Riello RS 500/E LN, Installation, Use And Maintenance Instructions

Page 1: ...tallation use and maintenance instructions Forced draught gas burners Code Model Type 20011898 RS 300 E LN 1110 T72 20011900 RS 400 E LN 1111 T72 20011902 RS 500 E LN 1112 T72 GB Progressive two stage or modulating operation ...

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Page 3: ... 2 Handling 19 4 3 Preliminary checks 19 4 4 Operation position 19 4 5 Removal of the locking screws from the shutter 19 4 6 Securing the burner to the boiler 20 4 6 1 Boring the boiler plate 20 4 6 2 Blast tube length 20 4 6 3 Burner securing 20 4 6 4 Accessibility to the interior of the combustion head 20 4 7 Electrode positioning 21 4 8 Combustion head setting 21 4 9 Rotation of fan motor 22 4 ...

Page 4: ...modulation system 30 5 6 1 General information 30 5 7 Final calibration of the pressure switches 31 5 7 1 Air pressure switch 31 5 7 2 Maximum gas pressure switch 31 5 7 3 Minimum gas pressure switch 31 5 8 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 cleaning 33 6 ...

Page 5: ...erious injury death or long term health risks This symbol indicates operations which if not carried out correctly may cause damage to the machine and or injury to people 1 1 3 Danger live components This symbol indicates operations which if not carried out correctly lead to electric shocks with lethal con sequences Other symbols ENVIRONMENTAL PROTECTION This symbol gives indications for the use of...

Page 6: ...nents most subject to wear and tear use of non original components including spare parts kits accessories and optionals force majeure furthermore declines any and every responsibility 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 i...

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: ... E LN RS 400 E LN RS 500 E LN Output 1 max kW MBtu hr 1500 4220 3834 5112 14390 13082 2000 4995 4541 6817 17043 15494 2715 5740 5217 9468 19580 17800 min kW MBtu hr 555 1893 888 3030 1100 3787 Fuel max delivery pressure at max delivery 2 SCFH wc Natural gas 14070 7 Natural gas 16654 13 Natural gas 19138 15 Operation Low high or modulating Standard applications Boilers water steam thermal oil Ambie...

Page 9: ...ower consumption W 6550 Electrical control circuit consumption W max 750 Total electrical consumption W 7300 Electrical protection NEMA 1 Model RS 400 E LN RS 500 E LN RBNA Code Control circuit power supply V Ph Hz 120 1 60 Main power supply 10 V Ph Hz 460 3 60 Fan motor rpm HP V A 3460 10 460 14 9 3500 20 460 30 5 Ignition transformer Gas V1 V2 I1 I2 120 V 1 x 8 kV 1 6 A 20 mA Electrical power co...

Page 10: ...ectrical power consumption W 6300 6300 6250 Electrical control circuit consumption W max 750 Total electrical consumption W 7050 7050 7000 Electrical protection NEMA 1 Model RS 400 E LN RS 500 E LN RBNA Code Control circuit power supply V Ph Hz 120 1 60 Main power supply 10 V Ph Hz 460 3 60 575 3 60 460 3 60 575 3 60 Fan motor rpm HP V A 3510 10 460 11 5 3510 10 575 8 8 3545 20 460 23 5 3545 20 57...

Page 11: ...is supplied complete with Flange gasket 4 flange fixing screws M 16 x 50 4 screws to secure the burner flange to the boiler M 18 x 70 2 spacers Instruction manual and spare parts list inch A B C D E F G H I L R S RS 300 E LN 52 3 16 20 1 2 6 7 16 12 5 16 23 5 32 DN80 28 11 32 34 9 64 14 1 32 46 1 4 41 17 32 12 19 32 RS 400 E LN 52 3 16 20 1 2 6 7 16 12 5 16 23 5 32 DN80 30 1 2 34 9 64 14 1 32 46 1...

Page 12: ... 1893 RS 400 E LN 3030 RS 500 E LN 3787 WARNING 0 2 4 6 8 10 12 14 16 18 mba r MBtu h 7 6 5 4 3 2 0 1 w c 0 5200 kW 4800 4400 4000 3600 3200 2800 2400 2000 1600 1200 800 400 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 RS 300 E LN RS 400 E LN Burner power output Combustion chamber pressure 0 2 4 6 8 10 12 14 16 18 20 mbar 22 24 9 8 7 6 5 4 3 2 0 1 w c 0 5600 5200 4800 4400 4000 3600 3200 28...

Page 13: ...r movement of combustion head 17 Gears for movement of air damper 18 Air pressure switch differential operating type 19 Air pressure test point 20 Maximum gas pressure switch with pressure test point 21 QRI infrared sensor 22 Hinge for opening burner 23 Air pressure test point pressure test point 24 Air pressure test point pressure test point 25 Ignition pilot attachment The burner can be opened e...

Page 14: ...r and terminal strip XAUX 22 Horn 23 K1 relay 24 K3 relay 25 K5 relay 26 K2 relay 27 KL1 contactor only for star delta version 28 K7 relay 29 KT1 contactor only for star delta version 30 DIN bar for X2 terminal strip thermal relays and contactors 31 KST1 Star delta starter timer only for star delta version 32 Holes for cables grommets for electrical wirings accessories and power supply to be carri...

Page 15: ...uators maintain their positions until all actuators have reached the positions currently required This is essential for setting fuel air ratio control This means that during the time the fuel air ratio curves are programmed the person making the plant settings must con tinuously monitor the quality of the combustion process e g by means of a flue gas analyzer Also if combustion levels are poor or ...

Page 16: ...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 17: ...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 8 ...

Page 18: ...tn1 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 ...

Page 19: ...ch 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 LMV51 Continuous pilot gas oil Activated Pilot valve is also activated in...

Page 20: ...onnection with burner controls or electronic fuel air ratio control the associated controlling elements are con trolled depending on burner output Installation notes Always run the high voltage ignition cables separate from the unit and other cables while observing the greatest possible dis tance To ensure protection against electric shock hazard make cer tain that the AC 230 V section of the actu...

Page 21: ...various types of material Before proceeding with the installation operations carefully clean all around the area where the burner will be installed 4 3 Preliminary checks Checking the consignment After removing all the packaging check the integrity of the contents In the event of doubt do not use the burner contact the supplier The packaging elements wooden cage or cardboard box nails clips plasti...

Page 22: ...he boiler manufacturer 4 6 3 Burner securing Create a suitable hoisting system by hooking onto the rings 3 Fig 13 removing the fastening screws 7 securing the cover 8 first Slip the thermal protection onto the blast tube 4 Fig 13 Place entire burner on the boiler hole arranged previously see Fig 12 and fasten with the screws given as standard equipment The coupling of the burner boiler must be air...

Page 23: ...ded on the basis of diagram Fig 17 against the required maximum output Setting is pre arranged in the plant for the maximum run hole 3 Fig 16 When dealing with boilers featuring a strong back pressure if air delivery is insufficient even with the damper fully open you can use a different setting to that illustrated in diagram Fig 17 do this by moving the tie rod onto the next highest hole numerica...

Page 24: ...otation of fan motor The correct motor rotation direction is indicated by the phase se quence relay 16 Fig 6 After turning the power on to the burner check the green led lights up on the phase sequence relay If the phase sequence is not correct the burner does not fire 4 10 Gas train 4 10 1 Gas train assembly The gas train is to be connected on the right of the burner by flange 1 Fig 19 If necessa...

Page 25: ...f the burner from table refers to zero in the combustion chamber to obtain true pressure measured by a U type manometer Fig 36 add the counter pressure of the boiler Note See the accompanying instructions for the adjustment of the gas train M ai n gas suppl y 10 2 3 4 5 6 11 Vent 2 12 5 4 7 Vent 9 8 1 4 D3776 Fig 20 GCV MBtu hr Combustion Head WC Gas butterfly Adaptor WC RS 300 E LN 5112 3 3 0 63 ...

Page 26: ...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 27: ... is 400V To reset in the case of an intervention of the thermal relay press the button RESET Fig 22 The button STOP Fig 22 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 23 and move it in the sense of the arrow towards right 4 12 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay press the bu...

Page 28: ...t 575V only for RS 300 E LN 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 4 15 Reversible direction WARNING If it is necessary to reverse the direction then reverse the two main supply phases For example L1 with L2 there is not difference between IE1 and IE2 ...

Page 29: ...5V only for RS 400 E LN RS 500 E LN 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 4 18 Reversible direction WARNING If it is necessary to reverse the direction then reverse the two main supply phases For example L1 with L2 there is not difference between IE1 ...

Page 30: ... Adjust the air pressure switch Fig 35 to the start of the scale Purge the air from the gas line Continue to purge the air we recommend using a plastic tube routed outside the building until gas is smelt Fit a U type manometer Fig 36 to the gas pressure test point on the sleeve The manometer readings are used to calculate MAX burner power using the table on pag 23 Connect two lamps or testers to t...

Page 31: ... arrival of gas at the sleeve is indicated by the U type ma nometer Fig 36 Once the burner has fired now proceed with global calibration operations Once you have completed adjustments select AUTOMATIC op erating mode on the AZL display 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 voltage is present...

Page 32: ...S burn er series provides a set of integrated functions ensuring top lev el energy and operational performance from the burner both for single and grouped burners e g boiler with a double combus tion chamber 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 avoi...

Page 33: ...1 On RS 300 400 500 E burners the air pressure switch is fitted in a differential mode that is with two pipes connected to the specific pressure test points and 22 and 23 Fig 5 5 7 2 Maximum gas pressure switch Adjust the maximum gas pressure switch after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale Fig 39 With the burner operating ...

Page 34: ... maximum end of scale position Rotate the maximum oil pressure switch at the minimum of the scale Æ The burner must stop in lockout Switch off the burner and disconnect the voltage Disconnect the minimum gas pressure switch Rotate the minimum low oil pressure switch at the maximum of the scale Æ The burner must not start Cover the QRI flame detector Æ The burner must stop in lockout due to firing ...

Page 35: ...aintenance Combustion head Open the burner and make sure that all the components of the combustion head are undamaged not deformed due to high temperature free of ambient dirt or dust free of rusted materials adequately positioned Make sure that the gas outlet holes for the start up on the com bustion head distributor are free of dirt or rust deposits In case of doubt disassemble the elbow Measure...

Page 36: ...ect the gas pressure switch test point 4 Remove screws 5 At this point it is possible to open the burner at the hinge 6 4 Closing the burner Close the burner at the hinge Apply screw 5 Connect the gas pressure switch test point 4 Connect the gas servomotor test point 3 Apply the tire rod 1 Fig 42 of the head movement lever loosening nut 2 Connect the electrical supply from the burner DANGER 5 5 1 ...

Page 37: ...Appendix Spare parts 20008423 35 GB A Appendix Spare parts 57 28 66 61 65 4 53 45 44 52 54 56 55 67 62 58 58 62 RS 300 E 28 66 61 65 4 53 45 44 52 54 56 55 67 62 58 58 62 59 55 64 68 64 RS 400 500 E ...

Page 38: ... BAR C 13 3013312 BAR C 14 3013313 SLEEVE 14 3013641 SLEEVE 15 3013314 END CONE B 15 3013642 END CONE B 16 20013118 SHUTTER C 16 20013116 SHUTTER C 16 20013151 SHUTTER C 17 20006192 FAN C 17 20006205 FAN C 17 3013317 FAN C 18 3013319 AIR DAMPER C 19 3013320 GEAR TRAIN 20 3013321 STUD 21 3013322 STUD 22 3013323 HINGE 23 3013324 INTERNAL TIE ROD C 24 3013325 LEVER ASSEMBLY 25 3013326 AIR INTAKE ASSE...

Page 39: ... 43 3013331 GAS NOZZEL A 44 3013284 ELECTRONIC CAM TRANSFORMER A 45 3012956 TRANSFORMER B 46 3013328 FLANGE GASKET A 47 20010961 HORN 48 20010963 SWITCH OFF LOCAL REMOTE 49 20036017 GREEN SIGNAL LIGHT 50 20010962 BUTTON 51 3013354 RED RESET PUSH BUTTON 52 20014366 FUSE HOLDER 53 20043328 THERMAL RELAY BASE 54 20027917 OVERLOAD 55 20013967 NO AUXILIARY CONTACT C 56 20027247 CONTACTOR B 56 20043297 ...

Page 40: ...r minimum fittings A B Spare parts for basic safety fittings A B C Spare parts for extended safety fittings 65 3013283 AZL DISPLAY 66 20013932 ELECTRONIC CAM CONNECTOR C 67 20031413 WARNING 68 20013973 CONTACTOR B N CODE RS 300 E LN RS 400 E LN RS 500 E LN DESCRIPTION ...

Page 41: ...w 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 Pressure Low Gas Pressure Flame Safeguard Model Nu...

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