Riello RS 34/1 MZ Instrucciones de instalación y funcionamiento

Installation, use and maintenance instructions

安装，使用和维护说明书

20033803 (2) - 08/2011

Forced draught gas burners

强制通风燃气燃烧器

CODE - 编码 MODEL - 型号 TYPE - 类型

20033785 RS 34/1 MZ 886 T

20033725 RS 44/1 MZ 873 T

One-stage operation

一段火运行

The following symbols are used in this manual:

ATTENTION = for actions requiring special care and adequate preparation.

FORBIDDEN = for actions THAT MUST NOT be performed.

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.

GENERAL WARNINGS

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 thereforeadvised to consult the Technical Assistance Department beforechoosing thistype of burn-

er for the combination with a boiler.

Qualified personnel are those with the professional and technical requirements indicated by Law no. 46

dated 5 March 1990. The commercial organisation has a widespread network of agencies and technical of-

fices whose personnel participates periodically in instructional and refresher courses at the company train-

ing centre.

This burner must only be used for the application it was designed for.

The manufacturer cannot accept responsibility for any damage to persons, animals or property due to errors

in installation or in the burner adjustment, or due to improper or unreasonable use or non-observance of the

technical instructions enclosed with the burner, or due to the intervention of unqualified personnel.

USER INFORMATION

If faults arise in firing or operation, the burner performs a "safety stop", which is signalled by the red burner

lockout LED. To rearm start-up conditions, press the reset button. When the burner starts up again, the red

LED goes out.

This operation can be repeated for a maximum of 3 times. If the "safety stop" recurs, then the Technical

Assistance Centre must be contacted.

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 sup-

ply.

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 leave containers and inflammable products in the installation room.

INDEX

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2

Structural versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Max dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Burner equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Blast tube length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fixing the burner to the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Adjustment before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Burner calibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 - Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 - Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 - Minimum gas pressure switch. . . . . . . . . . . . . . . . . . . . . . . . 13

Flame presence check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 16

Reset of the control box and using diagnostics . . . . . . . . . . . . . 16

Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 17

Normal operation / flame detection time. . . . . . . . . . . . . . . . . . . 18

Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Electrical panel layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

N.B.

Figures mentioned in the text are identified as follows:

1)(A) =Part. 1 of figure A, same page as text;

1)(A)p.3 =Part .1 of figure A, page number 3.

INFORMATION ABOUT THE INSTRUCTION

MANUAL

INTRODUCTION

The instruction manual supplied with the burner:

- is an integral and essential part of the product and must not be

separated from it; it must therefore be kept carefully for any nec-

essary consultation and must accompany the burner even if it is

transferred to another owner or user, or to another system. If the

manual is lost or damaged, another copy must be requested from

the Technical Assistance Service of the area;

- is designed for use by qualified personnel;

- offers important indications and instructions relating to the instal-

lation safety, start-up, use and maintenance of the burner.

DELIVERY OF THE SYSTEM AND THE INSTRUCTION

MANUAL

When the system is delivered, it is important that:

- The instruction manual is supplied to the user by the system

manufacturer, with the recommendation to keep it in the room

where the heat generator is to be installed.

- The instruction manual shows:

- the serial number of the burner;

- the address and telephone number of the nearest Assistance

Centre;

- The system supplier carefully informs the user about:

- the use of the system,

- any further tests that may be necessary before the system is

started up,

- maintenance and the need to have the system checked at

least once a year by the manufacturer or another specialised

technician.

To ensure a periodic check, recommends the draw-

ing up of a Maintenance Contract.

..................................................................................

TECHNICAL DATA

(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.

(2) Pressure at the socket 8)(A)p.4 with zero pressure in the combustion chamber, at the maximum output of the burner.

(3) Noise emission tests carried out as specified in EN 15036-1 with measurement accuracy σ = ± 1.5 dB, in the manufacturer's combustion

chamber with burner operating on test boiler at maximum output.

MODEL RS 34/1 MZ RS 44/1 MZ

TYPE 886 T 873 T

OUTPUT (1) kW 70 - 390

60 - 336 100 - 550

86 - 473Mcal/h

FUEL NATURAL GAS: G20 - G21 - G22 - G23 - G25

G20 G25 G20 G25

- net calorific value kWh/Sm3

Mcal/Sm39.45

8.2 8.13

7.0 9.45

8.2 8.13

7.0

- absolute density kg/Sm30.71 0.78 0.71 0.78

- max. delivery Sm3/h 35 40 49 57

- pressure at maximum delivery (2) mbar 13,1 18,4 16,7 23,2

OPERATION • On-Off (1 stop min each 24 hours).

• One stage (all - nothing)

STANDARD APPLICATIONS Boilers: water, steam, diathermic oil

AMBIENT TEMPERATURE °C 0 - 40

COMBUSTION AIR TEMPERATURE °C max 60

ELECTRICAL SUPPLY V

Hz 230 ~ +/-10%

50/60 - single-phase

ELECTRIC MOTOR rpm

2800/3400

300

220 - 240

2.4

2820/3400

420

220 - 240

ACCELERATION CURRENT A15 17

WORKING CURRENT A3.2 3.5

MOTOR CAPACITOR F/V 12.5/400 12.5/450

IGNITION TRANSFORMER V1 - V2

I1 - I2 230 V - 1 x 15kV

1 A - 25mA

ELECTRICAL OUTPUT CONSUMPTION W max 600 700

PROTECTION LEVEL IP 40

IN CONFORMITY WITH EEC DIRECTIVES 90/396 - 2004/108 - 2006/95 - 2006/42

NOISE (3) SOUND PRESSURE

SOUND POWER dBA 68

79 70

APPROVAL CE 0085BR0380 0085BR0380

STRUCTURAL VERSIONS GAS CATEGORIES

Model Blast tube

length mm COUNTRY CATEGORY

RS 34/1 MZ 216

351 IT - AT - GR - DK - FI - SE

ES - GB - IE - PT

II2H3B/P

II2H3P

II2L3B/P

II2Er3P

II2ELL3B/P

I2E(R)B, I3P

II2E 3B/P

RS 44/1 MZ 216

351

ACCESSORIES (optional):

• RADIO DISTURBANCE PROTECTION KIT

If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10 V/m) owing to the presence of an

INVERTER, or in applications where the length of the thermostat connections exceeds 20 metres, a protection kit is available as an interface

between the control box and the burner.

• KIT LONG HEAD

• KIT FOR LPG OPERATION: the kit allows the RS 34-44/1 MZ burners to burn LPG.

• GAS TRAIN ACCORDING TO EN 676 (with valves, pressure governor and filter): see page 10.

NOTE: The installer is responsible for the addition of any safety device not foreseen in this manual.

BURNER RS 34/1 MZ - RS 44/1 MZ

Code 3010386

BURNER RS 34/1 MZ RS 44/1 MZ

Code 3010428 3010429

BURNER RS 34/1 MZ RS 44/1 MZ

Output kW 80 - 390 kW 120 - 530 kW

Blast tube length mm 216 - 351 216 - 351

Code 3010423 3010424

• KIT MAXIMUM GAS PRESSURE SWITCH Cod. 3010418

• KIT CLEAN CONTACTS Cod. 3010419

• KIT POST-PURGING Cod. 3010452

• KIT GROUND FAULT INTERRUPTER Cod. 3010448

• KIT CONTINUOUS PURGING Cod. 3010449

• KIT HOURCOUNTER Cod. 3010450

• KIT INTERFACE ADAPTER RMG TO PC Cod. 3002719

BURNER DESCRIPTION (A)

1 Combustion head

2 Ignition electrode

3 Screw for combustion head adjustment

4Sleeve

5 Minimum air pressure switch

(differential operating type)

6 Flame sensor probe

7 Air pressure test point

8 Gas pressure test point and head fixing

screw

9 Screw securing fan to pipe coupling

10 Slide bars for opening the burner and

inspecting the combustion head

11 Indexed selector.

Opens the fan gate to the value needed by

the burner delivery.

12 Pressure test point of

13 Air inlet to fan

14 Gas input pipework

15 Gas train connection flange

16 Boiler fixing flange

17 Flame stability disc

18 Flame inspection window

19 Motor capacitor (RS 34/1 MZ)

20 Control box with lockout pilot light and lock-

out reset button

21 Plugs for electrical wiring

22 Air damper

23 Plug-socket on ionisation probe cable

Note

If the control box 20)(A) pushbutton (red led)

lights up, it indicates that the burner is in lock-

out.

To reset, hold the pushbutton down for between

1 and 3 seconds.

PACKAGING - WEIGHT (B) - approximate

measurements

• The burner are shipped in cardboard boxes

with the maximum dimensions shown in

Table (B).

• The weight of the burner complete with pack-

aging is indicated in Table (B).

MAX. DIMENSIONS (C) -approximate meas-

urements

The maximum dimensions of the burner are

given in fig. (C).

Note that if you need to examine the combustion

head, the burner must be pulled backward on

the slide bars.

The maximum dimension of the burner,

without the cover, when open is given by meas-

urement H.

BURNER EQUIPMENT

1 - Gas train flange

1 - Flange gasket

4 - Flange fixing screws M 8 x 25

4 - Screws to secure the burner flange to the

boiler: M 8 x 25

1 - Thermal insulation screen

3 - Plugs for electrical connection

1-Instruction

1 - Spare parts list

(A)

mm ABCkg

RS 34/1 MZ 1000 500 485 -

RS 44/1 MZ 1000 500 485 -

(B)

(1) Blast tube: short-long

mm A D E F (1) HILONVM

RS 34/1 MZ 442 422 508 216-351 140 305 138 780 84 177 1”1/2

RS 44/1 MZ 442 422 508 216-351 152 305 138 780 84 177 1”1/2

(C)

D88

D3831

D11831

D7561

D11832

FIRING RATES (A)

The burner output must be selected within the

area of the adjacent diagrams.

Attention

the FIRING RATE value range has been

obtained considering an ambient temperature of

20 °C, and an atmospheric pressure of

1013 mbar (approx. 0 m a.s.l.) and with the

combustion head adjusted as shown on page 9.

TEST BOILER (B)

The firing rates were set in relation to special

test boilers, according to EN 676 regulations.

Figure (B) indicates the diameter and length of

the test combustion chamber.

Example: Output 350 Mcal/h:

diameter = 50 cm - length 1.5 m.

COMMERCIAL BOILERS

The burner/boiler combination does not pose

any problems if the boiler is CE approved and its

combustion chamber dimensions are similar to

those indicated in diagram (B).

If the burner must be combined with a commer-

cial 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.

(B) D497

Mcal/h

length of comb. chamber m

comb. chamber pressure mbarcomb. chamber pressure mbar

(A) D8589

GAS PRESSURE

The adjacent tables show minimum pressure

losses along the gas supply line depending on

the burner output.

Column 1

Pressure loss at combustion head.

Pressure of the gas at the socket 1)(B)p.7, with

combustion chamber at 0 mbar.

Column 2

Pressure loss of gas train 2)(B)p.7 includes: one

stage or two stage adjustment valve VR, safety

valve VS (both fully open), pressure governor R,

filter F.

The values shown in the various tables refer to:

natural gas G 20 PCI 9.45 kWh/Sm3

(8.2 Mcal/Sm3)

With:

natural gas G 25 PCI 8.13 kWh/Sm3

(7.0 Mcal/Sm3)

multiply the values of the table:

- column 1: by 1.5;

- column 2: by 1.35.

Calculate the approximate maximum output of

the burner in this way:

- subtract the combustion chamber pressure

from the gas pressure measured at test

point 1)(B)p.7.

- Find, in the table relating to the burner con-

cerned, the pressure value closest to the

result of the subtraction.

- Read the corresponding output on the left.

Example - RS 34/1/M MZ:

• Maximum output operation

• Natural gas G 20 PCI 9.45 kWh/Sm3

• Gas pressure at test point 1)(B)p.7 =8.9 mbar

• Pressure in combustion chamber = 2 mbar

8.9 - 2 =6.9 mbar

An output of 250 kW shown in table RS 34/1

corresponds to 6.9 mbar pressure, column 1.

This value serves as a rough guide; the effective

delivery must be measured at the gas meter.

To calculate the required gas pressure at test

point 1)(B)p.7, set the output required from the

burner:

- Find the nearest output value in the table for

the burner in question.

- Read, on the right (column 1) the socket

pressure 1)(B)p.7.

- Add this value to the estimated pressure in

the combustion chamber.

Example - RS 34/1 MZ:

• Required burner output: 250 kW

• Natural gas G 20 PCI 9.45 kWh/Sm3

• Pressure of the gas at an output of 250 kW, from

the table RS 34/1 MZ, column 1 =6.9 mbar

• Pressure in combustion chamber = 2 mbar

6.9 + 2 =8.9 mbar

pressure required at test point 1)(B)p.7.

RS 34/1 MZ One-stage gas train p (mbar)

RS 44/1 MZ One-stage gas train p (mbar)

RS 34/1 MZ Two-stage gas train p (mbar)

kW 1 2

MBC-DLE-120

(Rp 3/4") MB 407 S2

(Rp 3/4") MB 410 S2

(Rp 1.1/4") MB 412 S2

(Rp 1.1/4") MB 415 S2

(Rp 1.1/2") MB 420 S2

(Rp 2")

70 0,6 5,2 3,0 -- -- -- --

75 0,6 5,6 3,4 2,1 -- -- --

100 1,0 8,2 5,6 2,9 -- -- --

125 1,4 11,1 8,0 4,2 2,1 -- --

150 2,4 15,7 11,0 5,6 2,8 -- --

175 3,5 21,1 14,4 7,2 3,6 -- --

200 4,6 27,2 18,1 9,0 4,5 -- --

225 5,8 33,9 22,1 11,0 5,5 3,2 --

250 6,9 41,3 26,4 13,2 6,5 3,3 --

275 8,0 49,4 31,3 15,5 7,6 3,8 --

300 9,1 58,0 36,6 18,0 8,7 4,3 --

325 10,2 67,2 42,2 20,5 9,9 4,8 3,2

350 11,3 76,7 47,8 22,9 11,2 5,4 3,4

375 12,4 86,7 53,7 25,4 12,7 5,9 3,8

390 13,1 57,4 27,0 13,5 6,3 4,0

kW 1 2

MB 407 S5

(Rp 3/4") MB 410 S5

(Rp 1.1/4") MB 412 S2

(Rp 1.1/4") MB 415 S2

(Rp 1.1/2") MB 420 S2

(Rp 2")

100 0,2 5,6 2,9 2,1 3,2 3,2

150 1,6 11,0 5,6 2,8 3,2 3,2

200 3,0 18,1 9,0 4,5 3,2 3,2

250 4,9 26,4 13,2 6,5 3,3 3,2

300 6,9 36,6 18,0 8,7 4,3 3,2

350 8,9 47,8 22,9 11,2 5,4 3,4

400 10,8 59,9 28,1 14,0 6,5 4,1

450 12,8 73,2 33,6 16,8 7,7 4,9

500 14,7 87,6 39,5 19,8 9,0 5,7

550 16,7 103,0 45,8 23,1 10,2 6,6

kW 1 2

MB-ZR 407 S2

(Rp 3/4") MB-ZR 410 S2

(Rp 1") MB-ZR 412 S2

(Rp 1.1/4") MB-ZR 415 S2

(Rp 1.1/2") MB-ZR 420 S2

(Rp 2")

70 0,6 3,0 2,1 2,1 -- --

75 0,6 3,4 2,1 2,1 -- --

100 1,0 5,6 2,9 2,1 -- --

125 1,4 8,0 4,2 2,1 -- --

150 2,4 11,0 5,6 2,8 -- --

175 3,5 14,4 7,2 3,6 -- --

200 4,6 18,1 9,0 4,5 -- --

225 5,8 22,1 11,0 5,5 3,2 --

250 6,9 26,4 13,2 6,5 3,3 --

275 8,0 31,3 15,5 7,6 3,8 --

300 9,1 36,6 18,0 8,7 4,3 --

325 10,2 42,2 20,5 9,9 4,8 3,2

350 11,3 47,8 22,9 11,2 5,4 3,4

375 12,4 53,7 25,4 12,7 5,9 3,8

390 13,1 57,4 27,0 13,5 6,3 4,0

(A)

VS VR

D8065

RS 44/1 MZ Two-stage gas train p (mbar)

kW 1 2

MB-ZR 410 S2

(Rp 1") MB-ZR 412 S2

(Rp 1.1/4") MB-ZR 415 S2

(Rp 1.1/2") MB-ZR 420 S2

(Rp 2")

100 0,2 2,9 2,1 -- --

150 1,6 5,6 2,8 -- --

200 3,0 9,0 4,5 3,2 --

250 4,9 13,2 6,5 3,3 --

300 6,9 18,0 8,7 4,3 3,2

350 8,9 22,9 11,2 5,4 3,4

400 10,8 28,1 14,0 6,5 4,1

450 12,8 33,6 16,8 7,7 4,9

500 14,7 39,5 19,8 9,0 5,7

550 16,7 45,8 23,1 10,2 6,6

(A)

(B)

INSTALLATION

THE BURNER MUST BE INSTALLED

IN CONFORMITY WITH LEGISLATION

AND LOCAL STANDARDS.

WORKING POSITION (A)

The burner is designed to work only in

the positions 1, 2, 3 and 4.

Installation 1is preferable, as it is the only one

that allows the maintenance operations as de-

scribed in this manual. Installations 2, 3 and 4

allow the working, but make the operations of

maintenance and checking of the combustion

head more difficult page 15.

Any other position could compromise

the correct working of the appliance.

Installation 5is forbidden, for safety

reasons.

BOILER PLATE (B)

Pierce the closing plate of the combustion

chamber, as in (B). The position of the threaded

holes can be marked using the thermal screen

supplied with the burner.

BLAST TUBE LENGTH (C)

The length of the blast tube must be selected

according to the indications provided by the

manufacturer of the boiler, and in any case it

must be greater than the thickness of the boiler

door complete with its fettling.

The range of lengths available, L (mm), is as fol-

lows:

Blast tube 9) RS 34/1 MZ RS 44/1 MZ

• short 216 216

• long 351 351

For boilers with front flue passes 6) or flame

inversion chambers, protective fettling in refrac-

tory material 8), must be inserted between the

boiler fettling 7) and the blast tube 9).

This protective fettling must not compromise the

extraction of the blast tube.

For boilers with a water-cooled frontpiece, a

heat-resistant cover is not necessary 7)-8)(C),

unless expressly requested from the boiler man-

ufacturer.

FIXING THE BURNER TO THE BOILER (C)

Before fixing the burner to the boiler, check

(from the opening of the blast tube) that the

probe and the electrode are correctly posi-

tioned, as in (D).

Separate the combustion head from the rest of

the burner, fig. (C):

- remove the screws 2) from the two slide

bars 3);

- remove screw 1) and pull the burner back on

slide bars 3) by about 100 mm;

- disconnect the probe and electrode leads,

then unthread the burner completely from the

guides.

Fix the unit 4)(C) to the boiler plate, inserting the

supplied insulating gasket 5)(C).

Use the 4 screws, also supplied with the unit,

after first protecting the thread with an anti-lock-

ing product. The seal between burner and boiler

must be airtight.

If, in the previous check, the position of the

probe or electrode was not correct, remove the

screw 1)(E), extract the inner part 2)(E) of the

head, and adjust them.

Do not rotate the probe: leave it as in (D).

If it is located too close to the ignition electrode,

the control box amplifier may be damaged.

ATTENTION

Proceed with the assembly of the

inner part 2)(E) of the combustion

head, tightening the screw 1)(E) with

a tightening torque of 4 ÷ 6 Nm.

mm A B C

RS 34/1 MZ

RS 44/1 MZ 160

160 224

224 M8

(B)

(C)

D455

(D)

(E)

D3844

D3835

PROBE ELECTRODE

2 3 4 51

D3928

(A)

D7564

Este manual sirve para los siguientes modelos

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