Riello Rs blu series Quick start guide

Installation, use and maintenance instructions

20085953 (1) - 04/2014

Forced draught gas burners

Progressive two-stage or modulating operation

CODE MODEL TYPE

20085769 RS 120/EV BLU 85769X

20085770 RS 160/EV BLU 85770X

20085771 RS 200/EV BLU 85771X

Translation of the original instructions

1 20085953

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........................................................................................................................................................ 8

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

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

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

4.7 Firing rates .................................................................................................................................................................. 9

4.7.1 Firing rate on basis of air density .............................................................................................................................. 10

4.8 Test boiler.................................................................................................................................................................. 11

4.9 Burner equipment...................................................................................................................................................... 11

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

4.11 Control box for the air/fuel ratio (LMV52...)............................................................................................................... 14

4.12 Air servomotor (SQM45.2....) .................................................................................................................................... 16

5 Installation ................................................................................................................................................................................ 17

5.1 Notes on safety for the installation............................................................................................................................ 17

5.2 Handling.................................................................................................................................................................... 17

5.3 Preliminary checks.................................................................................................................................................... 17

5.4 Operating position..................................................................................................................................................... 18

5.5 Preparing the boiler................................................................................................................................................... 18

5.5.1 Introduction................................................................................................................................................................ 18

5.5.2 Boring the boiler plate ............................................................................................................................................... 19

5.5.3 Blast tube length........................................................................................................................................................ 19

5.6 Positioning electrode for RS 120/EV BLU................................................................................................................. 20

5.7 Positioning probe - electrode..................................................................................................................................... 20

5.8 Securing the burner to the boiler............................................................................................................................... 21

5.9 Pre-calibrating the combustion head......................................................................................................................... 22

5.10 Combustion head adjustment.................................................................................................................................... 22

5.11 Burner closing ........................................................................................................................................................... 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............................................................................................................................................................. 25

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

5.13.1 Supply cables and external connections passage .................................................................................................... 27

5.13.2 Speed sensor adjustment.......................................................................................................................................... 28

5.13.3 Inverter connection.................................................................................................................................................... 28

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

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

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

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

6.4 Burner adjustment..................................................................................................................................................... 30

6.4.1 Firing output .............................................................................................................................................................. 30

6.4.2 Maximum output........................................................................................................................................................ 30

6.4.3 Minimum output......................................................................................................................................................... 30

20085953 2

Contents

6.5 Final calibration of the pressure switches..................................................................................................................31

6.5.1 Air pressure switch.....................................................................................................................................................31

6.5.2 Maximum gas pressure switch...................................................................................................................................31

6.5.3 Minimum gas pressure switch....................................................................................................................................32

6.5.4 PVP pressure switch kit .............................................................................................................................................32

6.6 Steady-state operation...............................................................................................................................................32

6.7 Ignition failure.............................................................................................................................................................32

6.8 Checking the air and gas pressure on the combustion head.....................................................................................32

6.9 Burner flame goes out during operation.....................................................................................................................33

6.10 Stopping of the burner ...............................................................................................................................................33

6.11 Final checks (with burner operating)..........................................................................................................................33

7 Maintenance ..............................................................................................................................................................................34

7.1 Notes on safety for the maintenance.........................................................................................................................34

7.2 Maintenance programme...........................................................................................................................................34

7.2.1 Maintenance frequency..............................................................................................................................................34

7.2.2 Checking and cleaning...............................................................................................................................................34

7.3 Opening the burner....................................................................................................................................................35

7.4 Closing the burner......................................................................................................................................................35

7.4.1 Maintenance of the burner's electrical components located under the control box ...................................................36

A Appendix - Accessories ...........................................................................................................................................................37

B Appendix - Electrical panel layout...........................................................................................................................................39

3 20085953

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 burners

Model: RS 120/EV BLU

RS 160/EV BLU

RS 200/EV BLU

These products are in compliance with the following Technical Standards:

EN 676

EN 12100

and according to the European Directives:

MD 2006/42/EC Machine Directive

LVD 2006/95/EC Low Voltage Directive

EMC 2004/108/EC Electromagnetic Compatibility

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

Legnago, 10.10.2013 Executive Director

RIELLO S.p.A. - Burner Department Research & Development Director

RIELLO S.p.A. - Burner Department

Mr. G. Conticini Mr. R. Cattaneo

20085953 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 may be present. An explosive atmos-

phere is defined as a mixture - under atmospheric

conditions - of air and flammable substances in

the form of gases, vapours, mist or dust in which,

after ignition 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.

OBLIGATION TO ASSEMBLE THE HOOD AND

ALL THE SAFETY AND PROTECTION DEVIC-

This symbol signals the obligation to reassemble

the hood and all the safety and protection devices

of the burner after any maintenance, cleaning or

checking operations.

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 20085953

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.

20085953 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 chamber

and the room temperature must all be within the values indicated

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 20085953

Technical description of the burner

4.1 Burner designation

4.2 Models available

Tab. A

4 Technical description of the burner

BASIC DESIGNATION

EXTENDED DESIGNATION

Range : R

Size

Fuel : Natural gas

Light oil

Light oil / Natural gas

Adjustment :

Flame control system :

FS1

FS2 Standard (1 stop every 24h)

Continuous operation (1 stop every 72h)

Electrical supply of the system :

3/400/50

3/230/50

Voltage of auxiliaries :

230/50/60

110/50/60

3N / 400V / 50Hz

3 / 230V / 50Hz

230V / 50-60Hz

110V / 50-60Hz

Heavy oil

E Electronic cam

EV Electronic cam and variable speed (with Inverter)

M Mechanical cam

P Proportional air/gas valve

Head : TC Standard head

TL Long head

Emission : C01 or ...

BLU

Class 1 EN676

Class 2 EN676

Class 3 EN676

3/400-230/50 3N / 400V-230V / 50Hz

R S 200 EV TC FS1/FS2 3/400-230/50 230/50-60BLU

Designation Voltage Start-up Code

RS 120/EV BLU TC 3N / 400V-230V / 50Hz Direct 20085769

RS 160/EV BLU TC 3N / 400V-230V / 50Hz Direct 20085770

RS 200/EV BLU TC 3N / 400V-230V / 50Hz Direct 20085771

20085953 8

Technical description of the burner

4.3 Burner categories

Tab. B

4.4 Technical data

Tab. C

(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m above sea level.

(2) Pressure on the pressure switch socket (Fig. 33) 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 evaluated, in line with the regulations, on a spherical surface centred on the burner and with a radius of 1 metre.

4.5 Electrical data

Tab. D

Country of destination Gas category

BE I2E(R)

LV I2H

CY, MT I3B/P

BE I3P

LU, PL II2E3B/P

DE II2ELL3B/P

FR II2Er3P

AT, CH, CZ, DK, EE, FI, GR, HU, IS, IT, LT, NO, SE, SI, SK II2H3B/P

ES, GB, IE, PT II2H3P

NL II2L3B/P

Model RS 120/EV BLU RS 160/EV BLU RS 200/EV BLU

Output (1) Max. kW

Mcal/h 600 ÷ 1300

516 ÷ 1118 930 ÷ 1860

800 ÷ 1600 1380 ÷ 2400

1187 ÷ 2064

Min. kW

Mcal/h 300

258 300

258 550

473

Fuel Natural gas: G20 (methane gas) G21 - G22 - G23 - G25 - G31

Gas pressure at max. output (2)

- Gas: G20 / G25

- Gas: G31

mbar 22.5 / 33.6

19.6 17.7 / 26.4

19.6 28.0 / 41.8

19.6

Operation – Intermittent (min. 1 stop in 24 hours)

– Two progressive or modulating stages with kit (see ACCESSORIES)

Standard applications Boilers: water. steam. diathermic oil

Ambient temperature °C 0 - 40

Combustion air temperature °C max 60

Noise levels (3) Sound pressure

Sound power dB(A) 78.5

89.5 80.5

91.5 83.0

94.0

Weight kg 83 96 101

Model RS 120/EV BLU RS 160/EV BLU RS 200/EV BLU

Main electrical supply

Control circuit power supply 3 ~ 400V +/-10% 50Hz

1N ~ 230V +/-10% 50Hz 3 ~ 400V +/-10% 50Hz

1N ~ 230V +/-10% 50Hz

Fan motor IE2 Hz

rpm

2860

230-400

2.2

7.6 - 4.4

3500

265 - 460

2.2

6.8 - 3.9

2900

230-400

4.5

15 - 8.7

3460

265 - 460

4.5

13.7 - 7.9

2920

230-400

5.5

18 - 10.4

3500

265 - 460

6.6

16.1 - 9.3

Ignition transformer V1 - V2

I1 - I2 230 V - 1 x 8 kV

1 A - 20 mA

Absorbed electrical power kW max 2.2 4.5 6.5

Protection level IP 44

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