNER IN LOW FLAME SIGNALLING LAMP
LOW FLAME TIME METER
MV
FAN MOTOR
C2
HIGH FLAME TIME METER
ST
THERMOSTATS O PRESSURE SWITCHES SERIE
FU1
FAN MOTOR LINE FUSE
TAB
HIGH LOW FLAME THERMOSTAT/PRESSURE SWITCH
FU3
LINE FUSE
TS
SAFETY THERMOSTAT/PRESSURE SWITCH
IL
BURNER LINE SWITCH
CONN-MOTORE FAN MOTOR CONNECTOR
IM
FAN MOTOR LINE SWITCH
CONN-LINEA BURNER POWER SUPPLY CONNNECTOR
KM1
FAN MOTOR CONTACTOR
CONN-TAB HIGH-LOW FLAME CONNECTOR
LAF
BURNER IN HIGH FLAME INDICATOR LIGHT
LB
INDICATOR LIGHT FOR BURNER LOCK-OUT
($)
27
IF "TAB" USED REMOVE THE BRIDGE BETWEEN TERMINALS
T6-T8

Fully-modulating burners’ connectors:
Fig. 39 - 7-pin connector
Fig. 41 - Probes connectiion
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
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
The AZL2x.. display is shown below:
The keys functions are the following:
P
V
h
min s
VSD
F
%
nfo
ESC
A
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:
Lock+unlock codes
Flame
Open valves
Ignition transformers energised
Fan motor energised
Oil pre-heater energised
Plant heat request
Parametere setting mode
P
Info mode
Service mode
V
Closing actuator
h min s
%
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
200
Controllo bruciatore
Burner control
OEM / Service / Info
OEM / Service
400
Curve rapporto
Ratio curves
OEM / Service
500
Controllo rapporto
Ratio control
OEM / Service
600
Servocomandi
Actuators
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
OEM / Service
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
t22 = tempo di salita ventilatore (motore ventilatore = ON, t22 = fan ramp up time (fan motor = ON,
valvola intercettazione di sicurezza = ON)
safety shutoff valve = ON)
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
TSA1 = primo tempo sicurezza (trasformatore accensione ON)
TSA1= 1st safety time (ignition transformer
ON)
Ph42
TSA1 = primo tempo sicurezza (trasformatore accensione OFF)
TSA1 = 1st safety time (ignition transformer
OFF)
t42 = preignition time OFF
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
t62 = massimo tempo bassa fiamma (funzionamento 2, in t62 = max. time low-fire (operation 2, prepapreparazione per spegnimento, verso bassa fiamma)
ring for shutdown, traveling to low-fire)
Ph70
t13 = tempo postcombustione
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
t80 = tempo perdita pressione atmosferica, prova atmo- t81 = leakage time test time atmospheric
sferica
pressure, atmospheric test
Ph82
t82 = test perdita, test riempimento
t82 = leakage test filling test, filling
Ph83
t80 = tempo perdita pressione gas, test pressione
t83 = leakage test time gas pressure, pres
sure test
Ph90
Tempo attesa “mancanza gas”
Gas shortage waiting time
t13 = afterburn time
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.
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.
4
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
5
Free
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
2
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.
Once the last parameter is accessed (143) by pressing + , the End message will blink.
3
Press 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
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!
3
4
1
Keys
1 Valve group
2 Cover
3 Control panel
4 Blast tube
2
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
Recommended (%) CO2
Recommended (%) O2
Natural gas
9 ÷ 10
3 ÷ 4.8
LPG
11 ÷ 12
2.8 ÷ 4.3
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 differential 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
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).
C
VS T(VR)
VSB
RP
VB
.
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.
C
VS
T(VR) VSB
VB
RP
Dungs Multibloc MB-DLE
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
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.
ID
VRT
Fig. 43
Fig. 45 - Head in “fully-backward position”
Fig. 44 - Head in “fully-ahead 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
CMF = 1
CMF = 2
CMF = 3
stop at the current position
high flame operation
low flame operation
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 measured 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
PART II: OPERATION
LIMITATIONS OF USE
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
E
B
G
H
A
I
L
D
V1
M
C
V2
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
M
Fuse
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
PART III: MAINTENANCE
At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry
out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6
months.
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 current 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 Fig. 50.
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, pmax. = 360 mbar.
6
Pay attention that dirt does not fall inside the valve.
2
3
2 pe
0
1
6
6
6
1
➞
➞
43
34
5
pBr
1
0
5
4
pa
0
3
pe
4
pa
Fig. 49
5
Fig. 48
Fig. 50
42
5
pBr
Removing the filter in theMULTIBLOC DUNGS MB-DLE 415 - 420 B01 1” 1/2 - 2”
 Check the filter at least once a year!
 Change the filter if the pressure difference between pressure connection 1 and 2 (Fig. 51-Fig. 52) Dp> 10 mbar.
 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, pmax. = 360 mbar.
6
Pay attention that dirt does not fall inside the valve.
0
3
2 pe
0
1
5
5
4
pa
5
pBr
1
6
1
0
Fig. 51
E
D
A
B
4
pa
Fig. 52
32 4
4 23
3
pe
C
Fig. 53
43
5
pBr
Removing and cleaning the combustion head
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 (Fig. 57 - H). Clean the combustion head by a compressed air blow or, in case of scale, scrape it off by a
scratchbrush.
G
V1
V2
S1
LOCKED
VT1
G
TR
G
T
V4
S2
VT2
UNLOCKED
V3
Fig. 55
Fig. 54
H
CA
CR
Fig. 57
Fig. 56
44
Adjusting the electrodes position
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.
Ground
Ignition electrode
Detection electrode
detection electrode
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%)
1
2
3
4
5
Protective earth PE
X10-05
Ionization probe (ION)
+
QRB.../ QRC... signal voltage
1
2
QRB... GND
QRA... (-)
X10-06
QRA... (+)
L
Fig. 59
Error code
93
Diagnostic code
3
Cause
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
47
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
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
LG/NG280
1011803
2020474
2020477
2022115
2080108
2080218
2110059
2160053
2160077
2170138
2170232
2180717
2190341
2190342
21903L3
2480096
2570112
30600P9
30600Q3
30900L0
30900L1
3501842
6050153
6050214
COVER
BURNER MANAGEMENT SYSTEM - SIEMENS LMV2..
BURNER MANAGEMENT SYSTEM - SIEMENS LMV3..
USER INTERFACE/DISPLAY - SIEMENS AZL2..
DETECTION ELECTRODE
INGNITION ELECTRODE
GASKET
AIR PRESSURE SWITCH
GAS PRESSURE SWITCH
IGNITION TRANSFORMER MOD. COFI
IGNITION TRANSFORMER MOD. DANFOSS
MOTOR
VALVE GROUP Rp1
VALVE GROUP Rp1 1/4
VALVE GROUP Rp1 1/2
ACTUATOR - SIEMENS SQN14
ACTUATOR - SIEMENS RWF
COMBUSTION HEAD (GAS) mod. NG
COMBUSTION HEAD (L.P.G.) mod. LG
BLAST TUBE S*
BLAST TUBE L*
COMBUSTION HEAD (GAS) mod. NG
COMBUSTION HEAD (L.P.G.) mod. LG
INGNITION CABLE
DETECTION CABLE
Code
LG/NG350
1011803
2020474
2020477
2022115
2080108
2080218
2110059
2160053
2160077
2170138
2170232
2180714
2190341
2190342
21903L3
2480096
2570112
30600H3
30600H7
30900G3
30900G3**
3501841
3501844
6050153
6050214
LG/NG400
1011803
2020474
2020477
2022115
2080108
2080218
2110059
2160053
2160077
2170138
2170232
2180712
2190341
2190342
21903L3
2480096
2570112
30600H2
30600H6
30900F9
30900F9**
3501842
3501843
6050153
6050214
Spare parts for Low NOx Burners only
Desription
NGX280
30600Q7
30910P5
COMBUSTION HEAD (NOx)
BLAST TUBE S*
*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
Code
NGX350
30600H9
30910L6
NGX400
30600H8
30910L7
ELECTRICAL WIRING DIAGRAMS
See the attached wiring diagrams.
Wiring diagram SE04-755 - Progressive burners
Wiring diagram SE04-753 - Fully-modulating burners
49
C.I.B. UNIGAS S.p.A.
Via L.Galvani, 9 - 35011 Campodarsego (PD) - ITALY
Tel. +39 049 9200944 - Fax +39 049 9200945/9201269
web site: www.cibunigas.it - e-mail: [email protected]
Note: Specifications and and data subject to change. Errors and omissions excepted.