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Riello 3897304, Installation, Use And Maintenance Instructions

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Riello 3897304 Installation, Use And Maintenance Instructions Download Page 25

23 

20098687

GB

Installation

5.11.2

Modulating operation

In the event the RWF output power regulator kit is connected or
the converter 0...10V / 4...20mA, 3-point signal, the TR thermo-
stat/pressure switch should be removed.

In addition, the function Q13 - Q14 of the regulator RWF can sub-
stitute the TL thermostat/pressure switch terminals T2 and T1 of
the  socket  X7.  In  this  case,  the  thermostat/pressure  switch  TL
connected to the X7 must be removed.

On the contrary, if you want to maintain the thermostat/pressure
switch TL, it must be adjusted so as not to interfere with the work-
ing of the regulator RWF.

NOTE:
The TR and TL remote controls are not necessary when the RWF
is connected for modulating operation; their function is carried out
by the regulator itself.

After  carrying  out  maintenance,  cleaning  or
checking  operations,  reassemble  the  cover  and
all the safety and protection devices of the burner.

Summary of Contents for 3897304

Page 1: ... use and maintenance instructions 20098687 2 02 2017 Forced draught gas burners Progressive two stage or modulating operation CODE MODEL TYPE 3897304 3897306 RS 45 M BLU 827 T2 3897305 3897307 RS 45 M BLU 827 T2 GB ...

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

Page 3: ...ation 14 5 2 Handling 14 5 3 Preliminary checks 14 5 4 Operating position 15 5 5 Preparing the boiler 15 5 5 1 Boring the boiler plate 15 5 5 2 Blast tube length 15 5 6 Positioning the probe electrode 16 5 7 Securing the burner to the boiler 16 5 8 Combustion head adjustment 17 5 9 Closing the burner 18 5 10 Gas feeding 19 5 10 1 Gas feeding line 19 5 10 2 Gas train 20 5 10 3 Gas train installatio...

Page 4: ...eset 29 6 10 2 Visual diagnostics 29 6 10 3 Software diagnostics 29 6 11 Normal operation flame detection time 30 6 12 Flame presence check 30 6 13 Final checks with burner operating 31 7 Maintenance 32 7 1 Notes on safety for the maintenance 32 7 2 Maintenance programme 32 7 2 1 Maintenance frequency 32 7 2 2 Checking and cleaning 32 7 2 3 Safety components 33 7 3 Opening the burner 34 7 4 Closin...

Page 5: ... VR Italy Tel 39 0442630111 www rielloburners com Distributed by RIELLO NV Ninovesteenweg 198 9320 Erembodegem Tel 053 769 030 Fax 053 789 440 e mail info riello be URL www riello be This document certifies that the series of devices specified below is in compliance with the model described in the EC Declaration of Conformity and has been manufactured and distributed in compliance with the require...

Page 6: ... emission limits specified by German standard 1 BIm SchV revision 26 01 2010 Product Type Model Output Forced draught gas burners 827 T2 RS 45 M BLU 90 550 kW Legnago 01 12 2015 Executive General Manager RIELLO S p A Burner Department Research Development Director RIELLO S p A Burner Department Mr U Ferretti Mr F Comencini ...

Page 7: ...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 CRU...

Page 8: ...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 a...

Page 9: ...ance 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 under...

Page 10: ...3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION BLU 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 M Mechanical cam P Proportional air gas valve S L LS N Head TC Standard head TL Long head Emission C01 or MZ BLU MX Class 1 EN676 Class 2 EN676 Class 3 EN676 Class 3 EN676 3 400 230 50 3N 400V 230V 50Hz Desig...

Page 11: ...5 Electrical data Tab D Country of destination Gas category SE FI AT GR DK ES GB IT IE PT IS CH NO I2H DE I2ELL NL I2L I2E I2 43 46 45 3 MJ m3 0 C FR I2Er BE I2E R B LU PL I2E Model RS 45 M BLU Output 1 Max kW Mcal h 190 550 164 474 Min kW Mcal h 90 78 Fuel Natural gas G20 methane gas G21 G22 G23 G25 Gas pressure at max output 2 Gas G20 G25 mbar 12 4 18 5 Operation Intermittent min 1 stop in 24 ho...

Page 12: ... Firing rate During operation burner output varies between a MAXIMUM OUTPUT selected within area A Fig 2 and a MINIMUM OUTPUT that should not be less than the minimum limit of the diagram Fig 1 D1077 mm A B C D 1 E F G H I L M RS 45 M BLU 476 474 580 240 354 160 352 164 810 108 168 1 1 2 WARNING The firing rate value Fig 2 has been obtained considering an ambient temperature of 20 C an atmospheric...

Page 13: ...than H1 it is necessary to reduce the burner output The reduction in output is accompanied by a reduction in com bustion chamber pressure Qr reduced output H1r reduced pressure Example 5 reduction in output Qr Q x 0 95 H1r H1 x 0 95 2 With the new values Qr and H1r repeat steps 2 5 Tab F Qe Q F kW H3 H2 x F mbar WARNING The combustion head should be adjusted in rela tion to the equivalent output Q...

Page 14: ...oilers with a combustion chamber with run off from the bottom three flue passes on which the best results for low NOx emissions are obtained The maximum thickness of the boiler front door must not exceed 200 mm see Fig 5 The coupling is ensured when the boiler is EC type approved for boilers or ovens with combustion chambers of very different di mensions compared to those shown in the diagram of F...

Page 15: ... is not operating the air damper is fully closed in order to reduce heat dispersion from the boiler due to the flue draught which draws air from the fan suction inlet 12 Plate with four hole knock outs for electrical cable routing 13 Fan air inlet 14 Gas input pipe 15 Gas butterfly valve 16 Boiler fixing flange 17 Flame stability disc 18 Flame inspection window 19 Control box with lockout pilot li...

Page 16: ...rom hazardous mixes e g chloride fluoride halo gen if present it is highly recommended that cleaning and maintenance are carried out more frequently WARNING The handling operations for the burner can be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also that t...

Page 17: ...erted between the boiler refrac tory 12 and the blast tube 10 This protective fettling must not compromise the extraction of the blast tube For boilers with a water cooled front piece a refractory lining 11 12 Fig 12 is not necessary unless expressly requested by the boiler manufacturer Tab G WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 8 Installation 1 is preferable...

Page 18: ...tely off the slide bars after removing the split pin from the slide bar 3 Fix the flange 9 to the boiler plate interposing the insulating gasket 6 that has been supplied Use the 4 screws supplied with a tightening torque of 35 40 Nm after protecting their thread with anti seizing prod ucts WARNING Before securing the burner to the boiler check through the opening of the blast tube that the probe a...

Page 19: ...hich both the air and the gas should be adjusted and then Adjusting R1 external air Turn the screw 4 Fig 13 until the notch found lines up with the front surface 5 of the flange Gas adjustment R3 Loosen the screws 1 and 4 Fig 13 and rotate the ring nut 2 until the notch you have found lines up with the index 3 Central air adjustment R2 Turn the shutter 5 Fig 13 until the notch found lines up with ...

Page 20: ...he burner as far as the pipe coupling with the burner in the position shown in Fig 15 Refit screws 2 on slide bars 3 Fix the burner to the pipe coupling with the screw 1 and put back the split pin in one of the two slide bars 3 Reconnect the articulated coupling 8 to the graduated sec tor 7 WARNING When fitting the burner on the two slide bars it is advisable to gently draw out the high voltage ca...

Page 21: ...n control is compulsory for burners with maximum outputs over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer Explosion danger due to fuel leaks in the pres ence of a flammable source Precaution...

Page 22: ...r at 0 mbar burner working at maximum output Column 2 Pressure loss at gas butterfly valve 2 Fig 21 with maximum opening 90 To calculate the approximate output at which the burner oper ates subtract the pressure in combustion chamber from the gas pressure measured at test point 1 Fig 21 Find in Tab H related to the burner concerned the pressure value closest to the result of the subtraction Read o...

Page 23: ...culate the required gas pressure at test point 1 Fig 21 set the maximum modulating output required from the burner op eration find the nearest output value in Tab H for the burner in ques tion read on the right column 1 the pressure at the test point 1 Fig 21 Add this value to the estimated pressure in combustion chamber Example with G 20 natural gas Operating at the desired maximum output 400 kW ...

Page 24: ...rner corresponds to that shown on the identification label and in this man ual The burner has been type approved for intermittent operation FS1 This means they should compulsorily be stopped at least once every 24 hours to enable the control box to per form checks of its own start up efficiency Normally burner stopping is guaranteed by the boiler s thermostat pres sure switch If this is not the ca...

Page 25: ... socket X7 In this case the thermostat pressure switch TL connected to the X7 must be removed On the contrary if you want to maintain the thermostat pressure switch TL it must be adjusted so as not to interfere with the work ing of the regulator RWF NOTE The TR and TL remote controls are not necessary when the RWF is connected for modulating operation their function is carried out by the regulator...

Page 26: ...3 Servomotor The servomotor Fig 24 provides simultaneous adjustment for the air damper by means of the variable profile cam and the gas butterfly valve The angle of rotation of the servomotor is equal to the angle on the graduated sector controlling the gas butterfly valve The servomotor rotates 90 in 24 s Cam I 90 Limits rotation toward maximum position When the burner is at MAX output the gas bu...

Page 27: ...on output must be equal to or lower than 1 2 of max operation output for ts 3s ignition output must be equal to or less than 1 3 of the max operation output Example MAX operation 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 disconnect the plug socket 23 Fig 6 on page 13 on the ionisation probe cable the bu...

Page 28: ...to the minimum opening position and measure the gas delivery NOTE The servomotor follows the adjustment of cam III only when the angle of the cam is reduced If it is necessary to increase the angle of the cam you must first increase the angle of the servomotor by means of the output in crease key then increase the angle of cam III and finally bring the servomotor to the position of MIN output with...

Page 29: ... of the scale With the burner operating at MIN output increase adjustment pressure by slowly turning the relative knob clockwise until the burner locks out Then turn the knob anti clockwise by about 20 of the set point and repeat burner starting to ensure it is correct If the burner locks out again turn the knob anticlockwise a little bit more 6 7 2 Minimum gas pressure switch Adjust the minimum g...

Page 30: ...mperature or the pressure is low the reason why the thermostat pressure switch TR is in the output request posi tion the burner progressively increases the output up to the MAX value section C D If then the temperature or the pressure increases up to the TR switching the burner gradually decreases the output down to the MIN value section E F The sequence repeats endlessly The burner locks out when...

Page 31: ...ed 6 10 2 Visual diagnostics Indicates the type of burner malfunction causing lockout To view diagnostics proceed as follows Hold the button down for more than 3 seconds once the red LED burner lockout remains steadily lit A yellow light blink to tell you the operation is done Release the button once the light has blinked The number of blinks indicates the reason for the malfunctioning refer to th...

Page 32: ...resence check The burner is fitted with an ionisation system to check that a flame is present The minimum current for control box operation is 2 µA The burner provides a much higher current so controls are not normally required However if it is necessary to measure the ionisation current dis connect the plug socket 23 Fig 6 on page 13 on the ionisation probe cable and insert a direct current micro...

Page 33: ...ssure switch Open the thermostat pressure switch TL Open the thermostat pressure switch TS The burner must stop Disconnect the common wire P of the air pressure switch Disconnect the wire of the ionisation probe The burner must stop in lockout WARNING Make sure that the mechanical locking systems on the various adjustment devices are fully tight ened ...

Page 34: ...ioned Check the gas outlet holes for the ignition phase in the distributor of the combustion head are free of impurities or rust If in doubt disassemble the elbow Flame inspection window Periodically clean the glass of the flame inspection window Fig 34 Gas distributor Periodically check that the combustion head is clean A tool has to be used as shown in Fig 35 to make sure that the holes for the ...

Page 35: ...e combustion values found at the beginning of the inter vention do not respect the standards in force or in any case do not correspond to a proper combustion contact the Technical As sistance Service in order to carry out the necessary adjustments Tab L 7 2 3 Safety components The safety components should be replaced at the end of their life cycle indicated in the following table The specified lif...

Page 36: ...d the screw 8 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 sec tor 4 DANGER Turn ...

Page 37: ...s not come on and the lock out 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 blocked Clean Poorly adjusted head Adjust High pressure in the furnace Connect air pressure switch t...

Page 38: ... 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 comes to a halt Pressure increases again the pressure switch closes again and...

Page 39: ...ckness mm Code RS 45 M BLU 100 3010095 Burner Code RS 45 M BLU 3010094 Burner Type dB A Code RS 45 M BLU C1 3 10 3010403 Burner Probe Adjustment field Code RS 45 M BLU PT 100 temperature 100 500 C 3010110 Pressure 4 20 mA 0 2 5 bar 3010213 Pressure 4 20 mA 0 16 bar 3010214 Burner Output regulator Code RS 45 M BLU RWF50 20082208 RWF55 20099657 Burner Signal converter Code RS 45 M BLU 0 2 10V 0 4 20...

Page 40: ...20098687 38 GB Appendix Accessories Radio disturbance protection kit LPG kit Gas trains in compliance with EN 676 Please refer to manual Burner Code RS 45 M BLU 3010386 Burner Code RS 45 M BLU 3010432 ...

Page 41: ...trical panel layout Index of layouts 2 Indication of references 3 RMG M operational layout 4 Operational layout 5 Electrical wiring that the installer is responsible for 6 RWF50 kit electrical wiring external 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Page 42: ...QUS Z P AT R F 73 71 3F 6 4D 33 31 3D 3 3 39 1 1 1 8 D 3 3 1 8O 6D 6D F 3 1 41 3D 31 33 0 0 3 3U 3 1 1U 1 3D K 3 3U 3 9 9 6F 3 3 1 D F 0 11M 1DM2 3 3F52 8 9 3 K64 33 3M 33 8 8 0 _RY RA 8 3 3 1 3M 30 9 31 31 8 3 D 43 D 43 9 D 43 D G3 39 D G3 D 43 9 D 43 D 43 L 6I a 6 I 6 I 6 I 6 I 65 a E 6 45 E 4 C J B a E B EC b I 6 a 2 G 2 c G a E E G EI E C a 6 4E C 6 4 C E a 4 E E E E 2 a 2 E E 2 E 2 E 2 E Ba E...

Page 43: ... E 5 I 5 D 5 8 D 5 8 D 5 4 5 I 8A D 5 46 D A D 6 4A C8 I J 4 D C8 D K4 8 D J8 5 J I 8A78 D JA88 D 8AB D JAL A7 I A D A87 D A J8 D A B I 5 4 6 D B8 D 5 4 6 D 8 JI 4A4 6 D A4 J8 D A4 J8 D A4 J8 BI 8BB D 8B D 8B D 8BB JCI JA J D JA8C D JA D JA4 I A 4 D D A 8 D A 4 J7I A D J 7 D A D J 7 BHI B A6 8 8 D B AH 8 D B AH 8 D B A 5 4 AI 4AJ8 B D 8A D 4AJ8 B D 58A J C8I J 4 D 8A78 D C8 DJA88 D K4 8D 8AB D J8 ...

Page 44: ...B 7 G 7 I7 C B C C C D B BD B GC GC 0B 7EC 7 G 7 C KC C B D E 7 C B J N Q D 8 9 C R E ST 8 8 9 D U 0D V 0DC V 0CD V 07D F U C B V 07 F V B V 1W7 I AC U E 700B V AC00BW V X7D C V EC0 E U C GC V E CC V C V E L G U B B V CG V BDEC V B W1 U 7 B V W1 C V 07 V WC BEU 7 7 B V B 7 EC V B 7 EC V B 7 EC U B0C B V B0C V B0C V B0C EAU E E B V E CA V E V E 7D FU B 7 V F V B C V B 7 EGU B B V EB0G V B V EB0G U ...

Page 45: ...L 6 K 6 98IE 055 2 1 6 56 M3 K 6 98IE 6 3 6D 6G 6 6J 6A I 6 GEE G D H I A GE H A B1 98 IENNN 3 O 3 C 3 C 3 C 03 K O C 05K C C 5 90 4 7 O 0 C 7 9 C P03 C O 2 C C 6 C L 2 O C 2 C 3 C 6 9 O 0 5 C 9 6 C 0 5 C 9 O 0 0 5 C 0 C 0 C 0 6O 66 C 6 C 6 C 66 7O C 7 C C 03 KO 0 C K C C 0 2O C 2 C C 2 6MO 63 5 C 63 M3 C 63 M3 C 63 K 03 O 0 6 C C 0 6 C 7 O 0 C 2 C 7 9C C P03 C 6 C C 3 O 10 C 9 C 10 C 03 2 2 9 9 G...

Page 46: ...r counter h2 Hour counter K1 Relay KM Motor contactor MV Fan motor PA Air pressure switch PGMin Minimum gas pressure switch Q2 Single phase disconnecting switch RS Reset button S1 Off automatic manual selector S2 Power increase power reduction selector SM Servomotor TA Ignition transformer TL Limit thermostat pressure switch TR Adjustment thermostat pressure switch TS Safety thermostat pressure sw...

Page 47: ......

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 ...

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