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Riello RS 1300/E C01, Installation, Use And Maintenance Instructions

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Riello RS 1300/E C01 Installation, Use And Maintenance Instructions Download Page 51

49  

20089387

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Summary of Contents for RS 1300/E C01

Page 1: ...se and maintenance instructions 20089387 7 12 2021 Forced draught gas burners Modulating operation CODE MODEL TYPE 20081191 RS 1300 E C01 S001T1 20080872 RS 1600 E C01 S006T1 20080867 20110674 RS 2000 E C01 S007T1 GB ...

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

Page 3: ... ratio LMV51 14 4 15 Servomotor 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 Removing the shutter lockout screws 18 5 6 Preparing the boiler 18 5 6 1 Boring the boiler plate 18 5 6 2 Blast tube length 19 5 7 Coupling of the burner Centre of gravity position 19 5 8 Securing the burner to the boiler 19 5 9 Ac...

Page 4: ...ssure switch kit 29 6 7 Final checks with burner operating 29 7 Maintenance 30 7 1 Notes on safety for the maintenance 30 7 2 Maintenance programme 30 7 2 1 Maintenance frequency 30 7 2 2 Safety test with gas ball valve closed 30 7 2 3 Checking and cleaning 30 7 2 4 Electrical panel 31 7 2 5 Safety components 31 7 3 Opening the burner 32 7 4 Closing the burner 32 8 Faults Possible causes Solutions...

Page 5: ...ith the following Technical Standards EN 12100 EN 676 According to the European Directives MD 2006 42 EC Machine Directive LVD 2014 35 EU Low Voltage Directive EMC 2014 30 EU Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 1 Declarations ...

Page 6: ...hine 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 presen...

Page 7: ...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 8: ...ce 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 underta...

Page 9: ... Methane Adjustment Flame control system FS1 FS2 Standard 1 stop every 24 h Continuous operation 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 1600 E TC Emission C01 or Class 1 EN676 C03 or BLU Class 3 EN676 FS1 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION C01 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy ...

Page 10: ...u of the AZL Display 4 5 Electrical data Tab D Gas category Destination country I2H SE FI AT GR DK ES GB IT IE PT IS CH NO I2ELL DE I2L NL I2Er FR I2E R B BE I2E LU PL Model RS 1300 E C01 FS1 RS 1600 E C01 FS1 RS 2000 E C01 FS1 Type S001T1 1601T1 2001T1 Power 1 Delivery 1 min max kW 2500 7500 13000 3500 9500 16500 4000 12000 19500 Fuels Natural gas G20 methane gas G21 G22 G23 G25 Gas pressure at m...

Page 11: ...e opened and the rear part turned on the hinge The maximum dimensions of the open burner are indicated by the L and R positions The l position is reference for the refractory thickness of the boiler door Tab F Burner kg Burner packaging kg 1100 approx 1180 1 7 0 0 1080 2600 1710 Fig 1 20096814 C E D B I A F H G R R L Fig 2 20094543 mm A B C D E F G H I L R RS 1300 E C01 FS1 1880 450 220 544 960 DN...

Page 12: ...e manufac turer The firing rates were set in relation to special test boilers accord ing to EN 676 regulations In Fig 4 you can see the diameter and length of the test combus tion chamber Example Output 13000 kW diameter 120 cm length 9 m MODULATING RATIO The modulating ratio obtained in test boilers in accordance with standard EN 676 is 1 5 WARNING The firing rate value Fig 3 has been obtained co...

Page 13: ...ovement servomotor 17 Air damper movement levers 18 Minimum air pressure switch differential operating type 19 Combustion head air pressure test point 20 Pilot gas train 21 QRI cell 22 Pressure test point for air pressure switch 23 Gas butterfly valve servomotor 24 Screws to lock the shutter during transportation replace them with the M12x16 screws supplied as standard 9 4 23 14 8 15 5 12 16 7 19 ...

Page 14: ...se 17 Flame sensor plug sensor socket 18 Main terminal supply board 19 Air pressure switch 20 Kit terminal board 21 Timer 22 Servomotor Plug socket 23 Fan motor contactor and thermal relay star triangle starter NOTE Two types of burner failure may occur Control box lockout switching on of button 13 Fig 6 red led signals that the burner is in lockout release by pressing the pushbutton 13 Fig 6 Moto...

Page 15: ...ta Technical data Tab G WARNING To avoid accidents material or environmental damage observe the following instructions The AZL display is a safety device Avoid open ing or modifying it or forcing its operation Riello S p A cannot assume any responsibility for dam age resulting from unauthorised interventions Operating voltage AC 24 V 15 10 Power consumption 5W typical Protection level of the conta...

Page 16: ...lso 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 and equip...

Page 17: ... 188V 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 contacts Mains voltage Total unit input current safety circuit load on contacts due to Fan motor contactor Ignition transformer Valve Oil pump magnetic clutch AC 230V 15 10 Max 5 A ...

Page 18: ...he electrical 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 p...

Page 19: ...he integrity and suitableness of the available means of handling Check also that the area in which you are working is empty and that there is an adequate escape area i e a free safe area to which you can quick ly move if the burner should fall When handling keep the load at not more than 20 25 cm from the ground Lifting and transport of wooden crate must be done with caution to avoid falling or ti...

Page 20: ...e as it is the only one that allows the maintenance operations as described in this manual The installation 4 permits the operation but makes the maintenance and inspection oper ations of the combustion head more difficult DANGER Any other position could compromise the cor rect operation of the appliance Installations 2 3 and 5 are forbidden for safety reasons 2 3 4 5 1 S9249 Fig 11 WARNING Remove...

Page 21: ...h a water cooled front piece a refractory lining 2 5 Fig 15 is not necessary unless expressly requested by the boiler manufacturer 5 7 Coupling of the burner Centre of gravity position 5 8 Securing the burner to the boiler Insert the thermal protection supplied with the blast tube 4 Fit the entire burner onto the boiler hole prepared previ ously as in Fig 13 and fasten with the screws supplied tig...

Page 22: ... remove the 4 fixing screws 3 open the burner partially approx 150 mm on the hinges disconnect the cable of the pilot electrode 4 open the burner fully extracting the inner part of the head 6 after unscrewing the screws 5 that block it to the pipe coupling 5 10 Electrode positioning Fig 16 20094552 WARNING Place the electrode on the ignition pilot observing the indications in Fig 17 Elettrodo Diff...

Page 23: ...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 Precautions ...

Page 24: ...closest to the result of the subtraction Read off the corresponding output on the left DANGER Disconnect the electrical power using the main switch Check that there are no gas leaks Pay attention when handling the train danger of crushing of limbs Make sure that the gas train is properly installed by checking for any fuel leaks The operator must use the required equipment during installation 1 Fig...

Page 25: ...with natural gas G20 Operation at maximum modulating output Gas pressure at an output of 12500 kW 40 mbar Pressure in combustion chamber 10 mbar 40 10 50 mbar pressure required at test point 1 Fig 23 5 11 5 Pilot gas train connection The burner is fitted with a dedicated gas train that is fixed to the pipe coupling It should be connected to the main train downstream the fil ter or the pressure adj...

Page 26: ...o stop the burner at least once every 24 hours Refer to the wiring diagrams The burner is factory set for FS1 operation 1 stop every 24 hours it can be converted to FS2 operation continu ous 1 stop every 72 hours by changing the parameters using the menu of the AZL Display The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system made accor...

Page 27: ...he right to carry out the thermal relay test 5 14 Motor rotation As the burner is not fitted with a phase sequence checking de vice the motor rotation may be incorrect If this is not the case turn the burner switch to position 0 OFF and wait for the control box to carry out the switch off phase disconnect the power supply to the main panel invert the phases on the three phase power supply WARNING ...

Page 28: ...enoid valves is equipped with a pilot light that signals voltage passing through 6 3 Burner start up Close the remote controls and position the selector 1 Fig 29 to AUTO Make sure that the lights or testers connected to the solenoids or the pilot lights on the solenoids themselves indicate that no volt age is present If voltage is present stop the burner immediately and check the electrical connec...

Page 29: ...tioning using direct servocommands of the relevant valves eliminating the possible play in the calibration systems with mechanical cam lever mechanisms used on traditional modulating burners 2 The modulation of the burner output in accordance with the load required by the system with maintenance of the pres sure or temperature of the boiler at the operating values set 3 The sequence cascade adjust...

Page 30: ...he end of the scale To calibrate the maximum gas pressure switch open the tap and then connect a pressure gauge to its pressure test point The maximum gas pressure switch must be regulated to a value no higher than 30 of the measurement read on the gauge when the burner is working at maximum output After making the adjustment remove the pressure gauge and close the tap 6 6 3 Minimum gas pressure s...

Page 31: ...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 Turn off the burner and cut off the power Disconnect the minimum gas pressure switch connector The burner must not start Disconnect the QRI cell connection The burner must stop in lo...

Page 32: ...n on at the same time as their power supply 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 measure ments indicate the points where most care should be exercised during maintenance Combustion head Open the burner and make sure that all components of the combustion head are in go...

Page 33: ...ctrical panel with the appropriate screws 2 arranging the cables present 7 2 5 Safety components The safety components should be replaced at the end of their life cycle indicated in the following table The specified life cycles do not refer to the warranty terms indi cated in the delivery or payment conditions Tab O EN 676 Air excess CO Max output 1 2 Max output 1 3 GAS Theoretical max CO2 0 O2 CO...

Page 34: ...it following the steps described but in reverse order refit all burner components as they were originally assembled Secure screws 2 with a tightening torque of 250 300 Nm DANGER Turn off the burner s power supply using the main system switch DANGER Turn off the fuel interception tap Wait for the components in contact with heat sources to cool down completely 3 1 2 2 2 2 Fig 36 20094561 After carry...

Page 35: ...rts again the red LED goes out and the con trol box is reset 8 Faults Possible causes Solutions WARNING In the event the burner stops in order to prevent any damage to the installation do not unblock the burner more than twice in a row If the burner locks out for a third time contact the customer service DANGER In the event there are further lockouts or faults with the burner the maintenance inter...

Page 36: ...k detection control supplied as standard Gas trains in compliance with EN 676 Please refer to manual A Appendix Accessories Parameter to be checked Probe Adjustment field Type Code Temperature 100 500 C PT 100 3010110 Pressure 0 2 5 bar 0 16 bar Output probe 4 20 mA 3010213 3010214 Burner Code All models 3010388 Burner Code All models 3010469 Burner Code All models 3010344 ...

Page 37: ...MV51 operational layout 6 LMV51 operational layout 7 LMV51 operational layout 8 LMV51 operational layout 9 LMV51 operational layout 10 LMV51 operational layout 11 LMV51 operational layout 12 LMV51 operational layout 13 Electrical connections set by installer 14 Electrical connections set by installer 15 Electrical connections set by installer 1 2 Sheet no 1 A1 Co ordinates Indication of references...

Page 38: ...20089387 36 GB Appendix Electrical panel layout 01231 4 45 6 7 7 7 8 7 9 7 7 7 7 7 7 7 7 7 7 8 7 RS 1300 E ...

Page 39: ...37 20089387 GB Appendix Electrical panel layout 01231 4 45 6 7 7 7 8 7 9 7 7 7 7 7 7 7 7 7 7 8 7 RS 1600 E ...

Page 40: ...20089387 38 GB Appendix Electrical panel layout 01231 4 45 6 7 7 7 8 7 9 7 7 7 7 7 7 7 7 7 7 8 7 RS 2000 E ...

Page 41: ...39 20089387 GB Appendix Electrical panel layout ...

Page 42: ...20089387 40 GB Appendix Electrical panel layout ...

Page 43: ...41 20089387 GB Appendix Electrical panel layout 0 0 1 2 0 3 4 3 4 3 5 3 6 3 3 3 3 3 43 4 3 73 7 7 4 3 3 5 3 ...

Page 44: ...20089387 42 GB Appendix Electrical panel layout ...

Page 45: ...43 20089387 GB Appendix Electrical panel layout 0 1 1 1 ...

Page 46: ...20089387 44 GB Appendix Electrical panel layout 0 1 0 ...

Page 47: ...45 20089387 GB Appendix Electrical panel layout 0 1 1 1 2 1 3 1 1 1 1 1 1 1 41 4 4 1 1 2 1 ...

Page 48: ...20089387 46 GB Appendix Electrical panel layout 0 0 0 1 0 2 0 0 0 0 0 0 0 30 3 3 0 0 1 0 4 ...

Page 49: ...47 20089387 GB Appendix Electrical panel layout 0 0 1 2 0 0 3 3 3 0 1 4 ...

Page 50: ...l panel layout 0 1 1 22 2 3 4 5 4 5 4 5 221 221 2221 22 2 2 22 2 6 22 6 22 6 22 7 1 1 1 7 1 1 1 7 1 1 8 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 7 1 1 1 1 8 1 1 1 7 1 1 1 9 9 9 9 9 9 9 9 9 2 2 2 ...

Page 51: ...49 20089387 GB Appendix Electrical panel layout 0 0 1 0 2 3 2 4 4 1 0 0 0 0 3 0 4 0 3 5 0 2 0 0 6 6 0 0 7 4 8 0 0 0 8 0 0 0 0 999 0 0 0 0 0 2 0 0 3 0 0 0 0 0 0 0 3 0 2 0 0 0 0 0 0 0 0 ...

Page 52: ...20089387 50 GB Appendix Electrical panel layout ৼ 0 1 1 1 1 1 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 0 2 3 ...

Page 53: ... triangle contactor K1 Clean contacts output relay with fan motor working K2 Clean contacts output relay motor lockout K3 Clean contacts output relay for burner lockout K6 Clean contacts output relay burner switched on MV Fan motor PA Air pressure switch PE Burner earth PGMax Maximum gas pressure switch PGMin Minimum gas pressure switch PGVP Gas pressure switch for valve leak detection control dev...

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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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