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MODEL | RS 190 | |||
CODE | 3785813 20030087 | |||
OUTPUT(1) | 2nd stage | kW | 1279 - 2290 1100 - 1970 | |
Mcal/h | ||||
min. 1st stage | kW | 470 405 | ||
Mcal/h | ||||
FUEL | NATURAL GAS: G20 - G21 - G22 - G23 - G25 | |||
G20 | G25 | |||
| kWh/Sm3 Mcal/Sm3 | 9.45 8.2 | 8.13 7.0 | |
| kg/Sm3 | 0.71 | 0.78 | |
| Sm3/h | 230 | 267 | |
| mbar | 15 | 22 | |
OPERATION |
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STANDARD APPLICATIONS | Boilers: water, steam, diathermic oil | |||
AMBIENT TEMPERATUR | °C | 0 - 40 | ||
COMBUSTION AIR TEMPERATURE | °C max | 60 | ||
IN CONFORMITY WITH DIRECTIVES | 2009/142 - 2006/42 - 2014/35 - 2014/30 | |||
NOISE LEVELS(3) | Sound pressure Sound power | dBA | 83.1 94.1 | |
APPROVAL | CE | 0085AT0042 |
Motor IE3
MODEL | RS 190 | |
MAIN ELECTRICAL SUPPLY | 3 ~ 400V +/-10% 50Hz | |
AUXILIARY CIRCUIT ELECTRICAL SUPPLY | 1N ~ 230V +/-10% 50Hz | |
ELECTRIC MOTOR | rpm W V A | 2900 4500 400 8.7 |
IGNITION TRANSFORMER | V1 - V2 I1 - I2 | 230 V - 1 x 8 kV 1 A - 20 mA |
ELECTRICAL POWER CONSUMPTION | W max | 5500 |
ELECTRICAL PROTECTION | IP 44 |
GAS CATEGORY
COUNTRY | CATEGORY |
IT - AT - GR - DK - FI - SE ES - GB - IE - PT NL FR DE BE LU - PL | II2H3B/P II2H3P I2L - I2E - I2 (43.46 ÷ 45.3 MJ/m3 (0°C)) II2Er3P II2ELL3B/P I2E(R)B, I3P II2E 3B/P |
VARIANTS
Model | Code | Power supply electrical |
RS 190 | 3785813 | 400 V |
RS 190 | 20030087 | 400 V |
Two types of burner failure may occur:
The weight of the burner complete with packaging is indicated in Table.
Approximate measurements.
The maximum dimensions of the burner are given in (C).
Bear in mind that inspection of the combustion head requires the burner to be opened by withdrawing the rear part on the slide bars.
The maximum dimension of the burner when open is give by measurement I.
1 - Gas train flange
1 - Flange gasket
6 - Flange fixing screws M 10 x 30
1 - Thermal insulation screen
4 - Screws to secure the burner flange to the boiler: M 12 x 35
1 - Instruction booklet
1 - Spare parts list
The RS 190 model burner can work in two way: one-stage and two-stage.
MAXIMUM OUTPUT must be selected in area A.
MINIMUM OUTPUT must not be lower than the minimum limit shown in the diagram.
RS 190 = 470 kW
The FIRING RATE area values have been obtained considering a surrounding temperature of 20°C, and an atmospheric pressure of 1013 mbar (approx. 0 m above sea level) and with the combustion head adjusted.
The firing rates were set in relation to special test boilers, according to EN 676 regulations. Figure (B) indicates the diameter and length of the test combustion chamber.
Example:
Output 756 kW:
diameter = 60 cm; length = 2 m.
The burner/boiler combination does not pose any problems if the boiler is CE type-approved and its combustion chamber dimensions are similar to those indicated in diagram (B).
If the burner must be combined with a commercial boiler that has not been CE type-approved and/or its combustion chamber dimensions are clearly smaller than those indicated in diagram (B), consult the manufacturer.
The adjacent table shows minimum pressure losses along the gas supply line depending on the burner output in 2nd stage operation.
Pressure loss at combustion head.
Gas pressure measured at test point 1)(B), with:
The heat output and gas pressure in the head data refer to operating with the gas butterfly valve fully open (90°).
The values shown in the table refer to: natural gas G 20 NCV 9.45 kWh/Sm3 (8.2 Mcal/Sm3).
Calculate the approximate 2nd stage output of the burner thus:
Example:
A 2nd stage output of 1617 kW shown in Table (A) corresponds to 11.6 mbar pressure.
This value serves as a rough guide, the effective delivery must be measured at the gas meter.
To calculate the required gas pressure at test point 1)(B), set the output required from the burner in 2nd stage operation:
Example:
Drill the combustion chamber locking plate as shown in (A). The position of the threaded holes can be marked using the thermal screen supplied with the burner.
The length of the blast tube must be selected according to the indications provided by the manufacturer of the boiler, and in any case it must be greater than the thickness of the boiler door complete with its fettling.
For boilers with front flue passes 15) or flame inversion chambers, protective fettling in refractory material 13) must be inserted between the boiler fettling 14) and the blast tube 12).
This protective fettling must not compromise the extraction of the blast tube.
For boilers having a water-cooled front the refractory fettling 13)-14)(B) is not required unless it is expressly requested by the boiler manufacturer.
(B)
Before securing the burner to the boiler, check through the blast tube opening to make sure that the flame sensor probe and the ignition electrode are correctly set in position, as shown in (C).
Now detach the combustion head from the burner, fig.(B):
Secure the flange 11)(B) to the boiler plate, interposing the thermal insulating screen 9)(B) supplied with the burner. Use the 4 screws, also supplied with the unit, after first protecting the thread with an anti-locking product.
The seal between burner and boiler must be airtight.
If you noticed any irregularities in positions of the probe or ignition electrode during the check mentioned above, remove screw 1)(D), extract the internal part 2)(D) of the head and proceed to set up the two components correctly.
Do not attempt to turn the probe. Leave it in the position shown in (C) since if it is located too close to the ignition electrode the control box amplifier may be damaged.
Installation operations are now at the stage where the blast tube and sleeve are secured to the boiler as shown in fig. (B). It is now a very simple matter to set up the combustion head, as this depends solely on the output developed by the burner in 2nd stage operation.
It is therefore essential to establish this value before proceeding to set up the combustion head.
There are two adjustments to make on the head.
Air adjustment (B) See diagram (C).
Turn screw 4)(B) until the notch identified is aligned with the front surface 5)(B) of the flange.
Gas adjustment (A)
When the burner is installed for an output in 2nd stage ≤ 1300 Mcal/h (about 1500 kW) assemble the supplied disks 1)-2)(A) removing the inner pipe 3)(A). If there is little gas in the network, the head may be left in standard configuration, limiting the minimum modulation to 450 Mcal/h (circa 520 kW).
Example
Burner output = 1593 kW (1370 Mcal/h). If we consult diagram (C) we find that for this output, air must be adjusted using notch 3, as shown in fig. (B).
Continuing with the previous example, in the section "GAS PRESSURE" indicates that for burner with output of 1593 kW (1370 Mcal/h) a pressure of approximately 8 mbar is necessary at test point 6)(B).
Once you have finished setting up the head, refit the burner to the slide bars 3)(D) at approximately 100 mm from the sleeve 4)(D) - burner positioned as shown in fig. (B) in the section "BLAST TUBE LENGTH" - insert the flame detection probe cable and the ignition electrode cable and then slide the burner up to the sleeve so that it is positioned as shown in fig. (D).
Refit screws 2) on slide bars 3). Secure the burner to the sleeve by tightening screw 1).
Reconnect the articulation 7) to the graduated sector 6).
When fitting the burner on the two slide bars, it is advisable to gently draw out the high tension cable and flame detection probe cable until they are slightly stretched.
Explosion danger due to fuel leaks in the presence of a flammable source.
Precautions: avoid knocking, attrition, sparks and heat.
Make sure that the fuel interception tap is closed before performing any operation on the burner.
The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws.
KEY (A)-(B)-(C)-(D)
See the accompanying instructions for the adjustment of the gas train.
Use flexible cables according to EN 60 335-1 Regulations:
All the wires to connect to the burner terminal strip 9)(A) must enter through the supplied fairleads.
The fairleads and hole press-outs can be used in various ways; the following lists show one possible solution:
N.B.
The RS 190 burner has been type- approved for intermittent operation. This means it shoulds compulsorily be stopped at least once every 24 hours to enable the control box to perform checks of its own efficiency at start-up. Burner halts are normally provided for automatically by the boiler load control system.
If this is not the case, a time switch should be fitted in series to IN to provide for burner shutdown at least once every 24 hours.
The RS 190 burner is factory set for two-stage operation and must therefore be connected to control device TR.
Alternatively, if single stage operation is required, instead of control device TR install a jumper lead between terminals 6 and 7 of the terminal strip.
ATTENTION
In the case of phase-phase feed, a bridge must be fitted on the control box terminal strip between terminal 6 and the earth terminal.
ATTENTION
Do not invert the neutral with the phase wire in the electricity supply line. Inverting the wires will make the burner go into lock-out because of firing failure.
Adjustment of the combustion head, and air and gas deliveries has been illustrated in the section "SETTING THE COMBUSTION HEAD". In addition, the following adjustments must also be made:
Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e. with gas delivery at the minimum.
The servomotor provides simultaneous adjustment of the air gate valve, by means of the variable profile cam, and the gas butterfly valve. The servomotor rotates through 130 degrees in 15 seconds.
Do not alter the factory setting for the 4 levers; simply check that they are set as indicated below:
Cam I: 130°
Limits rotation toward maximum position. When the burner is in 2nd stage operation the gas butterfly valve must be fully open: 90°.
Cam II: 0°
Limits rotation toward the minimum position. When the burner is shut down the air gate valve and the gas butterfly valve must be closed: 0°.
Cam III: 15°
Adjusts the ignition position and the output in 1st stage operation.
Cam V: 125°
Not used.
Refer to paragraph "Safety test - with gas ball valve closed" before the first start-up.
Close the control devices and set:
As soon as the burner starts check the direction of rotation of the fan blade, looking through the flame inspection window 14)(A) in the section "BURNER DESCRIPTION".
Make sure that the lamps or testers connected to the solenoids, or pilot lights on the solenoids themselves, indicate that no voltage is present. If voltage is present, then immediately stop the burner and check electrical connections.
Having completed the checks indicated in the previous heading, the burner should fire. If the motor starts but the flame does not appear and the control box goes into lock-out, reset and wait for a new firing attempt.
If firing is still not achieved, it may be that gas is not reaching the combustion head within the safety time period of 3 seconds.
In this case increase gas firing delivery.
The arrival of gas at the sleeve is indicated by the U-type manometer (C).
Once the burner has fired, now proceed with global calibration operations.
The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet.
Adjust successively:
According to EN 676 Regulations:
Burners with max. output up to 120 kW
Firing can be performed at the maximum operation output level. Example:
Burners with max. output above 120 kW
Firing must be performed at a lower output than the max. operation output. If the firing output does not exceed 120 kW, no calculations are required. If firing output exceeds 120 kW, the regulations prescribe that the value be defined according to the control box safety time "ts":
Example: MAX operation output of 600 kW. Firing output must be equal to or lower than:
In order to measure the firing output:
Example: for gas G 20 (9.45 kWh/Sm3):
Max. operation output: 600 kW corresponding to 63.5 Sm3/h.
After 10 firings with lock-outs, the delivery read on the meter must be equal to or lower than:
63.5: 360 = 0,176 Sm3
2nd stage output of the burner must be set within the firing rate range.
In the above instructions we left the burner running in 1st stage operation. Now set switch 2)(A) to the 2nd stage position: the servomotor will open, simultaneously, the air gate valve and the gas butterfly valve to 90°.
Gas calibration
Measure the gas delivery at the meter.
A guideline indication can be calculated from the tables in the section "GAS PRESSURE", simply read off the gas pressure on the U-type manometer, and follow the instructions in the section "GAS PRESSURE".
Adjusting air delivery
Progressively adjust the end profile of cam 4)(A) by turning the screws 7).
Burner power in 1st stage operation must be selected within the firing rate range.
Set the switch 2)(A) in the section "AIR PRESSURE SWITCH" to the 1st stage position: the servomotor 1)(A) will close the air gate valve and, at the same time, closes the gas butterfly valve down to 15°, i.e. down to the original factory setting.
Adjusting gas delivery
Measure the delivery of gas from the gas meter.
Note
The servomotor follows the adjustment of the orange lever only when the angle is reduced. If, however the angle must be increased, switch to 2nd stage operation, increase the angle and then return to 1st stage operation to check the effect of the adjustment.
In order to adjust cam III, especially for fine movements, the key 10)(B), held by a magnet under the servomotor, can be used.
Adjustment of air delivery
Progressively adjust the starting profile of cam 4)(A) by turning the screws 5). It is preferable not to turn the first screw since this is used to set the air gate valve to its fully-closed position.
Adjustment of gas delivery
No adjustment of gas delivery is required.
Adjustment of air delivery
Switch off the burner using switch 1)(A) in the section "AIR PRESSURE SWITCH", disengage the cam 4)(A) from the servomotor, by pressing the button 3)(B) and moving it to the right, and check more than once that the movement is soft and smooth, and does not grip, by rotating the cam 4) forward and backward by hand.
Engage the cam 4) to the servomotor again by moving the button 2)(B) to the left.
As far as is possible, try not to move those screws at the ends of the cam that were previously adjusted for 1st and 2nd stage air gate valve control.
Finally fix the adjustment by turning the screws 6)(A).
Note
Once you have finished adjusting outputs 2ND STAGE - 1ST STAGE - INTERMEDIATE, check ignition once again: noise emission at this stage must be identical to the following stage of operation.
If you notice any sign of pulsations, reduce the ignition stage delivery.
AIR PRESSURE SWITCH 15)(A) in the section "BURNER DESCRIPTION"
Adjust the air pressure switch after having performed all other burner adjustments with the air pressure switch set to the start of the scale (A). With the burner operating in 1st stage, increase adjustment pressure by slowly turning the relative knob clockwise until the burner locks out.
Then turn the knob anti-clockwise by about 20% of the set point and repeat burner starting to ensure it is correct.
If the burner locks out again, turn the knob anticlockwise a little bit more.
Attention
As a rule, the air pressure switch must limit the CO in the fumes to less than 1% (10,000 ppm). To check this, insert a combustion analyser into the chimney, slowly close the fan suction inlet (for example with cardboard) and check that the burner locks out, before the CO in the fumes exceeds 1%.
The air pressure switch may operate in "differential" operation in two pipe system. If a negative pressure in the combustion chamber during pre-purging prevents the air pressure switch from switching, switching may be obtained by fitting a second pipe between the air pressure switch and the suction inlet of the fan. In such a manner the air pressure switch operates as differenzial pressure switch.
The use of the air pressure switch with differential operation is allowed only in industrial applications and where rules enable the air pressure switch to control only fan operation without any reference to CO limit.
MIN GAS PRESSURE SWITCH (A) in the section "ADJUSTMENTS BEFORE FIRST FIRING"
The purpose of the minimum gas pressure switch is to prevent the burner from operating in an unsuitable way due to too low gas pressure.
Adjust the minimum gas pressure switch (B) after having adjusted the burner, the gas valves and the gas train stabiliser. With the burner operating at maximum output:
1 kPa = 10 mbar
The burner is fitted with an ionisation system which ensures that a flame is present. The minimum current for plant operation is 5 µA.
The burner provides a much higher current, so that controls are not normally required. However, if it is necessary to measure the ionisation current, disconnect the plug-socket 6)(A) in the section "BURNER DESCRIPTION" on the ionisation probe cable and insert a direct current microamperometer with a base scale of 100 µA.
Carefully check polarities!
BURNER STARTING (A)
STEADY STATE OPERATION (A)
System equipped with one control device TR. Once the starting cycle has come to an end, control of the servomotor passes on to the control device TR that controls boiler temperature or pressure, point D.
(The control box will continue, however, to monitor flame presence and the correct position of the air pressure switch).
Systems not equipped with control device TR (jumper wire installed)
The burner is fired as described in the case above. If the temperature or pressure increase until control device TL opens, the burner shuts down (Section A-A in the diagram).
FIRING FAILURE (B)
If the burner does not fire, it goes into lock-out within 3 s of the opening of the gas solenoid valve and 49 s after the closing of control device TL. The control box red pilot light will light up.
BURNER FLAME GOES OUT DURING OPERATION
If the flame should accidentally go out during operation, the burner will lock out within 1s.
(with burner running)
the burner must lock out
Combustion
The optimum calibration of the burner requires an analysis of the flue gases. Significant differences with respect to the previous measurements indicate the points where more care should be exercised during maintenance.
Gas leaks
Make sure that there are no gas leaks on the pipework between the gas meter and the burner.
Gas filter
Change the gas filter when it is dirty.
Flame inspection window
Clean the flame inspection window (A).
Combustion head
Open the burner and make sure that all components of the combustion head are in good condition, not deformed by the high temperatures, free of impurities from the surroundings and correctly positioned. If in doubt, disassemble the elbow fitting 5)(B).
Burner
Check for excess wear or loose screws in the mechanisms controlling the air gate valve and the gas butterfly valve. Also make sure that the screws securing the electrical leads in the burner terminal strip are fully tightened.
Clean the outside of the burner, taking special care with the transmission joints and cam 4)(A) in the section "2ND STAGE OUTPUT".
Combustion
Adjust the burner if the combustion values found at the beginning of the operation do not comply with the regulations in force, or at any rate, do not correspond to good combustion. Use the appropriate card to record the new combustion values; they will be useful for subsequent controls.
TO OPEN THE BURNER (B):
Now extract the gas distributor 5) after having removed the screw 6).
TO CLOSE THE BURNER (B):
It is fundamental to ensure the correct execution of the electrical connections between the gas solenoid valves and the burner to perform safely the commissioning.
For this purpose, after checking that the connections have been carried out in accordance with the burner's electrical diagrams, an ignition cycle with closed gas ball valve -dry test- must be performed.
The start-up cycle must be as follows:
Since the manual gas ball valve is closed, the burner will not light up and its control box will go to a safety lockout condition.
The actual electrical supply of the solenoid gas valves can be verified by inserting a tester.
Some valves are equipped with light signals (or close/open position indicator) that turn on at the same time as their power supply.
IF THE ELECTRICAL SUPPLY OF THE GAS VALVES OCCURS AT UNEXPECTED TIMES, DO NOT OPEN MANUAL GAS BALL VALVE, SWITCH OFF POWER LINE; CHECK THE WIRES; CORRECT THE ERRORS AND REPEAT THE COMPLETE TEST.
During start-up, indication is according to the followin table:
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.
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:
VISUAL DIAGNOSTICS
Indicates the type of burner malfunction causing lock-out.
To view diagnostics, proceed as follows:
Reports burner life by means of an optical link with the PC, indicating hours of operation, number and type of lock-outs, serial number of control box etc..
To view diagnostics, proceed as follows:
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 |
Between 1 and 3 seconds | Control box reset without viewing visual diagnostics. |
More than 3 seconds | Visual diagnostics of lock-out condition: (LED pulses at 1-second intervals). |
More than 3 seconds starting from the visual diagnostics condition | Software diagnostics by means of optical interface and PC (hours of operation, malfunctions etc. can be viewed) |
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are listed in the table below.
SIGNAL | FAULT | PROBABLE CAUSE | SUGGESTED REMEDY |
2 x blinks![]() | After pre-purge and safety time, the burner goes tolock-out and the flame does not appear |
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3 x blinks![]() | The burner does not start and lock-out warning appears |
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The burner starts and then locks out | Air pressure switch inoperative due to insufficient air pressure:
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Lock-out during pre-purging |
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4 x blinks![]() | The burner starts and then locks out |
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Lock out when burner stops |
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7 x blinks![]() | The burner goes to lockout right after flame appearance |
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Burner locks out at transition between 1st and 2nd stage or between 2nd and 1st stage |
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During operation, the burner stops in lock out |
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10 x blinks![]() | The burner does not start and lock-out warning appears |
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The burner goes to lockout |
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No blink | The burner does not start |
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The burner repeats the starting cycle without lock out |
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Ignition with pulsation |
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The burner does not pass to 2nd stage |
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Burner stops with air gate valve open |
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(optional):
BURNER | RS 190 | |
Output | kW | 465 ÷ 2290 |
BURNER | RS 190 | |
Output | kW | 470 ÷ 2147 |
The installer is responsible for the addition of any safety device not forseen in the present manual.
Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.
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