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Dungs HeatEngine HEPM-P Series Installation Instructions Manual

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DUNGS HeatEngine®
Designation:
Date of issue:
Publication version:
Identification of the machine:
Extended installation instructions:
DUNGS HeatEngine®
HEPM-Pxx (HeatEngine PreMix Point-style)
HEPM-Lxx (HeatEngine PreMix Line-style)
2024-01-31
Version 1
see drawing (appendix)

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Summary of Contents for Dungs HeatEngine HEPM-P Series

  • Page 1 Extended installation instructions: DUNGS HeatEngine® Designation: DUNGS HeatEngine® HEPM-Pxx (HeatEngine PreMix Point-style) HEPM-Lxx (HeatEngine PreMix Line-style) Date of issue: 2024-01-31 Publication version: Version 1 Identification of the machine: see drawing (appendix)

  • Page 2: Table Of Contents

    Figure 4: HeatEngine in process chamber with outer and inner lining/insulation (line-style burner system) ............................... 15 Figure 5: HeatEngine in process chamber with outer and inner lining/insulation (point-style burner system) ............................... 15 Figure 6: Diagram for setting the main volume throttle ................ 19 DUNGS HeatEngine® Page 2 from 39 2024-01-31...

  • Page 3: Introduction And Purpose Of These Operating Instructions

    If the information contained in these operating instructions is not sufficient, please get in touch with your contact at Karl Dungs GmbH & Co. KG, the DUNGS Support Centre (+49 7181 804-804, supportcenter@dungs.com) or DUNGS Global Service (+49 7181 804-0, servicecenter@dungs.com).

  • Page 4: General Safety Instructions

    Danger All work on the HeatEngine (e.g. maintenance and repair work) may only be carried out by qualified, expert personnel. DUNGS service personnel and our authorised specialist dealers fulfil this requirement. Danger The HeatEngine is a burner system in which gas and air are mixed and burnt in a controlled manner as a premix.
  • Page 5 Danger The system includes a fan with rotating parts. When working on the system/machine, wait until all parts have come to a standstill. Wear appropriate clothing or keep your distance during operation DUNGS HeatEngine® Page 5 from 39 2024-01-31...

  • Page 6: System Overview

    From 117 kW / 400 kBTU/H besides the visual indicator one proof of closure is needed. The use of a MBC is not possible, instead a DMV with FRNG (including Proof of closure) is used. DUNGS HeatEngine® Page 6 from 39 2024-01-31...
  • Page 7 The burner head geometry and burner output must be selected according to the requirements. The modules and their possible combinations are illustrated graphically in the appendix using the poster (see Appendix 1). Available standard versions of the DUNGS HeatEngine are: Type Designation Item no.

  • Page 8: Intended Use And Misuse

    An exception to this is if no other spare parts are available and the alternative has been previously accepted by DUNGS. DUNGS HeatEngine® Page 8 from 39...

  • Page 9: Technical Data

    Variants based on the type code The exact design of the existing DUNGS HeatEngine can be found in the type code (Figure 2). This indicates whether it is a point- or line-style burner head, the output of the burner system, the medium with which the system is operated and the region for which it was designed.
  • Page 10 0, 1, 2, 3, 4 0, 1, 2, 3, …15 Input X17 0, 1, 2, 3, … 11 Configuration of output for operation Visible flame length when operating with natural gas in free range 0...100 [%] DUNGS HeatEngine® Page 10 from 39 2024-01-31...
  • Page 11 Duration for new start of pilot burner Shutdown 16…65534 [1/16 s] Follow-up time 16…65534 [1/16 s] Post-purge time 16…65534 [1/16 s] Restart protection Extension module 0…1920 [1/16 s] Maximum waiting time until motor position is reached DUNGS HeatEngine® Page 11 from 39 2024-01-31...

  • Page 12: Function Of The Control Unit

    The gas volume is set to the desired mixture on the MBC at the integrated main volume throttle A and via the offset (adjusting screw B). The procedure for setting the main volume throttle on the MBC is described in 5.4 Commissioning and 6 Manufacturer settings. Further information can be DUNGS HeatEngine® Page 12 from 39 2024-01-31...

  • Page 13: Transport And Storage

    Connectors for blowers, electrodes, MBC and pressure switches • Ignition cable (length e.g. 550 mm, 1000 mm or 1500 mm) • Ionization cable (length e.g. 550 mm, 1000 mm or 1500 mm) • Power supply cable for transformer DUNGS HeatEngine® Page 13 from 39 2024-01-31...

  • Page 14: Integration Into The Machine

    Figure 4 on the left, only minimally increases the temperature resistance. With this variant, it is important that the mounting flange and screws are not insulated. An inner lining, as shown in Figure 4 on the right, increases the temperature resistance to 450°C / 840F. DUNGS HeatEngine® Page 14 from 39 2024-01-31...

  • Page 15: Figure 4: Heatengine In Process Chamber With Outer And Inner Lining/Insulation (Line-Style Burner System)

    A sight glass placed perpendicular to the focal surface of a point-style burner head is shown in Figure 5. Figure 5: HeatEngine in process chamber with outer and inner lining/insulation (point-style burner system) DUNGS HeatEngine® Page 15 from 39 2024-01-31...

  • Page 16: Checking The Installation

    (see appendix). Check the on-site electrical fuse protection. After installation and before commissioning the DUNGS HeatEngine a) Check power supply. b) Carry out an electrical function test.

  • Page 17: Commissioning

    A of the MBC. The blower output is set by the MPA parameter 246 Maximum speed determined. The gas quantity can be determined by a gas meter, a gas counter or a measuring orifice in the gas supply line. DUNGS HeatEngine® Page 17 from 39 2024-01-31...
  • Page 18 If the pad surface glows too much (significantly more than 50% glowing surface), this can lead to thermal overload of the pad surface. At the end of commissioning, check the connections and closures for leaks using a foaming agent and retighten if necessary. DUNGS HeatEngine® Page 18 from 39 2024-01-31...

  • Page 19: Manufacturer Settings

    Therefore, these values are given in the following table (Table 4) in addition to the design of the HeatEngine and the setting value of the main volume throttle. DUNGS HeatEngine® Page 19 from 39 2024-01-31...

  • Page 20: Operation

    (see documentation). The MPA burner control unit monitors the gas and mixture pressure, controls the automatic shut-off valves and monitors the formation of the flame. The output is specified in realtion to the lower heating value (LHV) DUNGS HeatEngine® Page 20 from 39 2024-01-31...

  • Page 21: Product And Capacity Changes

    All maintenance and servicing work on the HeatEngine may only be carried out by qualified, expert personnel. DUNGS service personnel and our authorized specialist dealers fulfil this requirement. Carry out regular annual inspections to maintain and ensure functional safety. Observe the instructions for the components used.

  • Page 22: Cleaning

    To decommission, switch off the gas supply and power supply and close the gas ball valve. Once the intended service life has been reached or when the higher-level machine is decommissioned, the DUNGS HeatEngine can also be disposed of separately according to the components.

  • Page 23: Documents And Drawings

    Appendix 3: Block diagrams Appendix 3.1: Block diagram 3-point step Appendix 3.2: Block diagram analog control Appendix 4: Flame pattern catalogue Appendix 4.1: Flame pattern catalogue Point-style Appendix 4.2: Flame pattern catalogue Line-style DUNGS HeatEngine® Page 23 from 39 2024-01-31...
  • Page 24 Appendix 1: Modules and possible combinations (poster) DUNGS HeatEngine® Page 24 from 39 2024-01-31...
  • Page 25 Appendix 2: P&ID diagrams 1 Standard P&ID for ISO 13577-2 Page 25 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 26 2 Standard P&ID for NFPA 86:2023 up to 150 kBTU/H (44kW) Page 26 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 27 3 Standard P&ID for NFPA 86:2023 with more than 150 kBTU/H (44 kW) Page 27 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 28 4 Standard P&ID for NFPA 86:2023 with more than 400 kBTU/H (117 kW) Page 28 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 29 Appendix 3: Block diagrams Appendix 3.1: Block diagram 3-point step Page 29 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 30 Appendix 3.2: Block diagram analog control Page 30 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 31 Pad does not glow, burner rim glows a little dark red at most • • No secondary flame fronts No secondary flame fronts • Individual flame cones visible on pad • Flame is blue • Flame is blue Page 31 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 32 ➔ Min. fan speed too low turquoise-greenish ➔ Flame "too • • Flame only Secondary flame front, stoichiometric", slightly faintly visible wobbling • too much fuel gas Flame unstable page 32 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 33 Flame flickers, moves moves • • Flame partially lifts off Flame partially lifts off • • Flame faint blue Flame turquoise-greenish • Secondary flame fronts far above the flame • Possibly orange strands page 33 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 34 Point-style ignition sequence Correct settings 1. Pre-purge (blower max) 3. Ignition spark + gas on 4. Ignition 5. Stabilization 2. Blower on ignition power Page 34 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 35 Pad does not glow, burner rim glows a little dark red at most Pad only glows in isolated places • • No secondary flame fronts No secondary flame fronts • • Individual flame cones visible on pad Flame is blue • Flame is blue Page 35 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 36 Flame cones on pad change from blue to turquoise-greenish • • Secondary flame front, wobbling Flame roots take off • • Flame barely visible Possibly orange strands • Flame unstable ➔ Too much fuel gas ➔ Too little fuel gas Page 36 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 37 Flame flickers, moves Flame flickers, moves • • Flame partially lifts off Flame partially lifts off • • Flame faint blue Flame turquoise-greenish • Secondary flame fronts far above the flame • Possibly orange strands Page 37 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 38 Line-style ignition sequence Correct settings 1. Pre-purge (blower max) 2. Blower on ignition power 4. Local ignition 3. Ignition spark + gas on 5. Through-ignition line-style burner 6. Stabilization Page 38 from 39 DUNGS HeatEngine® 2024-01-31...
  • Page 39 Karl Dungs GmbH & Co KG Karl-Dungs-Platz 1 73660 Urbach, Germany Phone: +49 7181 804-0 Fax: +49 7181 804-166 E-mail: info(at)dungs.com DUNGS HeatEngine®Page 39 of 39 2024-01-31...

This manual is also suitable for:

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