Riello RS 120/E LN, Installation, Use And Maintenance Instructions

Page 1: ... 2014 Installation use and maintenance instructions Forced draught gas burners Progressive two stage or modulating operation Code Model Type C9342400 C9342410 RS 68 E LN 1132T1 C9343400 C9343410 RS 120 E LN 1132T GB ...

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Page 3: ...ratio LMV37 4 13 3 10 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 Boiler plate 18 4 5 2 Boiler fixing 18 4 6 Electrode positioning 19 4 6 1 Combustion head calibration 19 4 7 Adjustment of the combustion head 20 4 7 1 Air adjustment 20 4 7 2 Gas ...

Page 4: ... 29 5 5 Flame signal measurement 30 5 6 Final checks with the burner working 30 6 Maintenance 31 6 1 Notes on safety for the maintenance 31 6 2 Maintenance programme 31 6 2 1 Maintenance frequency 31 6 2 2 Checking and cleaning 31 6 3 Opening the burner 32 6 4 Closing the burner 32 A Appendix Spare parts 33 B Appendix Accessories 36 C Appendix Burner start up report 37 ...

Page 5: ...rtant that The instruction manual is supplied to the user by the system manufacturer with the recommendation to keep it in the room where the heat generator 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 tha...

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: ...th 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 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 ent...

Page 8: ...s designation 3 Technical description of the burner Model RS 68 E LN RS 120 E LN Output 1 High MBtu hr kW 1327 3258 389 955 2282 4924 666 1443 Low MBtu hr kW 570 167 1136 333 Fuel Natural gas Max delivery Pressure at maximum delivery 2 natural gas SCFH WC 3258 4 60 4924 8 85 Operation Low high or modulating Standard application Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Co...

Page 9: ...e C9342410 C9343410 Control circuit power supply V Ph Hz 120 1 60 Main electrical supply 10 V Ph Hz 460 3 60 Fan motor rpm HP V A 3400 2 4 460 4 3 3400 3 460 4 9 Ignition transformer V1 V2 I1 I2 120 V 1 x 8 kV 1 6 A 20 mA Electrical power consumption W max 2750 3150 Electrical control circuit cons W 750 Total electrical consumption W 3500 3900 Electrical protection NEMA 1 Fan motor IE1 Model RS 68...

Page 10: ...A Code C9342410 C9343410 Control circuit power supply V Ph Hz 120 1 60 Main electrical supply 10 V Ph Hz 460 3 60 Fan motor rpm HP V A 3500 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 2600 Electrical control circuit cons W 750 Total electrical consumption W 3350 Electrical protection NEMA 1 Fan motor IE2 EPACT Model RS 68 E LN RS 120 E L...

Page 11: ...n sliding bars 24 Switch OFF ON 25 Fan air inlet 26 Screws to secure fan to pipe coupling 27 Switch LOCAL REMOTE 28 Gas butterfly valve 29 Boiler fixing flange 30 Flame stability disc 31 Horn 32 Button ALARM SILENCE 33 Signal POWER ON 34 Signal IGNITION ON 35 Signal FUEL ON 36 Signal ALARM ON 37 RWF40 modulator with anolog output 4 20 mA 38 Hight voltage lead 39 Din bar available for accessories 4...

Page 12: ...burner are shown in Fig 3 Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the sliding bars The dimensions of the open burner are indicated by position I Inch A B C lbs RS 68 E LN 55 33 64 30 29 32 39 3 8 212 RS 120 E LN 55 33 64 30 29 32 39 3 8 205 D36 Fig 2 Inch A B C D E F G H I L M N O RS 68 E LN 23 27 64 12 3 4 10 5 8 23 11 3...

Page 13: ...nt s altitude in chart 1 and the corrected pressure in chart 2 Check in the firing rate graph of the burner Fig 4 if the working point defined by the values above is within the range limits If not higher burner size is needed Note Charts are based only on altitude variation reference temperature 68 F 20 C To get the combined correction in case of different air temperature a compensation of 1000 ft...

Page 14: ... 908 2 875 8 843 5 811 85 779 8 747 8 Average barometric pressure 68 F w c 399 394 385 371 358 345 332 320 307 294 CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE Altitude Rated Pressure m a s l 0 100 305 610 915 1220 1525 1830 2135 2440 ft a s l 0 328 1000 2000 3000 4000 5000 6000 7000 8000 0 50 0 49 0 50 0 51 0 53 0 55 0 57 0 59 0 62 0 64 0 67 1 00 0 99 1 00 1 02 1 06 1 10 1 14 1 19 1 23 1 2...

Page 15: ...uits 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 ob serving the greatest...

Page 16: ...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 voltag...

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: ...rs can be seen on the dis play 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 WARNING To avoid injury to persons damage to property ...

Page 19: ...ER All 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 manual and in compliance with the standards and regulations of the laws in force WARNING The handling operations for the burner can be high ly dangerous if not carried out w...

Page 20: ...n of the blast tube For boilers with a water cooled frontal a refractory lining is not necessary 11 12 Fig 12 unless expressly requested by the boiler manufacturer 4 5 2 Boiler fixing Secure the burner to the boiler fixing the flange 9 Fig 12 to the boiler plate and interposing the insulating gasket 8 Use the 4 screws with a tightening torque of 26 29 Lbf ft after pro tecting their thread with ant...

Page 21: ...e other hand it is in area B before starting the burner remove the 4 circular sectors 1 Fig 15 fastened behind the stabilizing disc by removing the 8 screws 2 Fig 15 Detach the combustion head from the burner Fig 12 loosen the 4 screws 3 and remove the cover 1 remove the screws 2 from the slide bars 5 remove the 2 screws 4 and pull the burner back on slide bars 5 by about 4 install the extension b...

Page 22: ...x 6 Tighten the 3 screws 1 fully down Example RS 120 E LN burner output 3750 MBtu hr If we consult diagram Fig 16 we find that for this output the ad justments are air R1 notch 2 gas R2 notch 5 Note Diagram Fig 16 indicates an optimal regulation for a type of boiler seen in Fig 5 page 11 If the pressure of gas allows it by closing ring nut Fig 5 page 11 a reduction of the formation of NOx is obtai...

Page 23: ...pe coupling burner in the position shown in Fig 19 unscrew the 2 screws 2 from the extension 5 and reposition them as previously Fig 19 refit the screws 2 on the sliding bars 3 fix the burner to the pipe coupling with the screws 1 4 2 5 3 4 1 Fig 18 D10593 WARNING When fitting the burner on the two sliding bars it is advisable to gently draw out the high volt age cable until it is slightly taut 5 ...

Page 24: ...essure necessary for the burner is included in the calibration field of the pressure regulator colour of the spring The pilot gas train must be connected to the gas attachment 5 Fig 20 and can enter the burner from the right or left side 4 9 Gas feeding line It must be type approved according to required standards and is supplied separately from the burner KEY Fig 21 1 Gas input pipe 2 Manual valv...

Page 25: ...ough guide the effective delivery must be measured at the gas meter NOTE To know the required gas pressure at test point 1 Fig 22 set the maximum output required from the burner operation then find the nearest output value in the table for the burner in ques tion read on the diagram Fig 23 the pressure test point 1 Fig 22 add this value to the estimated pressure in the combustion chamber Example f...

Page 26: ...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 connected to an efficient earthing system made according ...

Page 27: ... is a nominal value To reset in the case of an intervention of the thermal relay press the button RESET Fig 25 The button STOP Fig 25 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 26 and move it in the sense of the arrow towards right 4 12 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay p...

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 15 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: ...rge the air from the gas line Fit a U type manometer Fig 36 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 23 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 o...

Page 30: ...he motor rotation may be incorrect As soon as the burner starts up go in front of the cooling fan of the fan motor and check it is rotating anticlockwise See Fig 37 If this is not the case place the switch of Fig 37 in position 0 and wait for the control box to carry out the switch off phase disconnect the electrical supply from the burner invert the phases on the three phase power supply DANGER A...

Page 31: ...e 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 40 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 ...

Page 32: ... right the flame s intensity is displayed as a percentage Example 954 0 0 5 6 Final checks with the burner working S8171 P V h min s Fig 42 Open the control limit operation Open the high limit operation Æ The burner must stop Rotate the maximum gas pressure switch knob to the mini mum end of scale position Rotate the air pressure switch knob to the maximum end of scale position Æ The burner must s...

Page 33: ...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 combus tion head distributor are free of dirt or rust deposits In case of doubt disassemble the inner part 5 Fig 44 page 32 Combustion Adjust the burner if the combustion values found at the beginning of the operation do not comply with the regulations...

Page 34: ...crew 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 reverse procedure remove the 2 extensions 9 and re screw the screws 8 on the sliding bars 4 push the burner up to approximately 4 from the pipe coupling reinsert the electrode lead and slide the burner as far as the stop fix the screws 3 to secure the burner to the com...

Page 35: ...9324 A Appendix Spare parts 8 7 29 24 17 49 44 47 48 59 16 14 40 51 23 13 23 12 25 19 18 22 20 9 5 5 2 1 52 52 28 50 32 27 26 32 45 52 50 52 61 61 42 43 15 41 53 54 56 60 55 58 35 30 3 4 6 57 21 11 45 39 46 10 31 37 38 36 34 33 63 ...

Page 36: ...TORS ASSEMBLY C 21 20030201 MOTOR 1 8 KW C 21 20030200 MOTOR 2 2 KW C 22 3006211 FUSE 6 3A A 23 20027013 GREEN SIGNAL LIGHT C 24 20028310 CONTACTOR C 25 20027014 WITHE SIGNAL LIGHT C 26 3013681 SCREW C 27 3003891 CONNECTOR C 28 3014079 SPACER 29 20028312 OVERLOAD TERMAL RELAY C 30 3012393 ELECTRODE CONNECTION A 31 3013081 ELECTRODE A 32 20008601 SERVOMOTOR B 33 3012924 TUBE 33 3012925 TUBE 34 3013...

Page 37: ...PRESSURE SWITCH A 50 3013938 DISC 51 20010962 BUTTON 52 3013937 HUB 53 3012049 SCREW 54 3012639 CONTROL DEVICE 55 20030203 SHUTTER C 55 20030202 SHUTTER C 56 20030204 BRACKET 57 3003396 UV FLAME SENSOR A 58 20030206 END CONE 59 3020068 RELAY C 60 3003322 CONNECTOR 61 20028318 MANIFOLD 61 20029237 MANIFOLD 62 3013939 INDEX C 63 3013086 SUPPORT No CODE RS 68 E LN RS 120 E LN DESCRIPTION ...

Page 38: ...it Gas train according to UL Standards B Appendix Accessories Burner Code RS 68 E LN 3010247 RS 120 E LN 3010248 WARNING The installer is responsible for the supply and installation of any required safety device s not indicated in this manual ...

Page 39: ... 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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