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35 

20141174

GB

Maintenance

7.1

Notes on safety for the maintenance

The periodic maintenance is essential for the good operation,
safety, yield and duration of the burner.
It allows you to reduce consumption and polluting emissions and
to keep the product in a reliable state over time.

Before carrying out any maintenance, cleaning or checking oper-
ations:

7.2

Maintenance programme

7.2.1

Maintenance frequency

7.2.2

Safety test - with gas ball valve closed

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 per-
formed.
1

The manual ball gas valve must be closed

2

The electrical contacts of the burner limit switch need to be
closed

3

Ensures closed the contact of the low gas pressure switch

4

Make a trial for burner ignition

The start-up cycle must be as follows:

Starting the fan for pre-ventilation

Performing the gas valve seal control, if provided

Completion of pre-ventilation

Arrival of the ignition point

Power supply of the ignition transformer

Electrical Supply of solenoid gas valves

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 ver-
ified 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.

7.2.3

Checking and cleaning

Combustion

Check there are no occlusions or obstructions in the fuel supply
or return lines, in the air suction areas, and in the combustion
product waste pipe.
Carry out an analysis of the combustion flue gases. 
Significant differences with respect to the previous measure-
ments indicate the points where most care should be exercised
during maintenance.

Combustion head

Check that the positioning of the combustion head is correct and
that it is properly fixed to the boiler.
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.

Burner

Check that there are not excess wear or loosen screws. 
Clean the outside of the burner.

Fan

Check that the air damper is positioned correctly.
Check to make sure that no dust has accumulated inside the fan
or on its impellers, as this condition will cause a reduction in the
air flow rate and provoke polluting combustion.

7

Maintenance

DANGER

The maintenance interventions and the calibration
of the burner must only be carried out by qualified,
authorised personnel, in accordance with the con-
tents of this manual and in compliance with the
standards and regulations of current laws.

DANGER

Disconnect the electrical supply from the burner
by means of the main system switch.

DANGER

Close the fuel interception tap.

Wait for the components in contact with heat
sources to cool down completely.

The gas combustion system should be checked at
least once a year by a representative of the man-
ufacturer or another specialised technician.

WARNING

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.

The operator must use the required equipment
during maintenance.

Summary of Contents for Gulliver RS5DF

Page 1: ...aci n uso y mantenimiento 20141174 3 11 2020 Forced draught gas burners Quemadores de gas con aire soplado Two stage operation Funcionamiento a dos llamas CODE C DIGO MODEL MODELO TIPO TYPE 3761866 RS...

Page 2: ...Translation of the original instructions Traducci n de las instrucciones originales...

Page 3: ...nout or bad combustion of the burner 14 5 3 Handling 14 5 4 Preliminary checks 15 5 5 Operating position 15 5 6 Securing the burner to the boiler 16 5 7 Burner adjustment RS4D RS5D RS5D TL RS5DF 17 5...

Page 4: ...am for entering the menu 30 5 13 3 Shut down test 31 5 13 4 Post purging and continuous purging 31 5 13 5 Intermittent operation 31 5 13 6 Setting the opening delay of the 2nd stage 31 5 13 7 Setting...

Page 5: ...cording to the European Directives GAR 2016 426 EU Gas Appliances Regulation MD 2006 42 EC Machine Directive LVD 2014 35 UE Low Voltage Directive EMC 2014 30 UE Electromagnetic Compatibility The RS5D...

Page 6: ...ed out correctly may cause damage to the ma chine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not car ried out correctly lead to electric shocks wit...

Page 7: ...of damage to things or injury to people if such damage injury was due to any of the following causes incorrect installation start up use and maintenance of the burner improper incorrect or unreasonab...

Page 8: ...ance Only those parts envisaged by the manufacturer can be replaced 3 2 Personnel training The user is the person body or company that has acquired the machine and intends to use it for the specific p...

Page 9: ...1 230 50 3761866 RS5D TC 1 230 50 3762016 RS5D TC 1 230 50 3762058 RS5D TL 1 230 50 20052615 RS5DF TC 1 230 50 3761991 Range Size Fuel Natural gas LPG Variations Electrical power 1 230 50 1 220 60 R S...

Page 10: ...S5D TL RS5DF Thermal power 1 kW Mcal h 110 140 246 94 6 120 4 211 6 160 208 345 137 6 178 8 296 7 Fuel Gas G20 NCV 8 12 kWh m3 7 000 10 340 kcal m3 Pressure min 20 mbar max 100 mbar Operation Intermit...

Page 11: ...her mal insulation screen supplied with the burner Tab F F A G H L M I D E B C T Fig 1 S9695 Model A B C D E F G H I L M T RS4D 300 345 392 150 150 480 278 300 225 203 216 137 286 17 RS5D 300 345 392...

Page 12: ...tmospheric pressure of 1013 mbar approx 0 m a s l and with the combustion head adjusted as shown on page 17 Heat output Fig 3 RS4D Pressure in the combustion chamber mbar 4 8 1 6 0 8 2 4 3 2 4 0 D4692...

Page 13: ...ustion chamber dimensions are similar to those shown in the diagram EN 676 For applications where the boiler does not conform to EN 303 or where the combustion chamber is much smaller than the dimen s...

Page 14: ...Gas distributor 4 11 Burner equipment Flange with insulating gasket No 1 Screws and nuts for fixing the flange to the boiler No 4 Screw and nut for flange No 1 Remote reset connection No 1 4 pin plug...

Page 15: ...e control box from the burner it is necessary to Fig 7 disconnect all the connectors connected to it all the plugs the high voltage cables and the earth wire TB unscrew the screw A and pull the contro...

Page 16: ...ber If the smoke pipe is closed the burner must be drawn back till the extraction of blast tube from the furnace Before oper ating in this way take the voltage off 5 3 Handling The transport weight is...

Page 17: ...in the appro priate places WARNING The figure of the label Fig 8 is indicative Some of the data may be arranged in a different position WARNING A burner label that has been tampered with re moved or...

Page 18: ...between using the screws 4 and if necessary the nuts 2 but keeping one of the two top screws 4 Fig 12 loose Insert the combustion head of the burner into the flange 5 Fig 12 tighten the flange with th...

Page 19: ...mbly Reassemble with the reverse procedure to that described above repositioning the head assembly 1 Fig 13 as it was originally In Fig 14 the head is adjusted to an output of about 230 kW The notch 4...

Page 20: ...Cam III Fig 15 commands the opening of the 2nd stage valve factory calibration reference value 35 Cam II should always be anticipated by at least 15 CAM V Cam V Fig 15 is positioned in the factory fa...

Page 21: ...ectly the tube is positioned correctly so that there are no restric tions likely to impede air flowing to the pressure switch Gas train It is type approved in accordance with EN 676 and is supplied se...

Page 22: ...maximum modulating output at which you want the burn er to operate having been fixed find the nearest output value in the table Tab I for the burner in question Read on the right column 1 the pressur...

Page 23: ...is correctly connected to an efficient earthing system made according to current standards It is necessary to check this fundamental safety requirement In the event of doubt have the electrical syste...

Page 24: ...tch Brown Blue Black TO BE DONE BY BY THE INSTALLER WARNING Do not invert the neutral with the phase in the electrical supply line Check that the electrical supply of the burner corresponds to that sh...

Page 25: ...5 Delay time between the 1st and 2nd stage ts Safety time V1 1st stage valve V2 Valve 2nd stage t2 t1 t3 t4i ts HT FM ID V1 LED P M LED t4l PG P TR P M AD t5 V2 SO SO POWER SUPPLY Signal not requested...

Page 26: ...15 t3r A recycle attempt is made if there is an air pressure drop during the pre purging stage there is then a lockout in the event of a second loss of air pressure between the 16th second and the 29t...

Page 27: ...due to a drop in air pressure after the pre purging was repeated due to a previous lack of air or 10 sec before the end of the pre purging or during the safety time or during normal operation RED Bli...

Page 28: ...remote reset is pressed during op erations for more than 5 seconds and less of 10 seconds to not go to the successive menu the burner switches off the gas valve closes the flame goes out and the star...

Page 29: ...and by signalling a fault The fault is indicated by the blinking LED see paragraph Fault diagnostics lockouts on page 25 The burner restarts when the voltage exceeds approx 180V or if it goes below 27...

Page 30: ...time The burner switches off the flame when the heat request thermostat opens cutting off the fuel sup ply to the valves The post purging function is not performed after a lockout of the motor or valv...

Page 31: ...logging of the operating hours Together with the operating hours also the number of the burner s first stage valve openings is saved In the menu see paragraph Programming menu on page 30 it is possib...

Page 32: ...ff test 5s t 10s 2 blinks RED none none Automatic at the end of the blink Post purging Continuous purging 10s t 15s 1 GREEN blink 1 1 minute 2 2 minutes 3 3 minutes 4 4 minutes 5 5 minutes 6 6 minutes...

Page 33: ...e button GREEN led OFF Press the button 1 time to enable a shut down every hour Press the button 2 times to enable a shut down every 24 hours GREEN led ON and OFF every time press and release After 10...

Page 34: ...setting the programming menu parameters and the lockout log The control box allows you to reset the log and the number of lockouts the operating hours the number of ignitions and recov er the menu s d...

Page 35: ...equest or af ter a recycle due to flame loss during operation After 15 seconds the air pressure is too low the head has been poorly adjusted The air pressure switch is defective change it Lockout for...

Page 36: ...he average temperature of the wa ter in the boiler It is advisable to set the burner according to the type of gas used and following the indications in Tab R Tab R 6 Start up calibration and operation...

Page 37: ...g Combustion Check there are no occlusions or obstructions in the fuel supply or return lines in the air suction areas and in the combustion product waste pipe Carry out an analysis of the combustion...

Page 38: ...t refer to the warranty terms indicated in the delivery or payment conditions Tab S 7 3 Opening the burner If maintenance of the combustion head is required refer to the in structions given in Operati...

Page 39: ...The connections in the control box are wrongly inserted Check and connect completely all the plugs The air pressure switch is changed over to the operational position Replace the pressure switch Burn...

Page 40: ...tch Faults Possible Causes Solution Fault Possible Causes Solution The burner locks out during op eration Earth probe Check the right position and if necessary set it ac cording to the instructions of...

Page 41: ...kit Gas trains in compliance with EN 676 Please refer to manual A Appendix Accessories Burner Standard length mm Extended head length mm Code All models 203 225 357 372 3001016 Burner Kit code for sta...

Page 42: ......

Page 43: ...ares 15 5 5 Posici n de funcionamiento 15 5 6 Fijaci n del quemador a la caldera 16 5 7 Regulaci n de los quemadores RS4D RS5D RS5D TL RS5DF 17 5 7 1 Regulaci n cabezal de combusti n 17 5 7 2 Extracci...

Page 44: ...tinua 31 5 13 5 Funcionamiento intermitente 31 5 13 6 Configuraci n del retraso de apertura de la 2 llama 31 5 13 7 Configuraci n de la pre ventilaci n larga 31 5 13 8 Visualizaci n del historial de b...

Page 45: ...por las Directivas Europeas GAR 2016 426 EU Reglamento Aparatos de Gas MD 2006 42 CE Directiva M quinas LVD 2014 35 UE Directiva Baja Tensi n EMC 2014 30 UE Compatibilidad Electromagn tica Los produc...

Page 46: ...n correctamente podr an causar da os a la m quina y o a las personas PELIGRO PELIGRO COMPONENTES CON TENSI N Este s mbolo distinguir las operaciones que si no se ejecutan correctamente causar n descar...

Page 47: ...caducar n en caso de da os a personas y o cosas cuando los da os hayan sido originados por una o m s de las siguientes causas instalaci n puesta en funcionamiento uso y mantenimiento del quemador inco...

Page 48: ...ituirse 3 2 Adiestramiento del personal El usuario es la persona entidad o empresa que compra la m quina y cuya intenci n es usarla con el fin para el cual fue conce bida Suya es la responsabilidad de...

Page 49: ...digo RS4D TC 1 230 50 3761866 RS5D TC 1 230 50 3762016 RS5D TC 1 230 50 3762058 RS5D TL 1 230 50 20052615 RS5DF TC 1 230 50 3761991 Serie Tama o Combustible Gas natural GLP Variantes Alimentaci n el...

Page 50: ...cia t rmica 1 kW Mcal h 110 140 246 94 6 120 4 211 6 160 208 345 137 6 178 8 296 7 Combustible Gas G20 Pci 8 12 kWh m3 7 000 10 340 kcal m3 Presi n m n 20 mbar m x 100 mbar Funcionamiento Intermitente...

Page 51: ...oscados utilizando la junta aislante que se suministra con el quemador Tab F F A G H L M I D E B C T Fig 1 S9695 Modelo A B C D E F G H I L M T RS4D 300 345 392 150 150 480 278 300 225 203 216 137 286...

Page 52: ...ica de 1013 mbar aprox 0 metros s n m y con el cabezal de combusti n re gulado como se indica en la p g 17 Potencia t rmica Fig 3 RS4D Presi n en la c mara de combusti n mbar 4 8 1 6 0 8 2 4 3 2 4 0 D...

Page 53: ...a de combusti n se asemejan a aquellas previstas en la norma EN 676 Por el contrario si el quemador se combina con una caldera co mercial y no cumple con la norma EN 303 o cuya c mara de com busti n t...

Page 54: ...uidor gas 4 11 Material suministrado en dotaci n Brida con junta aislante N 1 Tornillos y tuercas para brida de fijaci n a la caldera N 4 Tornillo y tuerca para brida N 1 Conexi n desbloqueo a distanc...

Page 55: ...ro de choque el ctrico Para extraer la caja de control del quemador es necesario Fig 7 desconectar todos los conectores conectados a ella todos los conectors machos los cables de alta tensi n y el cab...

Page 56: ...busti n un tiraje natu ral Si la chimenea se cierra el quemador se debe retroce der hasta extraer el tubo llama del hogar Antes de esta operaci n corte la tensi n 5 3 Traslado El peso de transporte se...

Page 57: ...lugar preparado para ese fin ATENCI N La figura de la etiqueta Fig 8 es indicativa Algunos de los datos presentes podr an estar ubi cados en una posici n diferente ATENCI N La alteraci n eliminaci n l...

Page 58: ...on los cuatro tornillos 4 y si es necesario las tuercas 2 pero manteniendo apretado uno de los dos tornillos superiores 4 Fig 12 Introducir el cabezal de combusti n del quemador en la brida 5 Fig 12 a...

Page 59: ...procedimiento antes descri to en el orden inverso colocando el grupo cabezal 1 Fig 13 en su posici n original En el gr fico de Fig 14 el cabezal est regulado para un caudal de aprox 230 kW La muesca...

Page 60: ...rar los 65 La leva III Fig 15 acciona la apertura de la v lvula de la 2a lla ma valor de referencia calibrado en f brica 35 Siempre debe anticipar al menos 15 la leva II LEVA V La leva V Fig 15 es pos...

Page 61: ...tubo para evitar estrangula ciones e impedir que el aire pase al presostato Rampa de gas Est homologada seg n la norma EN 676 y se suministra por se parado del quemador Para su regulaci n ver las inst...

Page 62: ...desea que funcione el quemador buscar en la Tab I del quemador considerado el valor de po tencia m s cercano al valor deseado Leer a la derecha columna 1 la presi n en la toma M2 Fig 17 Sumar a este...

Page 63: ...un sistema de puesta a tierra eficiente seg n las normas actuales Es necesario controlar este requisito de seguridad esencial En caso de dudas pida que perso nal calificado controle la instalaci n el...

Page 64: ...27 Interruptor general Marr n Azul Negro A CARGO DEL INSTALADOR ATENCI N No invertir Neutro con Fase en la l nea de ali mentaci n el ctrica Controlar que la alimentaci n el ctrica del quemador corresp...

Page 65: ...Tiempo de retraso entre 1 y 2 etapa ts Tiempo de seguridad V1 V lvula 1 llama V2 V lvula 2 llama t2 t1 t3 t4i ts HT FM ID V1 LED P M LED t4l PG P TR P M AD t5 V2 SO SO ALIMENTACI N Se al no requerida...

Page 66: ...clado si se produce una p rdida de presi n airedurante la pre ventila ci n se produce un bloqueo en el caso de una segunda p rdida de presi n aire entre el segundo 16 y el 29 si se produce una p rdida...

Page 67: ...o r pido 0 2 0 2 Bloqueo por p rdida de presi n de aire o luego de la repe tici n de la pre ventilaci n por la p rdida de aire 10 seg antes de la finalizaci n de la pre ventilaci n durante el tiempo d...

Page 68: ...ante el funcionamiento se aprieta el pulsador de desblo queo o desbloqueo a distancia durante un tiempo superior a 5 se gundos e inferior a 10 segundos para no ir al men siguiente el quemador se apaga...

Page 69: ...indicada por el parpadeo del led v ase apartado Diagn stico anomal as bloqueos en la p g 25 El quemador se enciende cuando la tensi n supera aprox 180V o si se posiciona por debajo de 270V Si la anoma...

Page 70: ...abre y detiene la alimentaci n del combustible hacia las v lvulas No se produce la post ventilaci n despu s de un bloqueo del motor o de las v lvulas si se interrumpe la solicitud de calor durante la...

Page 71: ...ria se guardan tambi n las horas de funcionamiento Junto con las horas de funcionamiento se guarda tambi n el n mero de aperturas de la v lvula de la primera llama del quemador En el men v ase apartad...

Page 72: ...s del Led verde Salida del men Ensayo de apagado 5s t 10s 2 parpadeos ROJOS ninguno ninguno Autom tico desde las paradas intermitentes Post ventilaci n Ventilaci n continua 10s t 15s 1 parpadeo VERDE...

Page 73: ...Pulsador de desbloqueo Led VERDE OFF Presionar el pulsador 1 vez para habilitar un apagado cada hora Presionar el pulsador 2 veces para habilitar un apagado cada 24 horas Led VERDE ON y OFF cada vez q...

Page 74: ...torial de bloqueos La caja de control permite poner en cero el historial y el n mero de bloqueos las horas de funcionamiento el n mero de encen didos y el restablecimiento de los valores por default d...

Page 75: ...nterna defectuosa Bloqueo por presostato aire no cerra do despu s de la solicitud de calor o despu s de un reciclado por p rdida de llama durante el funcionamiento Despu s de los 15 segundos la presi...

Page 76: ...y de la temperatura media del agua de la caldera Se aconseja regular el quemador de acuerdo con el tipo de gas utilizado seg n las indicaciones suministradas en la Tab R Tab R 6 Puesta en funcionamie...

Page 77: ...n cierre apertura que se activan en el momento de su alimentaci n el ctrica 7 2 3 Control y limpieza Combusti n Controle que no haya obstrucciones o estrangulaciones en los tubos de alimentaci n y de...

Page 78: ...pecificados no se refieren a los t rminos de garant a indicados en las condiciones de entrega o de pago Tab S 7 3 Abertura del quemador Si fuese necesario realizar el mantenimiento del cabezal de com...

Page 79: ...rnes L1 N del co nector macho de 7 contactos Comprobar los fusibles Comprobar que el termostato de seguridad TS no est bloqueado Falta de gas Verificar la abertura de la compuerta Verificar que las v...

Page 80: ...entina al abrirse la v l vula provoca la abertura del presostato por lo cual la v lvula se cierra inmediatamente y se para el motor La presi n vuelve a aumentar el presostato se cierra y vuelve a repe...

Page 81: ...n norma EN 676 Consultar el manual A Ap ndice Accesorios Quemador Longitud est ndar mm Longitud cabezal largo mm C digo Todos los modelos 203 225 357 372 3001016 Quemador C digo kit para cabezal est...

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Page 84: ...Subject to modifications Sujeto a modificaciones RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com...

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