RIELLO bruciatori serie gas rs

RIELLO bruciatori serie gas rs
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 two-stage operation
Funcionamiento a dos llamas progresivas
Funcionamento a duas chamas progressivas
CODE - CÓDIGO
MODEL - MODELO
TYPE - TIPO
3783302
RS 28
809 T1
3783303
RS 28
809 T1
3784402
RS 38
810 T1
3784403
RS 38
810 T1
3784502
RS 38
810 T1
3784503
RS 38
810 T1
3784702
RS 50
811 T1
3784703
RS 50
811 T1
2915932 (0)
GB
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packaging - Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
3
3
3
3
4
4
4
5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting the combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustments before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner calibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 - Firing output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 - 2nd stage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 - 1st stage output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 - Intermediates outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 - Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 - Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . 15
Flame present check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . 18
Resetting the control box and using diagnostics. . . . . . . . . . . 18
Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 19
Status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
N.B.
Figures mentioned in the text are identified as follows:
1)(A)
= part 1 of figure A, same page as text;
1)(A)p.3 = part 1 of figure A, page number 3.
NOTE
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.
1
TECHNICAL DATA
MODEL
TYP
OUTPUT (1)
2nd stage
min. 1st stage
kW
Mcal/h
kW
Mcal/h
FUEL
- Net calorific value
kWh/Nm3
Mcal/Nm3
kg/Nm3
Nm3/h
mbar
- Absolute density
- Max delivery
- Pressure at maximum delivery (2)
OPERATION
STANDARD APPLICATION
AMBIENT TEMPERATURE
COMBUSTION AIR TEMPERATURE
ELECTRICAL SUPPLY
°C
°C max
V
Hz
rpm
W
V
A
ELECTRICAL MOTOR
MOTOR CAPACITOR
µF/V
V1 - V2
I1 - I2
W max
IGNITION TRASFORMER
ELECTRICAL POWER CONSUMPTION
ELECTRICAL PROTECTION
IN CONFORMITY WITH EEC DIRECTIVES
NOISE LEVELS (3)
APPROVAL
dBA
CE
RS 28
RS 38
RS 38
809 T1
810 T1
810 T1
163 - 325
232 - 440
232 - 440
140 - 280
200 - 378
200 - 378
81
105
105
70
90
90
NATURAL GAS: G20 - G21 - G22 - G23 - G25
G20
G25
G20
G25
G20
G25
10
8,6
10
8,6
10
8,6
8,6
7,4
8,6
7,4
8,6
7,4
RS 50
811 T1
290 - 581
249 - 500
116
100
G20
10
8,6
G25
8,6
7,4
0,71
0,78
0,71
0,78
0,71
0,78
0,71
0,78
32
38
44
51
44
51
58
68
7,5
11,1
6,6
9,7
6,6
9,7
7,2
10,6
• Intermittent (min. 1 stop in 24 hours)
• Two-stage (high and low flame) and single-stage (all - nothing)
Boilers: water, steam, diethermic oil
0 - 40
60
230 ~ +/-10%
230 - 400 with neutral ~ +/-10%
50 - single-phase
50 - three-phase
2800
2800
2800
2800
250
420
450
650
220 - 240
220 - 240
220/240-380/415 220/240-380/415
2,1
2,9
2 - 1,2
3 - 1,7
8/450
12,5/450
230 V - 1 x 8 kV
1 A - 20 mA
370
600
IP 44
90/396 - 89/336 - 73/23 - 92/42
68
70
0085AP0733
0085AP0734
560
750
70
0085AP0734
72
0085AP0735
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.
(2) Pressure at test point 8)(A)p.3, with zero pressure in the combustion chambre, with open gas ring 2)(B)p.7 an maximum burner output
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
VARIANTS
GAS CATEGORY
Model
Electrical
supply
Blast tube
length mm
RS 28
single-phase
single-phase
216
351
single-phase
single-phase
three-phase
three-phase
216
351
216
351
RS 38
RS 50
three-phase
three-phase
COUNTRY
CATEGORY
IT - AT - GR - DK - FI - SE
II2H3B / P
ES - GB - IE - PT
II2H3P
NL
II2L3B / P
FR
II2Er3P
216
351
DE
II2ELL3B /P
BE
I2E(R)B, I3P
LU
II2E 3B/P
ACCESSORIES (optional):
•
KIT FOR LPG OPERATION: The kit allows the RS 28-38-50 burners to operate on LPG.
BURNER
OUTPUT
BLAST TUBE LENGTH
CODE
kW
mm
RS 28
95 ÷ 325
216
3010079
RS 38
115 ÷ 440
351
3010080
216
3010081
351
3010082
RS 50
140 ÷ 581
216
3010083
•
GROUND FAULT INTERRUPTER: code 3010321
•
STATUS (see page 20): code 3010322
•
GAS TRAIN ACCORDING TO REGULATION EN 676 (with valves, pressure governor and filter) : see page 8.
Important:
The installer is responsible for the addition of any safety device not forseen in the present manual.
2
351
3010084
D492
D3045
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Sleeve
5 Minimum air pressure switch
(differential operating type)
6 Flame sensor probe
7 Air pressure test point
8 Gas pressure test point and head fixing screw
9 Screws securing fan to sleeve
10 Slide bars for opening the burner and
inspecting the combustion head
11 Servomotor controlling the gas butterfly valve
and of air gate valve (by means of a variable
profile cam mechanism).
When the burner is not operating the air gate
valve is fully closed in order to reduce heat
dispersion from the boiler due to the flue
draught which draws air from the fan suction
inlet.
12 Plate with four hole knock-outs for electrical
cable routing
13 Air inlet to fan
14 Gas input pipework
15 Gas butterfly valve
16 Boiler mounting flange
17 Flame stability disk
18 Flame inspection window
19 Plug-socket on ionisation probe cable
20 Motor contactor and thermal cut-out reset
button (RS 38 - 50 three-phase)
21 Motor capacitor (RS 28 - 38 single-phase)
22 Control box with lock-out pilot light and lockout reset button
23 Two switches:
- one “burner off - on”
- one for “1st - 2nd stage operation”
24 Plugs for electrical connections
25 Air gate valve
Two types of burner failure may occur:
• Control box lock-out: if the control box
22)(A) pushbutton (red led) lights up, it indicates that the burner is in lock-out.
To reset, hold the pushbutton down for
between 1 and 3 seconds.
• Motor trip (RS 38 three-phase - RS 50):
release by pressing the pushbutton on thermal cutout 20)(A).
(A)
D3026
mm
A
B
C
kg
RS 28
RS 38
RS 50
1010
1010
1010
625
625
625
495
495
495
38
40
41
(B)
D88
D495
(C)
mm
A
B
C
D (1)
E
F
G
H
I
L
M
RS 28
RS 38
RS 50
476
476
476
474
474
474
580
580
580
216 - 351
216 - 351
216 - 351
140
140
152
352
352
352
164
164
164
810
810
810
108
108
108
168
168
168
1”1/2
1”1/2
1”1/2
(1) Blast tube: short-lang
3
PACKAGING - WEIGHT (B) - Approximate
measurements
• The burner are shipped in cardboard boxes with
the maximum dimensions shown in Table (B).
• The weight of the burner complete with packaging is indicated in table (B).
MAX. DIMENSIONS (C)
Approximate measurements
The maximum dimensions of the burner are
given in (C).
Note that if you need to examine the combustion
head, the burner must be pulled backward on
the slide bars and turned upward.
The maximum dimension of the burner, without
the cover, when open is give by measurement
H.
STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
4 - Flange fixing screws M 8 x 25
1 - Thermal insulation screen
4 - Screws to secure the burner flange to the
boiler: M 8 x 25
5 - Fairleads for electrical connections
(RS 28 - 38 single-phase)
6 - Fairleads for electrical connections
(RS 38 - 50 three-phase)
1 - Instruction booklet
1 - Spare parts list
D948
pressure mbar
Combustion chamber
RS 28
FIRING RATES (A)
The RS 28-38-50 burners can work in two ways:
one-stage and two-stage
MAXIMUM OUTPUT must be selected in area A.
MINIMUM OUTPUT must not be lower than the
minimum limit shown in the diagram.
RS 28
RS 38
RS 50
= 81 kW
= 105 kW
= 116 kW
Important:
The FIRING RATE value range has been
obtained considering an ambient temperature of
20 °C, and an atmospheric pressure of 1000
mbar (approx. 100 m above sea level) and with
the combustion head adjusted as shown on
page 7.
RS 38
The firing rates were set in relation to special
test boilers, according to EN 676 regulations.
Figure (B) indicates the diameter and length of
the test combustion chamber.
Example:
Output 350 Mcal/h:
diameter = 50 cm; length = 1,5 m.
pressure mbar
Combustion chamber
TEST BOILER (B)
COMMERCIAL BOILERS
The burner/boiler combination does not pose
any problems if the boiler is CE type-approved
and its combustion chamber dimensions are
similar to those indicated in diagram (B).
If the burner must be combined with a commercial boiler that has not been CE type-tested and/
or its combustion chamber dimensions are
clearly smaller than those indicated in diagram
(B), consult the manufacturer.
pressure mbar
Combustion chamber
RS 50
Combustion chamber
length m
(A)
Mcal/h
kW
(B)
D497
4
GAS PRESSURE
The adjacent tables show minimum pressure
losses along the gas supply line depending on
the burner output in 2nd stage operation.
∆p (mbar)
RS 28
3
kW
165
185
210
235
260
285
310
325
1
2,5
3,1
4,0
4,7
5,5
6,3
7,0
7,5
2
0,1
0,1
0,1
0,2
0,2
0,3
0,3
0,3
Ø 3/4
3970076
Ø 1”
3970077
Ø 1”1/4
3970144
Ø 1”1/2
3970145
Ø 1”1/2
3970180
11,1
13,4
16,5
19,9
23,6
27,5
31,6
34,2
5,3
6,4
7,9
9,5
11,2
13,1
15,0
16,2
3,2
3,8
4,7
5,6
6,6
7,6
8,7
9,4
2,1
2,5
3,1
3,8
4,5
5,3
6,2
6,7
1,8
2,0
2,5
3,2
3,7
4,4
4,7
4,9
Column 1
Pressure loss at combustion head.
Gas pressure measured at test point 1)(B), with:
• Combustion chamber at 0 mbar
• Burner operating in 2nd stage
• Gas ring 2)(B)p.7 adjusted as indicated in diagram (C)p. 7.
Column 2
Pressure loss at gas butterfly valve 2)(B) with
maximum opening: 90°.
Column 3
Pressure loss of gas train 3)(B) includes: adjustment valve VR, safety valve VS (both fully open),
pressure governor R, filter F.
∆p (mbar)
RS 38
3
kW
1
2
230
260
290
320
350
380
410
440
2,6
3,1
3,7
4,3
4,8
5,4
6,0
6,6
0,2
0,2
0,3
0,3
0,4
0,4
0,5
0,6
Ø 2”
Ø 2”
Ø 1”
Ø 1”1/4 Ø 1”1/2 Ø 1”1/2
3970146 3970181
3970077 3970144 3970145 3970180
3970160 3970182
9,2
11,2
13,4
15,8
18,3
20,9
23,7
26,6
5,4
6,6
7,9
9,2
10,6
12,1
13,7
15,3
3,6
4,5
5,5
6,5
7,6
8,8
10,1
11,4
3,0
3,7
4,4
4,8
5,9
6,6
7,0
8,1
1,4
1,7
2,1
2,5
3,0
3,5
4,0
4,5
1,8
2,2
2,7
3,3
3,5
4,0
4,4
5,0
1
2
290
330
370
410
450
490
530
580
2,2
2,9
3,6
4,3
5,0
5,6
6,3
7,2
0,3
0,4
0,5
0,6
0,7
0,9
1,0
1,2
Ø 2”
Ø 2”
Ø 1”
Ø 1”1/4 Ø 1”1/2 Ø 1”1/2
3970146 3970181
3970077 3970144 3970145 3970180
3970160 3970182
13,4
16,6
20,0
23,7
27,6
31,7
36,1
41,8
7,9
9,7
11,6
13,7
15,9
18,2
20,6
23,9
5,5
6,9
8,4
10,1
11,9
13,7
15,7
18,5
natural gas G25 PCI 8.6 kWh/Nm3 (7.4 Mcal/Nm3)
multiply tabulated values by 1.3.
Example - RS 28:
• 2nd stage operation
3
kW
natural gas G20 PCI 10 kWh/Nm3 (8.6 Mcal/Nm3).
With:
Calculate the approximate 2nd stage output of
the burner thus:
- subtract the combustion chamber pressure
from the gas pressure measured at test point
1)(B).
- Find the nearest pressure value to your result
in column 1 of the table for the burner in question.
- Read off the corresponding output on the left.
∆p (mbar)
RS 50
The values shown in the various tables refer to:
4,4
5,0
6,1
7,0
8,3
9,7
10,5
12,0
2,1
2,7
3,3
4,0
4,7
5,5
6,3
7,4
2,7
3,4
3,9
4,4
5,1
5,9
6,6
7,8
(A)
• Natural gas G20 PCI 10 kWh/Nm3
• Gas ring 2)(B)p.7 adjusted as indicated in diagram (C)p.7.
• Gas pressure at test point 1)(B)
= 6 mbar
• Pressure in combustion chamber = 2 mbar
6 - 2 = 4 mbar
A 2nd stage output of 210 kW shown in Table RS
28 corresponds to 4 mbar pressure, column 1.
This value serves as a rough guide, the effective
delivery must be measured at the gas meter.
To calculate the required gas pressure at test
point 1)(B), set the output required from the
burner in 2nd stage operation:
- find the nearest output value in the table for
the burner in question.
- Read off the pressure at test point 1)(B) on
the right in column 1.
- Add this value to the estimated pressure in
the combustion chamber.
Example - RS 28:
• Required burner output in 2nd stage operation: 210 kW
• Natural gas G20 PCI 10 kWh/Nm3
• Gas ring 2)(B)p.7 adjusted as diagram (C)p.7.
• Gas pressure at burner output of 210 kW,
taken from table RS 28, column 1 = 4 mbar
• Pressure in combustion chamber = 2 mbar
4 + 2 = 6 mbar
pressure required at test point 1)(B).
(B)
D934
5
INSTALLATION
mm
A
B
C
RS 28
160
224
M8
RS 38
160
224
M8
RS 50
160
224
M8
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A).
The position of the threaded holes can be
marked using the thermal screen supplied with
the burner.
D455
(A)
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected
according to the indications provided by the
manufacturer of the boiler, and in any case it
must be greater than the thickness of the boiler
door complete with its fettling. The range of
lengths available, L (mm), is as follows:
Blast tube 10):
• short
• long
D499
(B)
PROBE
ELECTRODE RS 28-38
ELECTRODE RS 50
(C)
D880
RS 28
216
351
RS 38
216
351
RS 50
216
351
For boilers with front flue passes 13) or flame
inversion chambers, protective fettling in refractory material 11) must be inserted between the
boiler fettling 12) and the blast tube 10).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the
refractory fettling 11)-12)(B) is not required
unless it is expressly requested by the boiler
manufacturer.
SECURING THE BURNER TO THE BOILER (B)
Before securing the burner to the boiler, check
through the blast tube opening to make sure that
the flame sensor probe and the ignition electrode are correctly set in position, as shown in
(C).
Now detach the combustion head from the
burner, fig.(B):
- remove screw 14) and withdraw the cover 15).
- Disengage the articulated coupling 4) from
the graduated sector 5).
- Remove the screws 2) from the slide bars 3)
- Remove screw 1) and pull the burner back on
slide bars 3) by about 100 mm.
Disconnect the wires from the probe and the
electrode and then pull the burner completely
off the slide bars, after removing the split pin
from the slide bar 3).
Secure the flange 9)(B) to the boiler plate, interposing the thermal insulating screen 6)(B) supplied with the burner. Use the 4 screws, also
supplied with the unit, after first protecting the
thread with an anti-locking product.
The seal between burner and boiler must be airtight.
If you noticed any irregularities in positions of
the probe or ignition electrode during the check
mentioned above, remove screw 1)(D), extract
the internal part 2)(D) of the head and proceed
to set up the two components correctly.
Do not attempt to turn the probe. Leave it in the
position shown in (C) since if it is located too
close to the ignition electrode the control box
amplifier may be damaged.
(D)
D501
6
SETTING THE COMBUSTION HEAD
Installation operations are now at the stage
where the blast tube and sleeve are secured to
the boiler as shown in fig.(A). It is now a very
simple matter to set up the combustion head, as
this depends solely on the output developed by
the burner in 2nd stage operation.
It is therefore essential to establish this value
before proceeding to set up the combustion
head.
There are two adjustments to make on the
head:
air and gas deliveries.
In diagram (C) find the notch to use for adjusting
the air and the gas, and then proceed as follows:
D502
(B)
(A)
Notches nr. (Air = Gas)
D503
Air adjustment (A)
Turn screw 4)(A) until the notch identified is
aligned with the front surface 5)(A) of the flange.
Gas adjustment (B)
Loosen screws 1)(B) and turn ring 2) until the
notch identified is aligned with index 3).
Tighten the screw 1) fully down.
Example RS 38:
burner output = 337 kW (290 Mcal/h).
If we consult diagram (C) we find that for this
output, air and gas must be adjusted using
notch 3, as shown in figs.(A) and (B).
Note
Diagram (C) shows the ideal settings for the
combustion head. If the gas mains pressure is
too low to reach the 2nd stage operation pressure indicated on page 5, and if the ring 2)(B) is
not fully open, it can be opened wider by 1 or 2
notches.
Continuing with the previous example, page 5
indicates that for burner RS 38 with output of
337 kW (290 Mcal/h) a pressure of approximately 4,6 mbar is necessary at test point 6)(A).
If this pressure cannot be reached, open the
ring 2)(B) to notch 4 or 5.
Make sure that the combustion characteristics
are satisfactory and free of pulsations.
Burner output in 2nd stage operation
(C)
D504
(D)
Once you have finished setting up the head, refit
the burner 4)(D) to the slide bars 3) at approximately 100 mm from the sleeve 5) - burner positioned as shown in fig.(B)p.6 - insert the flame
detection probe cable and the ignition electrode
cable and then slide the burner up to the sleeve
so that it is positioned as shown in fig.(D).
Refit screws 2) on slide bars 3).
Secure the burner to the sleeve by tightening
screw 1) and then refit the split pin into one of
two slide bars 3).
Reconnect the articulation 8) to the graduated
sector 7).
Important
When fitting the burner on the two slide bars, it
is advisable to gently draw out the high tension
cable and flame detection probe cable until they
are slightly stretched.
7
(A)
D505
GAS LINE
• The gas train must be connected to the gas
attachment 1)(A), using flange 2), gasket 3)
and screws 4) supplied with the burner.
• The gas train can enter the burner from the
right or left side, depending on which is the
most convenient, see fig.(A).
• Gas solenoids 8)-9)(B) must be as close as
possible to the burner to ensure gas reaches
the combustion head within the safety time
range of 3 s.
• Make sure that the pressure governor calibration range (colour of the spring) comprises
the pressure required by the burner.
GAS TRAIN (B)
It is type-approved according to EN 676 Standards and is supplied separately from the burner
with the code indicated in Table (C).
(B)
D935
GAS BURNERS AND RELEVANT GAS TRAINS APPROVED ACCORDING TO EN 676
Gas train L
Burner
13
14
Ø
C.T.
Code
RS 28
RS 38
RS 50
Code
Code
3/4”
−
3970076
•
−
−
3010123
3000824
1”
−
3970077
•
•
•
3010123
3000824
1”1/4
−
3970144
•
•
•
3010123
−
1”1/2
−
3970145
•
•
•
3010123
−
1”1/2
−
3970180
•
•
•
3010123
−
2”
−
3970146
−
•
•
3010123
3000822
2”
−
3970181
−
•
•
3010123
3000822
2”
♦
3970160
−
•
•
−
3000822
2”
♦
3970182
−
•
•
−
3000822
(C)
GAS TRAIN COMPONENTS
Components
Code
Filter
5
Pressure governor
6
3970076
Multiblock MB DLE 407
3970077
Multiblock MB DLE 410
3970144
Multiblock MB DLE 412
3970145
GF 515/1
3970180
3970146
3970160
3970181
3970182
FRS 515
Solenoids
8-9
DMV DLE 512/11
Multiblock MB DLE 415
GF 520/1
FRS 520
DMV DLE 520/11
Multiblock MB DLE 420
8
KEY (B)
1 - Gas input pipe
2 - Manual valve
3 - Vibration damping joint
4 - Pressure gauge with pushbutton cock
5 - Filter
6 - Pressure governor
(vertical)
7 - Minimum gas pressure switch
8 - Safety solenoid
VS
(vertical)
9 - Adjustment solenoid
VR (vertical)
Two adjustments:
• ignition delivery
(rapid opening)
• maximum delivery
(slow opening)
10 - Standard issue burner gasket with flange
11 - Gas adjustment butterfly valve
12 - Burner
13 - Gas valve 8)-9) leak detection control
device.
In accordance with EN 676 Standards, gas
valve leak detection control devices are
compulsory for burners with maximum outputs of more than 1200 kW.
14 - Gas train/burner adaptor.
P1 - Pressure at combustion head
P2 - Pressure down-line from the pressure governor
P3 - Pressure up-line from the filter
L - Gas train supplied separately with the code
indicated in Table (C)
L1 - The responsibility of the installer
KEY TO TABLE (C)
C.T. = Gas valves 8) - 9) leak detection control
devices:
- = Gas train without gas valve leak detection control device; device that can be
ordered separately and assembled subsequently (see Column 13).
♦= Gas train with assembled VPS valve
leak detection control device.
13 = VPS valve leak detection control device.
Supplied separately from gas train on
request.
14 = Gas train/burner adaptor.
Supplied separately from gas train on
request.
Note
See the accompanying instructions for the
adjustment of the gas train.
ELECTRICAL SYSTEM
ELECTRICAL EQUIPMENT FACTORY-SET
RS 28 single-phase
ELECTRICAL SYSTEM as set up by the manufacturer
LAYOUT (A)
Burner RS 28 (single-phase)
Nero
Bianco
Blu
LAYOUT (B)
Burner RS 38 (single-phase)
LAYOUT (C)
Burners RS 38 - 50 (three-phase)
• Models RS 38 and RS 50 leave the factory
preset for 400 V power supply.
• If 230 V power supply is used, change the
motor connection from star to delta and
change the setting of the thermal cut-out as
well.
(A)
D3012
ELECTRICAL EQUIPMENT FACTORY-SET
RS 38 single-phase
Key to Layouts (A) - (B) - (C)
C
- Capacitor
CMV
- Motor contactor
F1
- Protection against radio interference
DA
- Control box (Landis RMG)
I1
- Switch: burner off - on
I2
- Switch: 1st - 2nd stage operation
MV
- Fan motor
PA
- Air pressure switch
RT
- Thermal cut-out
SM
- Servomotor
SO
- Ionisation probe
SP
- Plug-socket
TA
- Ignition transformer
TB
- Burner ground
XP1
- Connector for STATUS
XP4
- 4 pole socket
XP5
- 5 pole socket
XP6
- 6 pole socket
XP7
- 7 pole socket
ATTENTION
In the case of phase-phase feed, a bridge
must be fitted on the control box terminal strip
between terminal 6 and the earth terminal.
(B)
D3013
ELECTRICAL EQUIPMENT FACTORY-SET
RS 38 three-phase - RS 50
(C)
D3014
9
ELECTRICAL CONNECTIONS
Use flexible cables according to EN 60 335-1
Regulations:
• if in PVC sheath, use at least H05 VV-F
• if in rubber sheath, use at least H05 RR-F.
All the wires to connect to the burner plugs 7)(A)
must enter through the supplied fairleads, which
must be fitted into the relevant holes in the left
hand or right hand plate. To do this, first unscrew
screws 8), then split the plate into its parts 9)
and 10) and remove the menbrane press-outs
from the holes.
The fairleads and hole press-outs can be in various ways; the following lists show one possible
solution:
(A)
D3027
RS 28 - RS 38 single-phase without leak detection control device
RS 28 und RS 38 single-phase
1 - Pg 11 Single-phase power supply
2 - Pg 11 Gas valves
3 - Pg 9
Remote control device TL
4 - Pg 9
Remote control device TR
5 - Pg 11 Gas pressure switch or gas valve
leak detection control device
RS 38 three-phase and RS 50
1 - Pg 11 Three-phase power supply
2 - Pg 11 Single-phase power supply
3 - Pg 9
Remote control device TL
4 - Pg 9
Remote control device TR
5 - Pg 11 Gas valves
6 - Pg 11 Gas pressure switch or gas valve
leak detection control device
LAYOUT (B) - The RS 28 - 38 Models electrical
connection single-phase power supply
without leak detection control device.
(B)
D940
RS 28 - RS 38 single-phase with leak detection control device VPS
(C)
D941
10
LAYOUT (C) The RS 28 - 38 Models electrical
connection single-phase power supply
with VPS leak detection control device.
Gas valve leak detection control takes place
immediately before every burner start-up.
Key to layouts (B) - (C)
h1 - 1st stage hourcounter
h2 - 2nd stage hourcounter
IN - Burner manual stop switch
XP- Plug for leak detection control device
X4 - 4 pole plug
X6 - 6 pole plug
X7 - 7 pole plug
PC- Gas pressure switch for leak detection control device
PG- Min. gas pressure switch
S - Remote lock-out signal
S1 - Remote lock-out signal of leak detection
control device
TR- High-low mode load remote control system:
controls operating stages 1 and 2.
If the burner is to be set up for single stage
operation, replace of remote control device
TR with a jumper.
TL - Load limit remote control system:
shuts down the burner when the boiler temperature or pressure reaches the preset
value.
TS - Safety load control system:
operates when TL is faulty
VR- Adjustment valve
VS- Safety valve
LAYOUT (A) - The RS 38 - 50 Models electrical
connection three-phase power supply without leak detection control device
RS 38 - RS 50 three-phase without leak detection control device
LAYOUT (B) - The RS 38 - 50 Models electrical connection three-phase power supply
with VPS leak detection control device.
Gas valve leak detection control takes place
immediately before every burner starting.
(A)
D943
RS 38 - RS 50 three-phase without leak detection control device VPS
(B)
D944
CALIBRATION OF THERMAL RELAY
RS 38 three-phase - RS 50
(C)
D867
Key to layouts (A) - (B)
h1 - 1st stage hourcounter
h2 - 2nd stage hourcounter
IN - Burner manual stop switch
XP- Plug for leak detection control device
X4 - 4 pole plug
X5 - 5 pole plug
X6 - 6 pole plug
X7 - 7 pole plug
PC- Gas pressure switch for leak detection control device
PG- Min. gas pressure switch
S - Remote lock-out signal
S1 - Remote lock-out signal of leak detection
control device
TR- High-low mode load remote control system:
controls operating stages 1 and 2.
If the burner is to be set up for single stage
operation, replace of remote control device
TR with a jumper.
TL - Load limit remote control system:
shuts down the burner when the boiler temperature or pressure reaches the preset
value.
TS - Safety load control system:
operates when TL is faulty
VR- Adjustment valve
VS- Safety valve
LAYOUT (C)
Calibration of thermal cut-out 20)(A)p.3
This is required to avoid motor burn-out in the
event of a significant increase in power absorption caused by a missing phase.
• If the motor is star-powered, 400 V, the cursor
should be positioned to "MIN".
• If the motor is delta-powered, 230 V, the cursor should be positioned to "MAX".
Even if the scale of the thermal cut-out does not
include rated motor absorption at 400 V, protection is still ensured in any case.
N.B.
• The RS 38 and RS 50 three-phase leave the
factory preset for 400 V power supply. If 230 V
power supply is used, change the motor connection from star to delta and change the setting of the thermal cut-out as well.
• The RS 28-38-50 burners have been typeapproved for intermittent operation. This
means they should compulsorily be stopped
at least once every 24 hours to enable the
control box to check its own efficiency at startup. Burner halts are normally provided for
automatically by the boiler load control system. If this is not the case, a time switch
should be fitted in series to IN to provide for
burner shut-down at least once every 24
hours.
• The RS 28-38-50 burners are factory set for
two-stage operation and must therefore be
connected to control device TR. Alternatively,
if single stage operation is required, instead of
control device TR install a jumper lead
between terminals T6 and T8 of connector X4.
WARNING: Do not invert the neutral with
the phase wire in the electricity supply
line. Inverting the wires will make the
burner go into lock-out because of firing
failure.
11
(A)
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 up-line from the gas
train.
- Adjust the minimum gas pressure switch to
the start of the scale (A).
- Adjust the air pressure switch to the zero
position of the scale (B).
- 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 U-type 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.
AIR PRESSURE SWITCH
MIN GAS PRESSURE SWITCH
(B)
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.
(C)
D514
SERVOMOTOR
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 angle of rotation of the servomotor is equal
to the angle on the graduated sector controlling
the gas butterfly valve. The servomotor rotates
through 90 degrees in 12 seconds.
Do not alter the factory setting for the 4 cams;
simply check that they are set as indicated
below:
Cam St2
: 90°
Limits rotation toward maximum position. When
the burner is in 2nd stage operation the gas butterfly valve must be fully open: 90°.
Cam St0
: 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 St1
: 15°
Adjusts the ignition position and the output in 1st
stage operation.
Cam MV
: 85°
Lights up the 2nd stage LED (STATUS)
(D)
D517
1
2
Burner off
1st stage
Burner on
2nd stage
(E)
D469
12
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 18)(A)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.
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 lock-out, 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 U-type manometer (C).
Once the burner has fired, now proceed with
global calibration operations.
BURNER CALIBRATION
The optimum calibration of the burner requires
an analysis of the flue gases at the boiler outlet.
1
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
2
Burner off
1st stage
Burner on
2nd stage
(A)
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 plug-socket 19)(A)p.3 on the
ionization probe cable (the burner will fire and
then go into lock-out after the safety time has
elapsed).
- Perform 10 firings with consecutive lock-outs.
- 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:
Nm3/h (max. burner delivery)
360
Example for G 20 gas (10 kWh/Nm3):
Max. operation output: 600 kW corresponding to
60 Nm3/h.
After 10 firings with lock-outs, the delivery read
on the meter must be equal to or lower than:
60 : 360 = 0,166 Nm3.
2 - 2ND 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)(A)
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 U-type 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
Adjusting air delivery
Progressively adjust the end profile of cam 4)(A)
by turning the cam adjustment screws as they
appear through the access opening 6)(A).
- Turn the screws clockwise to increase air
delivery.
- Turn the screws counter-clockwise 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)(A)p.13 to the 1st stage position: the servomotor 1)(A) 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.
D518
1 Servomotor
2 Cam 4 engaged
/disengages
Adjusting gas delivery
Measure the delivery of gas from the gas meter.
- If this value is to be reduced, decrease the
angle of cam St1 (B) slightly by proceeding a
little at a time until the angle is changed from
15° to 13° or 11°....
- If it is necessary to increase the mains pressure, move to 2nd stage operation by altering
the setting of switch 2)(A)p.13 and increase
the angle of cam St1, proceeding a little at a
time until the angle is changed from 15° to
17° - 19°....
At this point return to 1st stage operation and
measure gas delivery.
3 Cam cover
4 Adjustable profile cam
5 Cam profile adjustment screws
6 Opening for access to screws 5
7 Index for graduated sector 8
8 Graduated sector for gas butterfly valve
(A)
Note
The servomotor follows the adjustment of cam
St1 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.
If you increase the angle of St1 while the burner
is operating in 1st stage, lock-out will result.
In order to adjust cam St1, remove press-fit
cover 1), as shown in fig.(B), extract the relevant
key 2) from inside, and fit it into the keyway in
cam St1.
(B)
D520
Adjustment of air delivery
Progressively adjust the starting profile of cam
4)(A) by turning the screws working throught the
access hole 6)(A). It is preferable not to turn the
first screw since this is used to set the air gate
valve to its fully-closed position.
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)(A)p.13, disengage the variable profile cam, set the servomotor shaft slot 2)(A) to a vertical position and
turn the central screws of the cam so that the
cam offers a progressive gradient. Try turning
the cam back and forth by hand a few times until
the movement is completely smooth with no
signs of sticking.
Do not alter the position of the screws at each
end of the cam track, which have already been
adjusted for 1st and 2nd stage air gate valve
control.
Note
Once you have finished adjusting 2nd stage 1st stage - intermediate outputs, 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
5 - AIR PRESSURE SWITCH (A)
Adjust the air pressure switch after having performed all other burner adjustments with the air
pressure switch set to the start of the scale (A).
With the burner operating in 1st stage, increase
adjustment pressure by slowly turning the relative knob clockwise until the burner locks out.
Then turn the knob anti-clockwise by about 20%
of the set point and repeat burner starting to
ensure it is correct.
If the burner locks out again, turn the knob anticlockwise a little bit more.
AIR PRESSURE SWITCH 5)(A)p. 3
Attention
As a rule, the air pressure switch must limit the
CO in the fumes to less than 1% (10,000 ppm).
To check this, insert a combustion analyser into
the chimney, slowly close the fan suction inlet
(for example with cardboard) and check that the
burner locks out, before the CO in the fumes
exceeds 1%.
(A)
D521
MIN GAS PRESSURE SWITCH 7)(B)p. 8
The air pressure switch may operate in "differential" operation in two pipe system. If a negative
pressure in the combustion chamber during prepurging prevents the air pressure switch from
switching, switching may be obtained by fitting a
second pipe between the air pressure switch
and the suction inlet of the fan. In such a manner the air pressure switch operates as differenzial pressure switch.
Warning
The use of the air pressure switch with differential operation is allowed only in industrial applications and where rules enable the air pressure
switch to control only fan operation without any
reference to CO limit.
(B)
D896
(C)
D3023
15
6 - MINIMUM GAS PRESSURE SWITCH (B)
Adjust the minimum gas pressure switch after
having performed all the other burner adjustments with the pressure switch set at the start of
the scale (B).
With the burner operating in 2nd stage, increase
adjustment pressure by slowly turning the relative knob clockwise until the burner locks out.
Then turn the knob anti-clockwise by 2 mbar
and repeat burner starting to ensure it is uniform.
If the burner locks out again, turn the knob anticlockwise again by 1 mbar.
FLAME PRESENT CHECK (C)
The burner is fitted with an ionisation system
which ensures that a flame is present. The minimum current for plant operation is 5 µA.
The burner provides a much higher current, so
that controls are not normally required. However, if it is necessary to measure the ionisation
current, disconnect the plug-socket 19)(A)p.3 on
the ionisation probe cable and insert a direct
current microamperometer with a base scale of
100 µA.
Carefully check polarities!
BURNER OPERATION
NORMAL FIRING
(n° = seconds from instant 0)
BURNER STARTING (A)
•
•
•
•
0s
2s
3s
• 28 s
• 43 s
• 45 s
• 53 s
RMG
LED *
*
Off
Yellow
For further details see page 17.
Green
Red
: Control device TL closes.
Servomotor starts: it rotates during
opening up to the angle set on cam
St1.
After about 3s:
: The control box starting cycle begins.
: Fan motor starts.
: Servomotor starts: it rotates during
opening until contact on cam St2 is
tripped.
The air gate valve is positioned to 2nd
stage output.
Pre-purge stage with air delivery at
2nd stage output.
Duration 25 seconds.
: Servomotor starts: it rotates during
closing up to the angle set on cam
St1.
: The air gate valve and the gas butterfly are positioned to 1st stage output.
Ignition electrode strikes a spark.
Safety valve VS and adjustment valve
VR (rapid opening) open. The flame
is ignited at a low output level, point
A. Output is then progressively
increased, with the valve opening
slowly up to 1st stage output, point B.
: The spark goes out.
: If remote control device TR is closed
or if it has been replaced by a jumper,
the servomotor will continue to turn
until the cam St2 come into operation,
setting the air gate valve and the gas
butterfly valve to the 2nd stage operation position, section C-D.
The control box starting cycle ends.
RMG
LED *
STEADY STATE OPERATION (A)
System equipped with one control device TR.
Once the starting cycle has come to an end,
control of the servomotor passes on to the control device TR that controls boiler temperature or
pressure, point D.
(The control box will continue, however, to monitor flame presence and the correct position of
the air pressure switch).
• When the temperature or the pressure
increases until the control device TR opens,
the servomotor closes the gas butterfly valve
and the air gate valve and the burner passes
from the 2nd to the 1st stage of operation,
section E-F.
• When the temperature or pressure decreases
until the control device TR closes, the servomotor opens the gas butterfly valve and the
air gate valve and the burner passes from the
1st to the 2nd stage of operation, and so on.
• The burner stops when the demand for heat
is less than the amount of heat delivered by
the burner in the 1st stage, section G-H. Control device TL now opens, the servomotor
returns toward the 0° position, limited in this
movement by cam St0. The air gate valve
closes completely to reduce heat losses to a
minimum.
Systems not equipped with control device TR
(jumper wire installed)
The burner is fired as described in the case
above. If the temperature or pressure increase
until control device TL opens, the burner shuts
down (Section A-A in the diagram).
*
FIRING FAILURE (B)
If the burner does not fire, it goes into lock-out
within 3 s of the opening of the gas solenoid
valve and 49 s after the closing of control
device TL. The control box red pilot light will light
up.
(A)
D3028
NO FIRING
Off
Yellow
For further details see page 17.
Red
(B)
D3029
16
BURNER FLAME GOES OUT DURING OPERATION
If the flame should accidentally go out during
operation, the burner will lock out within 1s.
FINAL CHECKS (with burner running)
• Disconnect one of the wires on the minimum
gas pressure switch:
• Open remote control device TL:
• Open remote control device TS:
the burner must stop
FLAME INSPECTION WINDOW
• Disconnect the common wire P from the air
pressure switch:
• Disconnect the ionisation probe lead:
the burner must lock out
• Make sure that the mechanical locking systems on the various adjustment devices are
fully tightened.
MAINTENANCE
(A)
D484
Combustion
The optimum calibration of the burner requires
an analysis of the flue gases. Significant differences with respect to the previous measurements indicate the points where more care
should be exercised during maintenance.
Gas leaks
Make sure that there are no gas leaks on the
pipework between the gas meter and the burner.
OPENING THE BURNER
Gas filter
Change the gas filter when it is dirty.
Flame inspection window
Clean the flame inspection window (A).
Combustion head
Open the burner and make sure that all components of the combustion head are in good condition, not deformed by the high temperatures,
free of impurities from the surroundings and correctly positioned. If in doubt, disassemble the
elbow fitting 7)(B).
Servomotor
Disengage the cam 4)(A)p.14 from servomotor,
by turning slot 2)(A)p.14 through 90° and turn it
backward and forward by hand to make sure it is
free moving. Now engage cam 4)(A)p.14 again.
Burner
Check for excess wear or loose screws in the
mechanisms controlling the air gate valve and
the gas butterfly valve. Also make sure that the
screws securing the electrical leads in the
burner connections are fully tightened.
Clean the outside of the burner, taking special
care with the transmission joints and cam
4)(A)p.14.
Combustion
Adjust the burner if the combustion values found
at the beginning of the operation do not comply
with the regulations in force, or at any rate, do
not correspond to good combustion. Use the
appropriate card to record the new combustion
values; they will be useful for subsequent controls.
(B)
D535
TO OPEN THE BURNER (B):
- Switch off the electrical power.
- Remove screw 1) and withdraw cover 2).
- Disengage the articulated coupling 3) from
the graduated sector 4).
- Remove screw 5), the split pin 9) and pull the
burner back by about 100 mm on the slide
bars 6). Disconnect the probe and electrode
leads and then pull the burner fully back.
- Turn the burner as shown in the figure and fit
the split pin 9) into one of the slide bar holes
so that the burner remains in position.
Now extract the gas distributor 7) after having
removed the screw 8).
TO CLOSE THE BURNER (B):
- Remove the split pin 9) and push the burner
until it is about 100 mm from the sleeve.
- Re-connect the leads and slide in the burner
until it comes to a stop.
- Refit screw 5), the split pin 9) and pull the
probe and electrode leads gently out until
they are slightly stretched.
- Re-couple the articulated coupling 3) to the
graduated sector 4).
17
BURNER 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
Legenda:
Off
Yellow
Green
Red
RESETTING THE CONTROL BOX AND USING DIAGNOSTICS
The control box features a diagnostics function through which any causes of malfunctioning are easily identified (indicator: RED LED).
To use this function, you must wait at least 10 seconds once it has entered the safety condition (lock-out), and then press the reset button.
The control box generates a sequence of pulses (1 second apart), which is repeated at constant 3-second intervals.
Once you have seen how many times the light pulses and identified the possible cause, the system must be reset by holding the button
down for between 1 and 3 seconds.
RED LED on
wait at least 10s
Lock-out
Press reset
for > 3s
Pulses
Interval
3s
Pulses
The methods that can be used to reset the control box and use diagnostics are given below.
RESETTING THE CONTROL BOX
To reset the control box, proceed as follows:
- Hold the button down for between 1 and 3 seconds.
The burner restarts after a 2-second pause once the button is released.
If the burner does not restart, you must make sure the limit thermostat is closed.
VISUAL DIAGNOSTICS
Indicates the type of burner malfunction causing lock-out.
To view diagnostics, proceed as follows:
- Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.
A yellow light pulses to tell you the operation is done.
Release the button once the light pulses. The number of times it pulses tells you the cause of the malfunction, according to the coding
system indicated in the table on page 19.
SOFTWARE DIAGNOSTICS
Reports burner life by means of an optical link with the PC, indicating hours of operation, number and type of lock-outs, serial number of
control box etc ...
To view diagnostics, proceed as follows:
- Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.
A yellow light pulses to tell you the operation is done.
Release the button for 1 second and then press again for over 3 seconds until the yellow light pulses again.
Once the button is released, the red LED will flash intermittently with a higher frequency: only now can the optical link be activated.
Once the operations are done, the control box’s initial state must be restored using the resetting procedure described above.
BUTTON PRESSED FOR
CONTROL BOX STATUS
Between 1 and 3 seconds
Control box reset without viewing visual diagnostics.
More than 3 seconds
Visual diagnostics of lock-out condition:
(LED pulses at 1-second intervals).
More than 3 seconds starting from the visual
diagnostics condition
Software diagnostics by means of optical interface and PC (hours of operation, malfunctions etc. can be viewed)
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are listed in the table on page 19.
18
SIGNAL
FAULT
PROBABLE CAUSE
2 x blinks
After pre-purge and
safety time, the burner
goes tolock-out and the
flame does not appear
1
2
3
4
5
6
7
8
9
10
11
12
13
-
3 x blinks
The burner does not start 14 - Air pressure switch in operating position
and lock-out warning
appears
The burner starts and
then locks out
15
16
17
18
-
Lock-out during pre-purg- 19 ing
20 21 22 4 x blinks
7 x blinks
SUGGESTED REMEDY
The solenoid VR allows little gas through . . . . . . . . . . . . . . Increase
Solenoid valves VR or VS fail to open . . . . . . . . . . . . . . . . . Renew the coil or rectifier panel
Gas pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Increase pressure at governor
Ignition electrode wrongly adjusted . . . . . . . . . . . . . . . . . . . Adjust, see fig. (C)p. 6
Electrode grounded due to brocken insulation . . . . . . . . . . Replace
High voltage cable defective . . . . . . . . . . . . . . . . . . . . . . . . Replace
High voltage cable deformed by high temperature . . . . . . . Replace and protect
Ignition trasformer defective . . . . . . . . . . . . . . . . . . . . . . . . Replace
Erroneous valve or trasformer electrical connections . . . . . Check
Control box defective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
A cock down-line of the gas train is closed . . . . . . . . . . . . . Open
Air in pipework. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleed air
VS and VR gas valves unconnected or with interrupted coil . . Check connections or replace coil
Adjust or replace
Air pressure switch inoperative due to
insufficient air pressure:
Air pressure switch adjusted badly . . . . . . . . . . . . . . . . . . . Adjust or replace
Pressure switch pressure point pipe blocked . . . . . . . . . . . Clean
Head wrongly adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust
High negative draft in chamber . . . . . . . . . . . . . . . . . . . . . . . . . Connect air pressure switch to fan suction inlet
Defective capacitor (RS 28 - RS 38 single-phase) . . . . . . . Replace
Defective motor remote control switch (RS 38 - 50 three-phase). Replace
Defective electrical motor . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
Motor protection tripped (RS 38 three-phase - RS 50) . . . . . . Reset thermal cut-out when third phase
is re-connected
The burner starts and
then locks out
23 - Flame simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace control box
Lock out when burner
stops
24 - Flame remains in combustion head . . . . . . . . . . . . . . . . . . Eliminate persistence of flame
or flame simulation
or replace control box
The burner goes to lockout right after flame
appearance
25
26
27
28
29
30
31
-
The solenoid VR allows little gas through . . . . . . . . . . . . . . Increase
Ionisation probe wrongly adjusted. . . . . . . . . . . . . . . . . . . . Adjust, see fig. (C)p. 6
Insufficient ionisation (less than 5 µA). . . . . . . . . . . . . . . . . Check probe position
Probe grounded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Withdraw or replace cable
Burner poorly grounded . . . . . . . . . . . . . . . . . . . . . . . . . . . Check grounding
Phase and neutral wires inverted . . . . . . . . . . . . . . . . . . . . Correct by interventing
Defective control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
Burner locks out at transi- 32 - Too much air or too little gas . . . . . . . . . . . . . . . . . . . . . . . . Adjust air and gas
tion between 1st and 2nd
stage or between 2nd and
1st stage
During operation, the
burner stops in lock out
10 x blinks
The burner does not start 35 - Erroneous electrical connections . . . . . . . . . . . . . . . . . . . . Check connections
and lock-out warning
appears
The burner goes to lockout
No blink
33 - Probe or ionisation cable grounded . . . . . . . . . . . . . . . . . . Replace worn parts
34 - Fault on air pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . Replace
36 - Control box defective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
The burner does not start 37
38
39
40
41
42
43
44
-
No electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . Close all switches - Check connections
A limiter or safety control device is open . . . . . . . . . . . . . . . Adjust or replace
Control box fuses blown . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
Control box lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset control box
No gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open the manual valves between meter and train
Mains gas pressure insufficient . . . . . . . . . . . . . . . . . . . . . . Contact your GAS COMPANY
Minimum gas pressure switch fails to close . . . . . . . . . . . . Adjust or replace
Servomotor fails to move to St1 position . . . . . . . . . . . . . . . Replace
The burner repeats the
45 - Mains gas pressure is near the value to which the . . . . . . . Reduce operating pressure
starting cycle without lock
min. gas pressure switch gas is adjusted. The
of minimum gas pressure switch.
out
repeated drop in pressure which follows valve
Replace gas filter
opening causes temporary opening of the pressure
switch itself, the valve immediately closes and the
burner comes to a halt. Pressure increases again, the
pressure switch closes again and the firing cycle is
repeated. The sequence repeats endlessly.
Ignition with pulsation
46
47
48
49
-
Poorly adjusted head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust, see p. 7
Ignition electrode wrongly adjusted . . . . . . . . . . . . . . . . . . . Adjust, see fig. (C)p. 6
Poorly adjusted fan air gate: too much air . . . . . . . . . . . . . . Adjust
Output during ignition phase is too high . . . . . . . . . . . . . . . Reduce
The burner does not pass 50 - Remote control device TR does not close. . . . . . . . . . . . . . Adjust oe replace
to 2nd stage
51 - Defective control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
52 - Servomotor faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
Burner stops with air gate 53 - Sevomotor faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
valve open
54 -
19
STATUS
Accessory available on request.
See page 2.
STATUS (optional)
ASSEMBLY
The burners are preset to accept the Status. To
assemble, proceed as follows:
- Connect Status 1) using connector 2) fitted on
the bracket 3).
- Fasten Status to the bracket using the screws
4) supplied with the kit.
Assembly
The STATUS unit has three functions:
1
2
3
4
1
Status
Connector
Bracket of the burner
Fixing screws
3
4
2
1 - BURNER OPERATING HOURS AND THE
NUMBER OF FIRINGS ARE SHOWN ON
DISPLAY V
Total operating hours
Press button "h1".
2nd stage operating hours
Press button "h2".
1st stage operating hours (calculated)
Total hours - 2nd stage operating hours.
Number of firings
Press button "count".
Resetting operating hours and number of firings
Press the three "reset" buttons simultaneously.
Non-volatile memory
The operating hours and the number of firings
will remain in memory even in the case of electrical power failures.
2 - INDICATES THE TIMES RELATIVE TO THE
FIRING STAGE
The leds illuminate in the following sequence, fig. A:
D3057
WITH REMOTE CONTROL THERMOSTAT TR
CLOSED:
1 - Burner off, TL open
2 - Control device TL closed
3 - Motor start:
seconds count starts on read-out V
4 - Burner firing
5 - Transition to 2nd stage
seconds count stops on read-out V
6 - 10 seconds after stage 5 the code I I I I will
appear on the read-out: this indicates that
the starting phase is terminated.
WITH REMOTE CONTROL THERMOSTAT TR
OPEN
1 - Burner off, TL open
2 - Control device TL closed
3 - Motor start:
seconds count starts on read-out V
4 - Burner firing
7 - 30 seconds after stage 4:
seconds count stops on read-out V
8 - 10 seconds after stage 7 the code I I I I will
appear on the read-out: this indicates that
the starting phase is terminated.
The times, in seconds, shown on read-out V,
indicate the succession of the various starting
stages described on page 16.
3 - IN THE CASE OF BURNER MALFUNCTIONS, THE STATUS PANEL INDICATES
THE EXACT TIME AT WHICH THE FAULT
OCCURRED.
There are 12 possible combinations of illuminated leds, see fig. (B). For the causes of the
malfunction refer to the numbers shown
between brackets; see the legend on page 19
for interpretation of the numbers.
1 ................(24)
2 ................(44)
3 ................(15 ÷ 23)
4 ................(22)
5 ................(1 ÷ 13, 32 ÷ 34, 36)
6 ................(22)
7 ................(32)
8 ................(22)
9 ................(32 ÷ 34)
10 ..............(32 ÷ 34)
11 ..............(22)
12 ..............(22)
Led flashing
Key to symbols:
Led illuminated
Time in seconds
Burner start cycle terminated
= Power on
= Fan motor blocked (red)
= Burner lock-out (red)
D947
= 2nd stage operation
= 1st stage operation
= Load level reached (Stand-by),
D978
20
led: on
RIELLO S.p.A.
Via degli Alpini 1
I - 37045 Legnago (VR)
Tel.: +39.0442.630111 Fax: +39.0442.630375
http:// www.rielloburners.com
Subject to modifications - Sujeto a modificaciones - Sujeito a modificações
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