Gas-Gebläsebrenner Brûleur gaz à air soufflé Forced draught gas

Gas-Gebläsebrenner Brûleur gaz à air soufflé Forced draught gas
Montage und Bedienungsanleitung
Manuel d’entretien
Installation, use and maintenance instructions
Instrucciones para la instalaciГіn, uso y mantenimiento
D
Gas-Gebläsebrenner
F
BrГ»leur gaz Г air soufflГ©
GB
E
Forced draught gas burner
Quemador de gas de aire soplado
Zweistufiger Betrieb
Fonctionnement Г 2 allures
Two stage operation
Funcionamiento de dos llamas
CODE - CГ“DIGO
MODELL - MODELE - MODEL - MODELO
TYP - TYPE - TIPO
3757714
GS20D
577T1
2902746 (2)
INDEX
1.
1.1
BURNER DESCRIPTION . . . . . . . . . . . .
Burner equipment . . . . . . . . . . . . . . . . .
1
1
2.
2.1
2.2
2.3
TECHNICAL DATA
Technical data . . . .
Overall dimensions
Working field . . . . .
.......
.......
.......
.......
...
...
...
...
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
2
2
2
2
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
3
3
4
4
4
5
3.4.2 Electrical wiring with gas leak control
device . . . . . . . . . . . . . . . . . . . . . . . . . .
6
3.
INSTALLATION . . . . . . . . .
3.1 Boiler fixing . . . . . . . . . . . .
3.2 Probe-electrode positioning
3.3 Gas feeding line . . . . . . . . .
3.4 Electrical wiring . . . . . . . . .
3.4.1 Standard electrical wiring .
1.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
WORKING . . . . . . . . . . . . . . . . . . .
Combustion adjustment. . . . . . . . . .
Combustion head setting. . . . . . . . .
Setting of the air damper actuator . .
Combustion check. . . . . . . . . . . . . .
Air pressure switch . . . . . . . . . . . . .
Burner start-up cycle . . . . . . . . . . . .
Start-up cycle diagnostics . . . . . . . .
Resetting the control box and using
diagnostics . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
6
6
6
7
7
8
8
8
....
9
5.
MAINTENANCE . . . . . . . . . . . . . . . . . . . 10
6.
FAULTS / SOLUTIONS . . . . . . . . . . . . . 11
BURNER DESCRIPTION
Gas burner with two stage working.
вћ¤
вћ¤
вћ¤
вћ¤
CE marking according to Gas Appliance Directive 90/396/EEC; PIN 0063AP6680.
According to Directives: EMC 89/336/EEC, Low Voltage 73/23/EEC and Efficiency 92/42/EEC.
The burner is approved for intermittent operation as per Directive EN 676.
The burner meets protection level of IP X0D (IP 40), EN 60529.
Gas train according to EN 676.
Fig. 1
1
1 – Air damper actuator
10
2 – Air dampers
3 – 4 pole socket for 2nd stage
4 – 7 pole socket for electrical supply
and control
5 – 6 pole socket for gas train
9
8
6 – Cable grommet
7 – Screw for fixing the cover
8 – Air pressure switch
9 – Control box
10 – Reset button with lock-out lamp
D4175
7
6
5
4
3
2
NOTE
The cable grommet (6) and the screw for fixing the cover (7) supplied with the burner, must be fitted to the
same side of the gas train.
1.1 BURNER EQUIPMENT
Insulating gasket .
Cable grommet . .
Hinge . . . . . . . . .
4 pin plug . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
No.
No.
No.
No.
1
1
1
1
Screws and nuts for flange to be fixed to boiler . . . No. 4
Screw for fixing the cover . . . . . . . . . . . . . . . . . . . No. 1
7 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
2746
1
GB
2.
TECHNICAL DATA
2.1 TECHNICAL DATA
Thermal power
Natural gas
(1)
58 / 81 – 220 kW
-
50,000 / 70,000 – 189,000 kcal/h
Net heat value: 8 – 12 kWh/Nm3 - 7,000 – 10,340 kcal/Nm 3
(Family 2)
Pressure:
min. 20 mbar
Electrical supply
Single phase, 230 V В± 10%
Motor
230V / 1.4 A
Capacitor
5 ВµF
Ignition transformer
Primary 230V / 1.8A
Absorbed electrical power
0.25 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
DE
AT
II2ELL3B/P
II2H3B/P
ES - GB - IE
II2H3P
LU
II 2E3B/P
2.2 OVERALL DIMENSIONS
Burner
63
Гё 125
350
Flange
120
в– 280
389
в—Џ 379
170
45
В°
45В°
в—Џ
в– 15
20 5
0
170
230
152
298
Rp 3/4
11
33
67
D4159
Length available using a separate kit.
Combustion head extension, supplied separately.
Pressure in the combustion
chamber – mbar
2.3 WORKING FIELD (as EN 676)
D5512
6
5
4
3
2
1
0
50
50,000
70
90
110
130
150
100,000
170
190
210
150,000
Thermal power
2746
2
GB
230
200,000
kW
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 5.9 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
50
70
90
110
130
150
170
190
210
230
kW
D5088
50,000
3.
200,000
150,000
Thermal power
100,000
kcal/h
INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
в– 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 100 mm,
refractory lining included.
If thickness is greater (max. 260 mm), a combustion
head extension must be fitted, which is supplied
separately.
в– Fix the head assembly group (B) to the boiler
(2) insert the supplied insulating gasket (3).
1
HINGE
ASSEMBLY
3
2
S7393
D4160
A
2746
3
GB
B
3.2 PROBE - ELECTRODE POSITIONING
~ 47 mm
Ignition electrode
Ionization probe
Diffuser
Probe
Electrode
3.7
=
=
D5104
WARNING 2 – 3 mm
3.3 GAS FEEDING LINE
1
1
2
3
4
5
6
7
–
–
–
–
–
–
–
2
3
M1
4
5
6
7
8
D4161
Gas supply pipe
Manual cock (supplied by the installer)
Gas pressure gauge (supplied by the installer)
Filter
Gas pressure switch
Safety valve
Pressure governor
M2
8 – 1st and 2nd stage adjustment valve
M1 – Gas-supply pressure test point
M2 – Pressure coupling test point
GAS TRAIN ACCORDING TO EN 676
The gas train is supplied separately, for its adjustment see the enclosed instructions.
GAS TRAIN
CONNECTIONS
USE
TYPE
CODE
INLET
OUTLET
MBZRDLE 407 B01
3970537
Rp 3/4
Rp 3/4
Natural gas ≤ 180 kW and LPG
MBZRDLE 410 B01
3970534
Rp 1
Rp 3/4
Natural gas and LPG
3.4 ELECTRICAL WIRING
ATTENTION:
вћ¤ Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth connection.
вћ¤ The section of the conductors must be at least 1mmВІ. (Unless requested otherwise by local standards and legislation).
вћ¤ The electrical wiring carried out by the installer must be in compliance with the rules in force in the country.
2746
4
GB
вћ¤
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.
NOTES
The burners have been type-approved for intermittent operation. This means they must stop at least once every 24 hours in
order to allow the electrical control box to check its efficiency on start-up. The boiler limit thermostat (TL) normally ensures
the burner halts. If this does not happen a time switch halting the burner at least once every 24 hours must be applied in series to limit thermostat (TL).
3.4.1 STANDARD ELECTRICAL WIRING
Air damper actuator
Ionization probe
Connector
Electrode
ATTENTION
Ignition
transformer
Air pressure
switch
Control box
RMG 88.620A2
Blue
White
Black
Motor
Burner earth
CARRIED-OUT
IN THE FACTORY
KEY TO LAY-OUT
XP4 – 4 pole socket
XP6 – 6 pole socket
XP7 – 7 pole socket
X4 – 4 pin plug
X6 – 6 pin plug
X7 – 7 pin plug
B4 – 1st stage working signal
B5 – 2nd stage working signal
h1 – 1st stage hour counter
h2 – 2nd stage hour counter
PG – Min. gas pressure switch
S3 – Remote lock-out signal
(230V - 0.5 A max.)
в—Џ
D4147
T6A – Fuse
TL – Limit thermostat
TR – 2nd stage thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – 1st stage valve
V12 – 2nd stage valve
230V
в—Џ
~ 50Hz
Connect 2nd stage thermostat between clamps T6 and T8
removing the bridge
2746
5
GB
TO BE DONE BY
THE INSTALLER
Capacitor
Suppressor
In the case of phasephase feed, a bridge
must be fitted on the
control box terminal
board between terminal 6 and the earth terminal.
3.4.2 ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE (DUNGS VPS 504)
TO BE DONE BY
THE INSTALLER
в—Џ
230V
KEY TO LAY-OUT
X4 – 4 pin plug
X6 – 6 pin plug
X7 – 7 pin plug
B4 – 1st stage working signal
B5 – 2nd stage working signal
h1 – 1st stage hour counter
h2 – 2nd stage hour counter
PG – Min. gas pressure switch
S3 – Remote lock-out signal
(230V - 0.5 A max.)
T6A – Fuse
TL – Limit thermostat
TR – 2nd stage thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – 1st stage valve
V12 – 2nd stage valve
~ 50Hz
D4148
в—Џ
Connect 2nd stage thermostat between clamps T6 and T8 removing
the bridge.
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.
C
A
4.2 COMBUSTION HEAD SETTING
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 155 kW
boiler with an efficiency of 90%, the
burner input is about 172 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
200,000
kW
D5109
240
220
180,000
200
160,000
180
172
140,000
160
120,000
140
100,000
120
80,000
70,000
100
80
0
1
2
3
4
5
Set point
2746
6
GB
4.3 SETTING OF THE AIR DAMPER ACTUATOR
PAUSE
I CAM
The I cam is factory set to allow the air damper to fully
close on shutdown. (Reference value 0В°).
Do not modify this setting for any reason.
Open
+
Micrometric screws
FIRST STAGE
Shut
–
V CAM
The V cam controls the air for the 1st stage flame (2, fig. 2).
The cam must be adjusted on decrease (damper closing)
by adjusting the micrometer screw.
The definitive position is obtained after 2nd stage adjustment.
D1777
SECOND STAGE II CAM
The II cam controls the air for the 2nd stage flame.
(Reference value 60В°, not to exceed 70В°).
Do not modify this setting for any reason.
The regulation of airflow at 2nd stage is carried out by operating the
air damper (1, fig. 2).
The III cam controls the opening of the gas valve at 2nd stage and
must precede the II cam by at least 15В°.
Warning:
For power adjustment at 1st and 2nd stage, apply the following indications:
– the power ratio between 1st and 2nd stage must be 1 : 2 at a maximum, if the above ratio is exceeded, valve seal control must be
used;
– in any case, the minimum burner power at 1st stage must not be
less than the firing rate range.
Fig. 2
2
1
E9085
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
G 25
G 30
G 31
11.7
11.5
14.0
13.7
Setting
CO2 %
О» = 1.2
9.7
9.5
11.6
11.4
IONIZATION CURRENT
The minimum current necessary for the control
box operation is 3 ВµA.
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.
CO
mg/kWh
О» = 1.3
9.0
8.8
10.7
10.5
≤ 100
≤ 100
≤ 100
≤ 100
Terminal board
of control-box
NOx
mg/kWh
≤ 170
≤ 170
≤ 230
≤ 230
Connector
10
D5006
2746
7
GB
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%.
4.6 BURNER START-UP CYCLE
Normal
Lock-out, due to ignition failure
Thermostat
Motor
Ignition transformer
1st stage valve
1st stage flame
2nd stage valve
2nd stage flame
Lock-out
3s max.
2s max.
D4170
40s
10s
2s max.
40s
3s max.
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
в—Џ
в—Џ
Ignition phase
в—Џ
вќЌ в—Џ
в—Џ
вќЌ в—Џ
в—Џ
в—Џ
вќЌ в—Џ
в—Џ
в—Џ
вќЌ в—Џ
в—Џ
в—Џ
вќЌ в—Џ
вќ‘ вќЌ вќ‘ вќЌ вќ‘ вќЌ вќ‘ вќЌ вќ‘ вќЌ
Operating with weak flame signal.
в—Џ
~ 170V
в–І в—Џ
в–І в—Џ
в–І в—Џ
в–І в—Џ
в–І в—Џ
в–І в–І в–І в–І в–І в–І в–І в–І в–І в–І
Lock-out
в–І вќ‘ в–І вќ‘ в–І вќ‘ в–І вќ‘ в–І вќ‘ в–І
Extraneous light
Index:
в—Џ
вќ‘ вќ‘ вќ‘ вќ‘ вќ‘ вќ‘ вќ‘ вќ‘ вќ‘ вќ‘ вќ‘ вќ‘
Operation, flame ok
Electrical supply lower than
в—Џ
вќЌ Off
в—Џ
Yellow
вќ‘ Green
2746
8
GB
в–І Red
4.8 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:
вћЈ 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:
вћЈ 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, indicated in the table below.
SOFTWARE DIAGNOSTICS
Reports the life of the burner 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:
вћЈ 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)
2746
9
GB
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are
listed in the table below.
SIGNAL
PROBABLE CAUSE
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).
2 pulses
Minimum air pressure switch does not close:
– make sure VPS trips to produce lockout;
– air pressure switch faulty;
– air pressure switch incorrectly regulated;
– fan motor does not run;
– maximum air pressure switch operating.
3 pulses
Min. air pressure switch does not open or light in the chamber before firing:
– air pressure switch faulty;
– air pressure switch incorrectly regulated.
4 pulses
Loss of flame during operations:
– poor burner regulation (insufficient gas);
– faulty or soiled gas valves;
– short circuit between ionisation probe and earth.
7 pulses
10 pulses
– 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 1st and 2nd stage settings of
all the components stated in this manual.
в—Џ
CO2 ( %) content
в—Џ
Smoke temperature at the chimney
2746
10 GB
в—Џ
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 (10, 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 burner does not start at
the limit thermostat closing.
The servomotor did not open in the 1st stage, it is broken or incorrectly
regulated.
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 ВµA). (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.
The servomotor is blocked
The burner does not pass onto the 2nd stage
The servomotor opens in the
2nd stage, but the flame doe
not increase
The cams are incorrectly set.
The 2nd stage thermostat does not cut off the connection between the T6
and T8 terminals
Cam III is incorrectly set
The 2nd stage valve is faulty. Replace.
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.
2746
11 GB
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement