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

Page 1: ...20062968 2 03 2014 Installation use and maintenance instructions Forced draught gas burners Progressive two stage or modulating operation Code Model 20065627 RS 120 EV LN ...

Page 2: ......

Page 3: ...ll dimensions 8 3 6 Burner equipment 8 3 7 Firing rate 9 3 7 1 Minimum furnace dimensions 9 3 8 Commercial boilers 9 3 9 Burner components 10 3 10 Control box for the air fuel ratio LMV37 4 11 3 11 Actuators SQM33 5 14 4 Installation 15 4 1 Notes on safety for the installation 15 4 2 Handling 15 4 3 Preliminary checks 16 4 4 Operating position 16 4 5 Securing the burner to the boiler 16 4 5 1 Boil...

Page 4: ...art up 30 5 3 Burner start up 31 5 4 Final calibration of the pressure switches 31 5 4 1 Air pressure switch 31 5 4 2 Maximum gas pressure switch 32 5 4 3 Minimum gas pressure switch 32 5 5 Flame signal measurement 32 5 6 Final checks with the burner working 32 6 Maintenance 33 6 1 Notes on safety for the maintenance 33 6 2 Maintenance programme 33 6 2 1 Maintenance frequency 33 6 2 2 Checking and...

Page 5: ...injury death or long term health risks CAUTION This symbol indicates operations which if not 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 mater...

Page 6: ...ore declines any and every respon sibility for the failure to observe the contents of this 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 f...

Page 7: ...ntenance 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 u...

Page 8: ...de Output 1 MAX MBtu hr kW 2282 4924 666 1443 MIN MBtu hr kW 1136 333 Fuel Natural gas Max delivery SCFH 4924 Pressure at max delivery 2 WC 8 85 Operation Low high or modulating Standard applications Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Combustion air temperature F max 140 60 C Noise levels 3 dBA 77 Model RS 120 EV LN RBNA code Control circuit power supply V Ph Hz 12...

Page 9: ...0 460 3 60 575 3 60 Fan motor rpm HP V A 3500 3 208 230 7 8 3500 3 460 3 9 3500 3 575 3 1 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 coms W 750 Total electrical consumption W 3350 Electrical protection NEMA 1 Model Code RBNA Code Voltage Flame safeguard RS 120 EV LN 208 220 3 60 Burner mounted 460 3 60 Burner mount...

Page 10: ... Blast tube short long obtainable with kit 3 6 Burner equipment The burner is supplied complete with 1 Gas train flange 1 Flange gasket 4 Flange fixing screws M10x35 1 Connector for pilot line 2 Extensions for slide bars for kit 1 Instruction manual and spare parts list inch A 1 B C lbs RS 120 EV LN 55 1 8 31 7 64 27 9 16 154 D36 Fig 1 D731 Fig 2 inch A B C D E F 1 G H I 1 L M N O RS 120 EV LN 212...

Page 11: ...ion on either flame inversion boilers or boilers with combustion chambers fea turing flow from the base three flue passes on which the best re sults are obtained in terms of low NOx emissions The maximum thickness of the boiler s front door must not exceed 8 see Fig 5 For flame inversion boilers a kit is available to reduce CO emis sions if required The kit includes 5 gas pipes identical to the ot...

Page 12: ...7 Holes for cable grommets for electrical wiring accessories and power supply to be carried out by the installer 18 Air actuator 19 Low air pressure switch Differential operative type 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...

Page 13: ...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 14: ...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 15: ...P P 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 fi...

Page 16: ... 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 I WARNING To avoid injury to persons damage to proper...

Page 17: ...is recommended that only the burner be connected to the chimney Be sure that it is clean and clear of obstructions WARNING ELECTRICAL CONNECTIONS CANADA All electrical connections should be done in accordance with the C E C Part 1 and all local codes The system should be grounded USA All electrical connections should be done in accordance with the National Electrical Code and all local ordinances ...

Page 18: ...ollected and dis posed of in the appropriate places WARNING The burner output must be within the boiler s firing rate WARNING A burner label or any other component that has been tampered with removed or is missing pre vents the definite identification of the burner and makes any installation or maintenance work difficult WARNING The burner is designed to operate only in posi tions 1 2 4 and 5 Fig ...

Page 19: ...tal a refractory lining is not necessary 11 12 Fig 12 unless expressly requested by the boiler manufacturer Tab K 4 5 3 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 anti seize products After the start up check there is...

Page 20: ...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 21: ...boiler as shown in Fig 16 It is therefore especially easy to adjust and this adjustment de pends only on the maximum output of the burner Two adjustments of the head are foreseen air adjustment R1 gas adjustment R2 In the diagram of Fig 16 find the notch at which to adjust both air and central gas air Fig 16 D2797 Notch Burner output ...

Page 22: ...tch 5 Note Diagram Fig 16 indicates an optimal regulation for a type of boiler seen in Fig 5 page 9 If the pressure of gas allows it by closing ring nut Fig 5 page 9 a reduction of the formation of NOx is obtained Continuing with the previous example Fig 22 page 23 indicates that for burner with output of 3750 MBtu hr a pressure of approxi mately 2 8 is necessary at test point 3 Fig 17 If this pre...

Page 23: ... Fig 22 page 23 indicates that for burner with output of 3750 MBtu hr a pressure of approxi mately 6 0 is necessary at test point 3 Fig 17 If this pressure cannot be reached open the ring 5 Fig 17 to notch 4 or 5 Make sure that the combustion characteristics are satisfactory and free of pulsations Once the combustion head adjustment is completed slide the burner on the guides 3 at about 4 from the...

Page 24: ...r from the right or left side see Fig 19 Gas safety shut off valves 5 6 Fig 20 must be as close as pos sible to the burner to ensure gas reaches the combustion head within the safety time range 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 10 Gas feeding line It must be type approved according to required standards and i...

Page 25: ... maximum output of 3030 MBtu hr shown diagrams RS 120 E LN corresponds to 3 93 WC pressure This value serves as a rough guide the effective delivery must be measured at the gas meter NOTE To know the required gas pressure at test point 1 Fig 21 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 F...

Page 26: ...30 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 3500 3455 3500...

Page 27: ...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 8 00 8 18...

Page 28: ...made according to current standards It is necessary to check this fundamental safety requirement In the event of doubt have the electrical system checked by qualified personnel Do not use the fuel tubes as an earthing system for electrical devices The electrical system must be suitable for the maximum input power of the device as indicated on the label and in the manual checking in particular that...

Page 29: ...met 3 Speed sensor cable used in the factory 4 Available consents safety other devices with 3 8 inch cable grommet 5 UV cable used in the factory 6 Available for ground terminals 7 Horn 8 High gas pressure switch cable used in the factory 9 Gas actuactor cable used in the factory 10 Air actuator cable used in the factory 11 Available devices with 1 4 inch grommet 12 Air pressure switch negative ca...

Page 30: ...4 13 2 Adjustment of speed sensor WARNING The measurement of speed sensor 1 Fig 25 must be respected WARNING It is important that the disc 2 is installed on the burner as shown in the Fig 26 5 64 Fig 25 D9323 1 2 Fig 26 D9408 2 ...

Page 31: ...ence between IE1 and IE2 Epact WARNING the motors manufactured for 208 230 460 IE2 Ep act voltage have a different connection than IE1 motors no more star delta but star double star D3686 IE1 IE2 Epact U2 V2 W2 U3 V3 W3 U1 V1 W1 S8379 U2 V2 W2 U3 V3 W3 U1 V1 W1 S8380 460V 208 230V 460V 208 230V Fig 27 WARNING The motors manufactured for 575V IE2 Epact volt age have the same control box base of the...

Page 32: ...e Purge the air from the gas line Fit a U type manometer Fig 33 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 safe ty i e with gas delivery at the minimum 5 Start up calibration ...

Page 33: ...f the set point and start up the burner again to ensure the set point is correct If the burner locks out again turn the knob counter clockwise a little bit more 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 volt age is present stop the burner immediately and check the electrical wiring WARNIN...

Page 34: ...rm If the burner locks out again turn the dial anti clockwise again by 0 4 WC 5 5 Flame signal measurement Check the flame signal through the parameter 954 as indicated in Fig 38 The displayed value is expressed in percentage The value during the operation must be higher than 24 If at the burner start up the value is higher or equal of 18 the burner locks out due to the extraneous light For furthe...

Page 35: ...tion chamber pressure Gas leaks Make sure that there are no gas leaks in the following areas on the meter burner pipework on the mixer valve connection on the burner fastening flange where the seal is fitted Electrode unit Make sure neither the electrodes nor probe feature marked warp ing or oxidation on surfaces Make sure distances are still in line with those indicated in this manual readjusting...

Page 36: ...dicating and recording gages SEMI ANNUALLY Check flame failure detection system components SEMI ANNUALLY Check firing rate control SEMI ANNUALLY Check piping and wiring of all interlocks and shutoff valves SEMI ANNUALLY Inspect burner components SEMI ANNUALLY Flame failure detection system test for hot refractory hold in ANNUALLY Replace flame rod in accordance with manufacturer s instructions ANN...

Page 37: ...2 extensions 9 and re screw the screws 8 on the guides 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 combustion head fix the 4 screws 1 to install the hood 2 Connect the electrical supply from the burner DANGER Disconnect the electrical supply from the bur ner DANGER Di...

Page 38: ...20062968 36 Appendix Spare parts A Appendix Spare parts ...

Page 39: ...0008601 SERVOMOTOR B 21 20010969 RELAY C 22 3003763 INSPECTION WINDOW 23 3003891 CONNECTOR C 24 3012013 BAR C 25 3003481 SCREW 26 3013933 INSPECTION WINDOW 27 3013934 O RING B 28 3012403 FAN C 29 3012012 HALF SHELL 30 20062892 MOTOR C 31 20039760 TUBE 32 3012974 IGNITION PILOT TUBE C 33 3013081 ELECTRODE A 34 3012014 SHUTTER 35 3012925 TUBE 36 3013087 U BOLT C 36 3013083 TUBE 37 3013085 DISTRIBUTO...

Page 40: ...ety fittings 51 3012417 SHUTTER C 52 3012415 END CONE B 53 3003991 FLANGE GASKET A 54 3003322 CONNECTOR C 55 20043700 MANIFOLD 56 3006211 FUSE A 57 3013940 CONNECTORS ASSEMBLY B 58 3013937 HUB 59 3014011 DISC A 60 3013939 INDEX 61 3012413 FRONT PIECE 62 3003396 UV PHOTOCELL A 63 20031413 HORN 64 20010972 RWF40 ASSEMBLY 65 3013087 U BOLT C N CODE DESCRIPTION ...

Page 41: ...8 Tubes kit Gas train according to UL Standards B Appendix Accessories optional Burner Code RS 120 EV LN 3010248 WARNING The installer is responsible for the supply and installation of any required safety device s not indicated in this manual ...

Page 42: ......

Page 43: ......

Page 44: ...RICA 35 Pond Park Road 1 800 4 RIELLO 2165 Meadowpine Blvd Hingham Massachusetts 1 800 474 3556 Mississauga Ontario U S A 02043 Canada L5N 6H6 http www riello ca RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...