Riello Rs 810/e fgr Quick start guide

Installation, use and maintenance instructions

20163821 (2) - 06/2021

Forced draught gas burner

Modulating operation

CODE MODEL TYPE

20160290 RS 810/E FGR S033T1

Translation of the original instructions

1 20163821

Contents

1 Declarations................................................................................................................................................................................ 3

2 Information and general warnings............................................................................................................................................ 4

2.1 Information about the instruction manual .................................................................................................................... 4

2.1.1 Introduction.................................................................................................................................................................. 4

2.1.2 General dangers.......................................................................................................................................................... 4

2.1.3 Other symbols ............................................................................................................................................................. 4

2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5

2.2 Guarantee and responsibility....................................................................................................................................... 5

3 Safety and prevention................................................................................................................................................................ 6

3.1 Introduction.................................................................................................................................................................. 6

3.2 Personnel training ....................................................................................................................................................... 6

4 Technical description of the burner ......................................................................................................................................... 7

4.1 Burner designation ...................................................................................................................................................... 7

4.2 Models available.......................................................................................................................................................... 7

4.3 Burner categories - Countries of destination ............................................................................................................... 8

4.4 Technical data ............................................................................................................................................................. 8

4.5 Electrical data.............................................................................................................................................................. 8

4.6 Maximum dimensions.................................................................................................................................................. 9

4.7 Burner equipment........................................................................................................................................................ 9

4.8 Firing rates ................................................................................................................................................................ 10

4.9 Test boiler.................................................................................................................................................................. 11

4.10 Burner description ..................................................................................................................................................... 12

4.11 Electrical panel description........................................................................................................................................ 13

4.12 Control box for the air/fuel ratio (LMV51.300) ........................................................................................................... 14

4.13 Servomotor................................................................................................................................................................ 16

4.14 Calibration of the thermal relay ................................................................................................................................. 17

5 Installation ................................................................................................................................................................................ 18

5.1 Notes on safety for the installation ............................................................................................................................ 18

5.2 Handling .................................................................................................................................................................... 18

5.3 Preliminary checks .................................................................................................................................................... 18

5.4 Operating position ..................................................................................................................................................... 19

5.5 Removal of the locking screws from the shutter........................................................................................................ 19

5.6 Preparing the boiler ................................................................................................................................................... 19

5.6.1 Boring the boiler plate ............................................................................................................................................... 19

5.6.2 Blast tube length........................................................................................................................................................ 19

5.7 Securing the burner to the boiler............................................................................................................................... 20

5.8 Access to head internal part...................................................................................................................................... 20

5.9 Position of electrodes ................................................................................................................................................ 20

5.10 Combustion head adjustment.................................................................................................................................... 21

5.11 FGR duct system....................................................................................................................................................... 22

5.11.1 Flue gas recirculation line sizing ............................................................................................................................... 23

5.11.2 Calculating the percentage of recirculated flue gas .................................................................................................. 23

5.12 Gas feeding ............................................................................................................................................................... 24

5.12.1 Gas feeding line ........................................................................................................................................................ 24

5.12.2 Gas train.................................................................................................................................................................... 25

5.12.3 Gas train installation.................................................................................................................................................. 25

5.12.4 Gas pressure............................................................................................................................................................. 26

5.13 Electrical wiring ......................................................................................................................................................... 27

5.13.1 Supply cables and external connections passage .................................................................................................... 28

6 Start-up, calibration and operation of the burner ................................................................................................................. 29

6.1 Notes on safety for the first start-up .......................................................................................................................... 29

20163821 2

Contents

6.2 Adjustments prior to ignition.......................................................................................................................................29

6.3 Burner start-up ...........................................................................................................................................................30

6.4 FGR commissioning...................................................................................................................................................31

6.5 Air / fuel adjustment ...................................................................................................................................................32

6.5.1 Air adjustment for maximum output ...........................................................................................................................32

6.5.2 Air/fuel adjustment and output modulation system ....................................................................................................32

6.5.3 Burner adjustment......................................................................................................................................................32

6.5.4 Output upon ignition...................................................................................................................................................32

6.5.5 Maximum output ........................................................................................................................................................32

6.6 Final adjustment of the pressure switches.................................................................................................................33

6.6.1 Air pressure switch.....................................................................................................................................................33

6.6.2 Maximum gas pressure switch...................................................................................................................................33

6.6.3 Minimum gas pressure switch....................................................................................................................................34

6.6.4 PVP pressure switch kit .............................................................................................................................................34

6.7 Final checks (with burner operating)..........................................................................................................................34

7 Maintenance ..............................................................................................................................................................................35

7.1 Notes on safety for the maintenance .........................................................................................................................35

7.2 Maintenance programme ...........................................................................................................................................35

7.2.1 Maintenance frequency..............................................................................................................................................35

7.2.2 Safety test - with gas ball valve closed ......................................................................................................................35

7.2.3 Checking and cleaning...............................................................................................................................................35

7.2.4 QRI flame detector.....................................................................................................................................................36

7.2.5 Voltage on the QRI sensor.........................................................................................................................................36

7.2.6 Checking the air and gas pressure on the combustion head .....................................................................................37

7.2.7 Safety components ....................................................................................................................................................37

7.3 Opening the burner ....................................................................................................................................................38

7.4 Closing the burner......................................................................................................................................................38

8 Faults - Probable causes - Solutions ......................................................................................................................................39

A Appendix - Accessories ...........................................................................................................................................................40

B Appendix - Electrical panel layout...........................................................................................................................................41

3 20163821

Declarations

1 Declarations

Declaration of conformity in accordance with ISO / IEC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 7

37045 Legnago (VR)

Product: Forced draught gas burner

Model and type: RS 810/E FGR S033T1

These products are in compliance with the following Technical Standards:

EN 676

EN 12100

and according to the European Directives:

GAR 2016/426/EU Gas Appliances Regulation

MD 2006/42/EC Machine Directive

LVD 2014/35/EU Low Voltage Directive

EMC 2014/30/EU Electromagnetic Compatibility

PED 2014/68/EU (only FS2) Pressure Equipment Directive

Such products are marked as follows:

CE-0123CU1078 RS 810/E FGR (Class 3 EN 676)

The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.

Manufacturer's Declaration

RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BIm-

SchV revision 26.01.2010”.

Product Model Type Output

Forced draught gas burner RS 810/E FGR S033T1 1100 - 7000 kW

Legnago, 03.05.2021 Research & Development Director

RIELLO S.p.A. - Burner Department

Mr. F. Maltempi

0085

20163821 4

Information and general warnings

2.1 Information about the instruction manual

2.1.1 Introduction

The instruction manual supplied with the burner:

is an integral and essential part of the product and must not

be separated from it; it must therefore be kept carefully for

any necessary consultation and must accompany the burner

even if it is transferred to another owner or user, or to

another system. If the manual is lost or damaged, another

copy must be requested from the Technical Assistance Ser-

vice of the area;

is designed for use by qualified personnel;

offers important indications and instructions relating to the

installation safety, start-up, use and maintenance of the

burner.

Symbols used in the manual

In some parts of the manual you will see triangular DANGER

signs. Pay great attention to these, as they indicate a situation of

potential danger.

2.1.2 General dangers

The dangers can be of 3 levels, as indicated below.

2.1.3 Other symbols

Abbreviations used

Ch. Chapter

Fig. Figure

Page Page

Sec. Section

Tab. Table

2 Information and general warnings

DANGER

Maximum danger level!

This symbol indicates operations which, if not car-

ried out correctly, cause serious injury, death or

long-term health risks.

WARNING

This symbol indicates operations which, if not car-

ried out correctly, may cause serious injury, death

or long-term health risks.

CAUTION

This symbol indicates operations which, if not car-

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: CRUSHING OF LIMBS

This symbol indicates the presence of moving

parts: danger of crushing of limbs.

WARNING: MOVING PARTS

This symbol indicates that you must keep limbs

away from moving mechanical parts; danger of

crushing.

DANGER: EXPLOSION

This symbol signals places where an explosive at-

mosphere is present. An explosive atmosphere is

defined as a mixture of dangerous substances

with air, under atmospheric conditions, in the form

of gases, vapours, mist or dust in which, after ig-

nition has occurred, combustion spreads to the

entire unburned mixture.

PERSONAL PROTECTION EQUIPMENT

These symbols indicate the equipment that must

be worn and kept by the operator for protection

against threats against safety and/or health while

at work.

MOUNT CASING

This symbol indicates that it is mandatory to

mount casing again after maintenance, cleaning

or checks.

ENVIRONMENTAL PROTECTION

This symbol gives indications for the use of the

machine with respect for the environment.

IMPORTANT INFORMATION

This symbol indicates important information that

you must bear in mind.

This symbol indicates a list.

5 20163821

Information and general warnings

2.1.4 Delivery of the system and the instruction

manual

When the system is delivered, it is important that:

the instruction manual is delivered to the user by the system

manufacturer, with the recommendation to keep it in the

room where the heat 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 must carefully inform the user about:

– the use of the system;

– any further tests that may be required before activating the

system;

– maintenance, and the need to have the system checked at

least once a year by a representative of the manufacturer

or another specialised technician.

To ensure a periodic check, the manufacturer recom-

mends the drawing up of a Maintenance Contract.

2.2 Guarantee and responsibility

The manufacturer guarantees its new products from the installa-

tion date, in accordance with the regulations in force and/or the

sales contract. At the moment of the first start-up, check that the

burner is integral and complete.

In particular, the rights to the guarantee and the responsibility will

no longer be valid, in the 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 and/or not working;

installation of untested supplementary components on the

burner;

powering of the burner with unsuitable fuels;

faults in the fuel supply system;

use of the burner even following an error and/or an irregular-

ity;

repairs and/or overhauls incorrectly carried out;

modification of the combustion chamber with inserts that

prevent the regular development of the structurally estab-

lished flame;

insufficient and inappropriate surveillance and care of those

burner components most likely to be subject to wear and

tear;

the use of non-original components, including spare parts,

kits, accessories and optional;

force majeure.

The manufacturer furthermore declines any and every re-

sponsibility for the failure to observe the contents of this

manual.

.........................................................................................

WARNING

Failure to observe the information given in this

manual, operating negligence, incorrect installa-

tion and carrying out of non authorised modifica-

tions will result in the annulment by the

manufacturer of the guarantee that it supplies with

the burner.

20163821 6

Safety and prevention

3.1 Introduction

The burners have been designed and built in compliance with

current regulations and directives, applying the known technical

rules of safety and envisaging all the potential danger situations.

It is necessary, however, to bear in mind that the imprudent and

clumsy use of the equipment may lead to situations of death risk

for the user or third parties, as well as the damaging of the burner

or other items. Inattention, thoughtlessness and excessive confi-

dence often cause accidents; the same applies to tiredness and

sleepiness.

It is a good idea to remember the following:

The burner must only be used as expressly described. Any

other use should be considered improper and therefore dan-

gerous.

In particular:

it can be applied to boilers operating with water, steam, diather-

mic oil, and to other users expressly named by the manufacturer;

the type and pressure of the fuel, the voltage and frequency of the

electrical power supply, the minimum and maximum deliveries for

which the burner has been regulated, the pressurisation of the

combustion chamber, the dimensions of the combustion cham-

ber and the room temperature must all be within the values indi-

cated in the instruction manual.

Modification of the burner to alter its performance and desti-

nations is not allowed.

The burner must be used in exemplary technical safety con-

ditions. Any disturbances that could compromise safety must

be quickly eliminated.

Opening or tampering with the burner components is not

allowed, apart from the parts requiring maintenance.

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;

undertakes to inform his personnel in a suitable way about

the application and observance of the safety instructions.

With that aim, he undertakes to ensure that everyone knows

the use and safety instructions for his own duties;

Personnel must observe all the danger and caution indica-

tions shown on the machine.

Personnel must not carry out, on their own initiative, opera-

tions or interventions that are not within their province.

Personnel must inform their superiors of every problem or

dangerous situation that may arise.

The assembly of parts of other makes, or any modifications,

can alter the characteristics of the machine and hence com-

promise operating safety. The manufacturer therefore

declines any and every responsibility for any damage that

may be caused by the use of non-original parts.

In addition:

3 Safety and prevention

WARNING

The manufacturer guarantees safety and proper

functioning only if all burner components are intact

and positioned correctly.

the user must take all the measures neces-

sary to prevent unauthorised people gaining

access to the machine;

the user must inform the manufacturer if

faults or malfunctioning of the accident pre-

vention systems are noticed, along with any

presumed danger situation.

Personnel must always use the personal pro-

tective equipment envisaged by legislation

and follow the indications given in this man-

ual.

7 20163821

Technical description of the burner

4.1 Burner designation

4.2 Models available

Tab. A

4 Technical description of the burner

Designation Voltage Start-up Code

RS 810/E FGR 3/400/50 Star/Delta 20160290

Range: R

Size

Fuel: Natural gas

Gas oil

Gas oil / Methane

Adjustment:

Flame control 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 810 ETC 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 cam with variable speed (with Inverter)

P Proportional air/gas valve

BP Two stage (light oil) / Proportional valve (gas)

M Mechanical cam

Head: TC Standard head

TL Long head

Emission: C01 - ...

C02 - MZ

C03 - BLU

C03 - MX

Class 1 EN676

Class 2 EN676

Class 3 EN676

FGR: Induced Flue Gas Recirculation

FGR FS1/FS2

20163821 8

Technical description of the burner

4.3 Burner categories - Countries of destination

Tab. B

4.4 Technical data

Tab. C

(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.

(2) Pressure at the test point (21)(Fig. 4) with zero pressure in the combustion chamber and at maximum burner output.

(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound

power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in

EN ISO 3746.

4.5 Electrical data

Tab. D

Gas category Destination country

I2E DE - LU - PL

I2H AT - BG - CH - CZ - DK - EE - ES - FI - FR - GB - GR - HU IE - IS

-IT - LT - LV - NO - PT - RO - SE - SI - SK - TR

I2E(R) BE

Model RS 810/E FGR

Power (1)

Output (1)

min -

max kW 1100/3500 ÷ 7000

Fuels Natural gas: G20 (methane gas)

Gas pressure at max. output (2) -

Gas: G20 mbar 74.2

Operation

FS1: Intermittent (min. 1 stop in 24 hours)

FS2: Continuous (min 1 stop 72 hours)

The burner leaves the factory set for the intermittent operation

Standard applications Boilers: water, steam, diathermic oil

Ambient temperature °C 0 - 40

Combustion air temperature °C max 60

Burner weight Kg 300

Noise levels (3) Sound pressure

Sound power dB(A) 90

104.6

Model RS 810/E FGR

Main electrical supply 3N ~ 400V +/-10% 50 Hz

Fan motor IE3

rpm

2950

400/690

39.4/22.7

Ignition transformer V1 - V2

I1 - I2

230 V - 2 x 5 kV

1.9 A - 35 mA

Absorbed electrical power kW max 24.5

Protection level IP 54

This manual suits for next models

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