Riello RS 250/EV, Installation, Use And Maintenance Instructions

Page 1: ...20044771 2 07 2012 Installation use and maintenance instructions Forced draught gas burner Progressive two stage or modulating operation Code Model 20044529 RS 250 EV GB ...

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Page 3: ...rol box for the air fuel ratio LMV52 12 3 11 Actuators 17 4 Installation 18 4 1 Notes on safety for the installation 18 4 2 Handling 18 4 3 Preliminary checks 18 4 4 Operation position 18 4 5 Boiler plate 19 4 6 Securing the burner to the boiler 19 4 7 Electrode positioning 20 4 8 Combustion head adjustment 21 4 8 1 Air adjustment 21 4 8 2 Gas adjustment 21 4 9 Gas supply 23 4 9 1 Gas train 23 4 9...

Page 4: ... 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 cleaning 33 6 2 3 Maintenance of burner electrical components under the control box 34 6 3 Opening the burner 35 6 4 Closing the burner 35 A Appendix Spare parts 36 B Appendix Accessories 39 C Appendix Burner start up report 40 ...

Page 5: ... 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 that may be necessary before the system is started up maintenance and the need to have the system checked at least once a year by the manufacturer or...

Page 6: ...is 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 serv...

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 machine and intends to use it for the specific purpose He is re sponsible for the machine and for the training of the people working around it The user Undertakes to entr...

Page 8: ...Standard application Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Combustion air temperature F max 140 60 C Noise levels 3 dB A 83 Model RS 250 EV Control circuit power supply V Ph Hz 120 1 60 Main power supply 10 V Ph Hz 208 220 3 60 460 3 60 575 3 60 Fan motor rpm HP V A 3480 7 5 208 230 19 4 3480 7 5 460 9 7 3480 7 5 575 8 7 Ignition transformer V1 V2 I1 I2 120 V 1 x 8 kV...

Page 9: ...er to be opened and the rear part drawn back on the sliding bars The dimensions of the open burner are indicated by position I Tab E 3 6 Burner equipment The burner is supplied complete with Gas train flange No 1 Flange gasket No 1 Connector for pilot line No 1 Screws M10 x 40 to fix the flange No 4 Screws M4 x 7 No 2 Disc No 1 Small disc No 1 Instruction manual No 1 Model Code Code RBNA Main Volt...

Page 10: ...itch 25 Fan air inlet 26 Screws to secure fan to pipe coupling 27 LOCAL REMOTE switch 28 Gas butterfly valve 29 Boiler fixing flange 30 Flame stability disc 31 Horn 32 ALARM SILENCE button 33 POWER ON signal 34 IGNITION ON signal 35 FUEL ON signal 36 ALARM ON signal 37 Control box transformer T1 38 Hight voltage lead 39 Din bar for K7 relay and available for accessories 40 Optional holes 41 Din ba...

Page 11: ...fferent air temper ature a compensation of 1000 ft each 20 F 305 m each 11 C is applicable 100 ft 2 F Example Rated capacity 3000 MBtu hr Rated air pressure 1 5 WC Real altitude 5000 ft Real temperature 108 F 108 F 68 F reference temp 40 F equivalent 2000 ft variation 40 2 20 x 100 2000 ft Proceeding as descripted above and considering a virtual altitude of 5000 2000 ft 3000 MBtu hr at 7000 ft the...

Page 12: ... 8 908 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...

Page 13: ...inimum furnace dimensions The firing rates were obtained in special test boilers Fig 5 indicates the diameter and length of the test combustion chamber Example Output 6400 Mbtu hr diameter 31 5 inch length 10 4 ft Fig 5 Length of combustion chamber ft D9086 ...

Page 14: ...ust also be observed Condensation and ingress of humidity must be avoided Should such conditions occur make sure that the unit will be completely dry before switching on again Static charges must be avoided since they can damage the unit s electronic components when touched Mechanical design The LMV5 is a microprocessor based burner management sys tem with matching system components for the contro...

Page 15: ...use externally Max 16 AT Undervoltage Safety shutdown from operating position at mains voltage Restart on rise in mains voltage AC 96 V AC 100 V Oil pump magnetic clutch nominal voltage Nominal current Power factor 1 6A cos 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cos 0 4 Terminal loading Outputs Total contact loading Mains voltage Input current of unit ...

Page 16: ...V Fuel valve V1 Fuel valve V2 Fuel valve V1 Fuel valve V2 Fuel valve V3 Fuel valve SV Oil INPUTS Timer 1 Timer 2 Fuel 1 oil Fuel 2 gas Controller ON internal external Air pressure switch LP Start release oil Fuel selection Fan conductor contact GSK Interval 1 ti1 Operation 2 LK K POS SR ON Pressure test Direct start Air Aux VSD Actuator 1 4 5 CPI function with LMV52 alternative start signal Fig 7 ...

Page 17: ...1 t78 Postpurge time 3 gas oil tn3 t80 Valve proving evacuate time t81 Leakage test time atmospheric pressure t82 Leakage test filling test t83 Leakage test time gas pressure tmn1 Min time extraneous light test 5 s after skip over of pre purge tmx1 Max damper running time tmx2 Max time startup release tmx3 Max time circulation heavy oil tn Postpurge time TSA1 Safety time 1 TSA2 Safety time 2 tv Pr...

Page 18: ...h Output is active when fan is on and for another 15 s after fan is switched off 17 Parameter Start pressure switch valve PS_Reli_Inv Output pressure switch valve will be logically inverted 18 Parameter Alarm act deact deactivated The alarm output can temporarily be deactivated for cur rent error only 19 Parameter Only with LMV52 Continuous pilot gas oil Activated Pilot valve is also activated in ...

Page 19: ... V section of the actuator is strictly segregat ed from the functional low voltage section The holding torque is reduced when the actuator s power supply is switched off Technical data Tab F WARNING To avoid injury to persons damage to property or the environment the following warning notes should be observed Do not open interfere with or modify the actua tors WARNING The housing cover may only be...

Page 20: ...ce WARNING The handling operations for the burner can be high ly dangerous if not carried out with the greatest at tention keep any unauthorised people at a distance check the 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 quickly move if the bur...

Page 21: ...last tube For boilers with a water cooled frontal a refractory lining is not necessary 11 12 Fig 11 unless expressly requested by the boiler manufacturer Tab G 4 6 Securing the burner to the boiler Secure the burner to the boiler fixing the flange 9 Fig 11 to the boiler plate and interposing the insulating gasket 8 Use the 4 screws supplied with a tightening torque of 26 29 Lbf ft after protecting...

Page 22: ...o sliding bars 5 install the extensions 15 and re screw the screws 2 remove the two screws 4 pull back the burner on the sliding bars 5 of about 4 disconnect the electrode lead then unthread the burner com pletely from the sliding bars remove the screw 1 Fig 13 and extract the inner part 2 of the head check the correct position of ignition electrode as shown in Fig 12 Re install all components wit...

Page 23: ... Gas adjustment When the burner is working at the maximum output 5680 MBtu hr fit the discs 1 and 2 Fig 16 supplied as part of the standard equipment removing the internal tube 3 Fig 16 If the mains gas pressure is low the head can be left in the stan dard set up limiting the modulation minimum to 1970 MBtu hr Example Burner output 6000 MBtu hr The diagram of Fig 14 shows that the adjustments for ...

Page 24: ... shown in Fig 18 unscrew the 2 screws 2 from the extension 5 and reposition them as previously Fig 18 refit the screws 2 on the sliding bars 3 fix the burner to the pipe coupling with the screws 1 Key Fig 17 and Fig 18 1 Screws 2 Screws 3 Sliding bars 4 Pipe coupling 5 Extension sliding bars 6 Lifting rings WARNING When fitting the burner on the two sliding bars it is advisable to gently draw out ...

Page 25: ...head within the safety time of 3s Ensure that the maximum pressure necessary for the burner is included in the calibration field of the pressure regulator colour of the spring 4 9 2 Gas feeding line It must be type approved according to required standards and is supplied separately from the burner Key Fig 20 1 Gas input pipe 2 Manual valve 3 Pressure regulator 4 Minimum gas pressure switch 5 1st s...

Page 26: ...sure in combustion chamber 1 2 wc 6 8 1 2 5 6 wc A maximum output of 8500 MBtu hr corresponds to 5 6 wc pres sure This value serves as a rough guide the effective output 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 ...

Page 27: ...uts 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 to current stand...

Page 28: ...ment WARNING It is very importatnt to shield the motor cable 1 as shown in Fig 24 fix the cable shielding as shown in Fig 24 The connection from the Inverter to LMV52 must be done as shown in Fig 24 1 2 3 Fig 24 D12184 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 Fi...

Page 29: ... clamping the cable to the earth plate The screen must be earthed on both side of the cable take care for good earthing system Example number 1 2 3 show not proper ways to earth a cable screen WARNING Following it is reported an example how to con nect the Inverter For further information please refer to the relevant Inverter instruction manual L1 L2 N PE 3 M U PE L1 L2 VWPE PE Fig 27 S8203 Ground...

Page 30: ...voltage maintenance or substitu tion 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 30 D3686 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 575V Fig 31 S8382 WARNING If it is necessary to reverse...

Page 31: ...tion of the burner WARNING The first start up of the burner must be carried out by qualified personnel as indicated in this manual and in compliance with the standards and regula tions of the laws in force WARNING Check the correct working of the adjustment com mand and safety devices CAUTION Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in ...

Page 32: ...d grouped burners e g boiler with a double combustion cham ber or several generators in parallel The system includes the following basic functions air and fuels are supplied in correct quantities by positioning the valves by direct servo control thus avoiding the possibility of play typical of systems used for traditional modulating burn ers in which settings are obtained by levers and a mechanica...

Page 33: ... switch Adjust the maximum gas pressure switch Fig 37 after having per formed all other burner adjustments with the maximum gas pres sure switch set to the end of the scale 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 34: ...i mum end of scale position Rotate the air pressure switch knob to the maximum end of scale position Æ The burner must stop in lockout Switch off the burner and disconnect the voltage Disconnect the minimum gas pressure switch Æ The burner must not start Cover the QRI flame sensor Æ The burner must stop in lockout due to firing failure WARNING Make sure that the mechanical locking systems on the d...

Page 35: ...dosplay flame approx 50 If the value is lower it can depend on photocell positioned incorrectly low corrent lower than 96V bad regulation of the burner To measure power use a voltometer with a 10 Vdc scale connect ed as illustrated in Fig 39 QRI flame detector In order to reach the QRI flame detector proceed as follows loosen without removing the screws 1 extract the QRI flame detector 2 clean the...

Page 36: ...n case of possible regulations and maintenance to the underlying control box parts Proceed as follows unscrew completely the screw 1 Fig 41 loosen the three screws 2 and lift the control box as indicated by the arrows The screws 3 move inside the slide until reaching the correct po sition indicated in View A At the end of maintenace loosen the screws 3 and lower the control box see View B fix the ...

Page 37: ... screw 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 c...

Page 38: ...ts A Appendix Spare parts 5 21 6 50 4 27 3 32 62 28 59 1 2 32 29 28 62 59 59 45 16 60 61 55 58 56 53 54 41 15 43 26 46 39 38 10 10 36 33 35 52 34 37 31 10 30 42 5 24 9 47 48 11 47 48 23 13 23 12 25 51 40 14 17 19 44 20 18 22 49 7 8 57 ...

Page 39: ...ER C 20 20013932 CONNECTORS ASSEMBLY C 21 3014152 MOTOR 7 5 HP C 22 3006211 FUSE 6 3A A 23 20036020 GREEN SIGNAL LIGHT C 24 3013501 SPEED SENSOR 25 20027014 WITHE SIGNAL LIGHT C 26 3013681 SCREW C 27 3003891 CONNECTOR C 28 3014081 BRACKET 29 3013939 INDEX 30 3012393 ELECTRODE CONNECTION A 31 3012980 ELECTRODE A 32 3013253 SERVOMOTOR B 33 3012025 TUBE 34 20027310 DIFFUSER DISC 35 20011348 DISTRIBUT...

Page 40: ...ngs A B C Spare parts for extended safety fittings 50 20011454 PLUG 51 20010962 BUTTON 52 3013694 DISC C 53 3012049 SCREW 54 3012639 CONTROL DEVICE 55 3012560 SHUTTER C 56 3013698 BRACKET 57 3013279 IR SENSOR A 58 3013699 END CONE 59 3013937 HUB 60 3003322 CONNECTOR 61 20011351 MANIFOLD 62 3013938 DISC C N CODE DESCRIPTION ...

Page 41: ...essories 39 20044771 GB Gas train according to UL Standards B Appendix Accessories WARNING The installer is responsible for the supply and instal lation of any required safety device s not indicated in this manual ...

Page 42: ...O2 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 Press...

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