Riello RS 150/M, Installation, Use And Maintenance Instructions

Page 1: ...ion use and maintenance instructions 20054085 2 05 2013 Forced draught gas burners Progressive two stage or modulating operation CODE MODEL TYPE 20044638 20044639 RS 150 M 890T 20051315 20051316 RS 150 M 890T GB ...

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

Page 3: ... 11 4 11 Control box RMG M 88 62C2 12 4 12 Servomotor SQN31 76 13 5 Installation 14 5 1 Notes on safety for the installation 14 5 2 Handling 14 5 3 Preliminary checks 14 5 4 Operating position 15 5 5 Preparing the boiler 15 5 5 1 Boring the boiler plate 15 5 5 2 Blast tube length 15 5 6 Securing the burner to the boiler 16 5 7 Positioning the probe electrode 17 5 8 Combustion head adjustment 17 5 ...

Page 4: ...6 7 2 Operation 29 6 7 3 Ignition failure 29 6 7 4 Burner flame goes out during operation 29 6 8 Stopping of the burner 30 6 9 Final checks with burner operating 30 6 9 1 Checking the air and gas pressure on the combustion head 30 7 Maintenance 31 7 1 Notes on safety for the maintenance 31 7 2 Maintenance programme 31 7 2 1 Maintenance frequency 31 7 2 2 Checking and cleaning 31 7 3 Opening the bu...

Page 5: ...12100 and according to the European Directives GAD 2009 142 EC Gas Devices Directive MD 2006 42 EC Machine Directive LVD 2006 95 EC Low Voltage Directive EMC 2004 108 EC Electromagnetic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001 Legnago 18 02 2013 Executive Director RIELLO S p A Burner ...

Page 6: ...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 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 CRU...

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: ...intenance 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 ...

Page 9: ...trol system FS1 FS2 Standard 1 stop every 24 h Continuous working 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 150 M TC Emission C01 or Class 1 EN676 BLU or BLU Class 3 EN676 FS1 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam EV Electronic c...

Page 10: ...ry SE FI AT GR DK ES GB IT IE PT IS CH NO I2H DE I2ELL NL I2L FR I2Er BE I2E R B LU PL I2E Model RS 150 M Code 20044638 20044639 20051315 20051316 Power 1 Delivery 1 min max kW 300 900 1850 Fuels Natural gas G20 methane gas G21 G22 G23 G25 Gas pressure at max output 2 Gas G20 G25 mbar 17 5 27 1 Operation Intermittent min 1 stop in 24 hours Progressive two stage or modulating by kit See Accessories...

Page 11: ...ust discharge head of the fan are reduced It is therefore important to know if the maximum output requested from the burner at a determinate combustion chamber pressure remains within the firing rate of the burner even with the changed temperature and altitude conditions To check it proceed as follows 1 find the corrective factor F relating to the air temperature and altitude of the system in Tab ...

Page 12: ...ING The combustion head should be adjusted in rela tion to the equivalent output Qe H1r H1 x Qr Q 2 Altitude Average baro metric pressure F Air temperature C m above sea level mbar 0 5 10 15 20 25 30 40 0 100 200 300 400 500 600 700 800 900 1000 1200 1400 1600 1800 2000 2400 2800 3200 3600 4000 1013 1000 989 978 966 955 944 932 921 910 898 878 856 836 815 794 755 714 675 635 616 1 087 1 073 1 061 ...

Page 13: ...g to be carried out by the installer 12 Control box with lockout pilot light and lockout reset button 13 Flame inspection window 14 Minimum air pressure switch differential operating type 15 Slide bars for opening the burner and inspecting the com bustion head 16 Gas pressure test point and head fixing screw 17 Air pressure test point 18 Flame sensor probe 19 Air damper 20 Fan air inlet 21 Screws ...

Page 14: ...separately as far as possi ble from the control box and the other cables When wiring the unit make sure the 230V AC mains voltage cables are run strictly separate from extra low voltage cables to avoid the risk of electrocution Electrical wiring of the flame detector It is important for signal transmission to be almost totally free of any disturbances or loss Always separate the detector cables fr...

Page 15: ...he servomotor and connecting the damp er the gears can be disengaged by means of a lever allow ing the drive shaft to be easily adjusted in both directions of rotation Technical data Tab H WARNING To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the actuators The servomotor contains electric and electronic components that mus...

Page 16: ...must be free from hazardous mixes e g chloride fluoride halo gen if present it is highly recommended to carry out cleaning and maintenance more frequently WARNING The handling operations for the burner can be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also ...

Page 17: ...ce in refractory material 13 must be inserted between the boiler fettling 14 and the blast tube 12 For boilers with a water cooled frontal a refractory lining 13 14 is not necessary unless expressly requested by the boiler manu facturer Tab J WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 10 Installation 1 is preferable as it is the only one that allows the maintenance...

Page 18: ...e screw 1 Fig 13 take out the inner part 2 Fig 13 of the head and then cali brate them Once this operation if necessary has been carried out fix the flange 11 Fig 12 to the boiler plate interposing the insulating gasket 9 Fig 12 supplied Use the 4 screws supplied with a tightening torque of 35 40 Nm after protecting their thread with anti seizing products Provide an adequate lifting system WARNING...

Page 19: ...s with the indicator 3 tighten the screws 4 Example burner output 1300 kW and combustion chamber pressure equal to 0 mbar The diagram Fig 15 shows that the gas and air adjustments for this output are carried out on notch 4 WARNING When positioning the probe and electrode re spect the dimensions shown in Fig 14 WARNING Do not rotate the probe leave it as in Fig 14 since if it is located too close t...

Page 20: ...nnect the socket of the maximum gas pressure switch refit the screws 2 on the slide bars 3 fix the burner to the pipe coupling with the screws 1 reconnect the articulated coupling 7 to the graduated sector 6 WARNING When fitting the burner on the two slide bars it is advisable to gently draw out the high voltage ca ble and the flame detection probe cable until they are slightly stretched Carry out...

Page 21: ... outputs over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upline 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 avoid knocking attrition sparks and heat Make su...

Page 22: ...te output at which the burner oper ates subtract the combustion chamber pressure from the gas pressure measured at test point 1 Fig 23 Find in Tab K related to the burner concerned 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...

Page 23: ...eter To calculate the required gas pressure at test point 1 Fig 23 set the maximum modulating output required from the burner op eration find the nearest output value in Tab K for the burner in ques tion Read on the right column 1 the pressure at the test point 1 Fig 23 Add this value to the estimated pressure in the combustion chamber Example with natural gas G20 Operation at maximum modulating o...

Page 24: ... up efficiency Normally burner stopping is guaranteed by the boiler s thermostat pres sure switch If this is not the case a time switch should be fitted in series to TL to stop the burner at least once every 24 hours Refer to the wiring diagrams 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...

Page 25: ...hermal relay press but ton 1 Fig 25 5 12 Measuring the ionisation current The burner is fitted with an ionisation system to check that a flame is present The minimum current for control box operation is 6 µA The burner provides a much higher current so controls are not normally required If it is necessary however to measure the ionisation current dis connect the plug socket 2 Fig 26 on the ionisat...

Page 26: ...ding so you can notice the smell of gas Connect two lamps or testers to the two gas line solenoids to check the exact moment in which voltage is supplied This operation is unnecessary if each of the two solenoids is equipped with a pilot light that signals voltage passing through 6 Start up calibration and operation of the burner WARNING The first start up of the burner must be carried out by qual...

Page 27: ... 30 simultaneously adjusts the air damper by means of the variable profile cam and the gas butterfly valve The servomotor rotates by 130 in 42 seconds Cam I 130 Limits rotation toward maximum position When the burner is at MAX output the gas butterfly valve must be fully open 90 Cam II 0 Limits rotation toward minimum position When the burner is shut down the air damper and gas butterfly valve mus...

Page 28: ...y the formula for ts 3s Vg volume supplied in ignitions carried out Sm3 Qa ignition delivery Sm3 h n number of ignitions 10 ts safety time sec Example for gas G20 9 45 kWh Sm3 ignition output 150 kW corresponding to 15 87 Sm3 h After 10 ignitions with lockout the output read on the meter must be equal to or less than 6 6 2 Maximum output MAX output must be selected within the firing rate range sho...

Page 29: ...ic key 10 Fig 32 Air adjustment Progressively adjust the initial profile of the cam 4 Fig 31 by turning the screws 5 6 6 4 Intermediate outputs Adjustment of gas delivery No adjustment of gas delivery is required Air adjustment Lightly press the increase output button 2 Fig 28 so the ser vomotor rotates by about 15 Adjust the screws until optimal combustion is obtained Proceed in the same way with...

Page 30: ...f cardboard until the CO value does not exceed 100 ppm Slowly turn the appropriate knob clockwise until the burner goes into lockout Check the indication of the arrow pointing upwards on the graduated scale Turn the knob clockwise again until the value shown on the graduated scale corresponds with the arrow pointing down wards and so recovering the hysteresis of the pressure switch shown by the wh...

Page 31: ...lame and the correct position of the air and maximum gas pressure switches If the temperature or pressure is low so the TR is closed the burner progressively increases the output up to the MAX value tract C D If the temperature or pressure then increases until the TR opens the burner progressively decreases its output to the MIN value section E F The sequence repeats endlessly The burner stops whe...

Page 32: ...rations then reassemble the hood and all the burner safety and protection de vices Open the thermostat pressure switch TL Open the thermostat pressure switch TS Æ 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 Æ The burner must stop in lockout Turn off the burner and cut off the ...

Page 33: ...ase the cam 4 Fig 31 on page 26 from the servomotor by pressing and shifting the button 3 Fig 32 on page 27 to the right Manually rotate it backwards and forwards to make sure it moves smoothly Now engage the cam again by shifting the button 2 Fig 31 on page 26 to the left Burner Check for excess wear or loose screws in the mechanisms con trolling the air damper and the gas butterfly valve Also ma...

Page 34: ... fully back Now extract the gas distributor 5 after having removed the screw 6 7 4 Closing the burner Push the burner to approximately 100mm from the pipe cou pling Reconnect the cables and slide in the burner until it comes to a stop Replace the screws 3 Fig 40 and carefully pull the probe and electrode cables out until they are slightly taut Reconnect the articulated coupling 7 to the graduated ...

Page 35: ...place High voltage cable defective Replace High voltage cable deformed by high tempera ture Replace and protect Ignition transformer defective Replace Incorrect valve or transformer electrical wiring Check Defective control box Replace A closed valve upline the gas train Open Air in pipework Bleed air Gas valves unconnected or with interrupted coil Check connections or replace coil 3 blinks The bu...

Page 36: ...ice is open Adjust or replace Line fuse blocked Replace Defective control box Replace No gas supply Open the manual valves between contactor and train Mains gas pressure insufficient Contact your gas company Minimum gas pressure switch fails to close Adjust or replace Servomotor fails to move to min ignition position Replace The burner continues to repeat the start up cy cle without lockout The ga...

Page 37: ...every burner start up Once read the burner repeats the start up cycle by briefly press ing the control box button GREEN LED ON press the reset button for 10s Press the button for 3s Signal 3s interval Signal Signal Flame detection time 1 blink 0 4 s 2 blinks 0 8 s 6 blinks 2 8 s WARNING If the result is 2 s ignition will be retarded Check the adjustment of the hydraulic brake of the gas valve the ...

Page 38: ...egulator kit Two components should be ordered the analogue signal converter the potentiometer PC interface kit A Appendix Accessories Burner Standard head length mm Extended head length mm Code RS 150 M 280 415 20052186 Burner Thickness mm Code RS 150 M 135 3010129 Burner Code RS 150 M 3010094 Burner Type Reduction of noise average Code RS 150 M C4 5 10 dB A 3010404 Burner Type Code RS 150 M RWF40...

Page 39: ... of signals exceeding 10V m owing to the presence of an INVERTER or in applications where the length of the thermostat connections exceeds 20 metres a protection kit is available as an interface between the control box and the burner Gas trains in compliance with EN 676 Please refer to manual Burner Head length mm Code RS 150 M TC 20050064 TL 20050065 Burner Code RS 150 3010386 ...

Page 40: ...tion of references 3 Functional layout RMG M 230V 3 Functional layout RMG M 400V 4 Functional diagram 5 Electrical wiring that the installer is responsible for 230V 5 Electrical wiring that the installer is responsible for 400V 6 Functional layout RWF40 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Page 41: ...39 20054085 GB Appendix Electrical panel layout ...

Page 42: ...20054085 40 GB Appendix Electrical panel layout ...

Page 43: ...41 20054085 GB Appendix Electrical panel layout ...

Page 44: ...20054085 42 GB Appendix Electrical panel layout ...

Page 45: ...43 20054085 GB Appendix Electrical panel layout ...

Page 46: ...20054085 44 GB Appendix Electrical panel layout ...

Page 47: ...F1 Fan motor thermal relay H Remote lockout signal K1 K1 relay K2 K2 relay MV Fan motor PA Air pressure switch PE Burner earth PGM Maximum gas pressure switch PGMin Minimum gas pressure switch S1 Off automatic manual selector S2 Power increase power reduction selector SM Servomotor TA Ignition transformer TL Limit thermostat pressure switch TR Adjustment thermostat pressure switch TS Safety thermo...

Page 48: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www rielloburners com ...