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operation manual for the authorized specialist gas duoblock burner rpd 30 100 g-r 03/2005 102.873.7142

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contents inhalt general information 3 technical data sheet 4 burner construction 10 mounting the burner to the boiler 11 combustion air fan drive modes 12 dimensioned drawing for rpd burner 20 100 13 burner scheme gas train 15 mounting position leak test ignition gas connection ignition burner type zt0 16 ignition gas solenoid valve 20 burner electrical connection 21 dimensions of the mixing unit 22 draw-out and swing mechanism 23 air flow adjustment gas rate adjustment 24 mechanical compound controller 25 adjusting instructions 26 gas pressure switch air pressure switch 26 setting pressure switches and control system 27 automatic furnace controller lfl 1 lgk 16 28 flame monitor sensor current measurement 29 actuator type aris wan 3 4 4a 5 30 gas connection 31 gas motor valve vk 32 gas pressure regulator 34 gas pressure regulator 35 gas filter safety vent valve 37 diagram pressure loss 38 discharge speed gas nozzles 39 preoperational checks functional test without fuel gas start-up 41 burner shutdown measures in case of trouble 42 exhaust gas test 43 o2 co2 lambda conversion table 44 trouble shooting instructions 46 2

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general information important information the burners of type rpd 30 100g-e/r have been designed for the combustion of natural gas the burners should be installed and taken into operation by qualified personnel only who will be responsible for the proper performance of this work in accordance with the applicable regulations and guidelines only duly authorized specialists should be entrusted with the installation of the gas system any repair work on monitors limiters and automatic furnace controllers and on the other safety facilities are allowed to be done only by the manufacturers themselves or specialists authorized by them original parts should only be exchanged by a duly qualified specialist standards and regulations the following standards should be observed in the interest of a safe easyon-the-environment and energy-saving operation of the burner en 676 din 4788 vde 0116 gas burners with fans electrical equipment of furnaces start-up the furnace system should be started initially by the installer manufacturer or other specialized personnel prior to taking the furnace system into operation make a test of all automatic control safety and control facilities for proper functional order and check them for correct setting if of adjustable type furthermore check the control circuits fans etc for proper fuse rating and whether suitable precautions have been taken to prevent accidental contact inspection and maintenance the furnace system should be inspected and serviced at least once a year by an authorized specialist of the installer to ensure its proper functional order operational safety and energy-saving operation check the system for absence of leaks and functional order for the combustion analysis proceed as described in the section entitled exhaust gas test it is recommended to conclude a maintenance agreement to this effect warranty manufacturer will not accept any warranty if the operating instructions have not been duly observed in the start-up and maintenance of the burner and damages have been caused by improper installation incorrect adjustment unauthorized interference or operating errors burner installation and accessories boiler lining the boiler lining should be made of heat-resistant materials temperature resistance >1400°c take care that the burner flame tube is covered by the boiler lining over its full length the open space between the burner flame tube and the boiler lining should be packed with mineral wool checks prior to burner installation 1 check the mixing ignition unit according to the boiler output pilot burner setting see dimensioned drawing for setting dimensions of mixing ignition unit check the air cylinder for proper function possible damage in transport check the air damper setting according to flame pattern and furnace chamber geometry 2 3 4 according to en 676 the user must be instructed in the operation of the burner and according to din 4756 the user must be introducted in to gas firing system for the installation of a gas furnace system care should be taken to observe din 4756 trgi technical regulation on gas installations the worksheets of dvgw german association of the gas and water sector and the local furnace construction regulations applicable in the country screwed unions of metal used in gas lines should be fitted with approved sealing elements prior to taking the burner into operation make sure to vent the gas line but this should in no case be done through the furnace chamber 5 3

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technical data sheet technical data sheet gas duoblock burner rpd 30 40 50 g-r feld52 rpd 30 40 50 g-r technical data burner output gas flow rate operating mode fuel type automatic burner controller flame sensor ignition burner ignition transformer rpd 30 669 5991 kw 67 599 m³/h rpd 40 910 8230 kw 91 823 m³/h fully modulating natural gas lfl 1 lgk 16 or other approved models qra 2 qra 53 or other approved models mat hegwein znvl zt0 d-52 l5 kv mat ignition burner z112 k5 hegwein ignition burner wan 4 r 3 wan 4 r 3 according to gas pressure 400 kg 430 kg 30 mbar or according to diagram 550 kg wan 4 r 5 rpd 50 1400 11160 kw 140 1116 m³/h actuator gas connection gas control organ weight pressure loss in mixing unit output range kw 1 2000 11 1 60 1 0000 8230 8000 5991 6000 4000 2000 1 400 669 0 rpd 30 rpd 40 rpd 50 91 0 02/02 art nr 102.867.761 8 4

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rpd 30 40 50 g-r description dimensions operating mode fully automatic forced draught gas burner safety equipment according to en 676 especially designed for high turn down ratios electric design burner pre-wired and ready to connect all burner components wired to the burner terminal rail burner control box supplied loose for installation in separate control panel combustion air separate combustion air blower with stable and pulsation-free characteristics also on appliances with a high flue gas resistance the combustion air volume is divided into a primary and a secondary stream the flame shape may be adapted by adjustable twist dampers d1 d2 a1 d7 control systems gas side fuel throughput controlled by compound controller with adjustable cam disc and gas inlet butterfly valve air side by means of compound controller with adjustable cam discs for primary air air damper and secondary air air cylinder monitoring system flame monitoring by means of flame sensor and tested burner control box combustion air monitoring achieved through differential air pressure switch resp speed control switch in case of burner with speed control ignition direct high voltage ignition 5000 v by means of an inbuilt ignition burner g l4 100 r h2 d5 100 t2 t3 h4 h1 h3 d6 50 l6 50 t v d4 w t1 444 b8 b3 b4 details of boiler front plate bohrungen kesselplatte z y 22,5 ° 22,5 ° 15° 15° rpd 20 60 p3 p4 x d2 d3 d2 d3 rpd 70 100 p1 p2 setgewinde screw m length k stift m länge k rpd a1 30 40 50 745 745 950 b1 l6 62 50 55 b2 m 12 12 12 b3 b4 b5 p3 b6 p4 b8 d1 d2 d3 d4 d5 d6 323,5 d7 g h1 h2 h3 h4 k 30 30 30 fi l1 f2 l4 124 95 110 f3 260 375 260 375 315 375 p1 p2 416 830 790 385 371 290 17,5 317 620 373 993 650 416 830 790 423 409 340 367 17,5 442 620 373 993 650 535 1030 990 470 456 380 410 17,5 370 675 475 1150 740 r t t1 t2 t3 u v 3 3 5 w 248 248 319 x y z 10 10 10 lb c rpd l5 30 40 50 580 670 320 410 1265 160 192 491 346 580 670 320 410 1265 160 192 491 346 740 830 416 506 1743 181 250 530 376 4x92 5x126 4x92 5x126 3x152 5x156 5

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technical data sheet technical data sheet gas duoblock duoblock gas burner rpd 60 70 80 g-r feld52 rpd 60 70 80 g-r technical data burner output gas flow rate operating mode fuel type automatic burner controller flame sensor ignition burner ignition transformer rpd 60 2232 14511 kw 223 1451 m³/h rpd 70 3000 20470 kw 300 2047 m³/h fully modulating natural gas lfl 1 lgk 16 or other approved models qra 2 qra 53 or other approved models mat hegwein znvl zt0 d-52 l5 kv mat ignition burner z112 k5 hegwein ignition burner wan 4 r 5 wan 4 a r 5 according to gas pressure 600 kg 760 kg 30 mbar or according to diagram 1060 kg wan 4 a r 8 rpd 80 5500 34500 kw 550 3450 m³/h actuator gas connection gas control organ weight pressure loss in mixing unit output range kw 40000 35000 34500 30000 25000 20470 20000 1 5000 1 1 451 1 0000 5000 2232 0 3000 5500 rpd 60 rpd 70 rpd 80 02/02 art nr 102.867.762 9 6

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rpd 60 70 80 g-r description dimensions operating mode fully automatic forced draught gas burner safety equipment according to en 676 especially designed for high turn down ratios electric design burner pre-wired and ready to connect all burner components wired to the burner terminal rail burner control box supplied loose for installation in separate control panel combustion air separate combustion air blower with stable and pulsation-free characteristics also on appliances with a high flue gas resistance the combustion air volume is divided into a primary and a secondary stream the flame shape may be adapted by adjustable twist dampers d1 d2 a1 d7 control systems gas side fuel throughput controlled by compound controller with adjustable cam disc and gas inlet butterfly valve air side by means of compound controller with adjustable cam discs for primary air air damper and secondary air air cylinder monitoring system flame monitoring by means of flame sensor and tested burner control box combustion air monitoring achieved through differential air pressure switch resp speed control switch in case of burner with speed control ignition direct high voltage ignition 5000 v by means of an inbuilt ignition burner g l4 100 r h2 d5 100 t2 t3 h4 h1 h3 d6 50 l6 50 t v d4 w t1 444 b8 b3 b4 details of boiler front plate bohrungen kesselplatte z y 22,5 ° 22,5 ° 15° 15° rpd 20 60 p3 p4 x d2 d3 d2 d3 rpd 70 100 p1 p2 set screw m gewinde length k stift m länge k rpd a1 60 994 b1 l6 62,5 85 92 b2 m 12 12 b3 b4 b5 p3 b6 p4 b8 d1 d2 d3 d4 d5 d6 455,5 565,5 d7 18 18 18 w 379 410 489 g h1 h2 h3 h4 k 30 30 l1 f2 l4 125 170 185 f3 315 375 315 375 315 375 p1 p2 622 1080 1040 520 506 420 731 1240 1200 640 626 520 312 700 497 1197 825 469 780 580 1360 900 70 1160 80 1350 rpd l5 60 70 80 860 1450 1400 740 710 597 646 r t t1 t2 t3 u v 5 5 8 600 820 675 1495 1000 30 x y z 10 10 10 lb c fi 750 840 470 560 1760 181 270 555 401 936 1026 600 690 2010 181 365 610 450 4x129 5x160 5x128 7x140 6x125 9x128 12 1102 1192 700 790 2320 187 310 707 495 7

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technical data sheet technical data sheet gas duoblock burner duoblock gas burner rpd 90 100 g-r feld52 rpd 90 100 g-r technical data burner output gas flow rate operating mode fuel type automatic burner controller flame sensor ignition burner ignition transformer rpd 90 7000 42000 kw 700 4200 m³/h rpd 100 7000 45000 kw 700 4500 m³/h fully modulating natural gas lfl 1 lgk 16 or other approved models qra 2 qra 53 or other approved models mat hegwein znvl zt0 d-52 l5 kv mat ignition burner z112 k5 hegwein ignition burner wan 5 a r 8 wan 5 a r 8 according to gas pressure 1200 kg 1250 kg 30 mbar or according to diagram actuator gas connection gas control organ weight pressure loss in mixing unit output range kw 50000 45000 45000 40000 42000 35000 30000 25000 20000 1 5000 1 0000 5000 7000 7000 0 rpd 90 rpd 1 00 02/02 art nr 102.867.763 0 8

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rpd 90 100 g-r description dimensions operating mode fully automatic forced draught gas burner safety equipment according to en 676 especially designed for high turn down ratios electric design burner pre-wired and ready to connect all burner components wired to the burner terminal rail burner control box supplied loose for installation in separate control panel combustion air separate combustion air blower with stable and pulsation-free characteristics also on appliances with a high flue gas resistance the combustion air volume is divided into a primary and a secondary stream the flame shape may be adapted by adjustable twist dampers d1 d2 a1 d7 control systems gas side fuel throughput controlled by compound controller with adjustable cam disc and gas inlet butterfly valve air side by means of compound controller with adjustable cam discs for primary air air damper and secondary air air cylinder monitoring system flame monitoring by means of flame sensor and tested burner control box combustion air monitoring achieved through differential air pressure switch resp speed control switch in case of burner with speed control ignition direct high voltage ignition 5000 v by means of an inbuilt ignition burner g l4 100 r h2 d5 100 t2 t3 h4 h1 h3 d6 50 l6 50 t v d4 w t1 444 b8 b3 b4 details of boiler front plate bohrungen kesselplatte z y 22,5 ° 22,5 ° 15° 15° rpd 20 60 p3 p4 x d2 d3 d2 d3 rpd 70 100 p1 p2 set screw m gewinde length k stift m länge k rpd a1 90 1700 100 1700 rpd l5 90 100 b1 l6 b2 m b3 b4 b5 p3 b6 p4 b8 d1 d2 d3 d4 d5 d6 v 8 8 d7 18 18 w 494 494 g h1 h2 h3 h4 k l1 f2 l4 190 190 f3 420 375 420 375 p1 p2 890 1800 1750 883 870 675 890 1800 1750 935 920 830 r t t1 t2 t3 u 810 905 850 1755 1100 30 810 905 850 1755 1100 30 x y z 10 10 lb c fi 12 1300 1390 742 832 2720 224 310 832 620 12 1300 1390 742 832 2720 224 310 832 620 6x132 10x135 6x132 10x135 9

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burner construction 13 2 1 14 19 20 21 23 26 24 28 27 12 11 4 17 16 15 5 6 7 32 1 2 4 5 6 7 11 12 13 14 15 16 17 secondary air pressure switch ignition gas valve group inspection glasses terminal box gas flow rate control damper secondary air connection primary air damper sleeve combustion air for ignition burner flame monitor gas feed pipes air guide valve gas nozzles 19 20 21 23 24 26 27 28 32 turbulator flame tube burner tube secondary air control valve extracting assembly burner housing ignition burner fastener of nozzle rod electric actuator combustion air connection the combustion air connection item 7 may be mounted at intervals of 45° for the rpd 30-60 version and 30° for the rpd 70-90 version the burner equipment plate with control block and all valves and instruments will be retained in the vertical position in any case 10

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mounting the burner to the boiler the burner plate of the boiler must be fabricated to the specified dimensions mount the burner to the boiler with its insulation backing apply a layer to graphite or similar lubricant to the bolts and tighten by equal amounts mixing ignition units extended in length are available for boilers requiring a specific installation depth of the burner flame tube refer to the drawing for the mounting dimensions of the burner and air duct and exhaust gas connection if any boiler lining the boiler lining must consist of heatresistant materials temperature resistance >1400°c take care that the burner flame tube is covered by the boiler lining over its full lenght the space between the burner flame tube and lining is packed with mineral wool burner mounting inspection 1 check the mixing ignition unit according to the boiler output 2 adjust the pilot burner 3 refer to the dimensioned drawing for adjusting the mixing ignition unit insulation boiler plate mounting bracket boiler lining burner flange sealing mineral wool burner textile compensator air duct combustion air fan baseframe to anti-vibration mounting 11

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combustion air fan drive modes 1 direct drive in this concept the motor is coupled directly to the fan impeller the fan impeller is mounted directly on the motor shaft end the speeds used are those of the drive motors only the bearing of the motor shaft must be specifically designed for the fan impeller used recommendation up to 10 mw output air duct and fan baseframe pre-mount exactly do not prestress for mounting direction of rotation check for proper direction of rotation fans with v-belt drive should be chekked for v-belt tension after about 12 hours of operation and the v-belts retensioned if necessary if the v-belts are not properly tensioned this will cause slip with resultant lower speed and a considerably reduced service life mount the air ducts in a way to ensure an accurate and reliable fixing of the fan connect the air duct by means of a compensator to avoid transmission of stress the air ducts are made from 3-4 mm metal sheet 2 drive via flexible coupling the fan impeller is mounted on its own shaft by means of a bearing specifically designed for the purpose the power is transmitted from the drive motor via a torsionally flexible coupling the speeds used are those of the drive motor 3 v-belt drive the fan impeller is mounted on its own shaft by means of a bearing specifically designed for the purpose the power is transmitted from the drive motor via vbelts which can provide practically any desired speed 12

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dimensioned drawing for rpd burner 20 100 oil gas and dual-fuel burners without external exhaust gas return boilerplate holes attention for burners type u mixing unit see on separate sheet 13 set screw m lenght k

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14 dimensions of rpd burner 20 100 oil gas and dual-fuel burners without external exhaust gas return note if longer flame tubes are used the extended lenght must be added to the dimensiones g r l5 d4 burner tube outside diameter flange acc to din 2631 for rpd 20 to 70 and acc to din 2633 for rpd 80 90 and 100 rpd a1 b1 b2 b3 b4 b5 b6 b8 d1 d2 d3 d4 d5 100 d6 50 d7 g h1 h2 h3 h4 k l1 l4 l5 mat dg75 100 20 30 40 50 60 70 80 90 530 745 745 950 994 1160 1350 1700 53 78 78 78 78 78 75 75 75 m 29 19 19 19 19 19 19 3 3 p1 90 260 260 315 315 315 315 420 420 p2 314 375 375 375 375 375 375 375 375 p3 91 70 70 70 70 75 75 75 75 p4 560 705 705 760 760 765 765 870 870 r 325 416 416 530 830 830 500 790 790 270 385 423 470 260 371 409 456 506 626 710 870 922 t2 210 290 340 380 420 520 597 675 830 t3 12 250 385 620 620 675 700 780 820 905 905 x 265 373 373 650 993 993 425 650 650 30 30 30 30 30 30 30 30 30 465 550 550 600 650 740 700 745 745 700 700 770 735 68 780 323 17,5 317 367 17,5 442 410 17,5 370 455 565 646 u 18 18 18 18 18 dn 124 1350 95 1425 535 1030 990 475 1150 740 497 1197 825 580 1360 900 675 1495 1000 850 1755 1100 850 1755 1100 y z 110 1620 125 1695 170 1995 185 2285 190 2585 190 2585 622 1080 1040 520 731 1240 1200 640 860 1450 1400 740 890 1800 1750 883 890 1800 1750 945 s1 s2 t t1 312 469 600 810 810 w 100 1700 rpd l6 50 20 30 40 50 60 70 80 90 100 62 50 55 62 85 92 10 12 12 12 12 12 12 12 12 430 580 580 740 750 510 670 670 830 840 236 320 320 416 470 316 497 497 595 622 705 800 845 845 112 160 160 181 181 181 187 224 224 150 192 192 250 270 365 310 310 310 240 491 491 530 555 610 707 832 832 1 ,5 8x1 50 80 80 190 2x1 4x1 43 20 248 248 4x92 5x1 26 4x92 5x1 26 10 10 10 10 10 10 10 410 1265 140 410 1265 140 506 1743 115 560 1760 195 690 2010 270 790 2320 310 832 2720 240 832 2720 240 346 22x1 ,5 346 22x1 ,5 376 22x1 125 ,5 401 22x1 125 ,5 450 28x1 125 ,5 495 28x1 200 ,5 620 28x1 200 ,5 620 28x1 200 ,5 319 3x1 5x1 52 56 379 4x1 5x1 29 60 410 5x1 7x1 28 40 489 6x1 9x1 25 28 936 1026 600 1102 1192 700 1300 1390 742 1300 1390 742 494 6x1 1 35 10 32 0x1 494 6x1 1 35 10 32 0x1

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burner scheme gas train rpd 30 100 g r burner scheme trd 604 72 h trd 604 72 hr the 310 313 and 313a pressure switches are approved in dual mode or under the code of special construction requirements trd 604 24 hr the 310 313 and 313a pressure switches are designed in single mode ignition gas ignition electrodes gas primary air secondary air air en the 310 313 and 313a pressure switches are designed in single mode the 313a max pressure switch is not available gas train trd 604 72 h 100 120 125 141 142 143 144 145 147 148 150 151 152 153 154 155 156 157 310 313 313a 314 349 burner secondary air cylinder primary air damper ball valve gas filter pressure gauge gas pressure regulator safety shutt-off valve test burner w push button valve safety blow off valve gas butterfly valve ignition burner lance air regulating valve main gas solenoid valve safety shutt-off solenoid valve ignition gas solenoid valve ignition gas solenoid valve gas regulating valve air pressure switch gas pressure switch min gas pressure switch max gas leakage control mechanical compound controller primary air secondary 15

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