Transcript
Installation, use and maintenance instructions
Light oil burners
One stage operation
CODE
3571000 3572080 20062926
MODEL
RC2-38 RC2.1-46 RC2.1-46 TL
TYPE
732T3 732T6 732T6 2903445 (1) - 11/2012
INDEX 1. 1.1
BURNER DESCRIPTION. . . . . . . . . . . . . . Burner equipment . . . . . . . . . . . . . . . . . . . .
1 1
2. 2.1 2.2 2.3 2.4
TECHNICAL DATA . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . Overall dimensions . . . . . . . . . . . . . . . . . . . Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . .
2 2 2 2 3
3. 3.1 3.2 3.3 3.4 3.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . Working position . . . . . . . . . . . . . . . . . . . . . Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . Burner assembly. . . . . . . . . . . . . . . . . . . . . Hydraulic systems. . . . . . . . . . . . . . . . . . . . Electrical wiring. . . . . . . . . . . . . . . . . . . . . .
4 4 5 5 7 9
4.
WORKING . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.
BURNER DESCRIPTION
4.1 4.2 4.3 4.4 4.5 4.6 4.7
Combustion adjustment. . . . . . . . . . . . . . . . Nozzles recommended . . . . . . . . . . . . . . . . Pump pressure . . . . . . . . . . . . . . . . . . . . . . Maintenance position . . . . . . . . . . . . . . . . . Electrodes adjustment . . . . . . . . . . . . . . . . . Air adjustment . . . . . . . . . . . . . . . . . . . . . . . Burner start-up cycle . . . . . . . . . . . . . . . . . .
10 10 10 11 11 12 12
5. 5.1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 13 Access to the fan . . . . . . . . . . . . . . . . . . . . . 13
6.
FAULTS / SOLUTIONS . . . . . . . . . . . . . . . 14
7. 7.1 7.2
SAFETY WARNINGS . . . . . . . . . . . . . . . . . 15 Burner identification. . . . . . . . . . . . . . . . . . . 15 Basic safety rules . . . . . . . . . . . . . . . . . . . . 15
One stage light oil burner. Burner with CE marking in conformity with EEC Directives: EMC 2004/108/EC, LVD 2006/95/EC and Machinery Directive 2006/42/EC.
Fig. 1
7
6
12
11
9
10 5 8
3
4 D7000
2 1 2 3 4 5 6
– – – – – –
7 8 9 10 11 12
Return line Suction line Oil pump Gauge connection Pressure adjuster Control box
– – – – – –
1
Reset button with lock-out lamp Air adjustment knob Suction gauge connection Flange with insulating gasket Combustion head Feeder
1.1 BURNER EQUIPMENT Flexible oil pipes with nipples . . . . . . No. 2
Nut and pin . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange with insulating gasket. . . . . . . No. 1 3445
1
2.
TECHNICAL DATA
2.1 TECHNICAL DATA TYPE Output Thermal power
732T3
732T6
2.0 3.2 kg/h 24 38 kW
2.8 3.9 kg/h 33,2 46,2 kW
Light oil, viscosity 4 6 mm2/s at 20°C
Fuel Electrical supply
Single phase,
Motor
~ 50Hz
Run current 0.75A –
(Hi = 11.86 kWh/kg)
230V ± 10%
2800 rpm
– 294 rad/s
4,5 F
Capacitor Ignition transformer
Secondary 8 kV –
16 mA
Pressure: 7 15 bar
Pump Absorbed electrical power
0,115 kW
2.2 OVERALL DIMENSIONS 120
A 109
146
191
130 150
D7010
D7001
BURNER CODE 3571000 - 3572080 20062926
A 109 177
2.3 FIRING RATES, (as EN 267) VERSION WITHOUT BAFFLE PLATE CF - BF
Pressure in combustion chamber – mbar
3
2
1 732T3
0 22 D8792
24 2
26
28
30 2.5
32
34
36
38
3
40 kW kg/h
3445
2
256
85 183
75
45
°
11
72
45
°
180
VERSION WITH BAFFLE PLATE CF - BF
Pressure in combustion chamber – mbar
4
3
2
732T3
732T6
1
0 22 D8793
2.4
24
26
28
2
30 2.5
32
34
36 3
38
40
42
44
46
48 4
3.5
kW kg/h
ACCESSORIES
Fig. 2
BF AIR INTAKE In case of BF application, air is fed in through a flexible or rigid pipe connected to the air intake (A, fig. 5, page 4). This component is supplied separately. To install this fitting, you must: remove the knob unit (1) from the burner by unscrewing the two screws (2), see fig. 2; apply the O-ring (4) to the air intake (3) as illustrated in figure 3; place the air intake (3) horizontally against the feeder (5), making sure you pull the locking device (6, fig. 5, page 4); turn clockwise to fasten the air intake (3) to the burner and release the locking device (6). The air intake can be turned to meet installation needs, as illustrated in figure 4. To adjust, you must pull the locking device (6, fig. 5, page 4) and turn the air intake until you are happy with the position.
2
5
1 2 D7014
9
Fig. 3
4 Fig. 4
3
D7005
3
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To adjust delivery, proceed as follows: loosen screw (7) and adjust the ring (8), turning it to the desired setting; secure in place by tightening screw (7) with a driving torque of 0.8 Nm.
Fig. 5
A
8
7 6 D7011
BAFFLE PLATE (see fig. 6) The baffle plate is installed whenever the burner’s purging performance needs increasing. This component is supplied separately. To install this fitting, you must: unscrew the three screws (9, fig. 2 page 3) and remove the air adjustment unit (5); apply the baffle plate (10) by means of the two screws (11), screwing it on with a driving torque of 0.8 Nm; follow the above procedure in the reverse order, restoring the feeder (5) to its original position, tightening the two screws (9) with a driving torque not exceeding 0.8 Nm; make extra sure you position the O-ring (12) correctly.
3.
Fig. 6
5 12 11
10 D7013
INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 WORKING POSITION (CF and BF version) The burner is designed to work only in the positions 1, 2 and 3. Any other position could compromise the correct working of the appliance. Installations 4 and 5 are forbidden for safety reasons.
1
2
3
4
5
D7003
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3.2 BOILER FIXING
Secure the flange to the burner as follows: fit the screw and the two nuts (see fig. 7) on the flange (1). Widen, if necessary, the insulating gasket holes (2,fig. 8), taking care not to damage them. Fix the flange (1) to the boiler door (5, fig. 9) interposing the insulating gasket (2), using the screws (3) and (if necessary) the nuts (4). Fig. 7
4 2
Fig. 9
1 1
3
E9238
Fig. 8
3
5
2 D5012 E9239
3.3 BURNER ASSEMBLY A
CF APPLICATIONS In the case of CF application, combustion air is fed through the feeder unit (A).
BF APPLICATIONS In the case of BF application, combustion air is fed through a flexible or rigid pipe connected to the air intake (B).
D7015
FOR CORRECT BF APPLICATION, THE BURNER MUST BE INSTALLED ON AN APPROPRIATE BF BOILER. Consequently, you must comply with the following requirements and instructions: The combustion air intake tube must be: - fastened securely to the burner; - made of a suitable material, with temperature characteristics in the range - 30 °C to 80 °C; - in compliance with all requirements of applicable regulations in force in the country of destination.
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S7011
B
The intake-tube / burner system must not allow a loss of over 2 m 3/h at 0.5mbar: for instance, the above requirements will be met if you use flues for pressure exhaust of flue gases (the condensation kind). Make sure the air intake tube’s inlet is positioned so that it is not likely to be obstructed by foreign matter and, where necessary, use suitable screens. The temperature of the incoming air must not exceed 40 °C; The inside diameter of the hose must be at least 80 mm. The intake tube can be up to 6 metres in length. Warning: length is reduced if there are bends in the intake section. For instance, using a tube with a smooth inside surface, you must allow for the following losses: - for each 45° bend, tube length is reduced by 0.5 m; - for each 90° bend, tube length is reduced by 0.8 m.
BURNER INSTALLATION MUST COMPLY WITH ONE OF THE INSTALLATIONS ILLUSTRATED IN THE FIGURES BELOW. ATTENTION
Under no circumstances should the air’s entry in the hose intake area be obstructed. The hose must not be blocked in any way or feature a shutting device (valves, membranes etc.). Coaxial tubes must not be installed for any reason.
S7853 S7851 S7876
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3.4 HYDRAULIC SYSTEMS
Fig. 10
8
It is necessary to install a filter on the fuel supply line.
7
PUMP (see fig. 10)
The pump is designed to allow working with two pipes. Before starting the burner make sure that the return pipe-line is not clogged. An excessive back pressure (1 bar) would cause the damage of the pump seal, with subsequent fuel leaks inside the burner. In order to obtain one pipe working it is necessary to unscrew the return plug (2), remove the by-pass screw (3) and then screw again the plug (2) with a torque of 0.5 Nm.
5
6 4
The pump has a delivery pressure regulation device (5). Pressure increases if turned in a clockwise direction, and decreases if turned in the other direction. An indication of sensitivity is 1 bar per turn. The pressure can be regulated in a range of 7 15 bar. Do not loosen the knob (8) and periodically check that it is firmly fixed, for safety reasons.
3 1
2 D5912
1 2 3 4 5 6 7 8
PRESSURISED ONE PIPE SYSTEMS (fig. 11 and 12) Pressurised systems have a positive fuel pressure on intake to the burner. Usually the tank is higher than the burner, or the fuel pumping systems are on the outside of the boiler. Figure 12 is an example of connection to a pressurised ring, no matter what position the ring feeder tank is in.
- Suction line - Return line - By-pass screw - Gauge connection - Pressure adjuster - Suction gauge connection - Valve - Knob
SYSTEM NOT PERMITTED IN GERMANY
Fig. 12 H meters
H
max. 4 m
Fig. 11
0.5 1 1.5 2
L meters I. D. I. D. 8 mm 10 mm 10 20 40 60
20 40 80 100
D7007
D7006
ONLY FOR ITALY: Automatic shut-off device as per Ministry of Internal Affairs’ regulation no. 73 dated 7/29/71. The installer must ensure that the supply pressure is not above 0.5 bar. Above that level, the pump seal is subject to too much stress. H = difference of level;
L = max. length of the suction line;
I. D. = internal diameter of the oil pipes.
In the system in fig. 11, the table shows the maximum indicated lengths for the supply line, depending on the difference in level, length and the diameter of the oil pipes.
PRIMING PUMP it is sufficient to loosen the suction gauge connection (6, fig. 10) and wait until oil flows out.
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DEPRESSURISED SYSTEMS (fig. 13 and 14) Depressurised systems have a negative fuel pressure (depression) on intake to the burner. Usually the tank is lower than the burner. TWO PIPE SYSTEM
Fig. 14
H
max. 4 m
Fig. 13
max. 4 m
H
ONE PIPE SYSTEM
H
H
D7008
ONLY FOR ITALY: Automatic shut-off device as per Ministry of Internal Affairs’ regulation no. 73 dated 7/29/71.
The installer must ensure that the supply depression is not above 0.4 bar (30 cm Hg). Above that level, gas leaks out from the fuel. The pipes must all be perfectly sealed. H = difference of level; L = max. length of the suction line; I. D. = internal diameter of the oil pipes.
H meters 0 0.5 1 1.5 2 3 3.5
L meters I. D. I. D. 8 mm 10 mm 35 30 25 20 15 8 6
100 100 100 90 70 30 20
In the systems in figs. 13 and 14, the table shows the maximum indicated lengths for the supply line, depending on the difference in level, length and the diameter of the oil pipes.
PRIMING PUMP On the systems in fig. 13 and 14 start the burner and wait for the priming. Should lock-out occur prior to the arrival of the fuel, await at least 20 seconds before repeating the operation. In two pipe vacuum systems (fig. 14) the return line should terminate within the oil tank at the same level as the suction line. In this case a non-return valve is not required. Should however the return line arrive over the fuel level, a non-return valve is required. This solution however is less safe than previous one, due to the possibility of leakage of the valve.
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3.5 ELECTRICAL WIRING
230V N
~
WARNING DO NOT EXCHANGE NEUTRAL WITH PHASE
50Hz L
NOTES: – Wires of min. 1 mm2 section. (Unless requested otherwise by local standards and legislation). – The electrical wiring carried out by the installer must be in compliance with the rules in force in the Country.
Main switch
Neutral
T6A
N
4
5
6
Blue
Oil valve
Brown Black
Black Capacitor
7
8
9
Brown
3
L
White (50V)
2
Limit thermostat
T
Safety thermostat
Remote lock-out signal (230V - 0.5A max.), if required
Blue
1
T
Terminal block of control-box 530SE
*
CARRIED-OUT IN THE FACTORY CARRIED-OUT BY THE INSTALLER
TESTING Check the shut-down of the burner by opening the thermostats.
M
~ Motor D5228
ACCESS TO THE PHOTORESISTANCE (see fig. 16)
CONTROL BOX (fig. 15) To remove the control box from the burner, loosen screw (A) and pull to the arrow direction. Run of the electrical cable: 1 - Terminal block N - Neutral - Lock-out signal L - Phase - Burner-earth
The photoresistance (A) is fitted directly into the control-box, underneath the ignition-transformer (B), on a plug-in support. Fig. 15
Fig. 16
B
A S7701
A
1
S7057
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4.
WORKING
4.1 COMBUSTION ADJUSTMENT
The values shown in the table are measured on a CEN boiler (as per EN 267), if they refer to 12.5% CO2 at sea level (1013 hPA) and with light oil and room temperature of 20°C, and combustion chamber pressure of 0 mbar. WARNING: Combustion air is drawn in from outside, meaning there may be notable changes in temperature, which can affect the percentage of CO2. You are advised to adjust CO2 in accordance with the graph featured. E.g.: outside air temperature 20 °C, adjust CO2 to 12% (± 0.2%).
% CO2
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, fit the nozzle then adjust the pump pressure and the air adjustment, in accordance with the following schedule.
°C
VERSION WITH BAFFLE PLATE
732T6
TYPE
Nozzle
Pump pressure CF
BF
Burner output CF
Head pressure
Air adjustment
BF
CF Feeder
BF Knob
Feeder
CF
Regulator
BF
GPH
Angle
bar
kg/h ± 4%
mbar
0.75
60°W
11
2.9
4
1
4
1.25
1.5
1.6
0.85
60°W
12
3.4
4
1.5
4
2.5
1.8
1.9
1.00
60°W
12
4.0
4
4
2
5
2.5
2.6
Set-point Set-point Set-point Set-point
VERSION WITHOUT BAFFLE PLATE
732T3
TYPE
Nozzle
Pump pressure CF
BF
Burner output CF
Head pressure
Air adjustment
BF
CF Feeder
BF Knob
Feeder
CF
Regulator
BF
GPH
Angle
bar
kg/h ± 4%
0.50
60°W
14
2.2
1
1.6
1
2.2
1.4
1.5
0.60
60°W
12
2.4
1
2.6
1
3
1.7
1.7
0.65
60°W
12
2.6
1
3.5
1
4.3
2.1
2.1
0.75
60°W
12
3.0
1
4.4
1
5.8
2.4
2.4
0.75
60°W
14
3.3
1
5.7
1
10
3.0
2.7
4.2 NOZZLES RECOMMENDED Delavan type W; Steinen type Q; Angle:
mbar
Set-point Set-point Set-point Set-point
Hago type SS; Danfoss type S.
60° - In most cases. 80° - In case of flame detachment, during ignitions at low temperatures.
4.3 PUMP PRESSURE 12 bar: The pump leaves the factory set at this value. 14 bar: Improves flame retention; it is therefore suitable for ignitions at low temperatures.
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4.4 MAINTENANCE POSITION
Fig. 17
Remove the flange-fixing nut and pull out the burner. Place the burner on a horizontal surface as illustrated in figure 17. Loosen the two screws (1) and remove the blast tube (2). Remove the diffuser disc assembly (3) from the nozzle-holder assembly, loosening the screw (3, fig. 18) first. Screw the nozzle (4) on, holding it as illustrated in figure 17. Refit following the above procedure in the reverse order.
2
3 4
4.5 ELECTRODES ADJUSTMENT To reach the electrodes, proceed as described in chapter “4.4 MAINTENANCE POSITION”.
1
ATTENTION Electrode position A is not adjustable. If there is a problem, make sure the distances are as recommended.
E9237
For other adjustments, proceed as follows: Place the diffuser disc assembly (1) against the nozzle holder (2), and secure in place with the screw (3). Fine adjustment is achieved by loosening screw (4) and moving the electrodes (5).
Fig. 18
A
5
0
4
4.5 – 0.5 mm
3
2
D7009
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11
1
+ 0.2
2 – 0.2 mm
4.6 AIR ADJUSTMENT, (fig. 19)
Fig. 19
Depending on burner output, air must be adjusted by turning the feeder (2) first, followed by the knob (3). FEEDER ADJUSTMENT To adjust, proceed as follows: Loosen the three screws (1). Turn the feeder (2), positioning it according to the values given in the table on page 10. Tighten the three screws (1) with a driving torque not exceeding 0.8 Nm. Warning It is essential you make sure the feeder is screwed on sufficiently tightly to avoid de-setting the burner while it is in operation.
1
2
1
3 1 D7004
KNOB ADJUSTMENT
This is done by turning the knob (3). Turning clockwise limits the cross-section of the air passage area and increases CO2 value. The opposite occurs when turned anticlockwise. Adjustments in the table on page 10 are given as an approximate guide only. Each system features operating conditions that cannot be known in advance: actual nozzle delivery, pressure or vacuum in the combustion chamber, necessary excess air etc... All these conditions may call for a different air setting. ATTENTION
Under no circumstances should the air's entry in the knob area (3, fig. 19) be obstructed. Placing fingers or tools of any kind inside the knob’s intake opening (3, fig. 19) is prohibited. Check the position of the feeder and knob as indicated in the table on page 10. Check the Bacharach device and CO2.
4.7 BURNER START-UP CYCLE
Thermostat Motor Ignition transformer Valve Flame Lock-out lamp
Normal
Lock-out, due to light-failure
~ 12s
~ 12s
~ 5s D5229
3445
12
5.
MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity with legislation and local standards. Periodic 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:
Check that there are no obstructions or bends in the supply or return oil pipes, in the air intake pipes and the combustion product discharge tubes. Clean the filter in the oil suction line and in the pump. Clean the photoresistance (see fig. 16, page 9). Check for correct fuel consumption. Replace the nozzle (4, fig. 17, page 11) and check the correct position of electrodes (fig. 18, page 11). Clean the combustion head in the fuel exit area. Leave the burner working without interruptions for 10 min. and set rightly all the components stated in this manual. Then carry out a combustion check verifying: Smoke temperature at the chimney; Content of CO 2 ( % ); Content of CO (ppm); Smoke value according to opacity smokes index according to Bacharach scale.
5.1
ACCESS TO THE FAN, (see Fig. 20)
Fig. 20
IMPORTANT Perform maintenance work only when strictly necessary, taking great care not to damage or unbalance the fan during cleaning. Take careful note of the original position before beginning any of these operations.
Proceed as follows: Unscrew the three screws (1) and remove the air adjustment unit (2). At this point, you can clean the fan: vacuum up any impurities, taking care they do not enter the air circuit. Refit following the above procedure in the reverse order, restoring the air adjustment unit (2) to its original position and being extra careful to ensure that the Oring (12, fig. 6, page 3) is positioned correctly. Tighten the three screws (1) with a driving torque not exceeding 0.8 Nm.
1
3445
13
2
1
3 1 D7004
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 (7, 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.
FAULTS
POSSIBLE CAUSES
SOLUTION Check that safety thermostat is not lock out. Check that the limit thermostat is not broken.
The burner doesn’t start when the limit thermostat closes.
The burner stays in pre-purging.
Electricity power failure.
Check the L-N terminals are powered in the command and control equipment. Faulty command and control equipment: replace.
Faulty resistance.
The red led on the command and control equipment is off, check the resistance and replace if necessary.
The photo-electric cell perceives external light.
Eliminate the source of light.
The photo-electric cell is in short-circuit.
Replace the photoelectric cell. No fuel: check the supply line, dirty filter.
The burner pre-purges and locks out without forming the flame.
The ignition electrodes are not correctly regulated, adjust according to the instruction manual. The flame does not form.
Missing or irregular electric ignition arc, replace the command and control equipment. Inadequate, dirty or worn nozzle: replace. The valve does not excite: replace the coil or the command and control equipment.
The burner performs pre-purging and ignition cycle but locks out within the safety limit.
The photo-electric cell does not perceive the flame.
Clean or replace.
The photo-electric cell does not perceive the flame well enough.
Clean or replace. Correctly adjust the air/fuel ratio (CO 2).
The burner continues recycling.
Inadequate, dirty or worn nozzle: replace. The valve does not remain excited: replace the command and control equipment, the coil or the pump valve.
The flame detaches.
Dirty filters: clean or replace. Burner starts with firing delay.
The ignition electrodes are incorrectly set. The air/fuel ratio is incorrect.
Adjust according to the instruction manual. Correclty adjust the air/fuel ratio (CO 2). Inadequate, dirty or worn nozzle: replace.
WARNING The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error in installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the technical instruction enclosed with the burner, or due to the intervention of unqualified personnel. 3445
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7.
WARNINGS AND SAFETY
The dimension of the boiler’s combustion chamber must respond to specific values, in order to guarantee a combustion with the lowest polluting emissions rate. You are therefore advised to consult the Technical Assistance Department before choosing this type of burner for the combination with a boiler. Qualified personnel are those with the professional and technical requirements indicated by law no. 46 dated March 5, 1990 n° 46. The commercial organisation has a widespread network of agencies and technical offices whose personnel participates periodically in instructional and refresher courses at the company training centre. This burner must only be used for the purposes it has specifically been designed for. All contractual and other liability on the part of the manufacturer is excluded for injury caused to people, animals or damage caused to property due to faulty installation, calibration, adjustment, maintenance or improper use.
7.1
BURNER IDENTIFICATION
The Identification Plate on the product gives the serial number, model and main technical and performance data. If the Identification Plate is tampered with, removed or missing, the product cannot be clearly identified thus making any installation or maintenance work potentially dangerous.
7.2
BASIC SAFETY MEASURES
Children or inexpert persons must not use the appliance. Under no circumstances must the intake grids, dissipation grids and ventilation vents in the installation room be covered up with cloths, paper or any other material. Unauthorised persons must not attempt to repair the appliance. It is dangerous to pull or twist the electric leads. Cleaning operations must not be performed if the appliance is not disconnected from the main power supply. Do not clean the burner or its parts with inflammable substances (e.g. petrol, alcohol, etc.). The cover must be cleaned with soapy water. Do not place anything on the burner. Do not block or reduce the size of the ventilation vents in the installation room. Do not leave containers and inflammable products in the installation room.
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RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.rielloburners.com
Subject to modifications
