Installation & Maintenance Manual

RGN 120-260

RGL 120-260

Gas Burner

Tel: +44 (0) 1905 794331 Fax: +44 (0) 1905 794017 Email: [email protected] Web: www.nu-way.co.uk

11/12

Overview ........................................................................................................... 3

General information / safety information .................................................................................... 3

Declaration of conformity ........................................................................................................... 3

Checking scope of delivery and connection data....................................................................... 3

Operating instructions ................................................................................................................ 4

Instruction of operating personnel.............................................................................................. 4

Maintenance and customer service ........................................................................................... 4

Key for code designation ........................................................................................................... 4

Technical specifications ............................................................................................................. 4

Installation ......................................................................................................... 5

Installing flange and burner........................................................................................................ 5

Checking electrode setting......................................................................................................... 5

Installing gas assembly .............................................................................................................. 5

Establishing electrical connections ............................................................................................ 6

Function ............................................................................................................. 7

Control unit DMG 970 / 972 ....................................................................................................... 7

Air flow setting, dimension "A" ................................................................................................... 8

Air flap positioning motor .......................................................................................................... 9

Compact gas unit ...................................................................................................................... 10

Gas pressure monitor ................................................................................................................ 10

Start-up .............................................................................................................. 11

Adjustment tables RGN 120 / RGL 120 ..................................................................................... 11

Adjustment tables RGN 120T / RGL 120T................................................................................. 12

Adjustment tables RGN 260 / RGL 260 ..................................................................................... 13

Adjustment tables RGN 260T / RGL 260T ................................................................................ 14

Adjusting gas burner and boiler ................................................................................................. 15

Calculation principle for gas burner adjustment ......................................................................... 19

Design ............................................................................................................... 21

Exploded drawing and spare parts/parts list RGN 120 / RGL 120............................................. 21

Exploded drawing and spare parts/parts list RGN 260 / RGL 260............................................. 22

Service instructions/dimensions ........................................................................ 23

Service position.......................................................................................................................... 23

Reference dimensions, ignition and ionisation electrodes ........................................................ 23

Measuring ionisation current ..................................................................................................... 24

Servicing air pressure monitor .................................................................................................. 24

Wiring diagrams ......................................................................................................................... 25

Troubleshooting ......................................................................................................................... 27

Burner overall dimensions / boiler connection dimensions ........................................................ 28

Working ranges .......................................................................................................................... 28

2

Overview

Overview

General information / safety information

The installation of a gas-fired system must conform to extensive regulations and requirements. It is therefore the duty of the installer to be familiar with all applicable regulations and requirements. Installation, startup and maintenance must be performed with utmost care.

The burner must not be operated in rooms with high levels of air humidity (laundry rooms), dust or corrosive vapours. The boiler room must be ventilated accordingly with ventilation air.

The Nu-Way RGN(L) 120/260 Series gas burners are suitable for burning natural gas or liquefied petroleum gas and comply with the European standard DIN EN 676.

Caution !

Improper installation, adjustment, modification, operation or maintenance may result in physical injury or damage to property/equipment.

Read the instructions prior to use.

This product must be installed in conformity with the valid regulations (e.g. DIN-VDE, DIN-DVGW).

The design and degree of protection of the burner make it suitable for operation in enclosed rooms.

Declaration of conformity

We declare that the Nu-Way RGN(L) 120/260 Series gas blower burners with the assigned product identification numbers:

RGN(L) 120 CE-0085 AP 0979

RGN(L) 260 CE-0085 AP 0979 satisfy the basic requirements of the following directives:

• "Low Voltage Directive" according to 73/23/EEC in conjunction with DIN VDE 0700 Part 1 / Ed. 04.88

and DIN VDE 0722 / Ed. 04.83

• "Electromagnetic Compatibility" according to Directive 89/336/EEC in conjunction with EN 55014 /

Ed. 04.93 and EN 50082-1 / Ed. 01.92

• "Gas Burning Installations Directive" according to Directive 90/396/EEC in conjunction with

DIN EN 676 / Ed. 12.96 and DIN EN 437 / Ed. 03.94

• "Efficiency Directive" according to Directive 92/42/EEC in conjunction with DIN EN 676/ Ed. 12.96

• "Machinery Directive" as per directive 98/37/EEC

These products conform to the design checked at the Department 0085 mentioned.

Checking scope of delivery and connection data

Before installing the Nu-Way gas burner, please check that all items included in the scope of delivery are present.

Scope of delivery:

Burner, sliding flange and gasket, 4 retaining screws, separate operating instructions, technical information, one 7-pin and one 4-pin connector (for -T only).

Compact gas unit and gaskets (for KEV only: additionally blue hoses for furnace and air pressure connections, see Overview, Page 10).

The gas pipe must be designed to conform to the flow rate and the available gas flow pressure and routed with the lowest pressure loss over the shortest distance to the burner. The loss of gas pressure via the compact unit and the burner and the resistance on the fuel gas side of the heat generator must be less than the connection flow pressure.

Caution !

Observe throughflow direction of compact unit.

3

Overview

Operating instructions

The operating instructions together with this technical information leaflet must be displayed in a clearly visible position in the boiler room. It is essential to write the address of the nearest customer service centre in the operating instructions.

Instruction of operating personnel

Faults are often caused by operator error. The operating personnel must be properly instructed in how the burner works. In the event of recurring faults, Customer Service should be notified.

Maintenance and customer service

The complete system should be checked once a year for correct functioning and leaks by a representative of the manufacturer or other suitably qualified person.

We accept no liability for consequential damage in cases of incorrect installation or repair, the fitting of nongenuine parts or where the equipment has been used for purposes for which it was not intended.

Key for code designation

RGN(L) 120-T

air damper, 2 stage burner type

Natural gas LL+E ="-N" or LPG = "F" burner series

Technical specifications

Technical data

Min. burner output in kW

Max. burner output in kW

Gas type

Method of operation

Voltage

Max. current consumption

Max. start / operation

Electric motor power

(at 2850 rpm) in kW

Flame failure controller

Control box

Air pressure monitor

Weight in kg

Noise emission in dB (A)

RGN 120

RGL 120

1-stage

Burner type

RGN 120T

RGL 120T

RGN 260

RGL 260

RGN 260T

RGL 260T

40 105

120 260 for natural gas LL + E = "-N" / for LPG 3B/P = „F“

2-stage sliding 1-stage

1 N / PE ~ 50 Hz - 230 V

2-stage sliding

2.5 A/1.2 A

0.18

2.6 A/1.3 A 3 A/1.4 A

0.25

3.1 A/1.5 A

DMG 970 DMG 972

Ionisation electrode

DMG 970

DL 2E-150 Pa

26

≤ 72

DL 2E - 40 Pa

29

DL 2E - 150 Pa

38

≤ 75

DMG 972

DL 2E - 40 Pa

40

4

Installation

Installation

Installation positions for KE...D,Z

90°

Installation position for KE...V

Installing flange and burner

When installing the sliding flange, only tighten screws

1 and 2 otherwise it will not be possible to secure the burner pipe with screw 3. Slide in the burner, adjust to furnace depth and tighten the screws in the following sequence: 3, 4, 5, raising the housing in the process.

Important: Secure the sliding flange so that the clamping screw 3 is positioned at the top.

Checking electrode setting

• Move the burner into the service position as described on Page 23.

• Check the setting of the ignition and ionisation electrodes (see Page 23).

90°

Installing gas assembly

• Remove plastic protective plug.

• Install unions including accompanying seals.

• Observe installation position.

• Check connecting point of gas assembly with noncorrosive foaming agent for leaks and vent gas pipe.

• When venting gas, discharge safely to atmosphere with a hose.

Comply with DVGW-TRGI 1986/96 Section 7,

TRF 1988, DIN 4756 and local regulations.

If proportional pressure control RGN(L)120/260T, with KEV:

Fit the furnace pressure meter tube to the boiler door with the gradient towards the boiler (if required).

Lay the control lines to the KEV to the corresponding ports P

L

and P

F

.

Use the blue PU hoses supplied.

• Lay the control line so that no condensate can flow into the KE.

• Connect hose to furnace pressure meter tube with port P

F

(if required).

• Connect hose to port P

L

with measuring nipple for air pressure on burner base plate.

If this connection is not made, the magnetic valves will not open.

5

Installation

Establishing electrical connections

• Disconnect system from power supply. Main switch "OFF".

• Check polarity of all connectors.

• Wire connector unit in accordance with connection diagram. Lay flexible control line so that boiler door can still be swivelled.

• Attach cube connector connected to 7-pin black-green connector X21 to gas pressure monitor connector A (grey) and to solenoid valves B1 (black), and secure with screw.

• Attach 7-pin black-green connector to compact gas unit (X21 & X22).

• Attach 4-pin connector unit for power control (X31) to black-green socket unit on burner (X32).

• Check correct pinout according to connection diagram, if connector unit X11 and X31 wired.

• Attach 7-pin connector unit for boiler control (X11) to black-brown socket unit on burner (X12).

• Supply lead to 7-pin connector unit X11 must be protected with a min. 6.3 A slow-blowing or max. 10

A quick-blowing fuse.

Connection diagram

N

N

N

PE

L1

Q1

H13 connector unit X31,X11 boiler control

H11

F21

F1 socket unit X32,X12 on burner

P11

F3

X11 X12

B4

S3

T2

T1

N

PE

L1

N connector unit X31,X11 boiler control

F22

P12

X31 socket unit X32,X12 on burner

T8

T7

T6

B5

X32

H12 socket unit X22 on burner

L1

PE

N

B5

T6

T7

T8 connector unit X21 compact unit

Y1

Y3

F51

Key:

F21,F22

F3

F51

Q1

H11,H12

H13

L1

PE

Y1,Y2

Y3

Y9

Ext. temp. controller,

1st/2nd stages

Ext. safety thermal cutout

Gas pressure monitor

Main heating switch

Ext. pilot lamp

Ext. fault signal lamp

Phase

Earth conductor

Solenoid valve

Safety solenoid valve

External controller

6

Function

Function

Control unit DMG 970 / 972

Function test of control box

Danger of death due to electric shocks!

Disconnect electrical cable from power supply before carrying out any work on live parts!

Faults may only be rectified by authorised trained personnel!

Unlocking may only be carried out by an authorised specialist.

Carry out the following checks after commissioning and each time after the burner has been serviced:

Jumper gas pressure monitor: to do so, detach grey cube connector on KE and remove cover. Close ball valve during operation with jumpered gas pressure monitor: device must go into fault mode immediately after flame failure.

Start-up with closed ball valve and jumpered gas pressure monitor: device must go into fault mode after safety time has elapsed.

After completion of check, reverse connection and re-establish original status.

Check air pressure monitor contact: device goes into fault mode when silicone connecting hose is detached. Re-attach hose to connecting point "+".

Jumper air pressure monitor before start-up: After 10 seconds, an intermittent fault is output and then automatically reset. A second start-up attempt is made. If the air pressure monitor contact is still closed, a true fault shutdown is triggered. If the air pressure monitor contact opens within 10 seconds, the burner becomes operational.

Safety and switching functions

In the event of a flame failure during operation, the fuel supply is immediately switched off and the control box goes into fault mode within 1 sec. A restart takes place in all cases following a mains power failure. A fault is triggered immediately if there is flame detection during pre-ventilation.

The position of the air pressure monitor is continuously checked. There can be no start-up if it is not in its neutral position. A fault is triggered if the working contact fails to close during pre-ventilation, or reopens.

In the event of a lack of air during operation, the air pressure monitor contact opens and the valves close immediately. The device goes into fault mode within 1 sec.

Fault cause diagnosis

In the event of a fault, the LED remains continuously lit. Every 10 seconds this is interrupted and a flash code is emitted that provides information about the fault. From this results the following sequence, which is repeated until the error is acknowledged, i.e. the fault on the unit has been cleared.

Following sequence:

Luminous phase

Dark phase Flash code Dark phase lasting 10 secs.

lasting 0.6 secs.

Readout device for display of the fault code:

SatroPen

SatroCom

Art. no. 47-10-22542

Art. no. 47-10-22563 lasting 1.2 secs.

7

Function

Fault message

Fault shutdown safety time

External light fault

Air controller in working position

Air controller time-out

Air controller opens

Flame failure

RGN(L)120

Flash code Cause of defect

No flame detection within the safety time

External light during monitored phase, sensor possibly defective

Air controller contact fused

Air controller does not close within a defined time span

Air controller contact opens during start-up or operation

Flame failure signal in operation

Air flow setting, dimension "A"

1 Dimension "A"

2 Adjusting screw for air restrictor (RGN([L)120)

3 Adjusting screw for air restrictor (RGN(L)260)

RGN(L)120:

Turn screw (2) anticlockwise: increase air "+"

Turn screw (2) clockwise: reduce air "-"

1

2

RGN(L)260

1

RGN(L)260:

Turn nut clockwise (3): increase air "+"

Turn nut (3) anticlockwise: reduce air "-"

3

Air flap positioning motor

Cooling of furnace avoided during burner standstill.

SA2-F [for RGN(L)120 only]:

Position "OPEN" - "CLOSED" of electric-motor-driven unit indicated at display lever. When servicing/retrofitting, refer to wiring diagram on Page 25.

Do not turn red positioning lever by hand as mechanism is destructible.

8

Function

STA:

The servomotor STA 13 B0 is for the purpose of air flap adjustment on burners with a 2-stage mode of operation. Adjustment is via limit switch cams on the positioning drive roller.

After each normal shutdown, the positioning motor moves into the air seal (ST0).

The cam positions for adapting the burner to the required min. output/1st stage are given in the preadjustment table.

Refer to adjustment tables on Pages 11-14.

To do so:

Remove cover from air flap positioning motor. Alter the cam positions via the adjusting screws with a standard screwdriver.

The switching cams can be readjusted when the burner is adjusted.

Higher number = increase air

Lower number = reduce air

Adjustments to ST1 and ST2 do not become effective until a brief switchover between 1st/2nd stage (or triggering of Up/Down on output controller) has taken place.

Adjust cam ST1/min. no greater than ST2/max.

After having readjusted the burner, refasten the servomotor hood and set the switch on the lower part of the control unit to the position 2nd stage.

Cam position (preset ex-works)

ST2 ST0 ST1

RGN 120T

RGN 260T

15

40

0

10°

5

30

9

Function

Compact gas units

The compact gas units for Nu-Way gas burners are preassembled and checked for leaks.

Version KE:

1-stage precision pressure regulator with high control quality and adjustable starting gas pressure.

Version KEV:

Exact pneumatic mixture control for optimum energy utilisation and combustion.

Technical data of compact gas unit

Gas types:

Inlet pressure:

Ambient temperature:

Connecting flanges:

Filter:

Natural gas, propane and butane, acc. to EN 437/EN 88 max. 100 mbar / 360 mbar (KE CG10 max. 50 mbar) min. 18 mbar

-15 °C to +60 °C

The connecting flanges are secured with 4 screws. The flanges can be turned through 90° or 180° in each case. Pressure measuring points in inlet and in outlet.

plastic gauze

Gas pressure monitor

The gas pressure monitor serves to monitor the gas inlet pressure. The burner is shut down if the gas inlet pressure drops below the set minimum value (preset at factory to 12 mbar). The burner starts up automatically when the minimum pressure is exceeded.

This setting should be retained.

p

W

10

Start-up

Start-up

The values given in the tables are only setting values for start-up. The system settings required in each case must be redefined if values such as boiler output, calorific value and altitude deviate.

A correction is required in any case.

Adjustment tables RGN 120

Burner output

[kW]

40

43

54

65

76

87

98

109

120

Boiler output at

η = 92%

[kW]

37

40

50

60

70

80

90

100

110

Gas nozzle pressure

[mbar]

8.2

10.4

12.6

15.2

1.9

2.2

3.3

4.7

6.4

Natural gas LL: H i,n

= 9.3

[kWh/m

3

]

Gas flow

[m 3

/h

]

9.9

11.2

12.4

13.7

4.6

5.0

6.2

7.5

8.7

Burner output Boiler output at

η = 92%

Natural gas E: H i,n

= 10.4

[kWh/m

3

]

[kW]

40

43

54

65

76

87

98

109

120

[kW]

37

40

50

60

70

80

90

100

110

Adjustment table RGL 120

Gas nozzle pressure

[mbar]

1.5

1.7

2.6

3.7

5.0

6.5

8.2

9.9

11.9

Gas flow

[m 3

/h

]

4.1

4.4

5.6

6.7

7.8

8.9

10.0

11.1

12.2

Burner output

[kW]

40

50

56

64

72

80

90

101

111

120

Boiler output at

η = 92%

[kW]

37

46

51

59

66

74

83

93

102

110

LPB 3B/P: H i,n

= 25,8

[kWh/m

3

]

Gas nozzle pressure

[mbar]

3.0

4.2

5.8

7.1

9.2

11.5

14.2

18,.3

21.3

25.3

Gas flow

[m

3

/h

]

1.6

2.0

2.3

2.6

2.9

3.3

3.7

4.1

4.5

4.9

Air flow dimension "A"

[mm]

11

12

15

17

20

22

25

29

46

Air flow dimension "A"

[mm]

11

12

15

17

20

22

25

29

46

Air flow dimension „A“

[mm]

11

14

15

17

19

21

23

26

30

46

11

Start-up

During start-up of the burner, observe the boiler manufacturer’s min. and max. heat output values.

Adjustment tables RGN 120T

Burner output Boiler output at

η = 92%

Air flap

Natural gas LL: H i,n

= 9.3

[kWh/m3]

Air flow dimension

"A"

Stage

2

Stage

1

[kW]

62

71

85

102

113

[kW]

43

47

58

72

79

Stage 2

[kW]

57

65

78

94

104

ST2

[°]

10

15

25

40

65

[°]

2

5

10

15

20

ST1 Gas nozzle pressure

Stage 2 Stage1

Gas flow

Stage 2 Stage 1

[mbar] [mbar]

4.2

5.5

7.9

11.3

13.9

2.0

2.4

4.3

5.5

6.8

[m 3

7.1

8.1

9.7

11.7

12.9

/h

] [m 3

/h

]

4.9

5.4

6.6

8.2

9.0

Compact gas unit

V

2.1

2.1

2.1

2.1

2.1

N

0

0

0

0

0

[mm]

46.0

46.0

46.0

46.0

46.0

Burner output

[°]

10

20

30

40

65

Air flow dimension

"A"

Stage

2

Stage

1

Stage 2 ST2

[kW]

62

71

85

102

113

[kW]

43

47

58

72

79

[kW]

57

65

78

94

104

Adjustment table RGL 120T

[°]

10

15

25

40

65

Brennerleistung Burner output at

η = 92%

Air flap

[°]

2

5

10

15

20

ST1 Gas nozzle pressure

Stage 2 Stage1

Gas flow

Stage 2 Stage 1

[mbar] [mbar]

3.2

4.2

6.0

8.6

10.6

1.5

1.8

3.2

4.2

5.2

[m 3

6.3

7.3

8.7

10.4

11.6

/h

] [m 3

/h

]

4.4

4.8

5.9

7.4

8.1

Compact gas unit

V

1.8

1.8

1.8

1.8

1.8

N

0

0

0

0

0

LPG 3B/P: H i,n

= 25,8

[kWh/m

3

]

[mm]

46.0

46.0

46.0

46.0

46.0

Air flow dimension

„A“

Stage

2

Stage

1

[kW]

75

91

101

110

120

[kW]

59

59

59

75

75

Boiler output at

η = 92%

Stage 2

[kW]

69

84

93

101

110

Air flap

ST2

Natural gas E: H i,n

= 10.4

[kWh/m

3

]

[°]

2

2

2

10

10

ST1 Gas nozzle pressure

Stage 2 Stage1

[mbar] [mbar]

11

16

20

23.5

28.5

6.5

6.5

6.5

11

11

Gas flow

Stage 2 Stage 1

[m 3

3.1

3.8

4.2

4.6

5.0

/h

] [m 3

/h

]

2.5

2.5

2.5

3.1

3.1

Compact gas unit

V

5.0

5.0

5.0

5.0

5.0

N

0

0

0

0

0

[mm]

46.0

46.0

46.0

46.0

46.0

12

Adjustment tables RGN 260

Burner output

[kW]

105

111

133

150

167

194

222

260

Boiler output at

η = 92%

[kW]

97

102

123

138

154

179

204

239

Natural gas LL: H i,n

= 9.3

[kWh/m

3

]

Gas nozzle pressure

[mbar]

3.0

3.3

4.7

5.9

7.1

9.0

11.7

16

Gas flow

[m 3

/h

]

12.0

12.7

15.2

17.2

19.1

22.2

25.4

29.7

Burner output Boiler output at

η = 92%

Natural gas E: H i,n

= 10.4

[kWh/m

3

]

[kW]

105

111

133

150

167

194

222

260

[kW]

97

102

123

138

154

179

204

239

Adjustment table RGL 260

Gas nozzle pressure

[mbar]

2.2

2.6

3.7

4.6

5.6

7.1

9.2

12.5

Gas flow

[m

3

/h

]

10.7

11.3

13.6

15.3

17.1

19.8

22.7

26.6

Burner output

[kW]

105

111

133

150

167

194

222

260

Boiler output at

η = 92%

[kW]

97

102

123

138

154

179

204

239

LPG 3B/P: H i,n

= 25,8

[kWh/m

3

]

Gas nozzle pressure

[mbar]

5.8

6.8

7.9

9.5

13.5

18.6

24.7

30.8

Gas flow

[m 3

/h

]

4.3

4.5

5.3

6.0

6.7

7.8

9.1

10.5

Air flow dimension "A"

[mm]

17.0

18.0

19.0

21.0

22.0

24.0

30.0

40.0

Air flow dimension "A"

[mm]

17.0

18.0

19.0

21.0

22.0

24.0

30.0

40.0

Air flow dimension „A“

[mm]

17.0

18.0

19.0

21.0

22.0

24.0

30.0

40.0

Start-up

13

Start-up

During start-up of the burner, observe the boiler manufacturer’s min. and max. heat output values.

Adjustment tables RGN 260T

Burner output Boiler output at

η = 92%

Air flap

Natural gas LL: H i,n

= 9.3

[kWh/m

3

] Air flow dimension

"A"

Stage

2

Stage

1

[kW]

112

138

165

180

203

222

236

[kW]

105

110

120

120

120

120

120

Stage 2

[kW]

103

127

152

166

187

204

217

[°]

30

40

50

60

80

100

115

ST2

[°]

35

35

35

25

30

35

35

ST1 Gas nozzle pressure

Stage 2 Stage 1

Gas throughput

Stage 2 Stage 1

[mbar] [mbar]

3.4

5.0

7.1

7.9

9.5

11.6

13.4

2.7

3.1

3.7

3.7

3.7

3.7

3.7

[m 3

12.8

15.8

18.9

20.6

23.3

25.4

27.0

/h

] [m 3

/h

12.1

12.6

13.7

13.7

13.7

13.7

13.7

]

Compact gas unit

V

2.5

2.5

2.5

2.5

2.5

2.5

2.5

N

0.5

0.5

0.5

0.5

0.5

0.5

0.5

Burner output

Stage

2

Stage

1

[kW]

111

133

167

176

194

222

236

Air flow dimension "A"

Stage

2

Stage

1

Stage 2

[kW]

112

138

165

180

203

222

236

[kW]

105

110

120

120

120

120

120

[kW]

103

127

152

166

187

204

217

Adjustment table RGL 260T

[°]

30

40

50

60

80

100

115

ST2

[°]

25

30

35

35

35

35

35

ST1 Gas nozzle pressure

Stage 2 Stage 1

Gas throughput

Stage 2 Stage 1

[mbar] [mbar]

2.7

4.0

5.7

6.3

7.5

9.2

10.7

2.1

2.4

2.9

2.9

2.9

2.9

2.9

[m 3

11.5

14.1

16.9

18.5

20.8

22.7

24.1

/h

] [m 3

/h

10.8

11.2

12.2

12.2

12.2

12.2

12.2

]

Burner output Boiler output at

η = 92%

Air flap

Compact gas unit

V

2.1

2.1

2.1

2.1

2.1

2.1

2.1

LPG 3B/P: H i,n

= 25,8

[kWh/m

3

]

N

0.5

0.5

0.5

0.5

0.5

0.5

0.5

Air flow dimension

„A“

[mm]

50.0

50.0

50.0

50.0

50.0

50.0

50.0

[kW]

107

109

120

120

120

120

120

Boiler output at

η = 92%

Stage 2

[kW]

102

122

154

162

178

204

217

Air flap

ST2

[°]

30

38

50

58

75

100

115

Natural gas E: H i,n

= 10.4

[kWh/m

3

]

[°]

35

35

35

25

30

35

35

ST1 Gas nozzle pressure

Stage 2 Stage 1

[mbar] [mbar]

6,8

7,9

13,5

15,0

18,6

24,7

27,5

5,5

6,0

7,4

7,4

7,4

7,4

7,4

Gas throughput

Stage 2 Stage 1

[m 3

4,5

5,3

6,7

7,1

7,8

9,1

9,7

/h

] [m 3

/h

]

4,3

4,4

4,9

4,9

4,9

4,9

4,9

Compact gas unit

V

4,8

4,8

4,8

4,8

4,8

4,8

4,8

N

0,5

0,5

0,5

0,5

0,5

0,5

0,5

[mm]

50,0

50,0

50,0

50,0

50,0

50,0

50,0

[mm]

50.0

50.0

50.0

50.0

50.0

50.0

50.0

14

Start-up

Adjusting gas burner and boiler

The burner can be put into operation once the installation and assembly work has been completed.

• Measure inlet pressure with U-pipe pressure gauge at measuring point "A".

max. 100 mbar min. 18 mbar (flow pressure) on RGN...-N min. 35 mbar (flow pressure) on RGL ...-F

• Burner and gas assembly are preset at factory to low output. This enables a soft burner start-up.

• Adjusting the burner to the desired nominal output is described on the following pages.

For this:

• Check gas working pressure with U-pipe pressure gauge at measuring point "B" outlet pressure.

Caution !

If the pressure difference is greater than 100 mbar, use an external pulse line !

• Adjust gas pressure and air flow dimension "A" according to adjustment tables, page 11-14.

• Check exhaust gas values here without fail (CO, CO

2

or O

2

).

Exhaust gas values

O

2

content

CO

2

content

Natural gas LL+E

9-10%

3.5-5.0%

LPG propane 3B/P

11-12%

• Depending on the system, the setting values must be corrected.

• After completion of adjustment, check the setting data.

• Check the gas pressure monitor after start-up. To do so, slowly close the ball valve on the gas meter further away (not the ball valve right in front of the KE). The burner must switch off, but not go over to fault.

15

Start-up

Single-stage gas burner with KE compact units

Burner type RGN 120/260, RGL 120/260

Installation position, vertical line:

Installation position, horizontal line:

Minimum distance to walling:

p

S p

G p

W

A

Installation of compact unit as desired tilted up to max. 90° to left or right, not over head

20 mm

p

L

B

Gas supply pressure measuring point A (P

inlet

)

Gas nozzle pressure measuring point B (P

outlet

)

p

S

= starting gas pressure

p

G

= main gas pressure

p w

= pressure, gas pressure monitor

p

L

= Sealing plug starting gas pressure p

S

setting

Dimension "A" = air flow setting (see Fig. P.8)

Presetting:

Locate relevant line of adjustment table according to boiler output and adopt setting values.

• Adjust dimension "A" according to specifications of adjustment table.

Gas nozzle pressure

≤ 5 mbar:

•

P

G

: adjust main gas pressure on min.

•

P s

: adjust starting gas pressure according to the spec-fications of the adjustment tables.

Gas nozzle pressure > 5 mbar:

•

P

G

:adjust main gas pressure according to the specifications of the adjustment tables.

P s

: starting gas pressure to approx. 40-60% of main gas pressure , min. 4 mbar.

Precision setting:

• At measuring point B measure gas nozzle pressure.

Gas nozzle pressure

≤ 5mbar:

• Start burner; if there is no flame formation, check adjustment.

• After approx. 10 sec. correct starting gas pressure ps according to adjustment table.

Air setting dimension "A"

Reduce if:

Increase if:

Exhaust gas values

CO

2 too low

CO

2

too high

O

2

too high

O

2 too low

Gas nozzle pressure > 5mbar:

•Start burner, if there is no flame formation, check adjustment. If necessary adjust starting gas pressure P

s

higher (attention: always adjust P

s

≤ P

G

)

•After approx. 10 sec re-adjust main gas pressure P

G

according to adjustment table.

•Then adapt dimension "A" air flow setting (see table).

Secure air setting with lock nut.

•Perform an exhaust gas analysis, paying special attention to eh CO emission.

•Seal off all measuring points.

16

Start-up

2-stage sliding gas burner with compact unit KEV (gas/air proportional pressure regulator)

Burner type RGN 120/260T, RGL 120/260T

Installation position

Minimum distance to walling

V

N p

W

Installation of compact unit only in horizontal line, not tilted

20 mm

B

Gas supply pressure measuring point A (P inlet

)

Nozzle pressure measuring point B (P outlet

)

N = zero point (gas nozzle pressure adjustment at min. output)

V = nozzle pressure/air pressure ratio in the burner pipe (gas nozzle pressure setting at max. capacity)

p w

= pressure, gas pressure monitor

A

Presetting:

Locate relevant line of adjustment table according to boiler output and adopt setting values.

• Air volume setting with air flap position as per adjustment table.

• Check setting of dimension "A“.

Burner start:

• Start gas burner at low load - if burner does not go into operation, turn at N a little in "+" direction and repeat start.

Precision setting:

Adjust max. output:

• Measure gas nozzle pressure at B.

• Set burner gradually to high load 2nd stage and correct exhaust gas analysis via "V".

To do so, set the output controller to max. output (contact from "T6" to "T8" in socket unit X32).

• Move air flap until max. position is reached (see adjustment table).

• With RGN120/260T, in addition set switch 1st/2nd stage to 2nd stage.

Setting "V"

KEV

Change in "+" direction if:

Change in "-" direction if:

Exh. gas analysis values

CO

2 too low

CO

2

too high

O

2

too high

O

2 too low

• Correct exhaust gas values at "V" (see table).

17

Start-up

Adapt nozzle pressure max. output at max. air flap position ST2

Increase position ST2 if:

Reduce max. output if:

Max. output

Output/nozzle pressure too low

Output/nozzle pressure too high

Adapt nozzle pressure min. output

Increase ST1/min. output if:

Reduce ST1/min. output if:

Min. output

Output/nozzle pressure too low

Output/nozzle pressure too high

• Set the nozzle pressure by adjusting the air flap

(see table item ST2/max.).

Set min. output 1st stage:

• Set burner to low load 1st stage and correct exhaust gas values via "N".

for RGN(L)120/260T:

Set 1st/2nd stage switch to 1st stage.

• Adjust nozzle pressure by adjusting cam

ST1/min. according to table.

Setting "N"

KEV

Change in "+" direction if:

Change in "-" direction if:

Exh. gas analysis values

CO

2 too low

CO

2

too high

O

2

too high

O

2 too low

• Correct exhaust gas values at "N" (see table).

• In order for the positioning drive to approach the newly adjusted cam position, the output controller must be set for a few seconds to max. output requirement (contact from "T6" to "T8").

The positioning drive starts to move.

• Reset output controller to min. output requirement (contact from "T6" to "T7").

The positioning drive moves to the newly adjusted min. position.

On the 2-stage sliding version set the switch 1st/2nd stage briefly to 2nd stage and then reset to

1st stage.

• Correct exhaust gas values at "N".

• If necessary, repeat adjustment procedure of cam position ST1/min. output as described above until desired nozzle pressure is achieved.

• As the adjustments "V“ and "N“ mutually influence each other, the burner must be run up and down several times between max. and min. heat requirement of the 1st/2nd stage output controller.

• For max. output correct 2nd stage exhaust gas emission by adjusting "V“ and for min. output correct

1st stage by adjusting "N“.

• Start the burner and if the burner does not start, alter "N“ in direction "+“ and start burner again. Check exhaust gas emission and, if necessary, alter 1st stage min./start output.

• Close the measuring connection pieces "A“ and "B“ - Do not close the possibly non-used connection p

F

.

Caution !

Difference between burner pipe pressure pL and furnace pressure pF must be at least 0.3.

To avoid any oscillation of the controller the pressure difference

(P inlet pressure

- P output pressure

) should be kept as small as possible at maximum output.

18

Start-up

Calculation principle for gas burner adjustment

The values given in the tables are setting values for start-up.

The necessary system adjustment must be newly determined in each case.

General:

The calorofic value (H i,n

) of fuel gasses is usually given for normal atmospheric conditions

(0°C, 1013 mbar).

Natural gas type E

Natural gas type LL

H i,n

= 10.4 kWh/m

3

H i,n

= 9.3 kWh/m

3

Gas counters measure the volume of gas in the operational state.

Specifying throughput:

To allow correct setting of the heat generator load, the gas throughput must be determined in advance.

Example:

Height above sea level 230 m

Atmospheric pressure B (according to table) 989 mbar

Gas pressure P

G

at counter

Gas temperature

ϑ

G

Boiler rating Q n

Efficiency

η

K

(assumed)

Calorific value H i,n

20 mbar

16°C

100 kW

92%

10.4 kWh/m

3

Gas flow in standard state (V n

)

V n

=

η

k

Q

×

H

=

0 92 10

,

4

m3

=

h

3

Gas flow in operating state (V

B

)

3

3

V

B

=

V

------

f n

= =

h

Conversion factor (f)

f

=

B P

--------------

1013

×

273

+

ϑ

G

Annual average air pressure

Mean geodesic height of supplied region ASL [m]

Annual average of air pressure from to 0

1

50

51

100

101

150

151

200

201

250

251

300

301

350

351

400

401

450

451

500

501

550

551

600

601

650

651

700

701

750

(mbar) 1016 1013 1007 1001 995 989 983 977 971 965 959 953 947 942 936 930

Key:

Q n

η

K

= boiler rating [kW]

= efficiency [%]

H i,n

= lower standard calorific value [kWh/m

3

] f = conversion factor

B = barometric pressure [mbar] p

G

= gas pressure at gas counter [mbar]

ϑ

G

= gas temperature at gas counter [°C]

19

Start-up

Flow measurement

Determining flow duration at gas meter.

Calculated flow duration in seconds t spec

for a flow volume of 200 litres (corresponding to 0.2 m for the example given above is:

3

)

V

B

= 11.2 m

3

/h

t soll

=

V

B

3

×

3600

h

3

720m

3

=

V

B m

3

------

h

=

720m

3

h

64s

3

=

h

Gas flow setting

Measured flow duration in seconds [s]

Greater than calculated flow duration t spec

Less than calculated flow duration t spec

Equal to calculated flow duration t spec

Measures

Increase gas flow

Reduce gas flow

Gas flow achieved gas flow in [m

3

/ h] flow volume in litres flow duration in seconds

20

Design

Design

Exploded view and parts list RGN 120 /RGL 120

1

2

3

4

29

28

27

5

6

7

8

9

10

11

12

13

14

15

16

26

25

24

23

Seq. No.

Designation

25

26

27

28

22

23

24

24

16

17

18

18

19

20

21

13

14

15

15

9

10

11

12

7

8

5

6

3

4

1

2

Flow plate with combination electrode

Combination electrode

Ignition cable with connector (black) for T

Ionisation cable with socket unit (red)

Connector unit, 4-pin, green

Connector unit, 7-pin, black/brown

Connecting cable CG for T

Socket unit, 7-pin, black/brown with cable, 480mm lg.

Socket unit, 7-pin, green, with cable

Socket unit, 4-pin, green, with cable for T

Cable gland G4 for ignition cable

Cable gland G6 for ionisation cable

Ionisation cable with connector unit

Lower section, control box

Control unit DMG 970

Control unit DMG 972 for T

Meter tube

Gas nozzle with pressure measuring nipple for -N

Air pressure switch DL2E for RGN120

Air pressure switch DL2E for T

Motor 230 V / 50 Hz 180 W

Ignition transformer with connecting cable

Burner cover

Actuating drive STA 13 B0

Fan wheel dia. 146 x 62 mm

Air flap

Air flap for T

Plastic housing insert

Housing with burner pipe

Fastening unit

Sliding flange

29 Flange gasket

No illustr.

Positioning drive SA2-F with cable

No illustr.

Compact unit KE 10 ½" for -N

No illustr.

Compact unit KE 15 ½" for -N

No illustr.

Compact unit KE 15 ½" with TC for -N

No illustr.

Compact unit KEV 15 ½" for -N, RGN120T

No illustr.

Compact unit KEV 15 ½" with TC for -N, RGN120T

No illustr.

Compact unit KE 20 ¾" for -N

No illustr.

Compact unit KE 20 ¾" with TC for -N

No illustr.

Compact unit KEV 20 ¾" for -N, RGN120T

No illustr.

Compact unit KEV 20 ¾" with TC for -N, RGN120T

No illustr.

Seal for gas union R½"

No illustr.

Gasket for gas union R¾"

No illustr.

Ball valve ½"

No illustr.

Ball valve ¾"

22

21

21

20

19

18

17

PU

1

1

10

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5

5

20

20

1

5

5

5

1

5

10

1

1

1

1

1

1

1

1

1

1

5

1

10

10

1

1

Order No.

34-30-10582

37-50-20644

47-50-20113

44-30-20634

37-50-11143

37-50-11015

47-20-20978

44-50-10897

47-50-11243

47-50-11840

37-50-11971

47-50-10890

37-10-10935

31-20-22393

47-10-22057

47-10-22232

42-20-23254

34-30-10593

47-10-22694

47-10-22464

32-10-11507

47-30-20927

34-20-10141

47-10-22472

32-10-10139

32-20-11595

32-20-10176

32-20-11744

44-30-11518

32-50-11646

32-20-10136

37-50-10137

57-30-11592

34-20-22761

34-20-22764

34-20-22942

34-20-22765

34-20-22766

34-20-22767

34-20-22768

34-20-22769

34-20-22770

37-50-20108

37-50-20109

34-20-40601

34-20-40602

Design

Exploded view and parts list RGN 260 / RGL 260

1

2

3

4

5

27

26

25

6

7

8

9

10

11

12

13

14

15

24

23

22

Seq. No. Designation

11

12

14

15

7

8

9

10

5

6

3

4

1

2

2

Combination electrode

Gas nozzle for -N with flow plate

Gas nozzle for -F with flow plate

Ignition cable with connector (black)

Ionisation cable with socket unit (red)

Ionisation cable with connector unit

Connector unit, 4-pin, green

Connector unit, 7-pin, black/brown

Connecting cable CG for T

Socket unit, 7-pin, green, with cable, 480 mm lg.

Socket unit, 11-pin, with cable for T

Cable gland G4 for ignition cable

Cable gland G6 for ionisation cable

Lower section, control box

Control unit DMG 970

15

16

16

17

18

19

20

Control unit DMG 972 for T

Air pressure switch DL2E

Air pressure switch DL2E forT

Motor 230 V / 50 Hz 250 W

Ignition transformer with connecting cable

Actuating drive STA 13 B0

Air flap

21

22

23

24

Burner cover

Fan wheel, dia. 180 x 74 mm

Housing with burner pipe

Intake silencer

25

26

Fastening unit

Sliding flange

27 Flange gasket

No illustr. Compact unit KE 20 ¾"

No illustr. Compact unit KE 20 ¾" with TC

No illustr. Compact unit KEV 20 ¾" for T

No illustr. Compact unit KEV 20 ¾" with TC for T

No illustr. Compact unit KE 25 1"

No illustr. Compact unit KE 25 1" with TC

No illustr. Compact unit KEV 25 1" for T

No illustr. Compact unit KEV 25 1" with TC for T

No illustr. Ball valve ¾"

No illustr. Ball valve 1"

No illustr. Gasket for gas union R¾"

No illustr. Seal for gas union R1"

21

20

19

18

17

PU

10

1

5

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

10

10

1

1

1

1

20

20

1

1

5

1

5

1

10

1

1

1

5

1

1

16

Order No.

37-50-20644

34-30-10558

34-30-10557

47-50-20113

44-30-20636

37-10-10935

37-50-11143

37-50-11015

47-20-20978

44-50-10897

37-20-11144

37-50-11971

47-50-10890

31-20-22393

47-10-22057

47-10-22232

47-10-22694

47-10-22885

33-10-10335

47-30-20927

47-10-22472

43-20-23298

34-20-10148

33-10-10590

34-30-10587

33-20-12009

32-50-11014

33-20-10681

33-50-10191

34-20-22776

34-20-22777

34-20-22778

34-20-22779

34-20-22780

34-20-22781

34-20-22782

34-20-22783

34-20-40602

34-20-40603

37-50-20109

37-50-20110

22

Service instructions/dimensions

Service instructions/dimensions

Service position

B

2

2

±0,5

±0,5

A

RG20

RG30

Zünd-

Risk of injury by fan wheel during activation in service position.

• Release quick-release locks and detach base plate.

• Suspend base plate with retaining buttons in cross recesses of housing.

Reference dimensions, ignition and ionisation electrodes

The ignition electrodes are preset at the factory. The dimensions are specified for checking purposes.

Dimension in mm

A

B

RGN 120

RGL 120

2

±0.5

3

±0.5

RGN 260

RGL 260

2

±0.5

3

±0.5

elektrode

23

Service instructions/dimensions

Measuring ionisation current

The ionisation current must be measured during burner start-up and maintenance or after a fault indication in the control box.

Measurement of ionisation current shortly after burner start during:

• Maintenance

• Start-up

• Fault indication.

The ionisation current can also be read out as a percentage via SatroPen.

To do so:

• Open plug connection between cable to control box and cable from ionisation electrode.

• Connect ammeter in series. Measuring range 0...200

µA DC.

l > 2 µA l < 2 µA

- OK

- Unsafe operation !

- Clean burner pipe

- Bend ionisation rod in flame area

- If necessary, replace combination electrode

- If necessary, reverse polarity on ignition transformer (induction current)

- Eliminate moisture and deposits.

Servicing air pressure monitor

• Detach silicone connecting hose and clean, check switching function.

• Replace air pressure monitor if switching function is no longer O.K.

To do so:

• Switch burner voltage-free and disconnect (7-pin connector X11).

• Unscrew cover.

• Disconnect electrical connectors.

• Release retaining screws on motor.

• Reassemble in reverse order.

"+" denotes the connecting point for pressure metering connection !

24

Wiring diagrams

Wiring diagram RGN 120 / RGL 120

Wiring diagram RGN 120T / RGL 120T

Service instructions/dimensions

Boiler control

Burner

Compact unit

Boiler control

Key to RGN(L) 120/120T:

AH

BH

High terminal A

High terminal B

Q1

S1

S4

CH

F11

F21

F22

F3

F4

F51

H11

H12

H13

M1

P11

P12

High terminal C

External fuse

External temp. controller

External temp. controller

2nd stage

Safety temperature limiter

Air pressure switch

Gas pressure switch

External pilot lamp

External pilot lamp

2nd stage

External fault signal lamp

Burner motor

External time meter

External time meter 2nd stage

Main heater switch

Control unit Satronic

DMG 972

Push-button external fault clearance

Switch 1st/2nd stage

Loop terminal S1

Loop terminal S2

Ignition transformer

S5

SK1

SK2

T3

X11,X31 Plug unit boiler control

X12, X32,X42 Socket unit burner

X41 Plug unit compact unit

X81,X82 Single-pin connector

Y1

Y3

Y4

Y11 block

Solenoid valve

Safety solenoid valve

Actuating drive

External output controller

Burner

Colour key: bl = blue br = brown gr = grey rs = pink rt = red sw = black vio = violet ws = white

Compact unit

25

Service instructions/dimensions

Wiring diagram RGN 260 / RGL 260

Wiring diagram RGN 260T / RGL 260T

Boiler control

Burner

Compact unit

Boiler control

Key to RGN(L) 260/260T:

AH

BH

High terminal A

High terminal B

F3

F4

F51

H11

H12

H13

M1

P11

P12

P21

Q1

S1

S4

CH

F11

F21

F22

High terminal C

External fuse

External temp. controller

External temp. controller

2nd stage

Safety temperature limiter

Air pressure switch

Gas pressure switch

External pilot lamp

External pilot lamp

2nd stage

External fault signal lamp

Burner motor

External time meter

External time meter 2nd stage

Time meter

1st stage (optional)

Main heater switch

Control unit Satronic

DMG 970 / 972

Push-button external fault clearance

Switch 1st/2nd stage

Loop terminal S1

Loop terminal S2

Ignition transformer

S5

SK1

SK2

T3

X11,X31 Plug unit boiler control

X12, X32,X42 Socket unit burner

X41 Plug unit compact unit

X81,X82 Single-pin connector block

Y1

Y3

Y4

Solenoid valve

Safety solenoid valve

Actuating drive

Burner

Colour key: bl = blue br = brown gr = grey rs = pink rt = red sw = black vio = violet ws = white

Compact unit

26

Service instructions/dimensions

Troubleshooting

Defect determined:

Burner motor does not start up

Burner starts up and switches to fault mode before or after expiry of safety period

Flame extinguishes during operation

Flash code

DMG 970 / 972

-

-

-

-

-

-

-

-

-

-

-

-

Burner motor starts up briefly. Control unit goes back to fault

Random error flash code

Control box resets automatically

Intermittent fault

(10 sec.)

Cause: Remedy:

Electric supply lead faulty

Fuse faulty

Safety thermostat locked

Temperature of controller setting is exceeded

Control box faulty

Leak

No gas

Gas pressure monitor faulty

Filter in compact unit dirty

Burner motor faulty

No load at terminal 5

Mains voltage < 187 V

Rectify faults in electrical installation

Replace

Unlock

Renewed start attempt after temperature drop

Replace

Rectify leak

Safeguard gas supply

Replace compact unit

Clean or replace

Replace

Check plug connection and current path of solenoid valve

Rectify faults in electrical installation

Solenoid valve leaking

See Page 24

Ionisation message

Air pressure monitor does not switch through during pre-ventilation

Ignition influencing of ionisation monitor

See Page 24

Gas solenoid valve does not open

Replace compact unit

Starting gas quantity set too low Increase starting gas quantity

No ignition Check ignition electrode and setting, ignition transformer and cable (see Page 23)

Phase and zero mixed up

Ionisation monitor faulty

Connect connector unit in correct phase sequence

Check according to Page 23/24

Air pressure switch switches during operation

See Page 24

Gas nozzle dirty or faulty

No gas

Filter in compact unit dirty

Flame blow-off

Air pressure monitor contact opens

Flame signal too weak

Control unit has not been cleared of fault

Air pressure switch not in idle position

Intermittent (1-5 sec.) gas pressure fluctuations trigger gas pressure monitor.

Replace gas nozzle

Safeguard gas supply

Clean or replace

Incorrect burner setting

(see Page 17 onwards)

Check/replace air pressure monitor

(see Page 24)

Measure flame signal, check ionisation electrode (see Page 23/24)

Clear control units of fault

Check air pressure switch

Safeguard gas supply. If necessary, lower starting point of gas pressure monitor.

27

Burner overall dimensions / boiler connection dimensions

(RGN260 dimensions in brackets)

All dimensions in mm

90°

M 8

70 -165

(130 -190 )

392- 452

(405 - 500)

344

(368)

Working ranges

5

RGL120

4

5

RGL260

3

2 2

1

4

3

1

0

4 0 6 0 8 0 1 0 0 1 2 0

B u r n e r c a p a c i t y [ k W ]

0

1 0 0 1 5 0 2 0 0 2 5 0 3 0 0

B u r n e r c a p a c i t y [ k W ]

DVGW-checked working ranges as per DIN EN 676.

d k f

Pipe outside dia.

Hole circle dia. k

Outside dia. f

RGN 120

RGL 120

102

RGN 260

RGL 260

130

170(140-180) 170-200

194 220

Enertech Limited,

P O Box 1,

Vines Lane

Droitwich,

Worcestershire,

WR9 8NA

Tel: +44 (0) 1905 794331 Fax: +44 (0) 1905 794017

Email: [email protected] Web: www.nu-way.co.uk