Riello RS 1300/EV C01, Modulating Operation

Page 1: ...n use and maintenance instructions 20089633 5 11 2021 Forced draught gas burners Modulating operation CODE MODEL TYPE 20081190 RS 1300 EV C01 S001T2 20080871 RS 1600 EV C01 S006T2 20070919 RS 2000 EV C01 S007T2 GB ...

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

Page 3: ... fuel ratio LMV52 14 4 15 Servomotor 16 5 Installation 17 5 1 Notes on safety for the installation 17 5 2 Handling 17 5 3 Preliminary checks 17 5 4 Operating position 18 5 5 Removing the shutter lockout screws 18 5 6 Preparing the boiler 18 5 6 1 Boring the boiler plate 18 5 6 2 Blast tube length 19 5 7 Coupling of the burner Centre of gravity position 19 5 8 Securing the burner to the boiler 19 5...

Page 4: ...9 6 7 Final checks with burner operating 29 7 Maintenance 30 7 1 Notes on safety for the maintenance 30 7 2 Maintenance programme 30 7 2 1 Maintenance frequency 30 7 2 2 Safety test with gas ball valve closed 30 7 2 3 Checking and cleaning 30 7 2 4 Electrical panel 31 7 2 5 Positioning the rpm sensor 31 7 2 6 Safety components 32 7 3 Opening the burner 33 7 4 Closing the burner 33 8 Faults Possibl...

Page 5: ...ith the following Technical Standards EN 12100 EN 676 According to the European Directives MD 2006 42 CE Machine Directive LVD 2014 35 UE Low Voltage Directive EMC 2014 30 UE Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 1 Declarations ...

Page 6: ...hine 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 le thal 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 CRUSHING OF LIMBS This symbol indicates the presen...

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 incor rectly applied a...

Page 8: ...ce 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 re sponsible for the machine and for the training of the people work ing around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel underta...

Page 9: ...ame control system FS1 FS2 Standard 1 stop every 24 h Continuous operation 1 stop every 72 h Electrical supply of the system 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 R S 1600 EV TC Emission C01 or Class 1 EN676 C03 or BLU Class 3 EN676 FS1 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION C01 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam ...

Page 10: ...Display 4 5 Electrical data Tab D Gas category Destination country I2H SE FI AT GR DK ES GB IT IE PT IS CH NO I2ELL DE I2L I2E I2 43 46 45 3 MJ m3 0 C NL I2Er FR I2E R B BE I2E LU PL Model RS 1300 EV C01 FS1 RS 1600 EV C01 FS1 RS 2000 EV C01 FS1 Type S001T2 S006T2 S007T2 Power 1 Delivery 1 min max kW 2500 7500 13000 3065 9503 15560 4000 12000 19500 Fuels Natural gas G20 methane gas G21 G22 G23 G25...

Page 11: ...o be opened and the rear part turned on the hinge The maximum dimensions of the open burner are indicated by the L and R positions The l position is reference for the refractory thickness of the boiler door Tab F Burner kg Burner packaging kg 1100 approx 1180 1 7 0 0 1080 2600 1710 Fig 1 20096814 Fig 2 C E D B I A F H G R R L 20094543 mm A B C D E F G H I L R RS 1300 EV C01 FS1 1880 450 220 544 96...

Page 12: ...t the manufac turer The firing rates were set in relation to special test boilers accord ing to EN 676 regulations In Fig 4 you can see the diameter and length of the test combus tion chamber Example Output 13000 kW diameter 120 cm length 9 m MODULATING RATIO The modulating ratio obtained in test boilers in accordance with EN 676 is 1 5 WARNING The firing rate value Fig 3 has been obtained conside...

Page 13: ...d movement servomotor 17 Air damper movement levers 18 Minimum air pressure switch differential operating type 19 Combustion head air pressure test point 20 Rpm sensor 21 QRI cell 22 Pressure test point for air pressure switch 23 Gas butterfly valve servomotor 24 Screws to lock the shutter during transportation replace them with the M12x16 screws supplied as standard 25 Pilot gas train 9 4 23 14 8...

Page 14: ...xillary transformer fuses 16 Auxiliary circuits fuse 17 Flame sensor plug sensor socket 18 Main terminal supply board 19 Air pressure switch 20 Terminal board for O2 kit 21 Rpm sensor terminal board 22 Servomotor Plug socket NOTE Two types of burner failure may occur Control box lockout switching on of button 13 Fig 6 red led signals that the burner is in lockout release by pressing the pushbutton...

Page 15: ...ata Technical data Tab G WARNING To avoid accidents material or environmental damage observe the following instructions The AZL display is a safety device Avoid open ing or modifying it or forcing its operation Riello S p A cannot assume any responsibility for dam age resulting from unauthorised interventions Operating voltage AC 24 V 15 10 Power consumption 5W typical Protection level of the cont...

Page 16: ... followed 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 Mechanical structure The LMV5 control box is a system to check the burners based on a microprocessor and equipped wi...

Page 17: ... AC 188V Oil pump magnetic clutch nominal voltage Nominal current Power factor 2A cos 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cos 0 4 Load on output terminals Total load on the contacts Mains voltage Total unit input current safety circuit load on contacts due to Fan motor contactor Ignition transformer Valve Oil pump magnetic clutch AC 230V 15 10 Max 5...

Page 18: ...he electrical supply of the actuator is switched off The housing cover may only be removed for short periods of time for wiring or when making the addressing In similar cas es make sure that dust or dirt does not penetrate inside the actuator The actuator comprises a PCB with ESD sensitive compo nents The top side of the board carries a cover which affords pro tection against direct contact This p...

Page 19: ...e integrity 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 quick ly move if the burner should fall When handling keep the load at not more than 20 25 cm from the ground Lifting and transport of wooden crate must be done with caution to avoid falling or tip...

Page 20: ...e as it is the only one that allows the maintenance operations as described in this manual The installation 4 permits the operation but makes the maintenance and inspection oper ations of the combustion head more difficult DANGER Any other position could compromise the cor rect operation of the appliance Installations 2 3 and 5 are forbidden for safety reasons 2 3 4 5 1 S9249 Fig 11 WARNING Remove...

Page 21: ...ith a water cooled front piece a refractory lining 2 5 Fig 15 is not necessary unless expressly requested by the boiler manufacturer 5 7 Coupling of the burner Centre of gravity position 5 8 Securing the burner to the boiler Insert the thermal protection supplied with the blast tube 4 Fit the entire burner onto the boiler hole prepared previ ously as in Fig 13 and fasten with the screws supplied t...

Page 22: ...emove the 4 fixing screws 3 open the burner partially approx 150 mm on the hinges disconnect the cable of the pilot electrode 4 open the burner fully extracting the inner part of the head 6 after unscrewing the screws 5 that block it to the pipe coupling 5 10 Electrode positioning Fig 16 20094552 WARNING Position the electrode on the ignition pilot observ ing the indications in Fig 17 Elettrodo Di...

Page 23: ...control is compulsory for burners with maximum outputs over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer Explosion danger due to fuel leaks in the pres ence of a flammable source Precautions ...

Page 24: ...oncerned the pressure value closest to the result of the subtraction Read off the corresponding output on the left DANGER Disconnect the electrical power using the main switch Check that there are no gas leaks Pay attention when handling the train danger of crushing of limbs Make sure that the gas train is properly installed by checking for any fuel leaks The operator must use the required equipme...

Page 25: ...ural gas G20 Operation at maximum modulating output Gas pressure at an output of 14300 kW 122 mbar Pressure in combustion chamber 10 mbar 122 10 132 mbar pressure required at test point 1 Fig 23 5 11 5 Pilot gas train connection The burner is fitted with a dedicated gas train that is fixed to the pipe coupling It should be connected to the main train downstream the fil ter or the pressure adjuster...

Page 26: ...d be fitted in series to TL to stop the burner at least once every 24 hours Refer to the wiring diagrams The burner is factory set for FS1 operation 1 stop every 24 hours it can be converted to FS2 operation continu ous 1 stop every 72 hours by changing the parameters using the menu of the AZL Display The electrical safety of the device is obtained only when it is correctly connected to an efficie...

Page 27: ... check then close the motor casing by tightening the 4 screws 1 Fig 26 5 13 Motor rotation As the burner is not fitted with a phase sequence checking de vice the motor rotation may be incorrect If this is not the case turn the burner switch to position 0 OFF and wait for the control box to carry out the switch off phase disconnect the power supply to the main panel invert the phases on the three p...

Page 28: ...noid valves is equipped with a pilot light that signals voltage passing through 6 3 Burner start up Close the remote controls and position the selector 1 Fig 30 to AUTO Make sure that the lights or testers connected to the solenoids or the pilot lights on the solenoids themselves indicate that no volt age is present If voltage is present stop the burner immediately and check the electrical connect...

Page 29: ...tioning using direct servocommands of the relevant valves eliminating the possible play in the calibration systems with mechanical cam lever mechanisms used on traditional modulating burners 2 the modulation of the burner output in accordance with the load required by the system with maintenance of the pres sure or temperature of the boiler at the operating values set 3 the sequence cascade adjust...

Page 30: ...he 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 gauge when the burner is working at maximum output After making the adjustment remove the pressure gauge and close the tap 6 6 3 Minimum gas pressure s...

Page 31: ...pressure switch TS The burner must stop Turn the gas maximum pressure switch knob to the mini mum end of scale position Turn the air pressure switch 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 the QRI cell connection The burner must stop in lo...

Page 32: ...n on at the same time as their power supply 7 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 measure ments 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 go...

Page 33: ...g it with the brackets 3 in the profile of the electrical panel as shown in Fig 36 after performing the operation install the control panel 1 in the electrical panel with the appropriate screws 2 arranging the cables present 7 2 5 Positioning the rpm sensor To adjust proceed as follows loosen the screws 3 and rest the sensor against the plate of the disc 2 referring to the scale 4 draw back the rp...

Page 34: ...es Flame sensor 10 years or 250 000 operation cycles Gas valves solenoid 10 years or 250 000 operation cycles Pressure switches 10 years or 250 000 operation cycles Pressure adjuster 15 years Servomotor electronic cam if present 10 years or 250 000 operation cycles Oil valve solenoid if present 10 years or 250 000 operation cycles Oil regulator if present 10 years or 250 000 operation cycles Oil p...

Page 35: ...it following the steps described but in reverse order refit all burner components as they were originally assembled Secure screws 2 with a tightening torque of 250 300 Nm DANGER Turn off the burner s power supply using the main system switch DANGER Turn off the fuel interception tap Wait for the components in contact with heat sources to cool down completely 3 1 2 2 2 2 Fig 38 20094561 After carry...

Page 36: ...rts again the red LED goes out and the con trol box is reset 8 Faults Possible causes Solutions WARNING In the event the burner stops in order to prevent any damage to the installation do not unblock the burner more than twice in a row If the burner locks out for a third time contact the customer service DANGER In the event there are further lockouts or faults with the burner the maintenance inter...

Page 37: ...14 Parameter to be checked Probe Adjustment field Type Code Temperature 100 500 C PT 1000Ni1000 3010377 Burner Electrical Inverter Output Code RS 1300 EV C01 FS1 3Ph 400V 50Hz 30 kW 20030338 RS 1600 EV C01 FS1 3Ph 400V 50Hz 37 kW 20095475 RS 2000 EV C01 FS1 3Ph 400V 50Hz 45 kW 20095476 WARNING The use of inverters other than those indicated by the manufacturer may lead to burner failure and in ext...

Page 38: ...erational layout 6 LMV52 operational layout 7 LMV52 operational layout 8 LMV52 operational layout 9 LMV52 operational layout 10 LMV52 operational layout 11 LMV52 operational layout 12 LMV52 operational layout 13 Electrical connections set by installer 14 Electrical connections set by installer 15 Electrical connections set by installer 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Page 39: ...37 20089633 GB Appendix Electrical panel layout 0 1 223 223 45 6 45 0 7 223 45 1 223 22345 6 45 45 45 8 0 7 7 7 223 45 1 223 223 45 6 9 0 9 0 9 9 9 9 9 9 9 09 0 9 9 0 9 9 9 7 0 7 0 7 0 7 7 0 7 ...

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Page 51: ...49 20089633 GB Appendix Electrical panel layout ৼ 0 1 1 1 1 1 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 0 2 3 ...

Page 52: ...ut relay for burner lockout K6 Clean contacts output relay burner switched on MV Fan motor PA Air pressure switch PE Burner earth PGMax Maximum gas pressure switch PGMin Minimum gas pressure switch PGVP Gas pressure switch for valve leak detection control device Q1 Inverter power supply disconnect switch Q2 Line disconnect switch QRI Flame sensor RS Remote burner reset button S1 Emergency stop but...

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Page 56: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...