Riello RS 100/M, Installation, Use And Maintenance Instructions

Page 1: ...e instructions Forced draught gas burners Low high low or modulating operation CODE MODEL 20166044 RS 70 M 20166045 RS 70 M 20166046 RS 70 M 20166047 RS 100 M 20166048 RS 100 M 20166049 RS 100 M 20166101 RS 130 M 20166102 RS 130 M 20166103 RS 130 M GB ...

Page 2: ...Original instructions ...

Page 3: ...9 RFGO A13 control box 13 3 10 Servomotor SQM41 14 4 Installation 15 4 1 Notes on safety for the installation 15 4 2 Handling 15 4 3 Preliminary checks 15 4 4 Preparing the boiler 15 4 4 1 Boiler plate 15 4 4 2 Blast tube length 16 4 5 Combustion head calibration 16 4 6 Securing the burner to the boiler 17 4 7 Combustion head setting 17 4 7 1 Air adjustment 17 4 7 2 Gas adjustment 17 4 8 Ignition ...

Page 4: ... 5 8 3 Minimum burner output 31 5 8 4 Intermediate outputs 32 5 9 TRIM potentiometers functions calibration 32 5 9 1 Range Adjustment range 32 5 10 Final checks with the burner working 33 6 Maintenance 34 6 1 Notes on safety for the maintenance 34 6 2 Maintenance programme 34 6 2 1 Maintenance frequency 34 6 2 2 Safety test with gas ball valve closed 34 6 2 3 Checking and cleaning 34 6 2 4 Flame p...

Page 5: ... car ried 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 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...

Page 6: ...t of damage to things or injury to peo ple 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 and o...

Page 7: ...ance 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 ma chine and intends to use it for the specific purpose He is responsi ble 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 under...

Page 8: ...0 3 60 Burner mounted 20166045 460 3 60 20160227 20166046 575 3 60 RS 100 M TC FS1 20160233 20166047 208 230 3 60 Burner mounted 20166048 460 3 60 20160238 20166049 575 3 60 RS 130 M TC FS1 20160253 20166101 208 230 3 60 Burner mounted 20166102 460 3 60 20160256 20166103 575 3 60 Model RS 70 M RS 100 M RS 130 M Output 1 High MBtu hr kW 1761 3084 516 904 2644 4405 775 1291 3521 5545 1032 1625 Low M...

Page 9: ...tective device MOP A 9 16 65 16 65 Control circuit power supply Minimum Circuit Ampacity MCA A 6 3 Maximum rating of overcurrent protective device MOP Model RS 70 M RS 100 M RS 130 M Control circuit power supply V Ph Hz 120 1 60 Main electrical supply 10 V Ph Hz 460 3 60 Fan motor IE3 EPACT rpm HP kW V A 3500 1 5 460 2 3500 3 460 3 7 3500 3 460 3 7 Ignition transformer V1 V2 I1 I2 120 V 1 X 8 kV 1...

Page 10: ...on transformer V1 V2 I1 I2 120 V 1 X 8 kV 1 6 A 20 mA Electrical power consumption W max 1275 2510 2510 Electrical control circuit coms W 750 Total electrical consumption W 2025 3260 3260 Electrical protection NEMA 1 Main electrical power supply Minimum Circuit Ampacity MCA A 2 3 75 3 75 Maximum rating of overcurrent protective device MOP A 3 60 6 75 6 75 Control circuit power supply Minimum Circu...

Page 11: ...last tube short long obtainable with the kit 3 5 Standard equipment Gas train flange No 1 Flange fixing screws M10x40 No 6 Connector for gas pilot No 1 Instruction booklet No 1 P B C T D F N E V L M G H Fig 1 20161124 inch L G M H P T 1 D E V 1 B C N F RS 70 M 20 11 11 32 8 1 2 23 11 32 33 10 15 1 4 7 16 3 4 46 1 4 51 1 2 8 5 16 5 5 8 8 3 4 2 RS 100 M 21 1 4 12 3 4 8 1 2 23 11 32 33 10 15 1 4 7 16...

Page 12: ...h respect to the maximum range that can be reached See Procedure to refer burner operating condition at an altitude and or at a combustion supporter air tempera ture different to the standard values 328 ft above sea level 68 F to page 11 for operation at different ambient temperatures and or altitudes Model MBtu hr kW RS 70 M 512 150 RS 100 M 570 167 RS 130 M 607 178 WARNING The firing rate area v...

Page 13: ... 3 indicates the diameter and length of the test combustion chamber Example Output 2579 MBtu hr diameter 24 inch length 6 6 ft AIR TEMPERATURE Altitude Altitude bar press bar press 0 5 10 15 20 25 30 40 C ft a s l m a s l w c mbar 32 41 50 59 68 77 86 104 F 0 0 399 1013 00 1 087 1 068 1 049 1 031 1 013 0 996 0 980 0 948 328 100 394 1000 00 1 073 1 054 1 035 1 017 1 000 0 983 0 967 0 936 1 000 305 ...

Page 14: ... light signalling lockout and reset button 13 Flame inspection window 14 Low air pressure switch differential operating type 15 Slide bars for opening the burner and inspecting the combus tion head 16 Gas pressure test point and head fixing screw 17 Combustion head air pressure test point 18 Flame sensor 19 Air damper 20 Air inlet to fan 21 Screws securing fan to sleeve 22 Gas input pipework 23 Ga...

Page 15: ...e For the safety and reliability of the control box comply with the following instructions avoid conditions that can favour the development of conden sate and humidity Otherwise before switching on again make sure that the entire control box is perfectly dry Static charges must be avoided since they can damage the control box s electronic components when touched Technical data Tab F Mechanical str...

Page 16: ...ical data WARNING To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the ser vomotor Mains voltage 120 V 15 10 Mains frequency 50 60 Hz Power absorption 10 VA Motor Synchronous Drive angle Varying between 0 and 135 WARNING Absolutely do not adjust the red cam No 1 more than 135 to prevent serious or irreversible damage to the m...

Page 17: ...and suitableness of the available means of handling Check also that the area in which you are working is empty and that there is an adequate escape area i e a free safe area to which you can quickly move if the burner should fall During the handling keep the load at not more than 20 25 cm from the ground CAUTION After positioning the burner near the installation point correctly dispose of all resi...

Page 18: ...igh fire operation is contained in area A or in area B of the firing rate See Fig 2 page 10 If it is in area A then no operation is required If on the other hand it is in area B unscrew the screws 1 Fig 9 and disassemble the blast tube 2 move the fixing of the rod 3 from position A to position B thereby causing the shutter 4 to retract now refit the blast tube 2 and the screws 1 Once this operatio...

Page 19: ...nt Turn screw 4 Fig 11 until the notch identified is aligned with the front surface 5 of the flange 4 7 2 Gas adjustment Loosen the 3 screws 1 Fig 11 and turn ring 2 until the notch identified is aligned with index 3 Tighten the 3 screws 1 fully down Example RS 70 M MAX output 2200 MBtu hr If we consult diagram Fig 12 we find that for this output air must be adjusted using notch 3 Fig 11 NOTE Diag...

Page 20: ... adjustment Place the pilot and electrode as shown in Fig 14 The pilot works correctly at pressures ranging from 5 12 WC IMPORTANT To set the pilot without main burner operation proceed as follows disconnect all wires of the main valves V1 and V2 A Fig 15 carry out a jumper between VP1 2 and V1 V2 B Fig 15 At the end of the pilot adjustment restore the valves connection D Fig 15 Pay attention to t...

Page 21: ...Installation 19 20160778 GB 4 8 1 Electrical connections Fig 16 S9810 ...

Page 22: ...re switch 5 1st safety shut off valve 6 2nd safety shut off valve 7 Standard issue burner gasket with flange 8 Gas adjustment butterfly valve 9 Burner 10 High gas pressure switch On the burner Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure that the fuel interception tap is closed before performing any operatio...

Page 23: ... 11 page 17 adjusted as indicated in diagram Fig 12 Gas pressure at test point 1 Fig 19 3 15 WC Pressure in combustion chamber 1 18 WC 3 15 1 18 1 97 WC A maximum output of 3125 MBtu hr shown in Tab G corresponds to 1 97 WC pressure column 1 This value serves as a rough guide the effective delivery must be measured at the gas meter Tab G WARNING The heat output and gas pressure data in the head re...

Page 24: ...ner 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 connected to an efficient earthing system made according to current standards It is necessary to check this fundamental ...

Page 25: ...h cable grommet 2 single phase power supply and other devices with 1 2 inch cable grommet 3 Available consents safety minimum gas pressure switch gas valves and other devices with 3 8 inch cable grommet Cable grommets used in factory A Fan motor B Maximum gas pressure switch C Air Gas servomotor A 2 1 Z Z 3 3 3 3 3 B C 1 2 A 3 3 Fig 21 20161057 WARNING The control panel is in compliance with UL508...

Page 26: ...he motor is 400V To reset in the case of an intervention of the thermal relay press the button RESET Fig 22 The button STOP Fig 22 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 23 and move it in the sense of the arrow towards right 4 11 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay pres...

Page 27: ... the motors manufactured for 575V IE3 NEMA Premium Efficiency voltage have the same control box base of the IE1 and IE2 Epact motors Please pay attention to the indications in case of maintenance or substitution 4 14 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 IE2 Epact a...

Page 28: ... locks out when demand for heat is less than the heat supplied by the burner at min output Load control opens The servomotor returns to the 0 angle limited by contact with orange cam The air damper closes completely to reduce ther mal dispersion to a minimum Every time output is changed the servomotor automatically modi fies gas delivery gas butterfly valve and air delivery fan damper Tab H Key fo...

Page 29: ...Fig 34 to the gas pressure test point on the sleeve The manometer readings are used to calculate the MAX burner power using the diagram on page 21 Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety i e with gas delivery at the minimum 5 Start up calibration and operation of the burner WARNING The first start up of ...

Page 30: ...e shown below in the event of a modification follow what is described below for each cam 10 Potentiometer already set in factory do not carry out any adjustment The factory settings must not be changed for the first firing just check that they comply with the details below CAM I RED 130 The same for all models Limits the rotation towards the maximum WARNING In the event of a variation absolutely d...

Page 31: ...s check the direction of rotation of the fan blade looking through the flame inspection window 18 Fig 4 page 12 0 0 3 0 60 90 0 0 3 0 60 90 0 0 3 0 60 90 6 0 6 0 9 0 9 0 3 0 3 0 0 0 13 L SQ M4 0 SQ M 4 1 SQM 41 1 3 0 0 R R 5 0 135 1 35 40 1 35 40 0 0 3 0 60 90 0 0 3 0 60 90 0 60 90 8 0 0 0 35 1 L S Q M 4 0 SQ M 41 R 9 0 60 6 0 9 0 3 0 13 5 00R B A C D E 8 0 0 0 35 1 L SQM4 0 SQ M4 1 R 9 0 6 0 6 0 ...

Page 32: ...essure switch Adjust the maximum gas pressure switch Fig 41 after making all other burner adjustments with the maximum gas pressure switch set to the end of the scale To calibrate the maximum gas pressure switch open the tap and then connect a pressure gauge to its pressure test point The maximum gas pressure switch must be regulated to a value no higher than 30 of the measurement read on the gaug...

Page 33: ...Turn the screws counter clockwise to reduce air delivery 5 8 3 Minimum burner output Minimum output must be selected within the Firing rates range shown at page 10 Move the selector 1 Fig 38 page 29 in manual position Move the selector 2 Fig 38 page 29 in position reduc tion output until the servomotor has closed the air damper and the gas butterfly valve to 15 factory set adjustment Adjusting gas...

Page 34: ...h the switch positions mini mum and maximum position 1 Set cam I to the required high fire position e g 130 position is indicated on the scale next to the cam 2 2 Set cam V to the required low fire position e g 15 3 3 Pre set the signal at the analog input according to the required high fire position e g 20 mA 4 4 Turn the max potentiometer for maximum angular rotation a clockwise if the actuator ...

Page 35: ...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 The burner must not start Disconnect the plug of the ionization probe The burner must stop in lockout due to firing failure WARNING Make sure that the mechanical locking systems on ...

Page 36: ...rn on at the same time as their power supply 6 2 3 Checking and cleaning Combustion The optimum calibration of the burner requires an analysis of the flue gases Significant differences with respect to the previous measurements indicate the points where more care should be ex ercised during maintenance Adjust the burner if the combustion values found at the beginning of the operation do not comply ...

Page 37: ...ssed for at least 3 sec the button colour will change from green to yellow each operating status signalling LED will be compared to 20 of the maximum brightness press the reset button again 0 5 sec to reset the standard operation of the signalling LEDs Safety components Flame presence check with microamperometer instru ment disconnect the plug socket 6 Fig 4 page 12 on the ionisation probe cable a...

Page 38: ...e ignition electrode cables and then slide the burner up to the sleeve so that it is positioned as shown in Fig 49 secure the burner to the sleeve by tightening screw 3 reconnect the swirler joint 7 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 sourc es to cool down comp...

Page 39: ... 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 7 3 Flame control lock out or emergency stop condition The RFGO control device can be locked emergency stop at any time during the operating cycle and unlocked when already locked lock out by simply pressing the key on the front panel or by means of the termina...

Page 40: ...n damper Closed damper 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 41: ...se 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 attempt i...

Page 42: ...TFI Red 17 Wiring fault Red 18 Safety relay 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...

Page 43: ...back fault Red 51 Pilot feedback fault 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...

Page 44: ...ault Internal fault Replace the control device 15 Internal processor fault Internal fault Replace the control device o 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 flame sensor 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 mom...

Page 45: ...sts contact the distributor factory 51 Pilot feedback fault The 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...

Page 46: ...arts A Appendix Spare parts 28 27 26 30 31 32 33 34 35 36 37 38 40 41 42 43 45 46 47 49 50 51 52 53 54 56 57 57 59 60 61 57 62 64 57 70 66 67 68 69 65 24 21 22 23 4 5 17 19 20 1 2 3 8 12 13 15 16 18 9 10 11 31 29 63 39 58 6 6 25 7 55 ...

Page 47: ...4 PILOT TUBE 8 3012948 AIR PRESSURE SWITCH A 9 3013127 TERMINAL BOARD 10 20144930 CONTROL BOX B 11 20144947 BASE C 12 3007627 MEMBRANE 13 3012080 SWITCH C 15 20115409 STARTER C 15 20120289 STARTER C 16 3012956 TRANSFORMER B 17 3012934 COVER 18 3012941 MOTOR C 18 20084068 MOTOR C 18 3012943 MOTOR C 18 20062892 MOTOR C 19 20161230 ANCHOR PLATE 20 20161228 SERVOMOTOR B 21 3012012 HALF SHELL 22 201555...

Page 48: ... SWITCH C 39 3003220 CONNECTOR 40 3012049 SCREW 41 3003974 CONTROL DEVICE C 42 3003975 FRONT PIECE B 42 3003976 FRONT PIECE B 43 20028666 SQUARE B 43 20161284 SQUARE B 43 20162255 SQUARE C 45 3003987 FLAME FUNNEL 45 3012055 FLAME FUNNEL 45 3012057 FLAME FUNNEL B 46 3003983 SHUTTER B 46 3003984 SHUTTER 47 3003322 CONNECTOR 49 3013055 TUBE 50 3007166 SEAL 51 3005482 SEAL 52 3012971 FLANGE C 53 30039...

Page 49: ... LEVER C 57 3006098 PIN JOINT 58 20073810 U BOLT 59 3003841 BEARING 60 3012351 TIE ROD 61 3012352 BAR 62 20034953 LIFTING ASSEMBLY 63 3013204 SPRING 64 3012355 GRADUATE SECTOR C 65 3012356 SPRING 66 3012060 TIE ROD 67 3012357 BEARING 68 3006097 SPRING 69 20188969 CAM 70 3012601 LEVER N CODE 20160208 20166044 20166045 20160227 20166046 20160233 20166047 20166048 20160238 20166049 20160253 20166101 ...

Page 50: ...ssories Burner Standard length Length obtainable with kit Code RS 70 M 971 32 14 27 32 20029381 RS 100 M 9 17 32 14 27 32 20029382 RS 130 M 10 233 2 16 1 32 20029383 Burner MBtu hr Code RS 70 M 918 3084 3010273 RS 100 M 1320 4405 3010274 RS 130 M 1764 5545 3010275 WARNING The installer is responsible for the supply and instal lation of any required safety device s not indicated in this manual ...

Page 51: ... 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 Set point Low Oil Pressure High Limit Set point High Oil Pressure Low Gas Pressure Flame Safeguard Model N...

Page 52: ...BURNERS NORTH AMERICA 35 Pond Park Road http www riello ca 2165 Meadowpine Blvd Hingham Massachusetts Mississauga Ontario U S A 02043 1 800 4 RIELLO Canada L5N 6H6 RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello com ...