Riello 20166004, Installation, Use And Maintenance Instructions

Page 1: ...0175134 3 09 2020 Forced draught gas burners Modulating operation CODE MODEL TYPE 20166004 RS 310 EV O2 BLU 1138T2 20180649 RS 310 EV O2 BLU 1138T2 20174935 RS 410 EV O2 BLU 1135T2 20174936 RS 510 EV O2 BLU 1136T2 20174937 RS 610 EV O2 BLU 1137T2 GB ...

Page 2: ...Translation of the original instructions ...

Page 3: ...escription 13 4 13 Control box for the air fuel ratio LMV52 14 4 14 Actuator 16 4 15 PLL52 module optional 17 4 15 1 Terminal ratings cable lengths and cross sectional areas 17 4 16 Oxygen sensor QGO20 optional 18 4 16 1 Technical data QGO20 19 5 Installation 20 5 1 Notes on safety for the installation 20 5 2 Handling 20 5 3 Preliminary checks 20 5 4 Operating position 21 5 5 Preparing the boiler ...

Page 4: ...switch kit 34 6 7 Operation 35 6 8 Ignition failure 35 6 9 Burner flame goes out during operation 35 6 10 Stopping of the burner 35 6 11 Final checks with burner operating 35 6 12 Description of O2 trim control optional 36 6 12 1 Operating principle of O2 trim control 36 7 Maintenance 37 7 1 Notes on safety for the maintenance 37 7 2 Maintenance programme 37 7 2 1 Maintenance frequency 37 7 2 2 Sa...

Page 5: ...roducts are marked as follows RS 310 EV O2 BLU Class 3 EN 676 RS 410 EV O2 BLU Class 3 EN 676 RS 510 EV O2 BLU Class 3 EN 676 RS 610 EV O2 BLU Class 3 EN 676 The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German stand...

Page 6: ...e 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 with le thal consequences DANGER FLAMMABLE MATERIAL This symbol indicates the presence of flammable materials DANGER BURNING This symbol indicates the risks of burns due to high temperatures DANGER CRUSHING OF LIMBS This symbol indicates the ...

Page 7: ...event 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 unreasonable use of the burner intervention of unqualified personnel carrying out of unauthorised modifications on the equipment use of the burner with safety devices that are faulty incor rectly applied a...

Page 8: ...aintenance 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 purpose He is re sponsible for the machine and for the training of the people work ing around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel...

Page 9: ...1 C02 MZ C03 BLU C03 MX Class 1 EN676 Class 2 EN676 Class 3 EN676 Class 3 EN676 Adjustment E Electronic cam EV Electronic cam and variable speed with Inverter M Mechanical cam P Proportional air gas valve E O2 Electronic cam and suitable for Oxygen Control O2 EV O2 Electronic cam and variable speed with Inverter and suitable for Oxygen Control O2 EV O2 WARNING The burner leaves the factory set up ...

Page 10: ... EV O2 BLU RS 410 EV O2 BLU RS 510 EV O2 BLU RS 610 EV O2 BLU Power 1 Delivery 1 min max kW 400 1200 3630 500 1500 4450 680 1800 5250 1000 2200 6250 Fuels Natural gas G20 methane gas G21 G22 G23 G25 Gas pressure at max output 2 Gas G20 G25 mbar 50 1 74 7 53 1 79 2 59 7 89 1 77 6 115 8 Operation FS1 Intermittent min 1 stop in 24 hours FS2 Continuous min 1 stop in 72 hours Standard applications Boil...

Page 11: ...thickness of the boiler door Tab F Model kg RS 310 EV O2 BLU 250 RS 410 EV O2 BLU 250 RS 510 EV O2 BLU 250 RS 610 EV O2 BLU 280 Fig 1 20110496 WARNING The gas adaptor is set also for DN 80 bore D N C E F T P I R A H O O M L G R A Fig 2 20180807 mm A C D E F G H I L M N O P R T RS 310 EV O2 BLU 1090 178 306 520 DN65 500 790 446 900 400 528 290 1260 966 565 RS 310 EV O2 BLU 1090 178 306 520 DN65 500...

Page 12: ...0 RS 610 EV O2 BLU 1000 WARNING The firing rate value Fig 3 has been obtained considering an ambient temperature of 20 C an atmospheric pressure of 1013 mbar approx 0 m a s l and with the combustion head adjusted as shown on page 24 Fig 3 Thermal power kW Combustion chamber combustion head mbar 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 0 2 4 6 8 10 12 14 16 18 5200 5600 6000 6400 6...

Page 13: ... rates were set in relation to special test boilers accord ing to EN 676 regulations In Fig 4 you can see the diameter and length of the test combus tion chamber Example RS 510 EV O2 BLU Output 5000 kW diameter 100 cm length 5m 4 10 Burner equipment Gasket for gas train adaptor No 1 Adaptor for gas train No 1 Screws for fixing the gas train adaptor M 16 x 70 No 4 Thermal insulation screen No 1 M 1...

Page 14: ...ombustion head air pressure test point 20 Maximum gas pressure switch with pressure test point 21 Flame sensor probe 22 Hinge for opening the burner 23 Pressure test point for air pressure switch 24 Combustion head air pressure test points 25 Gas train adapter 26 Indication for checking the rotation direction of the purging motor 27 Flame inspection window 28 Adapt for flame sensor kit 29 Rpm sens...

Page 15: ...8 Relay with clean contacts for signalling the burner is in lock out 9 Relay with clean contacts for signalling the burner is operat ing 10 Auxiliary circuits fuse includes a spare fuse 11 Air pressure switch 12 Ignition transformer 13 Ionisation probe cable 14 Operator panel with LCD display 15 Light signalling burner lockout and reset button 16 Light signalling OVERLOAD FAN MOTOR 17 Control box ...

Page 16: ...grammed the person making the plant settings must continu ously monitor the quality of the combustion process e g by means of a flue gas analyser Also if combustion levels are poor or in the event of danger ous situations the commissioning engineer must take appropriate action e g switching off manually To ensure the safety and reliability of the LMV5 system the fol lowing instructions must also b...

Page 17: ...AC 188 V Oil pump magnetic clutch nominal voltage Nominal current Power factor 2A cos 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cos 0 4 Load on output terminals Total load on the contacts Mains voltage Total unit input current safety circuit load on contacts due to Fan motor contactor Ignition transformer Valve Oil pump magnetic clutch AC 230 V 15 10 Max ...

Page 18: ... The holding torque is reduced when the actuator s power sup ply is switched off Technical data Tab I WARNING To avoid injury to persons damage to prop erty or the environment the following warn ing notes should be observed Do not open interfere with or modify the ac tuators WARNING The housing cover may only be removed for short periods of time for wiring or when making the addressing It must be ...

Page 19: ...le lengths 10 m fino a QGO20 Cross sectional areas Refer to description of QGO20 Analog inputs Air temperature detector Pt1000 LG Ni1000 Flue gas temperature Pt1000 LG Ni1000 QGO20 Refer to data sheet N7842 Interface Communication bus for LMV52 Model PLL52 Mains voltage X89 01 AC 230 V 15 10 Safety class I class with parts according to II class DIN EN 60730 1 Mains frequency 50 60 Hz 6 Power consu...

Page 20: ...aning the inlet and outlet allow the sensor to cool down for at least 1 hour Mount the sensor such that the connecting part head to flange is free so that the exchange of air is ensured Other wise measurements might get distorted possibly leading to dangerous situations Ensure that there are no chemicals such as solvent vapors near the sensor Installation notes The flue gas flow passing the measur...

Page 21: ...ue gas velocity only with AGO20 1 10 m s Fuel type Fuel oil EL or Natural gas H Measuring range 0 2 20 9 O2 Permissible cable length Max 100 m Wire diameter 10 m Power supply lines Net cable Cable diameter Cable type Min 1 mm QGO20 000D27 e g NYM 3 x 1 5 QGO20 000D17 UL AWM Style 1015 MTW or CSA AWM TEW Required operating temperature of measuring cell 700 C 50 C Environmental conditions Storage Cl...

Page 22: ...iler must be free from hazardous mixes e g chloride fluoride halo gen if present it is highly recommended to carry out cleaning and maintenance more frequently WARNING The handling operations for the burner can be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check ...

Page 23: ...ng 2 5 Fig 14 is not necessary unless expressly requested by the boiler manufacturer Tab M 5 6 Securing the burner to the boiler Fit the heat insulation supplied onto the blast tube 4 Fig 14 Fit the entire burner onto the boiler hole prepared previously Fig 13 and fasten with the screws supplied WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 12 Installation 1 is prefer...

Page 24: ...g around the hinge and release the cables of the probe 5 and electrode 11 D fully open the burner as in Fig 15 E undo the screw 4 with pressure test point F release the head by lifting it from its housing 3 then take out the combustion head WARNING To open the burner from the opposite side before removing the pin 1 Fig 15 make sure that the 4 screws 2 are tight Then shift the pin 1 to the op posit...

Page 25: ...ce the gas butterfly valve The correct position is shown in Fig 17 WARNING Check that the probe and the electrode are placed as in Fig 16 according to the dimensions indicat ed Fig 16 20071251 Electrode Probe Place in line with the hole RS 410 510 610 EV O2 BLU RS 310 EV O2 BLU Fig 17 20078516 YES NO ...

Page 26: ...quipped with central air gas adjust ment The factory setting is the following AIR notch 9 GAS notch 0 Only for specific cases to change the central gas setting do as follows loosen the screws 1 and rotate the ring nut 3 until the notch you have found corresponds with the indicator 4 Fig 20 To change the central air setting do as follows loosen the screws 1 and rotate the ring nut 2 until the notch...

Page 27: ...er 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer Explosion danger due to fuel leaks in the pres ence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fu...

Page 28: ...n er gas train combination manual 5 11 3 Gas train installation DANGER Disconnect the electrical power using the main switch Check that there are no gas leaks Pay attention when handling the train danger of crushing of limbs Make sure that the gas train is properly installed by checking for any fuel leaks The operator must use the required equipment during installation Fig 25 20110504 ...

Page 29: ... the right column 1 the pressure at the test point P1 Fig 25 Add this value to the estimated pressure in the combustion chamber Example for RS 410 EV O2 BLU with G20 natural gas Required burner maximum output operation 4450 kW Gas pressure at an output of 4450 kW 53 1 mbar Pressure in combustion chamber 5 mbar 53 1 5 58 1 mbar Pressure required at test point P1 Fig 25 Tab N kW 1 p mbar 2 p mbar G ...

Page 30: ...ficiency at start up Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case a time switch should be fitted in series to TL to stop the FS2 burner at least once every 72 hours Refer to the wir ing diagrams The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system made according to current st...

Page 31: ... safety devices Bore for M20 3 Minimum gas pressure switch Bore for M20 4 VPS gas valve leak detection control kit Bore for M20 5 Gas train Bore for M20 6 Available Bore for M20 7 Available Bore for M16 8 Available Bore for M32 Cable grommets used in the factory A Rpm sensor B Maximum gas pressure switch C Servomotors After carrying out maintenance cleaning or checking operations reassemble the co...

Page 32: ...erential pressure gauge Fig 27 with socket on the gas pressure of the pipe coupling and in the combustion chamber The manometer readings are used to calculate MAX burner output using the Tab N Connect two lamps or testers to the two gas line solenoids to check the exact moment in which voltage is supplied This operation is unnecessary if each of the two solenoids is equipped with a pilot light tha...

Page 33: ...system The first start up and curve synchronisation manual is supplied with the burner At request the complete manual for the control and setting of all parameters is available DANGER Make sure that the lamps or testers connected to the solenoids or indicator lights on the solenoids themselves show that no voltage is present If voltage is present stop the burner immediately and check the electrica...

Page 34: ...3 MIN output 4 Intermediate outputs between Min and Max 5 Air pressure switch 6 Maximum gas pressure switch 7 Minimum gas pressure switch 6 4 4 Output upon ignition Ignition must occur at a lower output than the max operation out put Regulations provide that the ignition output of this burner must be equal to or less than 1 3 of the MAX operation output Example MAX operation output of 600 kW The i...

Page 35: ...f the pressure switch shown by the white mark on a blue background between the two arrows Now check the correct start up of the burner If the burner locks out again turn the knob anti clockwise a little bit more During these operations it may be useful to measure the air pressure with a pressure gauge The connection of the pressure gauge is shown in Fig 29 The standard configuration is that with t...

Page 36: ...t remove the pressure gauge and close the tap 6 6 2 Minimum gas pressure switch Adjust the minimum gas pressure switch Fig 31 after perform ing all the other burner adjustments with the pressure switch set to the start of the scale With the burner operating at maximum output increase adjust ment pressure by slowly turning the relative knob clockwise until the burner stops Now turn the knob anticlo...

Page 37: ... during operation the burner will lockout within 1s 6 10 Stopping of the burner The burner can be stopped by intervening on the disconnecting switch of the electrical sup ply line located on the boiler panel using the switch 0 AUTO of Fig 28 on page 31 6 11 Final checks with burner operating Tab O WARNING In the event the burner stops in order to prevent any damage to the installation do not unblo...

Page 38: ...e amount of air is reached by reducing the air rate of the air regulating actuators For that purpose the damper positions of these actuators are cal culated from some other load point on the ratio control curves Hence due to the parameterized ratio control curves the air reg ulating actuators are in a fixed relation to one another O2 trim control is supported by precontrol It calculates the air ra...

Page 39: ... turn on at the same time as their power supply 7 2 3 Checking and cleaning Combustion head Open the burner and make sure that all components of the combustion head are in good condition not deformed by the high temperatures free of impurities from the surroundings and correctly positioned Burner Check that there are not excess wear or loosen screws Clean the outside of the burner Fan Check to mak...

Page 40: ...onisation current dis connect the plug socket on the ionisation probe cable and insert a direct current microammeter with a base scale of 100 µA as shown in Fig 34 7 2 6 Checking the air and gas pressure on the combustion head To carry out this operation it is necessary to use a pressure gauge to measure the air and gas pressure at the combustion head as shown in Fig 35 EN 676 Air excess Max outpu...

Page 41: ... use the same procedure set out in Access to head internal part on page 22 7 5 Closing the burner Refit following the steps described but in reverse order refit all burner components as they were originally assembled 2 1 3 3 2 4 20082216 Fig 36 DANGER Disconnect the electrical supply from the burner by means of the main system switch DANGER Turn off the fuel interception tap Wait for the component...

Page 42: ... O2 BLU 400V 12 15 20163096 RS 610 EV O2 BLU 400V 15 15 20163096 WARNING The use of inverters other than those indicated by the manufacturer may lead to burner failure and in extreme cases a potential risk of harm to people and damage to property The manufacturing company shall not be liable for any such damage arising from non observance of the requirements contained in this manual Code On demand...

Page 43: ... control function See gas train booklet Gas trains in compliance with EN 676 Please refer to manual Burner Ramp type Code All models MB CB 3010344 WARNING The installer is responsible for the addition of any safety device not foreseen in this manual ...

Page 44: ... 52 6 Functional layout LMV 52 7 Functional layout LMV 52 8 Functional layout LMV 52 9 Functional layout LMV 52 10 Functional layout LMV 52 with Kit O2 11 Functional layout LMV 52 12 Functional layout PLL 52 QGO 20 with Kit O2 13 Electrical wiring that the installer is responsible for 14 Electrical wiring that the installer is responsible for 1 2 Sheet no 1 A1 Co ordinates Indication of references...

Page 45: ...43 20175134 GB Appendix Electrical panel layout 0 1 2 0 1 2 0 0 1 2 3 4 5 0 6 6 6 7 6 8 6 6 6 6 6 6 6 6 6 6 7 6 9 ...

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Page 47: ...45 20175134 GB Appendix Electrical panel layout 0 1 1 2 1 2 3 1 4 1 2 1 2 2 1 1 1 1 1 51 5 5 1 1 2 3 1 2 ...

Page 48: ...20175134 46 GB Appendix Electrical panel layout 0 1 2 1 2 3 1 3 4 1 5 1 3 1 3 3 1 1 1 21 2 1 61 6 6 2 1 1 3 4 1 3 ...

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Page 52: ...20175134 50 GB Appendix Electrical panel layout 0 0 0 1 0 2 0 0 0 0 0 0 0 30 3 3 0 0 1 0 ...

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Page 54: ...20175134 52 GB Appendix Electrical panel layout 01 2 2 2 01 2 2 3 3 3 4 3 5 3 3 3 3 3 3 3 3 3 3 4 3 01 01 0 0 0 ...

Page 55: ...53 20175134 GB Appendix Electrical panel layout 01 2 2 2 2 2 3 3 3 4 3 5 3 3 3 3 3 3 3 3 3 3 4 3 01 01 01 ...

Page 56: ...al panel layout 0 1 2 1 3 4 05 6789 7 4 0 5 6 4 0 5 678 3 4 05 6789 0 0 5 6 0 5 678 0 4 4 4 3 4 05 6789 3 4 05 6789 0 5 6 0 5 678 0 0 5 6 0 5 678 0 4 4 4 7 23 23 A A A B A A A A A A A A A A A B A C 9 D 2 2E A A A ਅ A F 7 7 7 G 7 H 7 G ...

Page 57: ...55 20175134 GB Appendix Electrical panel layout ৼ 0 1 1 1 1 1 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 0 2 3 ...

Page 58: ...1 Light signalling of mains live state H2 Fan motor lock out warning lamp ION Ionisation probe K1 Clean contacts output relay burner switched on K2 Clean contacts output relay burner lockout K3 Clean contacts output relay VSD alarm MV Fan motor PA Air pressure switch PE Burner earth PGMax Maximum gas pressure switch PGMin Minimum gas pressure switch PGVP Gas pressure switch for valve leak detectio...

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Page 60: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...