Installation, use and maintenance instructions

Forced draught gas burner

One stage operation

CODE MODEL TYPE

3756605 FS5 566M

2902654 (2)
TECHNICAL DATA

TYPE 566M

Thermal output 23 – 58 kW – 20,000 – 50,000 kcal/h

Gas Net heat value 8 – 12 kWh/m3 – 7,000 – 10,340 kcal/m3

(Family 2) Pressure min. 10 mbar – max. 40 mbar

Electrical supply single phase, 230 V ± 10% ~ 50Hz

Motor 230 V / 0.65 A

Capacitor 2 µF

Ignition transformer primary 230 V / 0.2 A – secondary 8 kV

Absorbed electrical power 0.11 kW

For gas family 3 (LPG) ask for separate kit.

COUNTRY IT - AT - GR - DK - SE GB - IE NL FR DE LU
GAS CATEGORY II2H3B/P II2H3P II2L3B/P II2Er3P II2ELL3B/P II2E3B/P

◆ The burner meets protection level of IP X0D (IP 40), EN 60529.

◆ CE marking according to Gas Appliance Directive 90/396/EEC; PIN 0063AP6680.
◆ According to directives: EMC 89/336/EEC, Low Voltage 73/23/EEC, Machines 98/37/EEC and
Efficiency 92/42/EEC.
◆ Gas train according to EN 676 .

Fig. 1

1 – Air-damper
2 – Screws for fixing the air-damper
3 – 7 pole socket for electrical supply 7
and control 1
4 – 6 pole socket for gas train
5 – Grommet 6 2

6 – Screw for fixing the cover 2

7 – Lock-out lamp and reset button

5 4 3 D4064

NOTES
– The grommet (5) supplied with the burner, must be fitted to the same side of the gas train.
– After having installed the burner verify the access to the fixing screws of the cover.
If necessary replace them with the fixing screws (6) fig. 1 supplied as equipment.

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OVERALL DIMENSIONS
Flange Burner

ø 170 272 100 295

125
45
° 45 *

ø 91
°

Rp 1/2
233
140

138
180
10

130 28 48

* Length available using an extended head kit. D5066

BURNER EQUIPMENT

Quantity Description
4 Screws with nuts
1 Insulating gasket
3 Screws for fixing the cover
1 Grommet
1 Hinge
1 7 pin plug

FIXING TO THE BOILER

Separate the combustion-head assembly from the HINGE ASSEMBLY
burner body by removing nut (1) and removing group (A).
Fix the head assembly group (B) to the boiler (2) insert
the equipped insulating gasket (3).

1 3 2

S7392

D5067

A B
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WORKING RANGE
Pressure in the combustion

1.0
chamber – mbar

0.8

0.6

0.4

0.2

0
20 30 40 50 60 kW

20.000 30.000 40.000 50.000 kcal/h

Burner output D5053

TEST BOILER
The working field has been defined according to DIN 4788 and EN 676 standards.

COMMERCIAL BOILERS
The burner-boiler matching is assured if the boiler is according to EN 303 and the combustion
chamber dimensions are similar to those shown in the diagram EN 676.

For applications where the boiler is not according to EN 303, or where the combustion chamber
dimensions differ from those shown in EN 676, please consult the manufacturers.

CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

To obtain the maximum output, a gas head pressure of 4.6 mbar is measured with the combustion
chamber at 0 mbar using gas G20 with a net heat value of 10 kWh/m3 (8,570 kcal/m 3).

5
Gas pressure

4
mbar

1
20 30 40 50 60 kW

20,000 30,000 40,000 50,000 kcal/h

Burner output D5054

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LINE OF GAS-SUPPLY

1 2 3 M1 4 5 6 7 8 MBC 65 DLE
6 8 7

D5069 D7279

1 – Gas supply pipe M2

2 – Manual cock (charged to the installer)
3 – Gas pressure gauge (charged to the installer) 7 – Pressure governor
4 – Filter 8 – Adjusting valve
5 – Gas pressure switch M1 – Gas-supply pressure test point
6 – Safety valve M2 – Pressure coupling test point

GAS TRAIN ACCORDING TO EN 676

CONNECTION
MULTIBLOC CODE EMPLOY
GAS TRAIN BURNER
MBC 65 DLE 3970569 Rp 1/2 Rp 1/2 Natural gas and LPG
MBDLE 405 B01 3970530 Rp 1/2 Rp 1/2 Natural gas and LPG

The gas train is supplied separately, for its adjustment see the enclosed instructions.

POSITIONING ELECTRODE-PROBE
Put the ceramic Ionization
near the diffuser disc probe Diffuser Ignition electrode

Probe
2 Electrode

D5033

WARNING 2.5 – 3.5 mm

IMPORTANT
Do not turn the starting electrode but leave it as shown in the drawing; if the starting electrode is
put near the ionization probe, the amplifier of the control box might be damaged.

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 BURNER ELECTRICAL WIRING
(carried out in the factory)

Ignition electrode Ionization probe

Connector
CONTROL BOX

525SE/3F Burner earth

Brown
Capacitor

White
Blue
Motor

Black
Air pressure
switch

Suppressor

D4065

6 pole socket 7 pole socket

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 ELECTRICAL WIRING
(to be carried-out by the installer)

7 pin plug 6 pin plug

B4 S3 T2 T1 N L1 3 2 1 N Ph

TS
h

6A
T
Black Grey
ADJUST.
1 2 3 1 2 3

N L PE P
VS V1
230V ~ 50Hz GAS

D5127

NOTES
– Do not exchange the neutral with the phase and connect exactly the above wiring.
– Wire of 1 mm2 section.
– Carry out a safe earth connection.
– Verify that the burner stops by operating the boiler control thermostats and that the burner goes
lock out by separating the red ionisation probe lead connector.
– The electric wiring carried out by the installer must be in compliance with the rules in force in
the Country.

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BURNER START-UP CYCLE
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valves
Flame
Lock-out
D5048

30s min. 3s max. 30s min. 3s max.

When flame-failure occurs during working, shut down takes place within one second; and the
cycle starts again; a lock-out follows if the flame do not start.

COMBUSTION-HEAD ADJUSTMENT

Loose the screw (A), move the elbow (B) so that the
rear plan of the coupling (C) coincides with the set
point. Tight the screw (A).
C

Example:
B S7015
The burner is installed on a 40 kW boiler with an effi-
ciency of 90%, the burner input is about 44 kW using
the diagram below, the combustion set point is 3.

kcal/h kW
60,000 70

50,000 60

50
40,000
44
40
30,000
30
20,000
20

10,000 10
0 1 2 3 4 5 Set point D5068

The diagram is to be used only for initial settings, to improve air pressure switch operation or
improve combustion, it may be necessary to reduce this setting (set point toward position 0).

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COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler,
adjustment and testing must be carried out observing the instruction manual of the boiler, includ-
ing verification of the CO and CO2 concentration in the flue gases, their temperatures and the
average temperature of the water in the boiler.

It is advisable to set the burner according to the type of gas used and following the indications of the
table:

EN 676 AIR EXCESS: max. output λ ≤ 1.2 – min. output λ ≤ 1.3

Theoretical max. CO2 Setting CO2 % CO NOx
GAS
0 % O2 λ = 1.2 λ = 1.3 mg/kWh mg/kWh
G 20 11.7 9.7 9.0 ≤ 100 ≤ 170
G 25 11.5 9.5 8.8 ≤ 100 ≤ 170
G 30 14.0 11.6 10.7 ≤ 100 ≤ 230
G 31 13.7 11.4 10.5 ≤ 100 ≤ 230

IONIZATION CURRENT
The minimum current required by the control box is 5 µA.
The burner would normally have a higher current value than this, but if a check is required, open
the connector fitted in the red probe lead and insert a microammeter as shown.

Connector

Control box 2 Ionization

terminal block probe
D5006

AIR PRESSURE SWITCH

The air pressure switch is set after all other adjustments have
been made. Begin with the switch at the lowest setting.
With the burner working at the minimum output, adjust the dial
clockwise, increasing its value until the burner shuts down. Now
reduce the value by one set point, turning the dial anti-clockwise.
Check for reliable burner operation, if the burner shuts down, re-
duce the value by a half set point.

D5049

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BURNER STARTING DIFFICULTIES AND THEIR CAUSES

DIFFICULTIES CAUSES

The ionization probe is earthed or not in contact with the flame, or

The burner goes through its wiring to the control box is broken, or there is a fault on its insula-
the pre-purge period nor- tion to earth.
mally, the flame ignites,
but the burner goes to The connection of the phase and neutral leads has been inverted:
lock-out within 3 seconds you need to exchange it.
after the ignition.
The wiring to the earth is lacking or ineffective.

The valves are passing too little gas (low pressure in the gas pipe-
work).
The burner goes to lock- The valves are defective.
out, after the pre-purge
period, because the flame It is irregular or the ignition arc is not present; in this case remove
does not ignite. the control box and insert it again, taking care that the electrode
push-rod is in the proper seat.

The pipe has not been purged from the air.

The burner does not pass The air pressure switch does not change over: it has failed or the air
through the pre-purge pe- pressure is too low (combustion head bad set).
riod and the control box
goes to lock-out. Flame simulation exists (or the flame really lights).

Gas is not supplied.

The gas pressure switch does not close its contact due to incorrect
setting or a faulty switch.
The burner does not start
at the thermostat closing. The air pressure switch is changed over to the operational position.

Before to replace the control box, check that short-circuits are not
present on the power-line: of the motor, of the gas electrovalve/s
and on the external signaling devices.

This concerns a very particular irregularity, caused by the fact that

the gas pressure in the gas-mains lies very close to the value to
which the gas pressure switch has been set.
The burner continues to As a result of this, the sudden falling-off of pressure at the opening
repeat the starting cycle of the valves causes the opening of the pressure switch.
without going on lock-out. However this only temporarily, because the valves immediately
close again, so then does the pressure switch, because the pres-
sure builds-up again the cycle to be repeated over and over.
This can be remedied by lowering the setting of the pressure switch.

OPERATING FAULTS
Re-cycle and lock-out may occur, because of : – Flame failure
– Ionization probe earthed

The burner goes to lock-out because of . . . . : – Opening of the air pressure switch

Burner stop because of. . . . . . . . . . . . . . . . . . : – Gas pressure switch opening

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 WARNINGS TO AVOID BURNOUT OR BAD COMBUSTION OF
THE BURNER

1 – When the burner is stopped, the smoke pipe must be opened and effect a natural
draught in the combustion chamber. If the smoke pipe is closed, the burner must be
drawn back till the extraction of blast tube from the furnace. Before operating in this
way take the voltage off.

2 – The place, where the burner works, must have same openings suitable for the passage
of air necessary for combustion. To be sure about this, you have to control CO2 and
CO in the exhaust gases with all the windows and doors closed.

3 – If in the place, where the burner works, there are air-breathings, check the existence
of air-input openings with dimensions suitable for the necessary air-exchange. In any
case check that, when the burner is stopped, the air-breathings do not draw warm
smokes from pipes through the burner.

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