Technical & Sales CD V3_8 R40GS10 Riello Gas Burner
User Manual: R40GS10 Riello Gas Burner
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Montage und Bedienungsanleitung Manuel d’entretien Installation, use and maintenance instructions Instrucciones para la instalación, uso y mantenimiento D Gas-Gebläsebrenner F Brûleur gaz à air soufflé GB E Forced draught gas burner Quemador de gas de aire soplado Einstufiger Betrieb Fonctionnement à 1 allure One stage operation Funcionamiento de una llama CODE - CÓDIGO MODELL - MODELE - MODEL - MODELO TYP - TYPE - TIPO 3755426 GS10 554T1 2902721 (0) INDEX 1. BURNER DESCRIPTION . . . . . . . . . . . 1 4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 Burner equipment . . . . . . . . . . . . . . . . . 1 4.1 Combustion adjustment. . . . . . . . . . . . . . 6 2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2 4.2 Combustion head setting. . . . . . . . . . . . . 6 2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2 4.3 Air damper setting . . . . . . . . . . . . . . . . . . 7 2.2 Overall dimensions . . . . . . . . . . . . . . . . 2 4.4 Combustion check . . . . . . . . . . . . . . . . . . 7 2.3 Working field . . . . . . . . . . . . . . . . . . . . . 2 4.5 Air pressure switch . . . . . . . . . . . . . . . . . 7 3. INSTALLATION. . . . . . . . . . . . . . . . . . . 3 4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 8 4.7 Start-up cycle diagnostics . . . . . . . . . . . . 8 3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3 4.8 Operating fault diagnostics . . . . . . . . . . . 9 3.2 Probe-electrode positioning. . . . . . . . . . 4 3.3 Gas feeding line . . . . . . . . . . . . . . . . . . 4 5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 9 3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5 6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 10 3.4.1 Standard electrical wiring . . . . . . . . . . . 5 3.4.2 Electrical wiring with gas leak control device . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1. BURNER DESCRIPTION Gas burner with one stage working. ■ The burner meets protection level of 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. 1 – Air damper actuator Fig. 1 9 1 2 – Air dampers 3 – 7 pole socket for electrical supply and control 8 4 – 6 pole socket for gas train 5 – Cable grommet 6 – Screw for fixing the cover 7 7 – Air pressure switch 2 8 – Control box 9 – Reset button with lock-out lamp D4181 6 5 4 3 NOTE The cable grommet (5) and the screw for fixing the cover (6) supplied with the burner, must be fitted to the same side of the gas train. 1.1 BURNER EQUIPMENT Insulating gasket . . . . . . . . . . . . . No. 1 Screws and nuts for flange to be fixed to boiler. . . No. 4 Cable grommet . . . . . . . . . . . . . . No. 1 Screw for fixing the cover . . . . . . . . . . . . . . . . . . . No. 1 Hinge . . . . . . . . . . . . . . . . . . . . . . No. 1 7 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1 2721 1 GB 2. TECHNICAL DATA 2.1 TECHNICAL DATA (1) Thermal power 42 – 116 kW 36,000 – 100,000 kcal/h Net heat value: 8 – 12 kWh/Nm3 - 7,000 – 10,340 kcal/Nm3 (Family 2) Natural gas - Pressure: min. 16 mbar - Electrical supply Single phase, 230 V ± 10% Motor 230V / 0.7 A Capacitor 2 µF Ignition transformer Primary 230V / 1.8 A Absorbed electrical power 0.13 kW - max. 100 mbar ~ 50Hz Secondary 8 kV / 30 mA (1) Reference conditions: Temp. 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level. For gas family 3 (LPG) ask for separate kit. COUNTRY GAS CATEGORY FR II2Er3P DK - AT - GR - SE - IT II2H3B/P LU II2E3B/P DE II2ELL3B/P GB - IE - ES - PT II2H3P NL II2L3B/P 2.2 OVERALL DIMENSIONS Burner Flange 36 305 110 346 185 ■ 170 45 ° 33 D4201 130 61 ■ 11 160 142 204 Rp 3/4 262 ø 105 45° Combustion head extension, supplied separately. 2.3 WORKING FIELD (as EN 676) Pressure in the combustion chamber – mbar 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0 40 50 60 70 90 80 100 110 120 kW D5256 40,000 50,000 60,000 70,000 2721 2 GB 80,000 90,000 100,000 Thermal power kcal/h TEST BOILER The working field has been defined according to EN 676 standard. COMMERCIAL BOILERS The burner-boiler matching is assured if the boiler conforms to EN 303 and the combustion chamber dimensions are similar to those shown in the diagram EN 676. For applications where the boiler does not conform to EN 303, or where the combustion chamber is much smaller than the dimensions given in EN 676, please consult the manufacturers. CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT To obtain the maximum output, a gas head pressure of 5.8 mbar is measured (M2, see chapter 3.3, page 4) with the combustion chamber at 0 mbar using gas G20 with a net heat value of 10 kWh/Nm3 (8,570 kcal/Nm3). Gas pressure in the combustion head – mbar 7 6 5 4 3 2 1 40 50 60 70 90 80 100 110 120 kW D5257 40,000 3. 50,000 60,000 70,000 80,000 90,000 100,000 Thermal power kcal/h INSTALLATION THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS. 3.1 BOILER FIXING ■ Separate the combustion-head assembly from the burner body by removing nut (1) and removing group (A). IMPORTANT Boiler door must have a max. thickness of 90 mm, refractory lining included. If thickness is greater (max. 150 mm), a combustion head extension must be fitted, which is supplied separately. ■ Fix the head assembly group (B) to the boiler (2) insert the supplied insulating gasket (3). 1 HINGE ASSEMBLY 3 2 S7392 D6323 A 2721 3 GB B 3.2 PROBE - ELECTRODE POSITIONING ~ 40 mm Ionization probe Ignition electrode Diffuser Probe Electrode 2.2 = = D5104 WARNING 2 – 3 mm 3.3 GAS FEEDING LINE 1 2 3 M1 4 5 6 7 8 D5050 1 2 3 4 5 6 7 8 – – – – – – – – M2 Gas supply pipe Manual cock (supplied by the installer) Gas pressure gauge (supplied by the installer) Filter Gas pressure switch Safety valve Pressure governor Adjustment valve M1 – Gas-supply pressure test point M2 – Pressure coupling test point GAS TRAIN ACCORDING TO EN 676 GAS TRAIN CONNECTIONS USE TYPE CODE INLET OUTLET MBDLE 405 B01 3970530 Rp 1/2 Rp 3/4 Natural gas ≤ 80 kW and LPG MBDLE 407 B01 3970531 Rp 3/4 Rp 3/4 Natural gas and LPG The gas train is supplied separately, for its adjustment see the enclosed instructions. 2721 4 GB 3.4 ELECTRICAL WIRING 3.4.1 STANDARD ELECTRICAL WIRING Connector Ionization probe Electrode Ignition transformer Control box RMG 88.620A2 Air pressure switch Capacitor Burner earth Motor Blue White Black Blue Black Brown Suppressor Air damper actuator CARRIED-OUT BY THE INSTALLER ATTENTION In the case of phase-phase feed, a bridge must be fitted on the control box terminal board between terminal 6 and the earth terminal. D4198 230V ~ 50Hz NOTES: – Do not exchange the neutral with the phase and connect exactly the above wiring. – Wires of min. 1 mm2 section. (Unless requested otherwise by local standards and legislation). – Carry out a safe earth connection. – Verify that the burner stops by operating the boiler control thermostats and that the burner locks out by separating the red ionisation probe lead connector. – The electric wiring carried out by the installer must be in compliance with regulations in force in the Country. 2721 5 GB LEGEND XP6 – 6 pole socket XP7 – 7 pole socket X6 – 6 pin plug X7 – 7 pin plug B4 – Working signal h1 – Hour counter PG – Minimum gas pressure switch S3 – Remote lock-out signal (230V - 0.5 A max.) T6A – Fuse TL – Limit thermostat TS – Safety thermostat V10 – Safety valve V11 – Adjustment valve 3.4.2 ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE (DUNGS VPS 504) CARRIED-OUT BY THE INSTALLER LEGEND X6 X7 B4 h1 – 6 pin plug – 7 pin plug – Working signal – Hour counter PG – Minimum gas pressure switch S3 – Remote lock-out signal (230V - 0.5 A max.) T6A – Fuse TL – Limit thermostat TS – Safety thermostat V10 – Safety valve 230V ~ 50Hz V11 – Adjustment valve D4199 4. WORKING 4.1 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, including verification of the CO and CO2 concentration in the flue gases, their temperatures and the average temperature of the water in the boiler. To suit the required appliance output, choose the proper setting of the combustion head, and the air damper opening. 4.2 COMBUSTION HEAD SETTING C A B S7015 Loose the screw (A), move the elbow (B) so that the rear plate of the coupling (C) coincides with the set point. Tighten the screw (A). Example: The burner is installed on a 81 kW boiler with an efficiency of 90%, the burner input is about 90 kW using the diagram, the combustion set point is 3. 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). kcal/h 100,000 90,000 80,000 kW 110 100 90 70,000 80 60,000 70 50,000 60 40,000 D5258 120 50 40 0 1 2 3 4 5 Set point 2721 6 GB 4.3 AIR DAMPER SETTING The air damper (1) is operated by the actuator (2) and assures that the air damper is fully open before the burner start cycle begins . 1 The regulation of the air-rate is made by adjusting the fixed air damper (3), after loosing the screws (4). When the optimal regulation is reached, screw tight the screws (4) to assure a free movement of the mobile air damper (1). 2 3 4 4 D5036 4.4 COMBUSTION CHECK It is advisable to set the burner according to the type of gas used and following the indications of the table: AIR EXCESS: max. output λ ≤ 1.2 – min. output λ ≤ 1.3 EN 676 GAS Theoretical max. CO2 0 % O2 G 20 11.7 G 25 11.5 G 30 14.0 G 31 13.7 Setting CO2 % λ = 1.2 9.7 9.5 11.6 11.4 λ = 1.3 9.0 8.8 10.7 10.5 CO mg/kWh NOx mg/kWh ≤ 100 ≤ 100 ≤ 100 ≤ 100 ≤ 170 ≤ 170 ≤ 230 ≤ 230 IONIZATION CURRENT The minimum current necessary for the control box operation is 3 µA. The burner normally supplies a higher current value, so that no check is needed. However, if you want to measure the ionization current, you must open the connector fitted to the red wire and insert a microammeter. Terminal board of control-box Connector 10 D5006 Probe 4.5 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, reduce the value by a half set point. Attention: To comply with the EN 676 standard, the air pressure switch must operate when the CO value exceeds 1% (10,000 ppm). To check this, insert a combustion analyser in the flue, slowly reduce the burner air setting and verify that the burner shuts down by the action of the air pressure switch before the CO value exceeds 1%. 2721 7 GB 4.6 BURNER START-UP CYCLE Normal Lock-out, due to ignition failure Thermostat Motor Ignition transformer Valves Flame Lock-out D4172 max. 2s 40s max. 2s 40s 3s When flame-failure occurs during working, shut down takes place within one second. 4.7 START-UP CYCLE DIAGNOSTICS During start-up, indication is according to the followin table: COLOUR CODE TABLE Sequences Colour code Pre-purging ●●●●●●●●●●● Ignition phase ●❍●❍●❍●❍●❍● Operation, flame ok ❑❑❑❑❑❑❑❑❑❑❑❑ Operating with weak flame signal. Electrical supply lower than ❑❍❑❍❑❍❑❍❑❍ ~ 170V ●▲●▲●▲●▲●▲● Lock-out ▲▲▲▲▲▲▲▲▲▲ Extraneous light ▲❑▲❑▲❑▲❑▲❑▲ Index: ❍ Off ● Yellow ❑ Green 2721 8 GB ▲ Red 4.8 OPERATING FAULT DIAGNOSTICS The control box has a self-diagnostic system, which easily allows identifying the operating faults (RED LED signal). To use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a minimum of 3 seconds. After releasing the button, the RED LED starts flashing as shown in the diagram below. RED LED on wait at least 10s 3s Press reset for > 3s Blink code = = = interval = = Blink code = = = = = The LED gives of a blink code every 3 seconds. The blink codes give the information about the possible faults, as follows: SIGNAL PROBABLE CAUSE 2 flashes == The flame does not stabilise at the end of the safety time: – faulty ionisation probe; – faulty or soiled gas valves; – neutral/phase exchange; – faulty ignition transformer – poor burner regulation (insufficient gas). 3 flashes === Min. air pressure switch does not close: – air pressure switch faulty; – air pressure switch incorrectly regulated; – max. air pressure switch triggered (if installed). 4 flashes ==== Min. air pressure switch does not open or light in the chamber before firing: – air pressure switch faulty; – air pressure switch incorrectly regulated. 7 flashes ======= Loss of flame during operations: – poor burner regulation (insufficient gas); – faulty or soiled gas valves; – short circuit between ionisation probe and earth. 10 flashes ===== ===== – Wiring error or internal fault. 5. MAINTENANCE The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity with legislation and local standards. Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and consequent pollution. Before carrying out any cleaning or control always first switch off the electrical supply to the burner acting on the main switch of the system. THE BASIC CHECKS ARE: Leave the burner working without interruption for 10 min., checking the right settings of all the components stated in this manual. Then carry out a combustion check verifying: ● CO2 ( %) content ● Smoke temperature at the chimney 2721 9 GB ● CO content (ppm). 6. FAULTS / SOLUTIONS Here below you can find some causes and the possible solutions for some problems that could cause a failure to start or a bad working of the burner. A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box (9, fig. 1, page 1). When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the burner functions correctly, the lock-out can be attributed to a temporary fault. If however the lock out continues the cause must be determined and the solution found. BURNER STARTING DIFFICULTIES FAULTS SOLUTIONS Gas is not supplied. The actuator is faulty. Replace. The burner does not start at the limit thermostat closing. The gas pressure switch does not close its contact due to incorrect setting or a faulty switch. The air pressure switch has changed over to the operational position. The burner does not pass through the pre-purge and locks out. The air pressure switch does not change over: it has failed or the air pressure is too low (combustion head incorrectly set). Flame simulation exists (or the flame really lights). The gas valve pass too little gas (low pressure in the gas pipework). The burner locks out, after the pre-purge period, because the flame does not ignite. The valves are faulty. The ignition arc is irregular or not present. The air has not been purged from the pipe. The burner goes through the normal pre-purge, the flame ignites but the burner locks out within 3 seconds after ignition. The ionization probe is earthed or not in contact with the flame, or its wiring to the control box is broken, or there is a fault on its insulation to earth. The ionization current is weak (lower than 3 µA). (See chapter 4.7). The gas pressure switch is set too close to its working-pressure. This concerns a very particular irregularity, caused by the fact that the pressure in the gas mains is very close to the value to which the gas pressure switch has been set. The burner continues to repeat the starting cycle without locking out. Consequently, the sudden falling off in pressure at the opening of the valves causes the pressure switch to open, the valves immediately close and the motor stops. The pressure then increases, the pressure switch closes and the starting cycle can be repeated, and so on. This can be remedied by lowering the setting of the pressure switch. N.B.: If problems still occur after all of the above checks have been made, check the electrical connections on the plug and sockets, the damper and burner motor, gas control wiring ignition transformer and external interlocks, if the burner still fails to function, replace the control box. 2721 10 GB
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