Riello RS 100 E, Installation, Use And Maintenance Instructions

Page 1: ...20017786 7 05 2012 Installation use and maintenance instructions Forced draught gas burners Progressive two stage or modulating operation Code Model 20016861 RS 70 E 20016862 RS 100 E 20016863 RS 130 E ...

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Page 3: ...operating condition in high altitude plants 10 3 9 Burner components 12 3 10 Control box for the air fuel ratio LMV37 4 13 3 11 Actuators SQM33 5 16 4 Installation 17 4 1 Notes on safety for the installation 17 4 2 Handling 17 4 3 Preliminary checks 17 4 4 Operation position 17 4 5 Securing the burner to the boiler 18 4 5 1 Boring the boiler plate 18 4 5 2 Length of the blast tube 18 4 6 Combustio...

Page 4: ... 5 Final calibration of the pressure switches 28 5 5 1 Air pressure switch 28 5 5 2 Maximum gas pressure switch 28 5 5 3 Minimum gas pressure switch 28 5 6 Final checks with the burner working 29 6 Maintenance 30 6 1 Notes on safety for the maintenance 30 6 2 Maintenance programme 30 6 2 1 Maintenance frequency 30 6 2 2 Checking and cleaning 30 6 3 Opening the burner 31 6 4 Closing the burner 31 A...

Page 5: ...enerator is to be installed The instruction manual shows the serial number of the burner the address and telephone number of the nearest Assis tance Centre The system supplier carefully informs the user about the use of the system any further tests that may be necessary before the system is started up maintenance and the need to have the system checked at least once a year by the manufacturer or a...

Page 6: ...s manual 1 2 1 Owner s responsibility Please pay attention to the Safety Warnings contained within this instruction manual Keep this manual for your records and provide it to your quali fi ed service agency for use in profession ally setting up and maintaining your burner Your burner will provide years of ef fi cient operation if it is pro fessionally installed and maintained by a qualifi ed servi...

Page 7: ...h the burner components is not allowed apart from the parts requiring maintenance Only those parts envisaged by the manufacturer can be replaced 2 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 working around it The user Undertakes to entru...

Page 8: ...plications Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Combustion air temperature F max 140 60 C Noise levels 3 dB A 75 77 78 5 Model RS 70 E RS 100 E RS 130 E Control circuit power supply V Ph Hz 120 1 60 Main electrical supply V Ph Hz 208 230 3 60 Fan motor rpm W HP V A 3400 1100 1 5 208 230 4 7 3360 1800 2 4 208 230 7 4 3400 2200 3 208 230 8 5 Ignition transformer V1 V2 ...

Page 9: ...umption W 2100 3350 3350 Electrical protection NEMA 1 Model RS 70 E RS 100 E RS 130 E Control circuit power supply V Ph Hz 120 1 60 Main electrical supply V Ph Hz 460 3 60 Fan motor rpm W HP V A 3475 1100 1 5 460 2 3500 2200 3 460 3 9 3500 2200 3 460 3 9 Ignition transformer V1 V2 I1 I2 120 V 1 X 8 kV 1 6 A 20 mA Electrical power consumption W max 1350 2600 2600 Electrical control circuit coms W 7...

Page 10: ...ng obtainable with kit 3 6 Burner equipment The burner is supplied complete with 1 Gas train flange 1 Flange gasket 4 Flange fixing screws 3 8 W x 1 1 Burner head gasket 2 Extensions for slide bars for kit 4 Screws to secure the burner flange to the boiler 1 2 W 1 Instruction manual and spare parts list inch A 1 B C lbs RS 70 E 46 27 32 52 5 32 29 1 8 27 1 4 154 RS 100 E 46 27 32 52 5 32 29 1 8 27...

Page 11: ...10 to refer burner operating condition in high altitude plants 3 7 1 Minimum furnace dimensions The firing rates were set in relation to certified test boilers Fig 4 indicates the diameter and length of the test combustion chamber Example output 2579 MBtu hr diameter 24 inch length 6 6 ft Model MBtu hr RS 70 E 512 RS 100 E 568 RS 130 E 607 WARNING The firing rate area values have been obtained con...

Page 12: ... 1220 1525 1830 2135 2440 ft a s l 0 328 1000 2000 3000 4000 5000 6000 7000 8000 500 494 500 512 530 551 571 593 616 641 669 1000 987 1000 1023 1061 1101 1142 1186 1232 1282 1337 1500 1481 1500 1535 1591 1652 1713 1778 1848 1924 2006 2000 1974 2000 2046 2121 2202 2284 2371 2464 2565 2675 2500 2468 2500 2558 2652 2753 2855 2964 3079 3206 3343 3000 2962 3000 3069 3182 3303 3425 3557 3695 3847 4012 3...

Page 13: ... 35 4 50 4 44 4 50 4 60 4 77 4 95 5 14 5 33 5 54 5 77 6 02 5 00 4 94 5 00 5 12 5 30 5 51 5 71 5 93 6 16 6 41 6 69 5 50 5 43 5 50 5 63 5 83 6 06 6 28 6 52 6 77 7 05 7 35 6 00 5 92 6 00 6 14 6 36 6 61 6 85 7 11 7 39 7 69 8 02 6 50 6 42 6 50 6 65 6 89 7 16 7 42 7 71 8 01 8 34 8 69 7 00 6 91 7 00 7 16 7 42 7 71 7 99 8 30 8 62 8 98 9 36 7 50 7 40 7 50 7 67 7 96 8 26 8 56 8 89 9 24 9 62 10 03 8 00 7 90 ...

Page 14: ...ng accessories and power supply to be carried out by the installer 18 Air actuator 19 Low air pressure switch 20 Guides for opening the burner and inspecting the combustion head 21 Gas pressure test point and head fixing screw 22 Air pressure socket 23 RWF40 modulator 24 Air damper 25 Fan air inlet 26 Screws to secure fan to pipe coupling 27 Gas input pipe 28 Gas butterfly valve 29 Boiler fixing f...

Page 15: ...its via which it is possible to easily identify any causes of malfunctioning Mechanical design The following system components are integrated in the LMV37 4 basic unit Burner control with gas valve proving system Electronic air fuel ratio control Control frequency converter air fan Modbus interface Installation notes Always run high voltage ignition cables separately while observ ing the greatest ...

Page 16: ...al voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 cos 0 4 Alarm output Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 A cos 0 4 Ignition transformer Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 or 250 VA ignition load declaration to UL372 cos 0 2 Fuel valves Nominal vol...

Page 17: ... T P 10 Shutdown Operation Startup Valve proving OUTPUTS INPUTS Phase number Fuel Actuator 2 Air Actuator 1 Actuators Safety limit thermostat STB Control thermostat or pressurestat R Flame signal FS Air pressure switch LP Pressure switch min Pmin Pressure switch max Pmax Valve proving leakage test P LT POC alternative to Pmax No load position Ignition load Postpurge position Nominal load Low fire ...

Page 18: ... can be seen on the display of the Operator Panel Index 0 for fuel actuator index 1 for air actuator Installation notes Always run the high voltage ignition cables separate from the unit and other cables while observing the greatest possible dis tance The holding torque is reduced when the actuator is disconnect ed from power Technical data Tab J WARNING To avoid injury to persons damage to proper...

Page 19: ...the installation maintenance and disassembly operations must be carried out with the electricity supply disconnected WARNING The installation of the burner must be carried out by qualified personnel as indicated in this manu al and in compliance with the standards and reg ulations of the laws in force WARNING The handling operations for the burner can be highly dangerous if not carried out with th...

Page 20: ...are those in dicated in the table below For boilers with front flue passes 13 Fig 11 or flame inversion chambers a protection in refractory material 11 must be insert ed between the boiler refractory 12 and the blast tube 10 This protection must not compromise the extraction of the blast tube See Fig 11 For boilers with a water cooled frontal a refractory lining is not necessary 11 12 Fig 11 unles...

Page 21: ...he seal between burner and boiler must be airtight 4 7 Electrode and ignition pilot adjustment To verify the correct position of the electrode Fig 13 you need to extract the internal part of the head 2 Fig 14 Place the electrode and the ignition pilot as shown in Fig 13 The ignition pilot works correctly at pressures ranging from 5 12 WC Proceed as follows loosen the 4 screws 3 Fig 11 and remove t...

Page 22: ...4 Fig 15 and turn ring 5 until the notch identified is aligned with index 6 Tighten the 3 screws 4 fully down Example RS 70 E MAX output 2200 MBtu hr If we consult diagram Fig 16 we find that for this output air must be adjusted using notch 3 on screw 2 Fig 15 Diagram Fig 16 shows the ideal settings for the ring 5 Fig 15 If the gas main pressure is too low to reach the max imum output operation pr...

Page 23: ...n the position shown in Fig 11 insert the electrode cable then slide the burner as far as the pipe coupling burner in the position shown in Fig 18 fix the burner to the pipe coupling with the screws 1 CAUTION When fitting the burner on the two guides it is ad visable to gently draw out the high voltage cable un til they are slightly taut Fig 17 D7975 ...

Page 24: ... head within the safety time of 3s Ensure that the maximum pressure necessary for the burner is included in the calibration field of the pressure adjuster col our of the spring 4 10 Gas feeding line It must be type approved according to required standards and is supplied separately from the burner Key Fig 19 1 Gas input pipe 2 Manual valve 3 Pressure regulator 4 Minimum gas pressure switch 5 1st s...

Page 25: ...sure from the gas pres sure measured at test point 1 Fig 21 Find the nearest pressure value to your result in the diagram for the burner in question Read off the corresponding output on the left Example RS 100 E Maximum output operation Natural gas Gas ring adjust as indicated in diagram Fig 16 Gas pressure at test point 1 Fig 21 3 15 WC Pressure in combustion chamber 1 18 WC 3 15 1 18 1 97 WC A m...

Page 26: ...tions or connections different from those shown in the electri cal layouts Check that the electrical supply of the burner corresponds to that shown on the identification label and in this manual Do not invert the neutral with the phase in the electrical supply line Any inversion would cause a lockout due to firing failure The electrical safety of the device is obtained only when it is correctly co...

Page 27: ...motor is 400V To reset in the case of an intervention of the thermal relay press the button RESET Fig 23 The button STOP Fig 23 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 24 and move it in the sense of the arrow towards right 4 14 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay press t...

Page 28: ...575V WARNING the motors manufactured for 575V IE2 Epact voltage have the same control box base of the IE1 motors Please pay attention to the indications in case of maintenance or substitution 4 17 Reversible direction WARNING If it is necessary to reverse the direction then reverse the two main supply phases For example L1 with L2 there is not difference between IE1 and IE2 Epact D3686 IE1 IE2 Epa...

Page 29: ...s train so that ignition takes place in conditions of maximum safe ty i e with gas delivery at the minimum 5 4 Burner start up Feed electricity to the burner via the disconnecting switch on the boiler panel Close the thermostats pressure switches and turn the switch of Fig 32 to position LOCAL 5 Start up calibration and operation of the burner WARNING The first start up of the burner must be carri...

Page 30: ... switch Adjust the maximum gas pressure switch after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale Fig 35 With the burner operating at MAX output reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out Then turn the dial clockwise by 0 8 WC and repeat burner firing If the burner l...

Page 31: ... mini mum end of scale position Rotate the air pressure switch knob to the maximum end of scale position The burner must stop in lockout Switch off the burner and disconnect the voltage Disconnect the minimum gas pressure switch connector The burner must not start Disconnect the UV flame sensor The burner must stop in lockout due to firing failure Make sure that the mechanical locking systems on t...

Page 32: ...Flame inspection window Clean the glass of the flame inspection window Combustion head Open the burner and make sure that all the components of the combustion head are undamaged not deformed due to high temperature free of ambient dirt or dust free of rusted materials adequately positioned Make sure that the gas outlet holes for the start up on the com bustion head distributor are free of dirt or ...

Page 33: ...remove the screw 6 and extract the inner part 5 of the head 6 4 Closing the burner In order to close the burner re install all components with re verse procedure remove the 2 extensions 9 and re screw the screws 8 on the guides 4 push the burner up to approximately 4 from the pipe cou pling reinsert the electrode lead and slide the burner as far as the stop fix the screws 3 to secure the burner to...

Page 34: ...re parts A Appendix Spare parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 22 23 24 25 26 27 28 29 30 31 32 33 20 35 36 37 38 39 40 42 40 43 44 45 46 47 48 49 50 51 52 53 54 55 56 58 59 60 61 18 58 59 62 63 64 64 65 57 21 ...

Page 35: ...41 BASE B 16 3003949 GRID 17 3013929 AIR DAMPER ASSEMBLY 18 3013930 AIR INTAKE 19 3003952 SOUND DAMPING C 20 20008601 SERVOMOTOR B 21 20028310 CONTACTOR C 22 3003763 INSPECTION WINDOW 23 3003891 CONNECTOR C 24 3012013 BAR 25 3003481 SCREW 26 3003396 UV PROBE 27 20010963 SWITCH 28 3012939 FAN C 28 3012403 FAN C 28 3012940 FAN C 29 3012012 HALF SHELL 30 3012941 MOTOR C 30 3012943 MOTOR C 31 20010962...

Page 36: ... PRESSURE SWITCH B 45 3013055 CONNECTOR C 46 3007891 SEAL A 47 3012049 SCREW 48 3012735 SEAL A 49 3003974 CONTROL DEVICE C 50 3012051 SQUARE 50 3003979 SQUARE 50 3012053 SQUARE 51 3003983 SHUTTER C 51 3003984 SHUTTER C 52 3003987 END CONE B 52 3012055 END CONE B 52 3012057 END CONE B 53 3014079 SPACER 54 3003322 CONNECTOR C 55 3005482 SEAL B 56 3012971 FLANGE AND ELBOW 57 3013263 MANIFOLD 58 30139...

Page 37: ...ccessories 35 20017786 Gas train according to UL Standards B Appendix Accessories WARNING The installer is responsible for the supply and instal lation of any required safety device s not indicated in this manual ...

Page 38: ... Low Fire High Fire Main Power Supply O2 Low Fire High Fire Control Power Supply CO Low Fire High Fire Burner Firing Rate NOX Low Fire High Fire Manifold Pressure Net Stack Temp Low Fire High Fire Pilot Flame Signal Comb Efficiency Low Fire High Fire Low Fire Flame Signal Overfire Draft High Fire Flame Signal CONTROL SETTINGS Operating Setpoint Low Oil Pressure High Limit Setpoint High Oil Pressur...

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