Riello RRS 68/E O2 BLU Installation, Use And Maintenance Instructions Download

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20169327

Appendix - Electrical panel layout

Wiring layout key

module - PLL type

Control box for the air/fuel ratio

AZL

Display control box

Suppressor

BA2

Load indicator

BA3

Probe for external modulation 4…20mA

Input in current DC 4...20 mA

BA1

Input in current DC 4...20 mA to modify remote set-
point

+BB

Burner components

+BC

Boiler components

Pressure probe

BP1

Pressure probe

BT3

Probe Pt100, 3 wires

BT4

Probe Pt100, 3 wires

BT5

PT/LG-Ni1000 probe

Input in voltage DC 0...10V

BV1

Input in voltage DC 0...10V to modify remote setpoint

BV2

Probe for external modulation 2…10V

CN1

Ionisation probe connector

Fan motor thermal relay

FU1

Auxiliary fuse

FU2

Protection fuse for three-phase line

FU3

Protection fuse for one-phase line

Motor speed sensor

G10

O2 sensor - OGO20 type

G20

Probe for combustion flue gases temperature control

G30

Probe for air temperature control

Green indicator “POWER-ON”

Green indicator “FUEL ON”

ION

Ionisation probe

Fan motor

K3 relay (free contact “BURNER LOCK-OUT”)

K6 relay (free contact “BURNER ON”)

Fan motor contactor

Air pressure switch

Burner earth

PGMax

Maximum gas pressure switch

PGMin

Minimum gas pressure switch

PGVP

Gas pressure switch for valve leak detection control
device

Three-phase disconnecting switch

Single phase disconnecting switch

Remote burner reset button

“EMERGENCY STOP” button

“0/AUTO” selector

SH3

Burner lock-out reset button and lock-out light signal

SM1

Air servomotor

SM2

Gas servomotor

Ignition transformer

Supply transformer of the control box

Extra transformer

Limit thermostat/pressure switch

Safety thermostat/pressure switch

Burner terminal strip

XPGMAX Maximum gas pressure switch connector
XAZL

Connector for control box display

Gas adjustment valve + gas safety valve

Summary of Contents for RRS 68/E O2 BLU

Page 1: ...enance instructions 20169327 3 06 2021 Forced draught gas burners Modulating operation CODE MODEL TYPE 20174458 RS 68 E O2 BLU 846T1 20174463 RS 68 E O2 BLU 846T1 20165996 RS 120 E O2 BLU 847T1 20174465 RS 120 E O2 BLU 847T1 GB ...

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

Page 3: ...3 1 Terminal ratings cable lengths and cross sectional areas 16 4 14 Oxygen sensor QGO20 optional 17 4 14 1 Technical data QGO20 18 5 Installation 19 5 1 Notes on safety for the installation 19 5 2 Handling 19 5 3 Preliminary checks 19 5 4 Operating position 20 5 5 Preparing the boiler 20 5 5 1 Introduction 20 5 5 2 Boring the boiler plate 20 5 5 3 Blast tube length 21 5 6 Positioning probe electr...

Page 4: ... 6 10 Final checks with burner operating 33 6 11 Description of O2 trim control optional 34 6 11 1 Operating principle of O2 trim control 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 feeding closed 35 7 2 3 Checking and cleaning 35 7 2 4 Measuring the ionisation current 36 7 2 5 Checking the ai...

Page 5: ...echnical Standards EN 676 EN 12100 and according to the European Directives GAR 2016 426 EU Gas Devices Regulation MD 2006 42 CE Machine Directive LVD 2014 35 EU Low Voltage Directive EMC 2014 30 EU 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 03 05 2021 Research Dev...

Page 6: ...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 7: ...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 ...

Page 8: ...nce 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 undert...

Page 9: ...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 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 E O2 Electronic cam and suitable for Oxygen Control O2 EV O2 Electronic cam and v...

Page 10: ...K DE I2ELL FR I2Er AT BG CH CZ DK EE ES FI GB GR HU IE IS IT LT LV NO PT RO SE SI SK TR I2H Model RS 68 E O2 BLU RS 120 E O2 BLU Output 1 Max kW Mcal h 350 860 301 740 600 1300 516 1118 Min kW Mcal h 150 130 300 258 Fuel Natural gas G20 methane gas G21 G22 G23 G25 G31 Gas pressure at max output 2 Gas G20 G25 Gas G31 mbar 11 7 17 5 22 5 33 6 Operation Intermittent min 1 stop in 24 hours Modulating ...

Page 11: ...89 425 2 305 640 200 335 575 270 221 1010 255 390 1350 1485 RS 120 E O2 BLU 217 137 189 425 2 330 640 200 335 600 270 221 1010 255 390 1350 1485 Fig 1 L M G E N F V V 1 P C B T T 1 H I 1 I D 20150720 WARNING to use area B RS 120 E O2 BLU as well the pre calibration of the combustion head is necessary as explained in the paragraph Pre calibrating the combustion head on page 23 CAUTION The firing ra...

Page 12: ...1 it is necessary to reduce the output of the burner The reduction in output is accompanied by a reduction in the combustion 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 outp...

Page 13: ...or boilers or ovens with combustion chambers of very different di mensions compared to those shown in the diagram of Fig 4 pre liminary checks are recommended 4 9 Burner equipment The burner is supplied complete with Gas train flange No 1 Gasket for gas train flange No 1 Thermal insulation screen No 1 Screws M10 x 35 to fix the flange No 4 Screws M12 x 35 to fix the burner flange to the boiler No ...

Page 14: ...er 18 Air servomotor 19 Minimum air pressure switch differential operating type 20 Slide bars for opening the burner and inspecting the com bustion head 21 Gas pressure test point and head fixing screw 22 Air pressure socket 23 Terminals for shielding of cables and O2 control 24 Air damper 25 Fan air inlet 26 Screws to secure fan to pipe coupling 27 Gas input pipe 28 Gas butterfly valve 29 Boiler ...

Page 15: ... must also be followed avoid conditions that can favour the development of conden sate 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 Mechanical structure The LMV5 control box is a system to check the burners based on a microprocessor an...

Page 16: ...ernal 6 3 AT Main fuse of perm network external Max 16 AT Undervoltage Safety switch off from operating position to mains voltage Restart when mains voltage picks up AC 186 V AC 188 V Oil pump magnetic clutch nominal voltage Nominal current Power factor 2A cos 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cos 0 4 Load on output terminals Total load on the con...

Page 17: ...l supply of the actuator is switched off The housing cover may only be removed for short periods of time for wiring or when making the addressing In similar cas es make sure that dust or dirt does not penetrate inside the actuator The actuator comprises a PCB with ESD sensitive compo nents The top side of the board carries a cover which affords pro tection against direct contact This protective co...

Page 18: ...ngths 10 m fino a QGO20 Cross sectional areas Refer to description of QGO20 Analog inputs Air temperature detector Pt1000 LG Ni1000 Flue gas temperature Pt1000 LG Ni1000 QGO20 Refer to data sheet N7842 Interface Communication bus for LMV52 Model PLL52 Mains voltage X89 01 AC 230 V 15 10 Safety class I class with parts according to II class DIN EN 60730 1 Mains frequency 50 60 Hz 6 Power consumptio...

Page 19: ...aning the inlet and outlet allow the sensor to cool down for at least 1 hour Mount the sensor such that the connecting part head to flange is free so that the exchange of air is ensured Other wise measurements might get distorted possibly leading to dangerous situations Ensure that there are no chemicals such as solvent vapors near the sensor Installation notes The flue gas flow passing the measur...

Page 20: ...ue gas velocity only with AGO20 1 10 m s Fuel type Fuel oil EL or Natural gas H Measuring range 0 2 20 9 O2 Permissible cable length Max 100 m Wire diameter 10 m Power supply lines Net cable Cable diameter Cable type Min 1 mm QGO20 000D27 e g NYM 3 x 1 5 QGO20 000D17 UL AWM Style 1015 MTW or CSA AWM TEW Required operating temperature of measuring cell 700 C 50 C Environmental conditions Storage Cl...

Page 21: ...be free from hazardous mixes e g chloride fluoride halo gen if present it is highly recommended to carry out cleaning and maintenance 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 ...

Page 22: ... this second group of tubes is substituted so that all the tubes are the same After assembling the kit check its efficiency by measuring the flue gases and CO 5 5 2 Boring the boiler plate Drill holes in the plate shutting off the combustion chamber as il lustrated in Fig 13 The position of the threaded holes can be marked using the ther mal insulation screen supplied with the burner Tab M WARNING...

Page 23: ...oled frontal a refractory cover is not necessary 11 12 Fig 16 unless expressly requested by the boiler manufacturer 5 6 Positioning probe electrode If in the previous check the position of the probe or electrode was not correct is necessary remove the screw 1 Fig 14 extract the inner part 2 Fig 14 of the head and adjust them Blast tube Short mm Long mm RS 68 E O2 BLU 255 390 RS 120 E O2 BLU 255 39...

Page 24: ... insulating gasket 8 supplied Use the 4 screws supplied with a tightening torque of 35 40 Nm after protecting their thread with anti seize products Provide an adequate lifting system of the burner WARNING Before fixing the burner to the boiler check for the model RS 120 E O2 BLU if its maximum output is included in area A or B of the firing rate Fig 2 at page 9 If it is in area A no intervention i...

Page 25: ...hown in Fig 14 It is therefore especially easy to adjust and this adjustment depends only on the maximum output of the burner Two adjustments of the head are foreseen external air R1 central gas air R2 In the diagram Fig 18 find the notch at which to adjust both air and central gas air WARNING The head must be pre calibrated for model RS 120 E O2 BLU only if its maximum output is within area B of ...

Page 26: ...e the combustion head adjustment is completed reassemble the burner on the guides 3 at about 100 mm from the pipe coupling 4 burner in the position shown in Fig 16 refit the screws 2 on the guides 3 insert the probe and electrode cables then slide the burner as far as the pipe coupling burner in the position shown in Fig 20 connect the socket of the maximum gas pressure switch fix the burner to th...

Page 27: ...ontrol 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 Precautions a...

Page 28: ...ompanying instructions for the adjustment of the gas train DANGER Disconnect the electrical power using the main system switch Check that there are no gas leaks Beware of train movements danger of crushing of limbs Make sure that the gas train is properly installed by checking for any fuel leaks The operator must use appropriate tools for instal lation WARNING The gas solenoids must be as close as...

Page 29: ...ssure in combustion chamber 3 0 mbar 17 0 3 0 14 0 mbar A maximum output of 955 kW shown in Tab O corresponds to 14 0 mbar pressure column 1 This value serves as a rough guide the effective output must be measured at the gas meter To know the required gas pressure at test point 1 Fig 26 set the maximum output required from the burner operation then find the nearest output value in the Tab O for th...

Page 30: ... for intermittent use 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 case a time switch should be fitted in series to TL to stop the burner at least once every 24 hours Refer to the wiring diag...

Page 31: ...arac teristics label Bleed the air from the piping of the gas train connecting a plastic tube to the pressure test point 1 Fig 26 of the mini mum gas pressure switch Take the vent tube outside the building so you can notice the smell of gas Connect two lamps or testers to the two gas line solenoids to check the exact moment at which voltage is supplied This operation is unnecessary if each of the ...

Page 32: ... ignitions 10 ts safety time sec Example for gas G 20 9 45 kWh Sm3 ignition output 150 kW corresponding to 15 87 Sm3 h After 10 ignitions with lockout the delivery indicated on the meter must be equal to or less than 6 4 2 Maximum output The MAX output must be set within the firing rate Fig 2 at page 9 Gas adjustment Measure the gas delivery on the meter As a general rule this value can be found o...

Page 33: ...of the pressure gauge is shown in Fig 30 The standard configuration is that with the air pressure switch connected in absolute mode Note the presence of a T connec tion not supplied In certain applications in strong depression situations the con nection of the pressure switch does not allow it to change over In this case it is necessary to connect the pressure switch in dif ferential mode applying...

Page 34: ...reduces the output as far as the MIN value The burner switches off when the request for heat is lower than the heat supplied by the burner at MIN output The thermostat pressure switch TL opens and the control box carries out the switching off phase The damper closes completely to reduce thermal disper sions to a minimum 6 7 Ignition failure If the burner does not switch on there is a lockout withi...

Page 35: ...th burner operating Tab P Open the thermostat pressure switch TL Open the thermostat pressure switch TS The burner must stop Turn the gas maximum pressure switch knob to the mini mum end of scale position Turn the air pressure switch to the maximum end of scale position The burner must stop in lockout Disconnect the minimum gas pressure switch connector The burner must not start Disconnect the ion...

Page 36: ...r positions of these actuators are cal culated from some other load point on the ratio control curves Hence due to the parameterized ratio control curves the air reg ulating actuators are in a fixed relation to one another O2 trim control is supported by precontrol Precontrol calcu lates the air rate reduction such that changes in burner load do not require the O2 trim controller to interfere Cons...

Page 37: ...ndicators that are activated when the electrical supply arrives 7 2 3 Checking and cleaning Combustion The optimum calibration of the burner requires an analysis of the flue gases Significant differences with respect to the previous measurements indicate the points where more care should be ex ercised during maintenance Combustion head Open the burner and make sure that all the components of the c...

Page 38: ...king the air and gas pressure on the combustion head To carry out this operation a pressure gauge must be used to measure the air and gas pressure at the combustion head as shown in Fig 36 7 2 6 Safety components The safety components should be replaced at the end of their life cycle indicated in Tab R The specified life cycles do not refer to the warranty terms indi cated in the delivery or payme...

Page 39: ...the burner up to approximately 100 mm from the pipe coupling reconnect the cables and slide in the burner until it comes to a stop connect the socket of the maximum gas pressure switch replace the screws 3 and carefully pull the probe and elec trode cables outwards until they are slightly taut disassemble the two extensions from the guides 4 DANGER Disconnect the electrical supply from the burner ...

Page 40: ...sure Valve Proving Supplied with RS 120 E O2 model Software interface kit Oxygen control kit A Appendix Accessories Burner Standard head length mm Extended head length mm Code RS 68 120 E O2 BLU 255 390 3010177 Burner Thickness mm Code RS 68 120 E O2 BLU 135 3010129 Burner Code RS 68 120 E O2 BLU 3010094 Burner Type dB A Code RS 68 120 E O2 BLU C4 5 10 3010404 Parameter to be checked Probe Adjustm...

Page 41: ... additional 2nd transformer AGG5 Gas trains in compliance with EN 676 Please refer to manual Burner Code RS 68 120 EV O2 BLU 3010377 Burner Code RS 68 120 EV O2 BLU 20044117 ATTENZIONE The installer is responsible for the addition of any safety device not foreseen in this manual ...

Page 42: ...ional layout LMV52 5 Operational layout LMV52 6 Operational layout LMV52 7 Operational layout LMV52 8 Operational layout LMV52 9 Operational layout LMV52 10 Operational layout LMV52 11 Electrical connection set by installer 11B Electrical connection set by installer 12 Electrical connection set by installer 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Page 43: ...69327 GB Appendix Electrical panel layout 0 1 0 1 0 1 2 2 2 2 1 3 0 1 0 1 4 0 0 0 4 0 0 0 4 0 0 5 0 4 0 0 0 6 4 0 0 0 4 0 0 0 4 0 0 0 4 0 0 0 4 0 0 0 4 0 0 0 4 0 0 0 4 0 0 0 4 0 0 0 4 0 0 0 0 5 0 0 0 4 0 0 0 ...

Page 44: ...20169327 42 GB Appendix Electrical panel layout ...

Page 45: ...43 20169327 GB Appendix Electrical panel layout 0 0 0 1 2 3 2 3 2 4 2 5 2 2 2 2 2 32 3 2 62 6 6 3 2 2 4 2 ...

Page 46: ...20169327 44 GB Appendix Electrical panel layout ...

Page 47: ...45 20169327 GB Appendix Electrical panel layout ...

Page 48: ...20169327 46 GB Appendix Electrical panel layout ...

Page 49: ...47 20169327 GB Appendix Electrical panel layout 0 0 0 0 0 1 1 1 2 1 3 1 1 1 1 1 1 1 41 4 4 1 1 2 1 ...

Page 50: ...20169327 48 GB Appendix Electrical panel layout 0 1 0 1 0 2 0 3 0 0 0 0 0 10 1 0 40 4 4 1 0 0 2 0 5 ...

Page 51: ...49 20169327 GB Appendix Electrical panel layout 0 12 34 5 5 5 5 5 6 6 6 7 6 6 6 6 6 6 6 6 6 6 6 7 6 0 0 34 34 3 0 12 3 0 12 3 0 12 ...

Page 52: ...20169327 50 GB Appendix Electrical panel layout 01 2 34 5 5 5 5 5 6 6 6 7 6 6 6 6 6 6 6 6 6 6 6 7 6 01 01 0 2 34 0 2 34 0 2 34 2 2 ...

Page 53: ...7 GB Appendix Electrical panel layout 0 1 2 10 3 3 6 7 6 7 08 6 97 6 7 6 7 08 6 97 6 7 6 7 6 7 6 7 08 08 5 5 9 6 7 9 6 7 5 5 9 6 7 9 6 7 0 0 0 0 0 0 3 0 0 0 0 0 0 0 2 2 0 0 0 0 0 3 0 ਅ 0 0 0 1 2 0 0 2 A 1 0 0 0 A ...

Page 54: ...obe for combustion flue gases temperature control G30 Probe for air temperature control H1 Green indicator POWER ON H2 Green indicator FUEL ON ION Ionisation probe MV Fan motor K3 K3 relay free contact BURNER LOCK OUT K6 K6 relay free contact BURNER ON KM Fan motor contactor PA Air pressure switch PE Burner earth PGMax Maximum gas pressure switch PGMin Minimum gas pressure switch PGVP Gas pressure...

Page 55: ......

Page 56: ...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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