Installation & Maintenance Manual

Transcription

1 Installation & Maintenance Manual RGN RGL Gas Burner 11/12 Tel: +44 (0) Fax: +44 (0) Web:

2 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 / Air flow setting, dimension "A"... 8 Air flap positioning motor... 9 Compact gas unit Gas pressure monitor Start-up Adjustment tables RGN 120 / RGL Adjustment tables RGN 120T / RGL 120T Adjustment tables RGN 260 / RGL Adjustment tables RGN 260T / RGL 260T Adjusting gas burner and boiler Calculation principle for gas burner adjustment Design Exploded drawing and spare parts/parts list RGN 120 / RGL Exploded drawing and spare parts/parts list RGN 260 / RGL Service instructions/dimensions Service position Reference dimensions, ignition and ionisation electrodes Measuring ionisation current Servicing air pressure monitor Wiring diagrams Troubleshooting Burner overall dimensions / boiler connection dimensions Working ranges E G

3 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 and DIN VDE 0722 / Ed "Electromagnetic Compatibility" according to Directive 89/336/EEC in conjunction with EN / Ed and EN / Ed "Gas Burning Installations Directive" according to Directive 90/396/EEC in conjunction with DIN EN 676 / Ed and DIN EN 437 / Ed "Efficiency Directive" according to Directive 92/42/EEC in conjunction with DIN EN 676/ Ed "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. E G Caution! Observe throughflow direction of compact unit. 3

4 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 Burner type Technical data RGN 120 RGL 120 RGN 120T RGL 120T RGN 260 RGL 260 RGN 260T RGL 260T Min. burner output in kw Max. burner output in kw Gas type for natural gas LL + E = "-N" / for LPG 3B/P = F Method of operation 1-stage 2-stage sliding 1-stage 2-stage sliding Voltage 4 1 N / PE ~ 50 Hz V Max. current consumption Max. start / operation 2.5 A/1.2 A 2.6 A/1.3 A 3 A/1.4 A 3.1 A/1.5 A Electric motor power (at 2850 rpm) in kw Flame failure controller Ionisation electrode Control box DMG 970 DMG 972 DMG 970 DMG 972 Air pressure monitor DL 2E-150 Pa DL 2E - 40 Pa DL 2E Pa DL 2E - 40 Pa Weight in kg Noise emission in db (A) E G

5 Installation Installation 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). Installation positions for KE...D,Z Installation position for KE...V 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. E G

6 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 H13 connector unit X31,X11 boiler control F21 F1 F3 Q1 X11 X12 connector unit X31,X11 boiler control F22 H11 P11 socket unit X32,X12 on burner B4 S3 T2 T1 N PE L1 socket unit X32,X12 on burner T8 T7 socket unit X22 on burner L1 PE N B5 T6 T7 T8 connector unit X21 compact unit Y1 Y3 F51 Key: F1 F21,F22 F3 F51 Q1 H11,H12 H13 L1 PE P11,P12 Y1,Y2 Y3 Y9 External fuse 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 Time meter Solenoid valve Safety solenoid valve External controller N P12 T6 B5 Connection for RGN 20/30-Z-L 120/260T H12 X31 X32 6 E G

7 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. lasting 1.2 secs. E G Readout device for display of the fault code: SatroPen Art. no SatroCom Art. no

8 Function Fault message Flash code Cause of defect Fault shutdown safety time External light fault Air controller in working position Air controller time-out Air controller opens Flame failure 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 RGN(L) 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 "-" 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 E G

9 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 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 E G

10 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: Natural gas, propane and butane, acc. to EN 437/EN 88 Inlet pressure: max. 100 mbar / 360 mbar (KE CG10 max. 50 mbar) min. 18 mbar Ambient temperature: -15 C to +60 C Connecting flanges: 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. Filter: 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. p W This setting should be retained. 10 E G

11 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 Boiler output at η = 92% Natural gas LL: H i,n = 9.3 [kwh/m 3 ] Air flow dimension "A" Gas nozzle pressure [mbar] Gas flow [m 3 /h] [mm] Burner output Boiler output at η = 92% Natural gas E: H i,n = 10.4 [kwh/m 3 ] Air flow dimension "A" Gas nozzle pressure [mbar] Gas flow [m 3 /h] [mm] Adjustment table RGL 120 Burner output Boiler output at η = 92% LPB 3B/P: H i,n = 25,8 [kwh/m 3 ] Air flow dimension A Gas nozzle pressure [mbar] Gas flow [m 3 /h] [mm] E G ,

12 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 Stage 2 ST2 ST1 Gas nozzle pressure Stage 2 Stage1 Gas flow Stage 2 Stage 1 Compact gas unit [ ] [ ] [mbar] [mbar] [m 3 /h] [m 3 /h] V N [mm] Burner output Boiler output at η = 92% Air flap Natural gas E: H i,n = 10.4 [kwh/m 3 ] Air flow dimension "A" Stage 2 Stage 1 Stage 2 ST2 ST1 Gas nozzle pressure Stage 2 Stage1 Gas flow Stage 2 Stage 1 Compact gas unit [ ] [ ] [mbar] [mbar] [m 3 /h] [m 3 /h] V N [mm] Adjustment table RGL 120T Brennerleistung Burner output at η = 92% Air flap LPG 3B/P: H i,n = 25,8 [kwh/m 3 ] Air flow dimension A Stage 2 Stage 1 Stage 2 ST2 ST1 Gas nozzle pressure Stage 2 Stage1 Gas flow Stage 2 Stage 1 Compact gas unit [ ] [ ] [mbar] [mbar] [m 3 /h] [m 3 /h] V N [mm] E G

13 Start-up Adjustment tables RGN 260 Burner output Boiler output at η = 92% Natural gas LL: H i,n = 9.3 [kwh/m 3 ] Air flow dimension "A" Gas nozzle pressure [mbar] Gas flow [m 3 /h] [mm] Burner output Boiler output at η = 92% Natural gas E: H i,n = 10.4 [kwh/m 3 ] Air flow dimension "A" Gas nozzle pressure [mbar] Gas flow [m 3 /h] [mm] Adjustment table RGL 260 Burner output Boiler output at η = 92% LPG 3B/P: H i,n = 25,8 [kwh/m 3 ] Air flow dimension A Gas nozzle pressure [mbar] Gas flow [m 3 /h] [mm] E G

14 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 Stage 2 ST2 ST1 Gas nozzle pressure Stage 2 Stage 1 Gas throughput Stage 2 Stage 1 Compact gas unit [ ] [ ] [mbar] [mbar] [m 3 /h] [m 3 /h] V N [mm] Burner output Boiler output at η = 92% Air flap Natural gas E: H i,n = 10.4 [kwh/m 3 ] Air flow dimension "A" Stage 2 Stage 1 Stage 2 ST2 ST1 Gas nozzle pressure Stage 2 Stage 1 Gas throughput Stage 2 Stage 1 Compact gas unit [ ] [ ] [mbar] [mbar] [m 3 /h] [m 3 /h] V N [mm] Adjustment table RGL 260T Burner output Boiler output at η = 92% Air flap LPG 3B/P: H i,n = 25,8 [kwh/m 3 ] Air flow dimension A Stage 2 Stage 1 Stage 2 ST2 ST1 Gas nozzle pressure Stage 2 Stage 1 Gas throughput Stage 2 Stage 1 Compact gas unit [ ] [ ] [mbar] [mbar] [m 3 /h] [m 3 /h] V N [mm] ,8 5,5 4,5 4,3 4,8 0,5 50, ,9 6,0 5,3 4,4 4,8 0,5 50, ,5 7,4 6,7 4,9 4,8 0,5 50, ,0 7,4 7,1 4,9 4,8 0,5 50, ,6 7,4 7,8 4,9 4,8 0,5 50, ,7 7,4 9,1 4,9 4,8 0,5 50, ,5 7,4 9,7 4,9 4,8 0,5 50,0 14 E G

15 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! Start-up Adjust gas pressure and air flow dimension "A" according to adjustment tables, page Check exhaust gas values here without fail (CO, CO 2 or O 2 ). Exhaust gas values Natural gas LL+E LPG propane 3B/P O 2 content % CO 2 content 9-10% 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. E G

16 Start-up Single-stage gas burner with KE compact units Burner type RGN 120/260, RGL 120/260 Installation of compact unit Installation position, vertical line: Installation position, horizontal line: Minimum distance to walling: as desired tilted up to max. 90 to left or right, not over head 20 mm p S p G p W A 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 % 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 E G

17 2-stage sliding gas burner with compact unit KEV (gas/air proportional pressure regulator) Burner type RGN 120/260T, RGL 120/260T Start-up Installation of compact unit Installation position Minimum distance to walling only in horizontal line, not tilted 20 mm Gas supply pressure measuring point A (P inlet ) V N p W A B 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 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). E G

18 Start-up Adapt nozzle pressure max. output at max. air flap position ST2 Increase position ST2 if: Reduce max. output if: Adapt nozzle pressure min. output Increase ST1/min. output if: Reduce ST1/min. output if: Max. output Output/nozzle pressure too low Output/nozzle pressure too high 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 E G

19 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 H i,n = 10.4 kwh/m 3 Natural gas type LL 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 20 mbar Gas temperature ϑ G 16 C Boiler rating Q n 100 kw Efficiency η K (assumed) 92% Calorific value H i,n 10.4 kwh/m 3 Gas flow in standard state (V n ) V n Q n kW = = η k Hin, 092, 10, 4 kwh = 10, 5 m h m 3 Gas flow in operating state (V B ) V B V 10, m n h = = = 11, 2 m f 094, h Conversion factor (f) B + P f G 273 = ϑ G Annual average air pressure Mean geodesic height of supplied region ASL [m] Annual average of air pressure from to (mbar) E G Key: Q n = boiler rating η K = 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

20 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 3 ) for the example given above is: V B = 11.2 m 3 /h 02m, s h -- t soll = m 3 = V B h 720m 3 s h m 3 = V B h 720m 3 s h = 64s 11, m3 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 flow volume in litres gas flow in [m 3 / h] flow duration in seconds 20 E G

21 Design Design Exploded view and parts list RGN 120 /RGL E G Seq. No. Designation PU Order No. 1 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 Control unit DMG 972 for T Meter tube Gas nozzle with pressure measuring nipple for -N Air pressure switch DL2E for RGN Air pressure switch DL2E for T Motor 230 V / 50 Hz 180 W Ignition transformer with connecting cable Burner cover Actuating drive STA 13 B Fan wheel dia. 146 x 62 mm Air flap Air flap for T Plastic housing insert Housing with burner pipe Fastening unit Sliding flange 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 Design Exploded view and parts list RGN 260 / RGL Seq. No. Designation PU Order No. 1 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 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 B Air flap Burner cover Fan wheel, dia. 180 x 74 mm Housing with burner pipe Intake silencer Fastening unit Sliding flange 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" E G

23 Service instructions/dimensions Service instructions/dimensions Service position 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. B 2 ±0,5 2 ±0,5 A Reference dimensions, ignition and ionisation electrodes The ignition electrodes are preset at the factory. The dimensions are specified for checking purposes. 3 4 ±0,5 3 ±0,5 Dimension in mm RGN 120 RGL 120 RGN 260 RGL 260 RG20 RG30 A 2 ±0.5 2 ±0.5 B 3 ±0.5 3 ±0.5 Zündelektrode ignition electrode ionisation Ionisationselektrode electrode E G

24 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 µa DC. l > 2 µa - OK l < 2 µa - 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 E G

25 Service instructions/dimensions Wiring diagrams Wiring diagram RGN 120 / RGL 120 Wiring diagram RGN 120T / RGL 120T Boiler control Burner Compact unit Boiler control Key to RGN(L) 120/120T: AH High terminal A BH High terminal B B2 Ionisation electrode CH High terminal C F11 External fuse F21 External temp. controller F22 External temp. controller 2nd stage F3 Safety temperature limiter F4 Air pressure switch F51 Gas pressure switch H11 External pilot lamp H12 External pilot lamp 2nd stage H13 External fault signal lamp M1 Burner motor P11 External time meter P12 External time meter 2nd stage Q1 Main heater switch S1 Control unit Satronic DMG 972 S4 Push-button external fault clearance S5 Switch 1st/2nd stage SK1 Loop terminal S1 SK2 Loop terminal S2 T3 Ignition transformer X11,X31 Plug unit boiler control X12, X32,X42 Socket unit burner X41 Plug unit compact unit X81,X82 Single-pin connector block Y1 Solenoid valve Y3 Safety solenoid valve Y4 Actuating drive Y11 External output controller Burner Colour key: bl = blue br = brown gr = grey rs = pink rt = red sw = black vio = violet ws = white Compact unit E G

26 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 High terminal A BH High terminal B B2 Ionisation electrode CH High terminal C F11 External fuse F21 External temp. controller F22 External temp. controller 2nd stage F3 Safety temperature limiter F4 Air pressure switch F51 Gas pressure switch H11 External pilot lamp H12 External pilot lamp 2nd stage H13 External fault signal lamp M1 Burner motor P11 External time meter P12 External time meter 2nd stage P21 Time meter 1st stage (optional) Q1 Main heater switch S1 Control unit Satronic DMG 970 / 972 S4 Push-button external fault clearance S5 Switch 1st/2nd stage SK1 Loop terminal S1 SK2 Loop terminal S2 T3 Ignition transformer X11,X31 Plug unit boiler control X12, X32,X42 Socket unit burner X41 Plug unit compact unit X81,X82 Single-pin connector block Y1 Solenoid valve Y3 Safety solenoid valve Y4 Actuating drive Burner Colour key: bl = blue br = brown gr = grey rs = pink rt = red sw = black vio = violet ws = white Compact unit 26 E G

27 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 Burner motor starts up briefly. Control unit goes back to fault Control box resets automatically Flash code DMG 970 / 972 Random error flash code Intermittent fault (10 sec.) Cause: Remedy: - Electric supply lead faulty Rectify faults in electrical installation - Fuse faulty Replace - Safety thermostat locked Unlock - Temperature of controller setting is exceeded Renewed start attempt after temperature drop - Control box faulty Replace - Leak Rectify leak - No gas Safeguard gas supply - Gas pressure monitor faulty Replace compact unit - Filter in compact unit dirty Clean or replace Burner motor faulty Replace - No load at terminal 5 Check plug connection and current path of solenoid valve Mains voltage < 187 V Rectify faults in electrical installation Ionisation message Air pressure monitor does not switch through during pre-ventilation Solenoid valve leaking See Page 24 Ignition influencing of ionisation See Page 24 monitor Gas solenoid valve does not Replace compact unit open 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 Connect connector unit in correct phase sequence Ionisation monitor faulty Check according to Page 23/24 Air pressure switch switches See Page 24 during operation Gas nozzle dirty or faulty Replace gas nozzle - No gas Safeguard gas supply - Filter in compact unit dirty Clean or replace Flame blow-off Incorrect burner setting (see Page 17 onwards) 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. 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. E G

28 Burner overall dimensions / boiler connection dimensions (RGN260 dimensions in brackets) All dimensions in mm 90 M8 292 (340) 377 (444) d k f ( ) ( ) 344 (368) RGN 120 RGL 120 RGN 260 RGL 260 Pipe outside dia Hole circle dia. k 170( ) Outside dia. f Working ranges Furnace resistance [mbar] RGN120 RG20 RGL Burner capacity Furnace resistance [mbar] RGN260 RG30 RGL Burner capacity DVGW-checked working ranges as per DIN EN 676.

29 Enertech Limited, P O Box 1, Vines Lane Droitwich, Worcestershire, WR9 8NA Tel: +44 (0) Fax: +44 (0) info@nu-way.co.uk Web: