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Installation, use and maintenance instructions Instrucciones de Instalación, Funcionamiento y Mantenimiento Instruções de Instalação, Funcionamento e Manutenção GB E P Forced draught gas burners

1 Installation, use and maintenance instructions Instrucciones de Instalación, Funcionamiento y Mantenimiento Instruções de Instalação, Funcionamento e Manutenção GB E P Forced draught gas burners Quemadores de gas Queimadores a gás Progressive twostage operation Funcionamiento a dos llamas progresivas Funcionamento a duas chamas progressivas CODE CÓDIGO MODEL MODELO TYPE TIPO RS T (0)

2 page N.B. 1

3 MODEL RS 190 TYP 835 T1 OUTPUT (1) 2nd stage kw Mcal/h min. 1st stage kw 470 Mcal/h 405 FUEL NATURAL GAS: G20 G21 G22 G23 G25 G20 net calorific value kwh/nm 3 10 Mcal/Nm absolute density kg/nm max. delivery Nm 3 /h pressure at max. delivery mbar OPERATION OnOff (1 stop min each 24 hours). Twostage (high and low flame) and single stage (all nothing) STANDARD APPLICATIONS Boilers: water, steam, diathermic oil AMBIENT TEMPERATUR C 0 40 COMBUSTION AIR TEMPERATURE C max 60 ELECTRICAL SUPPLY ELECTRIC MOTOR V Hz rpm W V G with neutral ~ +/10% 50 threephaes / /415 Running current A Startup current A IGNITION TRANSFORMER V1 V2 I1 I2 230 V 1 x 8 kv 1 A 20 ma ELECTRICAL POWER CONSUMPTION W max 5500 ELECTRICAL PROTECTION IP 44 IN CONFORMITY WITH EEC DIRECTIVES 90/396 89/336 73/23 NOISE LEVELS (2) dba 83.1 APPROVAL CE 0085AT0042 GAS CATEGORY COUNTRY IT AT GR DK FI SE ES GB IE PT NL FR DE BE LU CATEGORY II 2H3B / P II 2H3P II 2L3B / P II 2Er3P II 2ELL3B /P I 2E(R)B, I 3P II 2E 3B/P ACCESSORIES (optional): KIT FOR LPG OPERATION: The kit allows the RS 190 burners to operate on LPG. BURNER RS 190 OUTPUT kw CODE GROUND FAULT INTERRUPTER: code STATUS (see page 20): code GAS TRAIN ACCORDING TO REGULATION EN 676 (with valves, pressure governor and filter): see page 8. 2

4 D mm A B C kg RS D36 PACKAGING WEIGHT MAX. DIMENSIONS (C) D1261 mm A B C D E F G H I L M N O RS DN80 STANDARD EQUIPMENT (C) 3

5 Combustion chamber pressure mbar RS 190 D1262 Combustion chamber length m D715 4

6 RS 190 kw p (mbar) ,0 1,8 30,0 25,0 11,0 5, ,3 2,0 35,0 29,0 15,0 7, ,6 2,2 40,0 32,0 16,0 8, ,0 2,5 45,0 35,0 17,0 9,0 4, ,7 2,8 52,0 38,5 19,0 10,0 4, ,3 3,0 58,0 42,0 21,0 11,0 5, ,2 3,2 63,0 46,0 23,0 12,0 5, ,3 3,4 68,0 50,0 25,0 13,0 6, ,5 3,7 74,0 53,0 27,5 14,0 6, ,0 4,3 88,0 60,0 34,0 17,0 8,0 Column 1 Column 2 Column 3 D1263 = 8 mbar = 3 mbar 8 3 = 5 mbar Example RS 100: 5

7 mm A B C RS M 16 D455 BOILER PLATE BLAST TUBE LENGTH Blast tube 12): RS 190 short( 372 SECURING THE BURNER TO THE BOILER D3036 Probe Electrode COMBUSTION HEAD CALIBRATION D1265 (C) D1266 (D) 6

8 D1267 Nr. Notches (C) Burner output in 2nd stage operation D1268 (D) D3037 7

9 GAS LINE GAS TRAIN. BURNERS AND RELEVANT GAS TRAINS APPROVED ACCORDING TO EN 676 Gas train L Ø C.T. Code Code Code DN DN DN DN DN DN D1270 KEY GAS TRAINS COMPONENTS L Code Filter 5 Components Pressure governor 6 Valves 8 9 GF 520/1 FRS 520 DMVDLE 520/11 Multiblock MB DLE 420 GF 40065/3 FRS 5065 DMVDLE 5065/11 GF 40080/3 FRS 5080 DMVDLE 5080/11 GF40100/3 FRS 5100 DMVDLE 5100/11 14 P1 P2 P3 L L1 KEY TO TABLE (C) C.T. 13 = = = 14 = Note 8

10 ELECTRICAL EQUIPMENT FACTORYSET RS 190 D3056 Key to Layout CMV DA F1 I1 I2 MB MV PA RT SM SO SP TA TB XP1 9

11 ELECTRICAL CONNECTIONS RS 190 without leak detection control device D955 1 Pg 13,5 2 Pg 11 3 Pg 11 4 Pg 9 5 Pg 13,5 6 Pg 13,5 7 Pg 11 8 Pg 9 LAYOUT LAYOUT (C) RS 190 with leak detection control device VPS D956 KEY TO LAYOUTS (B C) IN XP MB PG S S1 TR TL (C) D957 TS VR VS RS V 400 V F A T25 T20 L mm 2 2,5 2,5 (D) 10

12 CALIBRATION OF THERMAL RELAY LAYOUT D867 11

13 MIN GAS PRESSURE SWITCH AIR PRESSURE SWITCH D897 ADJUSTMENTS BEFORE FIRST FIRING Adjustment of the combustion head, and air and gas deliveries has been illustrated on page 7. In addition, the following adjustments must also be made: open manual valves upline from the gas train. Adjust the minimum gas pressure switch to the start of the scale. Adjust the air pressure switch to the zero position of the scale. Purge the air from the gas line. Continue to purge the air (we recommend using a plastic tube routed outside the building) until gas is smelt. Fit a Utype manometer (C) to the gas pressure test point on the sleeve. The manometer readings are used to calculate the 2nd stage operation burner power using the tables on page 5. Connect two lamps or testers to the two gas line solenoid valves VR and VS to check the exact moment at which voltage is supplied. This operation is unnecessary if each of the two solenoid valves is equipped with a pilot light that signals voltage passing through. Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e. with gas delivery at the minimum. SERVOMOTOR (D) The servomotor provides simultaneous adjustment of the air gate valve, by means of the variable profile cam, and the gas butterfly valve. The servomotor rotates through 130 degrees in 15 seconds. Do not alter the factory setting for the 4 levers; simply check that they are set as indicated below: Cam I : 130 Limits rotation toward maximum position. When the burner is in 2nd stage operation the gas butterfly valve must be fully open: 90. Cam II : 0 Limits rotation toward the minimum position. When the burner is shut down the air gate valve and the gas butterfly valve must be closed: 0. Cam III : 15 Adjusts the ignition position and the output in 1st stage operation. Cam V : 125 Lights up the 2nd stage LED (STATUS) (C) SERVOMOTOR D3038 (D) D1272 BURNER STARTING Close the control devices and set: switch 1)(E) to "Burner ON" position; switch 2)(E) to "1st STAGE" position. As soon as the burner starts check the direction of rotation of the fan blade, looking through the flame inspection window 14)p.3. Make sure that the lamps or testers connected to the solenoids, or pilot lights on the solenoids themselves, indicate that no voltage is present. If voltage is present, then immediately stop the burner and check electrical connections. (E) Burner off Burner on 1 2 1st stage 2nd stage D469 BURNER FIRING Having completed the checks indicated in the previous heading, the burner should fire. If the motor starts but the flame does not appear and the control box goes into lockout, reset and wait for a new firing attempt. If firing is still not achieved, it may be that gas is not reaching the combustion head within the safety time period of 3 seconds. In this case increase gas firing delivery. The arrival of gas at the sleeve is indicated by the Utype manometer (C). Once the burner has fired, now proceed with global calibration operations. 12

14 BURNER CALIBRATION The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet. Adjust successively: 1 First firing output 2 2nd stage burner output 3 1st stage burner output 4 Intermediate outputs between 1st and 2nd stage 5 Air pressure switch 6 Minimum gas pressure switch Burner off Burner on 1 2 1st stage 2nd stage D469 1 FIRING OUTPUT According to EN 676 Regulations: Burners with max. output up to 120 kw Firing can be performed at the maximum operation output level. Example: Max. operation output : 120 kw Max. firing output : 120 kw Burners with max. output above 120 kw Firing must be performed at a lower output than the max. operation output. If the firing output does not exceed 120 kw, no calculations are required. If firing output exceeds 120 kw, the regulations prescribe that the value be defined according to the control box safety time "ts": for "ts" = 2s, firing output must be equal to or lower than 1/2 of max. operation output. For "ts" = 3s, firing output must be equal to or lower than 1/3 of max. operation output. Example: MAX operation output of 600 kw. Firing output must be equal to or lower than: 300 kw with "ts" = 2s 200 kw with "ts" = 3s In order to measure the firing output: disconnect the plugsocket 6)p.3 on the ionization probe cable (the burner will fire and then go into lockout after the safety time has elapsed). Perform 10 firings with consecutive lockouts. On the meter read the quantity of gas burned. This quantity must be equal to or lower than the quantity given by the formula, for ts = 3s: Nm 3 /h (max. burner delivery) 360 Example: for G 20 gas (10 kwh/nm 3 ): Max. operation output: 600 kw corresponding to 60 Nm 3 /h. After 10 firings with lockouts, the delivery read on the meter must be equal to or lower than: 60 : 360 = 0,166 Nm ND STAGE OUTPUT 2nd stage output of the burner must be set within the firing rate range shown on page 4. In the above instructions we left the burner running in 1st stage operation. Now set switch 2) to the 2nd stage position: the servomotor will open, simultaneously, the air gate valve and the gas butterfly valve to 90. Gas calibration Measure the gas delivery at the meter. A guideline indication can be calculated from the tables on page 5, simply read off the gas pressure on the Utype manometer, see fig.(c) on page 12, and follow the instructions on page 5. If delivery needs to be reduced, diminish outlet gas pressure and, if it is already very low, slightly close adjustment valve VR. If delivery needs to be increased, increase outlet gas pressure. 13

15 D891 Adjusting air delivery Progressively adjust the end profile of cam 4) by turning the screws 7). Turn the screws clockwise to increase air delivery. Turn the screws counterclockwise to reduce air delivery. 3 1ST STAGE OUTPUT Burner power in 1st stage operation must be selected within the firing rate range shown on page 4. Set the switch 2)p.13 to the 1st stage position: the servomotor 1) will close the air gate valve and, at the same time, closes the gas butterfly valve down to 15, i.e. down to the original factory setting. Adjusting gas delivery Measure the delivery of gas from the gas meter. If this value is to be reduced, decrease the angle of the orange lever slightly by proceeding a little at a time until the angle is changed from 15 to 13 or If it is necessary to increase the mains pressure, move to 2nd stage operation by altering the setting of switch 2)p.13 and increase the angle of the orange lever, proceeding a little at a time until the angle is changed from 15 to At this point return to 1st stage operation and measure gas delivery. Note The servomotor follows the adjustment of the orange lever only when the angle is reduced. If, however the angle must be increased, switch to 2nd stage operation, increase the angle and then return to 1st stage operation to check the effect of the adjustment. In order to adjust cam III, especially for fine movements, the key 10), held by a magnet under the servomotor, can be used. Adjustment of air delivery Progressively adjust the starting profile of cam 4) by turning the screws 5). It is preferable not to turn the first screw since this is used to set the air gate valve to its fullyclosed position. 1 Servomotor 2 Servomotor 1) Cam 4): engaged 3 Servomotor 1) Cam 4): disengaged 4 Adjustable profile cam 5 Cam starting profile adjustment screws 6 Adjustment fixing screws 7 Cam end profile adjustment screws 8 Graduated sector for gas butterfly valve 9 Index for graduated sector 8 10 Key for cam III adjustment D889 4 INTERMEDIATE OUTPUTS Adjustment of gas delivery No adjustment of gas delivery is required. Adjustment of air delivery Switch off the burner using switch 1)p.13, disengage the cam 4) from the servomotor, by pressing the button 3) and moving it to the right, and check more than once that the movement is soft and smooth, and does not grip, by rotating the cam 4) forward and backward by hand. Engage the cam 4) to the servomotor again by moving the button 2) to the left. As far as is possible, try not to move those screws at the ends of the cam that were previously adjusted for 1st and 2nd stage air gate valve control. Finally fix the adjustment by turning the screws 6). Note Once you have finished adjusting outputs 2ND STAGE 1ST STAGE INTERMEDIATE, check ignition once again: noise emission at this stage must be identical to the following stage of operation. If you notice any sign of pulsations, reduce the ignition stage delivery. 14

16 AIR PRESSURE SWITCH 15)p. 3 5 AIR PRESSURE SWITCH MIN GAS PRESSURE SWITCH 7)p. 8 D521 Attention Warning D896 6 MINIMUM GAS PRESSURE SWITCH (C) D3023 FLAME PRESENT CHECK (C) 15

17 NORMAL FIRING (n = seconds from instant 0) BURNER OPERATION : 0 s : 2 s : 3 s : 28 s : 43 s RMG LED * 45 s : 53 s : * Off Yellow Green Red For further details see page 18. NO FIRING D3051 STEADY STATE OPERATION System equipped with one control device TR. RMG LED * Systems not equipped with control device TR (jumper wire installed) FIRING FAILURE * Off Yellow Red For further details see page D3052 BURNER FLAME GOES OUT DURING OPER ATION

18 FLAME INSPECTION WINDOW FINAL CHECKS OPENING THE BURNER D709 MAINTENANCE Combustion Gas leaks Gas filter Flame inspection window Combustion head Burner D3041 Combustion TO OPEN THE BURNER : TO CLOSE THE BURNER : 17

19 BURNER STARTUP CYCLE DIAGNOSTICS During startup, indication is according to the followin table: COLOUR CODE TABLE Sequences Colour code Prepurging Ignition phase Operation, flame ok Operating with weak flame signal Electrical supply lower than ~ 170V Lockout Extraneous light Legenda: Off Yellow Green Red RESETTING THE CONTROL BOX AND USING DIAGNOSTICS RED LED on wait at least 10s Lockout Press reset for > 3s Pulses Interval 3s Pulses RESETTING THE CONTROL BOX SOFTWARE DIAGNOSTICS BUTTON PRESSED FOR Between 1 and 3 seconds More than 3 seconds More than 3 seconds starting from the visual diagnostics condition CONTROL BOX STATUS Control box reset without viewing visual diagnostics. Visual diagnostics of lockout condition: (LED pulses at 1second intervals). Software diagnostics by means of optical interface and PC (hours of operation, malfunctions etc. can be viewed) 18

20 2 x blinks x blinks x blinks x blinks x blinks No blink

21 RIELLO S.p.A. Via degli Alpini 1 I Legnago (VR) Tel.: Fax: Subject to modifications Con riserva di modifiche Sujeito a modificações

_GB.fm

_GB.fm 설치,사용,유지,보수에관한 사용설명서 (주)청우GNT RIELLO SPA ITALY TEL : 028095000 FAX : 028962100 강제 혼합식 가스버너 RS70100130 Progressive twostage operation CODE CÓDIGO MODEL MODELO TYPE TIPO 3785102 RS 70 821 T1 3785103 RS 70