Dungs HeatEngine HEPM-P Series User manual

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)

DUNGS HeatEngine®
2024-01-31
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Table of contents
1 Introduction and purpose of these operating instructions.............................................................3
2 General safety instructions..........................................................................................................4
3 Systemoverview.........................................................................................................................6
3.1 Functional description ..........................................................................................................6
3.2 Intended use and misuse.....................................................................................................8
3.3 Technical data .....................................................................................................................9
3.4 Function of the control unit.................................................................................................12
4 Transport and storage...............................................................................................................13
5 Installation and commissioning..................................................................................................13
5.1 Scope of delivery................................................................................................................13
5.2 Integration into the machine...............................................................................................14
5.3 Checking the installation ....................................................................................................16
5.4 Commissioning ..................................................................................................................17
6 Manufacturer settings................................................................................................................19
7 Operation..................................................................................................................................20
8 Product and capacity changes ..................................................................................................21
9 Maintenance and servicing........................................................................................................21
10 Cleaning ...................................................................................................................................22
11 Malfunctions..............................................................................................................................22
12 Decommissioning and disposal.................................................................................................22
13 Documents and drawings..........................................................................................................23
List of illustrations
Table 1: Standard versions of the HeatEngine ......................................................................................7
Table 2: Flame length of the standard versions...................................................................................10
Table 3: Default setting of important MPA parameters ........................................................................10
Table 4: Standard values for setting the main volume throttle .............................................................20
Table 5: Service life of the components...............................................................................................21
Figure 1: P&ID diagram of the HeatEngine............................................................................................6
Figure 2: Type code of the HeatEngine.................................................................................................9
Figure 3: Mounting flange and seals of the HeatEngine (left: line-style burner, right: point-style burner)
............................................................................................................................................................14
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

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1 Introduction and purpose of these operating instructions
The DUNGS HeatEngine burner system is an incomplete machine within the meaning of the
Machinery Directive for installation in a thermoprocessing system as a higher-level machine. This
document is the assembly instructions in accordance with Annex VI of the Machinery Directive
and contains a general description as well as the necessary information for installation and
integration into the control system of the higher-level machine (thermoprocessing system). It also
contains instructions for use and maintenance.
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 ([phone],
[e-mail]) or DUNGS Global Service ([phone],
[e-mail]). Contact our American colleagues for US-applications ([phone],
[e-mail]).
You can also find more information about your product at www.dungs.com.
Name and address of the manufacturer:
Karl Dungs GmbH & Co KG
Karl-Dungs-Platz 1
73660 Urbach Germany
Current version of this document: https://www.dungs.com/en/product/dungsheatengine

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2 General safety instructions
The basic prerequisite for safe handling and trouble-free operation of the
HeatEngine is knowledge of the basic safety instructions and safety regulations.
These operating instructions and the descriptions of the devices installed in the
HeatEngine contain the most important instructions for operating the HeatEngine
safely. These operating instructions, in particular the safety instructions, must be
observed by all persons who operate, run and maintain the HeatEngine. In
addition, the rules and regulations for accident prevention applicable to the
respective place of use must be observed.
Note
Before initial commissioning and before working on the HeatEngine, the
instructions in this operating manual and the operating and installation
instructions for the devices and components installed in the HeatEngine must be
observed. Maintenance and operating personnel must be trained accordingly.
Warning
Before commissioning this DUNGS HeatEngine, the procedure must be
agreed with the system operator and/or the installer. Improper adjustment,
modification, operation and maintenance can lead to property damage and
personal injury, possibly resulting in death.
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. Incorrect and/or improper use, installation,
control and maintenance can lead to fire or explosion.
Note
The system is intended for installation in a higher-level machine that provides
the necessary protection against accidental contact and protection against
foreign bodies and water. Operating the system without appropriate protection is
considered improper use.

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Danger
The product and the associated electrical equipment must be de-energised
before maintenance/repair.
Before starting work, check that the system is de-energised. Work and
troubleshooting on the electrical part of the HeatEngine may only be carried out
by trained specialists. The accident prevention regulations and relevant
standards must be observed.
Warning
The surfaces of the burner housing can become very hot during operation.
Beware of unintentional contact with hot surfaces. The HeatEngine must be
completely cooled down before maintenance/maintenance work can be carried
out. To ensure sufficient cooling, the HeatEngine must be installed in a well-
ventilated location.
Warning
Regular maintenance of the HeatEngine is necessary. Safety devices must be
checked for proper functioning after 10,000 operating hours at the latest and
repaired or replaced if necessary.
Danger
Sufficient forced or cross ventilation must be provided at the installation site of
the HeatEngine to prevent the formation of an explosive atmosphere in the event
of a fault.
Hint
If extraordinary noise exposure should occur during commissioning and
maintenance work, it is advisable to wear personal protective equipment
(hearing protection).
Danger
When working on the gas-carrying pipe system of the HeatEngine and the
components installed in it, the gas supply must be safely shut off before starting
work.
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

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3 System overview
3.1 Functional description
The HeatEngine is a premix surface burner system for generating heat in machines for thermal
processes. The system has a modular design and fulfils the requirements of the relevant standards for
thermal process plants (ISO 13577-2, EN 746-2).
For NFPA 86:2023 some smaller changes are needed. The NFPA version of the P&ID diagram is
shown in Appendix 2.
Figure 1: P&ID diagram of the HeatEngine
Figure 1 shows the P&ID diagram of the HeatEngine (see Appendix 2) and illustrates the
individual modules of the HeatEngine and their functions. The main modules are
• M1 Gas connection with ball valve (1.1) as main shut-off valve and
connection hose (1.2) if necessary
• M2 Gas train with filter (2.1), pressure gauge (2.2.1), minimum gas pressure switch
(2.3.1) and GasMultiBloc MBC (2.3) as a control and safety combination. The MBC
compact fitting (2.3) combines the function of two automatic shut-off valves and a
proportional/zero pressure regulator for mixture control.
Module 2 is different for NFPA 86:2023 versions. E.g. test ports, a maximum gas
pressure switch and a second ball valve are added (see NFPA 86 P&ID diagram in
Appendix 2). Following limitations and changes are required as well:
• Above 44 kW / 150 kBTU/H visual indicators are needed. The use of a MBC is not
possible, instead a DMV with FRNG (including visual indicator) is used.
• 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.

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• M3 Combustion air fan (radial fan, 3.1) with intake housing and WhirlWind gas/air mixer (3.2)
for zero pressure operation. An air filter (3.2.3) is fitted to the intake opening and the negative
pressure in the intake housing is connected to the MBC controller (2.3) as a pulse to
compensate for the power-dependent pressure losses
• M4 Connector with pressure switch (2.5.1) for monitoring the air/gas mixture pressure
• M5 Surface burner head (5.1) in point-style or line-style geometry
• M6 Burner control unit MPA with parameterization and ignition transformer
• M7 Electrical wiring and assembly
The burner system is supplied pre-assembled. Depending on the order, however, the M6 module
(burner control unit and ignition transformer) can be supplied separately to support integration into
the higher-level machine on site. The modular design enables customization to the individual
higher-level machine without fundamentally changing the function. 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.
Burner head
geometry
Burner
output1)
Gas
connection
HEPM-
P025
HEPM-P025/NG-
EU-S-IO-1W-E
294440
Point Ø 40 mm
Point Ø 1.5”
5 - 25 kW
15 / 85 kBTU/H
Rp ½
½” NPT
HEPM-
P040
HEPM-P040/NG-
EU-S-IO-1W-E
294441
Point Ø 60 mm
Point Ø 2.4”
7 - 40 kW
25 / 140 kBTU/H
Rp ½
½” NPT
HEPM-
P060
HEPM-P065/NG-
EU-S-IO-1W-E
294442
Point Ø 70 mm
Point Ø 2.75”
8 - 65 kW
30 / 225 kBTU/H
Rp ½
½” NPT
HEPM-
P090
HEPM-P090/NG-
EU-S-IO-1W-E
294443
Point Ø 98 mm
Point Ø 4”
11 - 90 kW
50 / 315 kBTU/H
Rp ¾
¾” NPT
HEPM-
P140
HEPM-P140/NG-
EU-S-IO-1W-E
294444
Point Ø 130 mm
Point Ø 5.1”
14 - 140 kW
60 / 500 kBTU/H
Rp ¾
¾” NPT
HEPM-
L025
HEPM-L025/NG-
EU-S-IO-1W-E
294445
Line 200 mm
Line 8”
5 - 25 kW
15 / 85 kBTU/H
Rp ½
½” NPT
HEPM-
L065
HEPM-L065/NG-
EU-S-IO-1W-E
294446
Line 440 mm
Line 17.3”
8 - 65 kW
30 / 225 kBTU/H
Rp ½
½” NPT
HEPM-
L140
HEPM-L140/NG-
EU-S-IO-1W-E
coming
soon
Line 880 mm
Line 34.6”
14 - 140 kW
60 / 500 kBTU/H
Rp ¾
¾” NPT
Table 1: Standard versions of the HeatEngine
Details of the equipment and burner head geometry as well as any technical data deviating from the
standard can be found in the order-specific drawing and parts list (see appendix) for the system. The
precise execution of the system varies dependending on used standards and needs for the application. The
detailed design can be read from the drawing using the type code. The type code is explained under 3.3
Technical data.
We reserve the right to make modifications in the course of technical development.
1
Burner output in relation to lower calorific value and at neutral back pressure

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3.2 Intended use and misuse
The HeatEngine is designed for installation in industrial thermoprocessing systems in accordance
with EN 746-2 or ISO 13577-2. The product may only be operated in the oven intended for this
purpose. For the installation and operation of the HeatEngine in a higher-level machine, the
relevant application standards and guidelines must be observed, e.g. EN 746-2, ISO 13577-2 or
NFPA 86:2023. Outdoor operation in a production environment is only permitted with suitable
protective measures. The product is intended for use in closed, dry rooms in an industrial
environment.
The HeatEngine is a burner system that provides the adequate mixture of gas and air for the
subsequent process. It is designed for natural gas (H/L) and LPG/propane (<5% butane).
Any use of the HeatEngine other than that described here is not permitted.
The following risks are possible in the event of misuse:
• The HeatEngine is only safe to operate if it is used as intended
• Failure to observe the instructions may result in personal injury or property damage, financial
loss or environmental damage
• In the event of incorrect operation or misuse, there is a risk to life and limb of the operator
as well as to the HeatEngine and other property
Warranty and liability
Warranty and liability claims for personal injury and damage to property are excluded if they are
attributable to one or more of the following causes:
• improper use of the HeatEngine
• Improper transport, commissioning, operation and maintenance
• Failure to observe the instructions in the operating instructions regarding transport,
commissioning, operation, maintenance and repair
• Operating the HeatEngine with defective or non-functional safety and protective
devices
• Unauthorized structural changes to the HeatEngine
• Unauthorized changes, e.g. to the control pressure
• Non-compliance with the required maintenance cycles
• Use of unauthorised spare and wear parts
Only use original spare and wear parts. In the case of externally sourced parts, there is no
guarantee that they are designed and manufactured to withstand the stress and ensure safety. An
exception to this is if no other spare parts are available and the alternative has been previously
accepted by DUNGS.

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3.3 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. It also
includes the control unit, flame monitoring, wiring, voltage and, if required, a customized
abbreviation with a sequential number.
Mechanics
Note: for order-specific deviations, see drawing (see appendix)
Medium: Natural gas (L/H)
LPG2/propane (<5% butane)
Gas pressure inlet ball valve: min. 30 mbar
0.5 Psig min
Pressure in the process chamber: min.-5 mbar, max. 3 mbar
-2” WC / +1.5” WC
Process air speed: max. 5 m/s
15 ft/s max
Installation: Coordination of the installation with DUNGS is recommended
(horizontal, vertical upwards, vertical downwards (increase low load if
necessary))
Dimensions: according to drawing (see appendix)
Flame length2: see table 1
2 Liquified Petroleum Gas
Figure 2: Type code of the HeatEngine

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Execution
Rated power
[kW] / [kBTU/H]
Flame length max. load
[cm] / [“]2
Flame length min. load
[cm] / [“]
HEPM-P025
25 / 85
40 / 16
10 / 4
HEPM-P040
40 / 140
50 / 20
12 / 5
HEPM-P065
65 / 225
60 / 24
14 / 5.5
HEPM-P090
90 / 315
80 / 32
17 / 7
HEPM-P140
140 / 500
100 / 40
20 / 8
HEPM-L025
25 / 85
35 / 14
8/ 3
HEPM-L065
65 / 225
40 / 16
8/ 3
Table 2: Flame length of the standard versions
Control/ electrical engineering
Mainsfrequency: 230 VAC / 120 VAC
Mainsfrequency: 50 / 60 Hz
Control: 3-point step control
Analog control on request
Protection class: IP 00 (like the blower)
Ambient temperature: min. -15°C,max. 60°C
Oven flange temperature: max. 150°C
Process temperature:max. 450°C downstream of the burner
max. 300°C upstream of the burner (incoming process air)
Important parameters of the automatic burner control MPA V2 and their standard setting:
Parameter-
No.
Parameter description
Possible values
Presetting
239
Extension module
0, 1 (= EM installed)
1
General
10
Release parameter settings***
0 = No, 1 = Yes
0
11
Fieldbus address configuration
0…254 (255 = off)
255
12
Number of restart attempts
0, 1, 2, 3, 4, 5
5
13
Number of restart attempts when flame is
missing
0, 1, 2, 3, 4, 5
0
14
Number of restart attempts after flame lift-
off
0, 1, 2, 3, 4, 5
0
15
Locking with open safety chain
0 = Restart attempt
1 = Immediate
malfunction lockout
1
16
Operating mode for LDW 1
0, 1, 2, …, 15
13
17
Temperature controller: Operating mode
0, 1, 2, 3, 4
0
18
Input X17
0, 1, 2, 3, …15
3
19
Configuration of output for operation
0, 1, 2, 3, … 11
3
2
Visible flame length when operating with natural gas in free range 0...100 [%]

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20
Safety chain open duration
0…65534 [1/ 16 s]
(65535 = infinite)
65535
21
Shutter test for flame detector device
0, 1, 2, 3
0
22
FM mode
0, 1
1
23
POC tolerance time
16…48 (in 1/16 s)
16
26
Input X16
see parameter 18
2
27
Input X18
see parameter 18
9
28
Input X19
see parameter 18
10
29
Input X20
see parameter 18
11
60
Network adress 3
0…255
192
61
Network adress 2
0…255
168
65
Behaviour when waiting for air purge /
cooling
0, 1
0
Start-up
30
Pre-aeration duration
0…32767 [1/16 s]
32767
31
Duration of pre-ignition time
2…65534 [1/16 s]
0
32
Safety time for start-up / first safety time
16…960 [1/16 s]
48
33
Active flame detector device(s) for safety
time for start-up
1, 2, 3, 4
1
34
Stabilization time A
0…65534 [1/16 s]
48
35
Second saftey time during start-up
16…480 [1/16 s]
16
36
Active flame detector device(s) for phase
2
1, 2, 3, 4
1
37
Stabilization time B
0…65534 [s]
0
38
Operating mode V1 V2
0, 1, 2, … 5
1
39
Maximum waiting time for start release
0…65534 [1/16 s]
(65535 = infinite)
2400
48
Ionization threshold
12…60 [0,1 µA]
12
49
Operating release control
0, 1 (= active)
1
Operation
40
Duration of normal operation
1…65534 [min]
(65535 = infinite)
65535
41
Safety time operation FLW 1
12…48 [1/16 s]
16
42
Safety time operation FLW 2
3…48 [1/16 s]
16
43
Duration for new start of pilot burner
8…960 [1/16 s]
16
Shutdown
50
Follow-up time
16…65534 [1/16 s]
16
51
Post-purge time
16…65534 [1/16 s]
96
52
Restart protection
16…65534 [1/16 s]
0
Extension module
25
Maximum waiting time until motor position
is reached
0…1920 [1/16 s]
480

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240
Pre-aeration position
0…100 [%]
100
241
Ignition position
0…100 [%]
30
242
Stabilization
0…100 [%]
30
243
Post-aeration
0…100 [%]
100
244
Start value
0…100 [%]
25
245
Minimum speed
0…100 [%]
19
246
Maximum speed
0…100 [%]
100
247
Schrittweite Drehzahländerung
0…100 [%]
1
248
Increment for speed changes
0…4095,875 [s]
5
249
Bit functionns
PWM / Analog
PWM
Table 3: Default setting of important MPA parameters
Note: The default setting may differ from customized settings. Please pay attention,
in the case of customer-specific parameterization, to the parameter setting supplied.
3.4 Function of the control unit
The burner system is controlled via the MPA burner control unit as an interface to the control unit
of the higher-level machine. Details can be found in the circuit diagram (see appendix). A 3-point
step control is used as standard. Analog control with 0-10V or 4-20mA is also possible, but must
be detailed for the specific project on request.
The following signal inputs and outputs are provided:
• Safety chain okay (emergency stop, overtemperature, machine-related safety limits)
• Heat request = switch on burner
• Increase performance.
• Reduce power.
• Interference suppression
• Operating message = Burner in operation
• Fault message
The combustion air fan and the automatic shut-off valves are controlled by the MPA burner
control unit in accordance with the specified sequence. The speed of the fan for pre-purge
and ignition as well as the maximum and minimum output are determined by the MPA
parameters.
When heat is requested by the control system of the higher-level machine, the combustion air fan
is started by the burner control system. The burner and the on-site combustion chamber are first
pre-purged; the duration and fan output correspond to the MPA parameterization. Following the
pre-purge, the blower output is reduced to the ignition output. To start the burner, the MPA opens
the gas shut-off valves and activates the ignition transformer to ignite the gas-air mixture
generated in the WhirlWind. The formation of the flame is detected by the ionization electrode and
the MPA burner control unit sends the operating signal to the control unit of the higher-level
machine, which then takes over the power control.
During operation, the power is determined by the fan speed. The blower output is specified via a
PWM signal. The air flow generates a negative pressure in the WhirlWind gas/air mixer, which
sucks in the fuel gas through the Venturi effect (zero pressure control).
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

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found in the MBC documentation.
When the heat request signal is switched off, the burner is switched off. The burner control unit
de-energizes the automatic shut-off valves of the MBC and the valves close. The burner is then
purged to remove the ignitable gas-air mixture from the burner and the on-site combustion
chamber. The duration and blower output correspond to the MPA parameterization.
The presetting of the MBC and the standard parameters of the MPA allow quick and easy
commissioning after installation and integration into the control system of the higher-level machine. A
converter is required for analog control.
This is necessary as the fan can only interpret signals in the form of pulse width modulation. The
converter is fed by the MPA and modulates a PWM signal using the analog input signal.
The structure of a 3-point step control and the analog control are shown as block diagrams (see
Appendix 3). However, this diagram is only a general representation. For effective analog control,
this must be detailed on a project-specific basis.
4 Transport and storage
Take care when storing and transporting the HeatEngine to the site. Handle the components with
care. This also includes vibration-free transport.
Do not throw or drop the product. Observe the relevant regulations, e.g. accident prevention
regulations. Only store the product in a dry and clean working environment. Only store the product
within the permitted temperature range. Correct operation of the HeatEngine is only guaranteed if
it is transported and stored correctly.
5 Installation and commissioning
5.1 Scope of delivery
The scope of delivery of the HeatEngine depends on the selection regarding module 7 - Wiring.
Ideally, a pre-assembled version should be ordered. In this case, the HeatEngine is delivered
assembled and wired. The associated automatic burner control unit is also preset. The
HeatEngine can be regarded as a plug & play system.
Alternatively, however, the HeatEngine can also be supplied with pre-wired loose individual parts
or completely without cabling. In principle, every HeatEngine system - regardless of the choice of
cabling - is supplied with the corresponding plugs and seals. When ordering a non-wired
HeatEngine, the following electrical components are supplied:
• 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

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5.2 Integration into the machine
Note
Ensure a firm, stable substructure during installation. Reinforce if necessary!
Note
Pay attention to external EMC interference signals on site during installation!
EMC interference signals can occur, for example, from motors with speed
control via frequency converters.
The burner system is attached to the burner head via the mounting flange using six mounting
screws. The mounting flange has two seals, which are shown in Figure 3. Information on the
flange dimensions and the positions of the screw openings can be found in the drawing of the
burner system.
The burner head is mounted on the housing of the process chamber using the mounting flange, position
1 in Figure 3. One seal, position 2 in Figure 3, is located on the transition piece between the burner
head and blower and on the mounting flange. The second seal, position 3 in Figure 3, is placed
between the mounting flange of the HeatEngine and the outer wall of the process chamber during
installation. The external components such as cables and gas line must be protected from heat. The
installation is suitable for applications up to 200°C / 400F without additional insulation. An outer lining,
as shown in 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.
Figure 3: Mounting flange and seals of the HeatEngine (left: line-style burner, right: point-style burner)

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The outer wall of the process chamber is represented by position 2 in Figure 4. Position 3 shows
the outer insulation and position 4 the inner insulation. Regardless of the type of insulation, a sight
glass must be provided in accordance with ISO 13577-2 and NFPA 86:2023. This is used for visual
inspection of the flame pattern and for burner adjustment. In Figure 4, position 1 corresponds to the
sight glass.
Installation via the mounting flange is equivalent for point-style and line-style burner heads. The
difference based on the burner type lies in the positioning of the sight glass. The sight glass,
which is required for visual inspection of the flame pattern, must always be aligned so that it is in
line of sight with the pad. For line-style burner heads, it is sufficient to place a sight glass above
the HeatEngine system, as shown in Figure 4. This is because the mounting wall is automatically
perpendicular to the focal surface. With point-style burner heads, on the other hand, a wall
adjacent to the mounting wall must be used. A sight glass placed perpendicular to the focal
surface of a point-style burner head is shown in Figure 5.
Figure 4: HeatEngine in process chamber with outer and inner lining/insulation (line-style burner system)
Figure 5: HeatEngine in process chamber with outer and inner lining/insulation (point-style burner system)

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In addition to installation via the burner head flange, the gas control line must be supported! This
must be realized on site according to the possibilities of the higher-level machine.
When determining the installation position, ensure that the burner system is accessible for
inspection and maintenance work. In accordance with EN 746-2, ISO 13577-2 and NFPA 86:2023
it must be possible to visually inspect the flame (see flame pattern catalogue, Appendix 4).
When determining the installation situation, it must be ensured that the combustion air fan can
draw in sufficient clean, dust-free air and that the exhaust gases produced during combustion are
safely discharged. Sufficient openings must be provided in the higher-level machine for the air
supply, through which clean ambient air can be drawn in.
Warning
Insufficient air supply represents a safety risk and must be ruled out.
After installing the burner system, establish a gas connection and check that the gas supply line is
adequately dimensioned. The ball valve must be installed as a manually operated main shut-off valve
in accordance with EN 746-2, ISO 13577-2 or NFPA 86:2023 and must be easily accessible. The
connection hose, if present, must be installed so that it is protected from damage.
Warning
Ensure that the gas pressure is secured on site. Excessive gas pressure
(greater than the specified maximum inlet pressure) can lead to damage.
After the mechanical installation of the burner system in the higher-level machine, establish
electrical connections and, if necessary, intermediate cabling in accordance with the circuit
diagram (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.
c) Check the gas system for leaks.
d) Check the ventilation of the installation room.
Depending on the installation location of the higher-level machine, obtain the necessary
authorizations in accordance with regional regulations before commissioning.
5.3 Checking the installation
The installation and commissioning of the HeatEngine must be carried out by qualified, expert
personnel. The relevant standards and regulations must be observed during installation and
commissioning. Commissioning must be prepared as follows:

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1. Check whether the higher-level machine is ready to start the burner system, e.g.
• Burner not blocked
• No flammable objects in front of the burner head
• Heat dissipation given
• Exhaust gas removal ensured
• All required interlocks in order and integrated into the safety chain
2. Check the position of the electrodes in the burner head, see HEPM-BH burner head documentation
3. Establish/check voltage and gas supply
4. Check the parameterization of the burner control unit MPA and adjust if necessary
• Parameter 30 Duration of pre-ventilation is preset to a maximum value of approx. 1
hour as standard and can be shortened according to the machine configuration.
Note: In accordance with EN 746-2 and ISO 13577-2, 5 complete air changes are
required. In accordance with NFPA 86:2023, 4 complete air changes are required.
• Parameter 51 Post-purge time is preset to 6 seconds as standard to purge the burner
itself and may need to be extended according to the machine configuration in order to
also purge the combustion chamber and exhaust gas system.
• Parameters 240 to 248 determine the blower control. They are preset with default
values and can be adjusted to optimize the process.
5.4 Commissioning
Warning
The system must be properly purged during initial commissioning or after work
on the gas system.
1. Open the gas ball valve and check the gas pressure on the pressure gauge
2. Check the setting of the gas pressure switch (item 2.3.1, Fig. 1) or set to
•25 mbar / 10”WC (approx. 80% of the minimum required inlet pressure of 30 mbar / 0.5
Psig)
3. Check setting of mixture pressure switch (item 2.5.1, Fig. 1) or set to 0.5 mbar / 0.2”WC
4. Switch on burner system (heat request signal)
The burner starts with a regular starting process with pre-purge, approaching the ignition
position, ignition spark and flame formation. The fan output during pre-purge and ignition as
well as the flame stabilization time is determined by MPA parameters 240 to 242.
Note
Before the system was delivered, the MBC was preset so that the burner should
ignite. During initial commissioning or after work on the gas system, several start
attempts may be necessary to fill the system with fuel.
5. Run the burner to MAX (high load) and check the flame pattern visually using the
flame pattern catalogue (see Appendix 4). If necessary, adjust the gas quantity at the
main volume throttle 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.

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Fig: Photo MBC with labelling of main volume throttle and offset screw
6. Set the burner to MIN (low load) and visually check the flame pattern (see flame pattern
catalogue, Appendix 4). If necessary, adjust the gas quantity at offset screw B of the
MBC. The blower output is determined by the MPA parameter 245 Minimum speed. The
gas quantity can be determined by a gas meter, a gas counter or a measuring orifice in
the gas supply line.
Note
Only change the offset in very small steps of e.g. ¼ turn and make a note of this.
7. Switch back and forth several times between high load and low load, repeating steps 5 and
6. Finally, document the settings of the pressure switches, MPA parameters, position (length)
of the main volume throttle, any changes made to the offset, controller outlet pressure
(measuring point 3) at MAX and MIN and, if possible, gas volume flows MAX and MIN
Note
The pad of the burner head should not glow during operation in order to avoid
excessive wear. 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.
A
B

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6 Manufacturer settings
The HeatEngine flame pattern catalogue contains images for the correct setting of a point- and
line-style burner system based on the flame pattern. The appearance of the flame varies
depending on the combustion mediumappendix 4).
The setting values of the MBC and the pressure monitor can also be used as an aid. The min.
pressure monitor on the MBC is set to 25 mbar / 10”WC as standard and the mixture pressure
monitor on the burner connection piece is set to 0.5 mbar / 0.2”WC. The setting values for the
main volume throttle, on the other hand, are not generally valid values, but merely reference
points for the setting. This is because each system is different due to various tolerances.
As already described under 5.4 Commissioning, there are two possible setting values for the
MBC. Offset B should not be adjusted if possible, or only minimally if absolutely necessary and
with documentation of the changes made.
The main volume throttle A, on the other hand, can and should be used to adjust the gas volume
at the MBC. This changes the ratio of the air/gas mixture. The position and direction of rotation of
the main volume throttle is shown in Figure 6.
Figure 6: Diagram for setting the main volume throttle
Guide values for the setting of the main volume throttle have been taken from various laboratory
tests. It should be emphasized once again that these are not explicit values. In addition to the
product's own tolerances, the setting values depend on the capacity, fuel and gas pressure,
among other things. 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.
MBC-65...
MBC-120...

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Execution
Rated power
[kW] / [kBTU/H]3
Fuel
Throttle
position[mm]
HEPM-P025
25 / 85
Natural gas (H)
15,3
Propane
14,5
HEPM-P040
40 / 140
Natural gas (H)
16,3
Propane
14,6
HEPM-P065
65 / 225
Natural gas (H)
16,7
Propane
15,1
HEPM-P090
90 / 315
Natural gas (H)
14
Propane
12,9
HEPM-P140
140 / 500
Natural gas (H)
19,1
Propane
13,2
HEPM-L025
25 / 85
Natural gas (H)
15,5
Propane
14,3
HEPM-L065
65 / 225
Natural gas (H)
16,2
Propane
14,9
Table 4: Standard values for setting the main volume throttle
7 Operation
The burner system is designed for fully automatic operation without supervision. The higher-level
machine monitors the safety-related interlocks, switches the burner on and off according to the
process requirements and controls the output by activating the corresponding inputs on the MPA
burner control unit (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.
3
The output is specified in realtion to the lower heating value (LHV)