Riello GI/EMME 1400, Manual

Page 1: ...uctions 20162463 2 11 2020 Dual fuel light oil gas burners Two stage progressive or modulating operation CODE MODEL TYPE 20163269 GI EMME 1400 680T80 20163270 GI EMME 2000 681T80 20163306 GI EMME 3000 682T80 20162389 GI EMME 4500 683T80 GB ...

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

Page 3: ... 5 Installation 15 5 1 Notes on safety for the installation 15 5 2 Handling 15 5 3 Preliminary checks 15 5 4 Operating position 16 5 5 Preparing the boiler 16 5 6 Lifting points 17 5 7 Positioning the electrode 17 5 8 Air damper setting 17 5 9 Nozzle installation 18 5 10 Combustion head adjustment 19 5 11 Light oil supply 20 5 12 Hydraulic operation diagram 21 5 13 Pressure variator 21 5 14 Pump 2...

Page 4: ...7 1 Notes on safety for the maintenance 38 7 2 Maintenance programme 38 7 3 Opening the burner 40 7 4 Closing the burner 40 8 LED indicator and special function 41 8 1 Description of LED lamps 41 8 2 Check mode function 41 8 3 Flame control lock out or emergency stop condition 41 8 4 LED lamps burner operating status 42 9 Problems Causes Remedies signalled by LED indicators 43 A Appendix Accessori...

Page 5: ...se products are in compliance with the following Technical Standards EN 676 EN 267 EN 12100 and according to the European Directives MD 2006 42 EC Machine Directive LVD 2014 35 EU Low Voltage Directive EMC 2014 30 EU Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Legnago 21 04 2018 General Manager RIELLO S p A B...

Page 6: ...rried out correctly may cause damage to the machine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not carried out correctly lead to electric shocks with lethal 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 CRUSH...

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 incorrectly applied an...

Page 8: ...ntenance 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 responsible for the machine and for the training of the people working around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel und...

Page 9: ...ME Size Fuel Natural gas Light oil Adjustment Voltage of auxiliaries 220 60 GI EMME 2000 TC Emission C11 or Class 1 EN267 EN676 C22 or MZ Class 2 EN267 EN676 C33 or BLU Class 3 EN267 EN676 FS1 3 220 380 60 220 60 BASIC DESIGNATION EXTENDED DESIGNATION 220V 60Hz Heavy oil E Electronic cam EV Electronic cam and variable speed with Inverter P Proportional air gas valve BP Two stage light oil Proporti...

Page 10: ... FR I2Er BE I2E R B LU PL I2E Model GI EMME 1400 GI EMME 2000 GI EMME 3000 GI EMME 4500 Type 680T80 681T80 682T80 683T80 Output Min Max kW 415 814 1660 590 1163 2370 890 1744 3560 1190 2325 5100 Mcal h 357 700 1428 507 1000 2040 765 1500 3061 1020 2000 4386 Fuel Natural Gas G20 methane gas 8 10 kWh Nm3 Light oil max viscosity at 20 C 6 cSt 1 5 E Maximum gas pressure mbar 200 360 360 360 Minimum ga...

Page 11: ...681T80 682T80 683T80 Electrical power supply V Hz 3N 220 380 60 3N 380 60 Fan motor IE3 rpm kW V A 3520 3 0 220 380 10 2 5 9 3530 4 0 220 380 15 5 9 3540 9 2 220 380 30 5 17 6 3520 15 380 660 28 4 16 4 Pump motor kW V A 1 1 220 380 4 2 3 1 5 220 380 5 2 3 Ignition transformer V1 V2 I1 I2 230 V 2 x 6 kV 2 3 A 35 mA Absorbed electric power Light oil kW max 5 6 2 12 3 18 6 Absorbed electric power Gas...

Page 12: ...on chamber dimensions are clearly smaller than those indicated in the diagram consult the manufacturer The firing rates were obtained in special test boilers according to EN 676 standard In Fig 3 you can see the diameter and length of the test combustion chamber Example Output 7000 kW diameter 120 cm length 6 m MODULATING RATIO The modulating ratio obtained in test boilers according to standard EN...

Page 13: ...vomotor 7 Air adjustment cam 8 Gas pressure socket to sleeve 9 Gas regulator 10 Return pressure adjustment cam 11 Oil pressure switch 12 Pressure gauge on return 13 Pressure gauge on delivery 14 Pump unit 15 Gas adjustment cam 16 Fan motor Fig 4 20163838 ATTENTION The motor overload relay release on the burner GI EMME 4500 is located inside the starter the pump motor overload relay release is loca...

Page 14: ...cket on servomotor cable 5 Flame sensor 6 Control box base 7 Ignition transformer 8 Oil valve coils 9 Pump motor contactor and thermal relay 10 Selector switch OIL 0 GAS 4 11 Burner equipment Gasket for gas train No 1 Thermal insulation screen No 1 Screws No 12 Extensions No 2 Insulating flange gasket No 1 Flexible hoses No 2 Nipples No 2 Fair leads No 4 Washers No 8 Instruction No 1 Spare parts l...

Page 15: ...ions Do not confuse the powered conductors with the neutral ones Ensure that spliced wires cannot get into contact with neighbouring terminals Use adequate ferrules Arrange the H V ignition cables separately as far as possible from the control box and the other cables When wiring the unit make sure that AC 230 V mains voltage cables are run strictly separate from extra low voltage cables to avoid ...

Page 16: ... be checked after long periods of non use Technical data ATTENTION To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the servomotor Mains voltage 230 V 15 10 Mains frequency 50 60 Hz Power absorption 10 VA Motor Synchronous Drive angle Varying between 0 and 135 Protection level Max IP 66 with appropriate cable entry Cable entr...

Page 17: ...on air inside the boiler must be free from hazardous mixes e g chloride fluoride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently ATTENTION Burner handling operations can be highly dangerous if not carried out with the greatest attention distance unauthorised personnel check integrity and suitability of the means available Check also that the area i...

Page 18: ...TION The burner is designed to operate only in positions 1 2 3 and 4 Fig 9 Installation 1 is preferable as it is the only one that allows the maintenance operations as described in this manual Installations 2 3 and 4 allow operation but make maintenance and inspection of the combustion head more difficult DANGER Any other position could compromise the correct operation of the appliance The install...

Page 19: ... rotation of the cam Calibrate in sequence the maximum output the minimum output and the intermediate outputs At the end of the operation check all calibrations restore the electrical connections of the servomotor and lock the adjustment screws by means of the transversal ones Provide an adequate lifting system Fig 11 Lift the burner by means of the hooks to fix it to the boiler without separating...

Page 20: ...330 360 400 450 Bergonzo 70 80 90 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 Angles of 45 50 are usually recommended for narrow combustion chambers use nozzles with 30 35 angles To calibrate the delivery range of the nozzle adjust the fuel maximum and minimum pressure on the nozzle return line as shown in Fig 14 Approximate ration between Nozzle type and delivery in Pressure on th...

Page 21: ...is needed act as follows with servomotor at 0 loosen the screws 5 and push in the arrow direction the ring 6 placed under the variable profile cam This allows obtaining a reduction of the eccentricity with a consequent reduction of the stroke Once the desired stroke has been found firmly lock the screws 5 In the previous example stroke 5 5 notches the start and end of the stroke must coincide with...

Page 22: ...erforming any operation on the burner ATTENTION The fuel supply line must be installed by qualified personnel in compliance with current standards and laws CAUTION Make sure that the hoses to the pump supply and return line are installed correctly ATTENTION Follow the instructions below Tighten the flexible hoses with the supplied gaskets During the installation hoses must not be stressed with twi...

Page 23: ...ntil the desired eccentricity is obtained by turning screw 4 to the right the eccentricity increases thereby increasing the difference between the maximum and minimum capacity of the nozzle by turning screw 4 to the left the eccentricity decreases thereby decreasing the difference between the maximum and minimum capacity of the nozzle At every eccentricity variation it may be necessary to offset t...

Page 24: ... 6 By pass screw 7 Pressure gauge attachment Pump GI EMME 1400 TA2C GI EMME 2000 TA3C GI EMME 3000 4500 TA4C Nozzle pressure range bar 7 40 7 40 7 40 Delivery pressure setting bar 30 30 30 Operating viscosity mm s cSt 3 75 3 75 3 75 Oil temperature in the pump C 0 150 0 150 0 150 Inlet pressure bar 0 45 0 45 0 45 Return pressure bar 5 5 5 Pressure calibration in the factory bar 30 30 30 Rated spee...

Page 25: ...ts over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train burner adaptor supplied separately P2 Pressure upstream of valves adjuster P3 Pressure upstream of the filter L Gas train supplied separately L1 Responsibility of the installer Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fu...

Page 26: ...talled by checking for any fuel leaks The operator must use the required equipment during installation Fig 25 20167882 kW 1 p mbar G 20 G 25 G M 1400 814 10 3 15 4 889 11 1 16 5 978 12 2 18 2 1067 13 3 19 8 1156 14 4 21 5 1244 15 6 23 2 1333 16 7 24 9 1422 17 8 26 5 1511 18 9 28 2 1660 21 5 32 G M 2000 1163 10 14 9 1258 11 7 17 4 1366 13 3 19 8 1473 14 6 21 8 1581 15 9 23 7 1689 17 2 25 6 1797 18 ...

Page 27: ...on the left Example G M 3000 with natural gas G20 Operation at maximum modulating output A pressure of 27 9 mbar column 1 corresponds in Tab L to an output of 2983 kW This value serves as a rough guide the effective output must be measured at the gas meter To calculate the required gas pressure at test point 2 Fig 26 set the maximum modulating output required from the burner operation find the nea...

Page 28: ...ications requiring a burner operating cycle longer than 24 hours When it is used as a UV control the system is considered as non permanent requiring one burner recycle every 24 hours Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case you must apply a time switch to L N in series to stop the burner at least once every 24 hours Refer to the wiri...

Page 29: ...it in the arrow direction to the right to carry out the thermal relay test 5 18 Motor rotation As soon as the burner starts place yourself in front of the cooling fan of the fan motor and check that it turns anticlockwise Fig 29 If this is not the case put the switch of the burner to 0 off and wait until the control box carries out the switching off phase Invert the phases on the three phase motor...

Page 30: ...st is sent At first ignition there is a momentary drop in fuel pressure due to the filling of the nozzle piping This lowering of the fuel pressure can cause the burner to lockout and can sometimes give rise to pulsations If the burner locks out again refer to chapter Problems Causes Remedies signalled by LED indicators on page 43 Once the following adjustments have been made the ignition of the bu...

Page 31: ...resence of voltage stop the burner immediately and check the electric connections When the limit thermostat TL closes the heat request is sent and the burner begins the starting cycle 6 6 Burner ignition If the motor starts but the flame does not appear and the control box goes into lockout reset and wait for a new ignition attempt If ignition does not occur it is possible that gas is not reaching...

Page 32: ...hat is described below for each cam Cam I RED 135 The same for all models Limits rotation toward maximum position ATTENTION Do not make any adjustments Cam II BLUE 0 The same for all models Limits rotation toward minimum position With the burner off the air damper is completely closed 0 ATTENTION It is recommended that no adjustments are made Cam III ORANGE 20 The same for all models Adjusts the p...

Page 33: ...t possible to the maximum opening 130 On the gas butterfly valve fuel step according to the burner output required with servomotor completely open is carried out by the pressure stabiliser placed on the train The values indicated in Tab M and Tab N can be a reference for a good combustion calibration Tab M Tab N EN 676 Air excess CO Max output 1 2 Max output 1 3 GAS Theoretical max CO2 0 O2 CO2 Ca...

Page 34: ...ormula Example for G20 Max operation output 1800 kW corresponding to 180 Nm3 h After 10 ignitions with a lockout the delivery indicated on the meter must be equal to or lower than 180 360 0 5 Nm3 6 10 Air fuel adjustment The following adjustments must be performed during the calibration of the air fuel ratio A Oil pump delivery pressure act on the screw 5 Fig 4 on page 11 located on the pump B Air...

Page 35: ...djustment increase the output supplied via the automatic return selector on the control panel Pause after a 15 rotation of the servomotor and perform another adjustment by means of the variable profile cam of the air It is recommended to perform a calibration that will prevent the formation of a smoky flame and arrive as soon as possible to the maximum output maximum stroke of the servomotor 130 o...

Page 36: ...e measurement read on the gauge when the burner is working at maximum output After making the adjustment remove the pressure gauge and close the tap 6 11 3 Minimum gas pressure switch Adjust the minimum gas pressure switch after performing all the other burner adjustments with the pressure switch set to the start of the scale Fig 36 With the burner operating at maximum output increase adjustment p...

Page 37: ...stment screw Fig 37 6 11 6 Air bleeding It is carried out by opening the relevant screw placed on the minimum gas pressure switch fitted on the gas train 6 11 7 Gas butterfly valve The gas butterfly valve is equipped with an external adjustment see Fig 39 that can facilitate the following calibration of the cam in case of low pressure values available in the network By means of ring nut B it is po...

Page 38: ...ly valve the airflow fan damper and the air pressure 2 shutters in the combustion head Burner with output regulator RWF50 See the manual supplied with the regulator Burner flame goes out during operation If the flame should accidentally go out during operation the burner will lock out within 1s 6 12 3 Ignition failure If the burner does not ignite it locks out within 3 seconds after the gas valve ...

Page 39: ...inimum end of scale position Turn the air pressure switch knob to the maximum end of scale position The burner must stop in lockout Turn off the burner and cut off the power Disconnect the minimum gas pressure switch connector The burner must not start Disconnect flame detection sensor electrical connections The burner must stop in lockout due to ignition failure ATTENTION Make sure that the mecha...

Page 40: ...with respect to the previous measurements indicate the points where most care should be exercised during maintenance 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 Combustion head maintenance Repeat the operations described in parag...

Page 41: ...If the combustion values measured before starting maintenance do not comply with applicable Standards or do not indicate efficient combustion consult the table below or contact our Technical Support Service to implement the necessary adjustments Tab P Gas leaks Make sure that there are no gas leaks on the pipe between the gas meter and the burner Gas filter Change the gas filter when it is dirty C...

Page 42: ... 5 leaving it open by approx 100 120 mm Refit the fork 7 fixing it with the screws 10 Completely close the burner fastening it with screws 3 fit the retainers 4 the split pin 2 the gas butterfly valve tie rod 11 and the pipes 6 With burner open it is possible to separate the gas sleeve 8 from the blast tube 7 4 Closing the burner Refit following the steps described but in reverse order refit all b...

Page 43: ...LED starting from the flame LED represents 20 of the signal power To exit the check mode function press the reset button the flame control will go back to the normal operating mode 8 3 Flame control lock out or emergency stop condition The RFGO control device can be locked out emergency stop at any time during the operating cycle and unlocked when already locked lock out by simply pressing the key...

Page 44: ...per open Damper closed Modulation Ignition Flame Status Icon Power OFF ON OFF Not ready Diagnostics Green Standby Green Servomotor movement Note 3 OFF Flashing Flashing OFF Green Waiting for closing Green blinking Green OPEN before ignition Green Minimum before ignition Green Ignition Green PTFI Green blinking Green MTFI Green Active modulation Green Minimum output position Green With flame presen...

Page 45: ... cause material problems severe injuries or death It is the owner or user s responsibility to make sure that the equipment described is installed used and commissioned in compliance with the requirements provided both by national and local law The lock out condition indicates the presence of a fault which occurred during the operating cycle or during stand by mode Before performing an unlock attem...

Page 46: ...elay fault Red 19 Combustion airflow switch fault in the rest position Red 20 UV no flame at the end of the 2nd safety time MTFI Red 21 Safety relay fault Red 22 Supervisor processor fault Red 23 Supervisor memory test fault Red 24 Flame loss during the operation AUTO Red 25 Supervisor processor data memory fault Red 26 Supervisor processor internal fault Red 27 Not used 28 Not used 29 Operating t...

Page 47: ... Red 52 Piloted valve feedback fault Red 53 Actuator feedback waiting time expired Red 54 Direct ignition valve feedback fault Red 55 Internal processor fault Red 56 UV false flame during operation Red 57 FR false flame during operation Red 58 T8 inlet fault Red 59 Internal hardware fault Red 60 Local reset fault Red 61 Open POC fault Red 62 UV strong UV flame fault Red 63 Internal hardware fault ...

Page 48: ...sor fault Internal fault Replace the control device 16 No flame 1st safety time PTFI No flame at the end of the first safety time Inspect the system check the gas pressure check the UV scanner check the wiring etc 17 Wiring fault The system detected the presence of voltage on critical terminals T16 T17 T18 or T19 at the wrong moment or there is no voltage when necessary Inspect the wiring and make...

Page 49: ... system detected the presence of voltage on T17 at the wrong moment or there is no voltage when necessary Check the wiring and make sure that the earthing is appropriate If the problem persists contact the distributor factory 52 Piloted valve feedback fault The system detected the presence of voltage on T19 at the wrong moment or there is no voltage when necessary Check the wiring and make sure th...

Page 50: ... kit Thermal relay kit A Appendix Accessories Parameter to be controlled Probe Output regulator Adjustment field Type Code Type Code Temperature 100 500 C PT 100 3010110 RWF50 2 RWF55 5 20100018 20101965 Pressure 0 2 5 bar 0 16 bar Output probe 4 20 mA 3010213 3010214 Burner Code GI EMME 1400 2000 GI EMME 3000 4500 3010021 Burner Thickness mm Code GI EMME 1400 2000 102 3000722 GI EMME 3000 4500 13...

Page 51: ...49 20162463 GB Appendix Accessories Gas trains in compliance with EN 676 Please refer to manual ATTENTION The installer is responsible for the addition of any safety device not foreseen in this manual ...

Page 52: ...ayout RFGO A23 4 Functional layout RFGO A23 5 Functional layout RFGO A23 6 Electrical wiring that is the responsibility of the installer 7 Electrical wiring that is the responsibility of the installer 8 Electrical wiring that is the responsibility of the installer 9 Functional layout RWF 1 2 Sheet no 1 A1 Coordinates Indication of references ...

Page 53: ...51 20162463 GB Appendix Electrical panel layout 0 112 0 112 0 112 0 112 3 4566 781 9 6 3 4 3 87 53 6 4 3 486 3 97 5 A A A B A C A A A A A A A A A A B A 0 112 ...

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Page 70: ...20162463 68 GB Appendix Electrical panel layout 001 001 001 001 2 3455 670 8 9 5 2939 2 76 42 5 3 29375 92986 4 A B A 001 ...

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Page 77: ...tection control IN Burner manual stop switch KMP Pump motor contactor KM Fan motor contactor KT1 Triangle contactor KS1 Star contactor KL1 Line contactor KST1 Timing relay for switching from star to triangle MP Pump motor MV Fan motor PA Air pressure switch PC Leak test pressure switch PGMin Minimum gas pressure switch POMax Maximum oil pressure switch Q1 Three phase disconnecting switch of fan mo...

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Page 80: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...