Riello RS 28, Installation, Use And Maintenance Instructions

Page 1: ...s 20144599 1 02 2018 Forced draught gas burners Progressive two stage operation CODE MODEL TYPE 3783302 RS 28 809 T1 3784402 RS 38 810 T1 3784403 RS 38 810 T1 3784502 RS 38 810 T1 3784503 RS 38 810 T1 3784702 RS 50 811 T1 3784703 RS 50 811 T1 GB ...

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

Page 3: ...iption 12 4 11 Control box RMG88 13 4 12 Servomotor SQM 14 5 Installation 15 5 1 Notes on safety for the installation 15 5 2 Handling 15 5 3 Preliminary checks 15 5 4 Operating position 16 5 5 Preparing the boiler 16 5 5 1 Boring the boiler plate 16 5 5 2 Blast tube length 16 5 5 3 Securing the burner to the boiler 16 5 6 Access to head internal part 17 5 7 Positioning the probe electrode 17 5 8 C...

Page 4: ...h TR remote control 29 6 8 3 Ignition failure 29 6 9 Burner start up cycle diagnostics 30 6 9 1 Resetting of control box and diagnostics use 30 6 9 2 Control box reset 30 6 9 3 Visual diagnostics 30 6 9 4 Software diagnostics 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 Safety test with no gas supply 31 7 2 3 Check...

Page 5: ... 12100 and according to the European Directives GAD 2009 142 EC Gas Devices Directive MD 2006 42 EC Machine Directive LVD 2014 35 UE Low Voltage Directive EMC 2014 30 UE Electromagnetic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Legnago 01 12 2015 General Manager RIELLO S p A Burners Depa...

Page 6: ...rried out correctly may cause damage to the machine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not carried out correctly lead to electric shocks with lethal 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 CRUSH...

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 incorrectly applied an...

Page 8: ...enance 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 responsible 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 under...

Page 9: ... gas Oil Gas oil Methane Adjustment Flame control system FS1 FS2 Standard 1 stop every 24 hours 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 28 TC Emission C1 or Class 1 EN676 C02 or MZ Class 2 EN676 C03 or BLU Class 3 EN676 3 230 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION 3N 400V 50Hz 3 230V 50Hz 230...

Page 10: ...232 440 200 378 295 600 254 516 Mcal h 1st stage min kW Mcal h 81 70 105 90 105 90 115 99 FUEL NATURAL GAS G20 G25 G31 G20 G25 G20 G25 G20 G25 G20 G25 Net calorific value kWh Nm3 Mcal Nm3 10 8 6 8 6 7 4 10 8 6 8 6 7 4 10 8 6 8 6 7 4 10 8 6 8 6 7 4 Absolute density kg Nm3 0 71 0 78 0 71 0 78 0 71 0 78 0 71 0 78 max delivery Nm3 h 32 38 44 51 44 51 58 68 pressure at maximum delivery 2 mbar 7 5 11 1 ...

Page 11: ...ge for gas train No 1 Seal for flange No 1 Flange fixing screws M 8 x 25 No 4 Thermal flange gasket No 1 Screws to fix the burner flange to the boiler M 8 x 25 No 4 Cable grommets for the electrical wiring No 4 RS 28 and RS 38 single phase Cable grommets for the electrical wiring No 6 RS 38 three phase and RS 50 Instruction No 1 Spare parts list No 1 mm A B C D 1 E F G H I L M RS 28 476 474 580 21...

Page 12: ...iagram RS 28 81 kW RS 38 105 kW RS 50 115 KW ATTENTION The firing rate value Fig 2 has been obtained considering an ambient temperature of 20 C an atmospheric pressure of 1013 mbar approx 0 m a s l and with the combustion head adjusted as shown on page 18 Pressure in the chamber pressure mbar Thermal power kW Fig 2 RS 28 D3612 Pressure in the chamber pressure mbar Thermal power kW RS 38 Pressure i...

Page 13: ...s were set in relation to special test boilers according to EN 676 regulations In Fig 3 you can see the diameter and length of the test combustion chamber Example Output 350 kW diameter 50 cm length 1 5 m 4 9 1 Commercial boilers The burner boiler combination does not pose any problems if the boiler is EC approved and its combustion chamber dimensions are similar to those indicated in the diagram ...

Page 14: ... the fan suction inlet 12 Plate with four hole knock outs for electrical cable routing 13 Air inlet to fan 14 Gas input pipe 15 Gas butterfly valve 16 Boiler fixing flange 17 Flame stability disc 18 Flame inspection window 19 Plug socket on ionisation probe cable 20 Motor contactor and thermal relay with reset button RS 38 three phase RS 50 21 Motor capacitor RS 28 RS 38 single phase 22 Control bo...

Page 15: ...the development of condensate 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 Technical data Mechanical structure The control box is made of plastic to resist knocks heat and flame propagation The control box contains the following compon...

Page 16: ... not allowed For safety reasons the servomotor must be checked after long periods of non use Technical data ATTENTION To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the servomotor Mains voltage 220 V 15 10 240 V 10 Mains frequency 50 60 Hz 6 Power absorption 8 VA Motor Synchronous Drive angle Varying between 0 and 90 Protec...

Page 17: ...nside the boiler must be free from hazardous mixes e g chloride fluoride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently ATTENTION Burner handling operations can be highly dangerous if not carried out with the greatest attention distance unauthorised personnel check integrity and suitability of the means available Check also that the area in which ...

Page 18: ... 3 Securing the burner to the boiler Separate the combustion head from the rest of the burner Fig 10 Remove screw 14 and extract cover 15 Disengage the articulated coupling 4 from the graduated sector 5 Remove the screws 2 from the two slide bars 3 Remove the screw 1 and draw the burner back on the slide bars 3 by about 100mm Disconnect the probe and electrode cables and then slide the burner comp...

Page 19: ... must be airtight 5 7 Positioning the probe electrode If in the previous check the position of the probe or electrode was not correct remove the screw 1 Fig 11 extract the inner part 2 Fig 11 of the head and adjust them Fig 11 D501 ATTENTION Before securing the burner to the boiler check through the opening of the blast tube that the probe and electrode are correctly positioned as in Fig 12 ATTENT...

Page 20: ...d lines up with the front surface 5 of the flange Gas adjustment Loosen the screws 1 Fig 13 and rotate the ring nut 2 until the notch you have found corresponds with the indicator 3 Block the 3 screws 4 Example RS 38 burner output 337 kW 290 Mcal h The diagram Fig 14 shows that the gas and air adjustments for this output are carried out on notch 3 NOTE The diagram indicates the optimum adjustment ...

Page 21: ...ster P3 Pressure upstream of the filter L Gas train supplied separately L1 Responsibility of the installer Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel shut off valve is closed before performing any operation on the burner ATTENTION The fuel supply line must be installed by qualified personnel in co...

Page 22: ... 20 NCV 10 kWh Sm3 8 6 Mcal Sm3 Natural gas G 25 NCV 8 6 kWh Sm3 7 4 Mcal Sm3 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 equipment during installation Fig 19 D505 Mo...

Page 23: ...2 Fig 13 on page 18 adjusted as per diagram Fig 14 on page 18 Gas pressure at test point 1 Fig 20 8 6 mbar Pressure in combustion chamber 2 0 mbar 8 6 2 0 6 6 mbar A pressure of 6 6 mbar column 1 corresponds in table RS 28 to a 2nd stage output of 289 kW This value serves as a rough guide the effective output must be measured at the gas meter To calculate the required gas pressure at test point 1 ...

Page 24: ...that shown on the identification label and in this manual The burner has been type approved for intermittent use This means they should compulsorily be stopped at least once every 24 hours to enable the control box to perform checks of its own start up efficiency Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case a time switch should be fitted...

Page 25: ... scale of the thermal relay does not include rated motor absorption at 400 V protection is still ensured in any case The RS 38 and RS 50 three phase models leave the factory pre set for 400 V power supply If 230 V power supply is used change the motor connection from star to delta and change the calibration of the thermal relay as well The RS 28 38 50 burners leave the factory ready for two stage ...

Page 26: ...he two solenoid valves is equipped with a pilot light that signals voltage passing through 6 3 Burner start up Close the remote controls and turn switch 1 Fig 25 in BURNER ON position switch 2 Fig 25 in 1st STAGE position As soon as the burner starts check that the lamps or the testers connected to the solenoid valves or the warning lights on the solenoid valves indicate no voltage presence If vol...

Page 27: ...ration output of 600 kW Ignition output must be equal to or lower than 300 kW con ts 2s 200 kW con ts 3s In order to measure the ignition output Remove the UV sensor 29 Fig 4 on page 12 the burner starts and locks out after the safety time Perform 10 ignitions with consecutive lockouts Read the quantity of gas burned on the meter This quantity must be equal to or lower than the quantity given by t...

Page 28: ...itch 2 Fig 25 on page 24 and slightly increase the angle of the orange lever with small regular movements i e bring it from an angle of 15 to 17 19 Then go back to 1st stage and measure the gas delivery NOTE The servomotor only follows the adjustment of the orange lever when the angle of the cam is reduced If the angle needs to be increased pass to the 2nd stage and increase the angle then return ...

Page 29: ...ting in 2nd stage increase adjustment pressure by slowly turning the relevant knob clockwise until the burner stops Then turn the knob anticlockwise by 0 2 kPa 2 mbar and repeat burner start up to ensure it is operating regularly If the burner locks out again turn the knob again anticlockwise by 0 1 kPa 1 mbar 6 6 3 Flame presence check The burner is fitted with an ionisation system to check that ...

Page 30: ...e gas butterfly valve The servomotor rotates 90 in 12 s Do not alter the factory setting for the 4 cams just check that they are as specified below Cam St2 90 Limits rotation toward maximum position When the burner is operating in 2nd stage the gas butterfly valve must be fully open 90 Cam St0 0 Limits rotation toward minimum position When the burner is shut down the air damper and gas butterfly v...

Page 31: ...tion failure If the burner does not fire it goes into lockout within 3 s from opening of the gas valve and within 49 s from closure of the TL remote control The red LED of the control box comes on Burner flame goes out during operation If the flame accidentally goes out during operation the burner will go into lockout within 1s Off Yellow Red For further details see page 30 Control remote control ...

Page 32: ...blinked The number of blinks indicates the reason for the malfunctioning refer to the coding in Tab L on page 35 6 9 4 Software diagnostics Provides an analysis of the life of the burner through optical connection with a PC showing the working hours number and types of lockout control box serial number etc To view diagnostics proceed as follows Press and hold the button for more than 3 seconds fro...

Page 33: ... or closing opening position indicators that activate as soon as they are powered 7 2 3 Checking and cleaning Combustion head Open the burner and make sure that all components of the combustion head are in good condition not deformed by the high temperatures free of impurities from the surroundings and correctly positioned Gas filter Change the gas filter when it is dirty Burner Check that there a...

Page 34: ...ion for example a variation in the tension could cause a combustion with an air defect and with the subsequent formation of CO CO It should not exceed 100 mg kWh 7 2 5 Safety components The safety components must be replaced at the end of their life cycle indicated in Tab K The specified life cycles do not refer to the warranty terms indicated in the delivery or payment conditions Tab K EN 676 Air...

Page 35: ... the screw 8 Fig 34 7 4 Closing the burner Remove the split pin 9 and push the burner until it is approx 100 mm from the pipe coupling Reconnect the cables and slide in the burner until it comes to a stop Replace the screws 5 and split pin 9 and carefully pull the probe and electrode cables outwards until they are slightly taut Reconnect the articulated coupling 3 to the graduated sector 4 DANGER ...

Page 36: ...ner does not switch on and the lockout appears Air pressure switch in operating position Adjust or replace The burner starts and then goes into lockout Air pressure switch does not switch owing to lack of air pressure Air pressure switch poorly adjusted Adjust or replace Pressure switch pressure point pipe clogged Clean Poorly adjusted head Adjust High pressure in the furnace Connect air pressure ...

Page 37: ...on Replace The burner continues to repeat the start up cycle without lockout The gas pressure in the gas mains lies very close to the value to which the gas pressure switch has been set The sudden drop in pressure after valve opening causes temporary opening of the pressure switch itself the valve immediately closes and the burner stops Pressure increases again the pressure switch closes again and...

Page 38: ... 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 A Appendix Accessories BURNER RS 28 RS 38 RS 50 Output kW 95 325 115 440 140 581 Nozzle length mm 216 351 216 351 216 351 Code 3010079 3010080 3010081 3010082 3010083 3010084 BURNER RS 28 RS 38 RS 50 Output kW 81 325 105 440 116 580 Nozzle leng...

Page 39: ...IAGRAM A Electrical system external connections without valve leak detection control for RS 28 38 SINGLE PHASE burners DIAGRAM B Electrical system external connections without valve leak detection control for RS 38 RS 50 THREE PHASE burners DIAGRAM B Electrical system external connections with valve leak detection control for RS 28 38 SINGLE PHASE burners DIAGRAM C Electrical system external conne...

Page 40: ...20144599 38 GB Appendix Electrical panel layout K1 RS 28 SINGLE PHASE 20129156 DIAGRAM A ...

Page 41: ...39 20144599 GB Appendix Electrical panel layout K1 RS 38 SINGLE PHASE 20129158 DIAGRAM A ...

Page 42: ...20144599 40 GB Appendix Electrical panel layout K1 RS 38 RS 50 THREE PHASE 20126558 DIAGRAM A ...

Page 43: ...41 20144599 GB Appendix Electrical panel layout RS 28 RS 38 SINGLE PHASE 20143439 DIAGRAM B ...

Page 44: ...20144599 42 GB Appendix Electrical panel layout RS 38 RS 50 THREE PHASE DIAGRAM B 20143440 ...

Page 45: ...43 20144599 GB Appendix Electrical panel layout 20143441 RS 28 RS 38 SINGLE PHASE DIAGRAM C ...

Page 46: ...20144599 44 GB Appendix Electrical panel layout 20143442 RS 38 RS 50 THREE PHASE DIAGRAM C ...

Page 47: ...ion control PG Min gas pressure switch S Remote lockout signal S1 Remote lockout signal due to leak detection control TR Adjustment remote control controls 1st and 2nd stage operation If you want the burner to have one stage operation replace the TR with a jumper TL Limit remote control shuts down the burner when the temperature or pressure in the boiler reaches the maximum pre set value TS Safety...

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