Riello RS 150 Installation, Use And Maintenance Instructions Download

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Installation, use and maintenance instructions

20191053 (1) - 06/2021

Forced draught gas burner

Progressive two-stage operation

CODE

MODEL

20190954

RS 150

Summary of Contents for RS 150

Page 1: ...Installation use and maintenance instructions 20191053 1 06 2021 Forced draught gas burner Progressive two stage operation CODE MODEL 20190954 RS 150 GB ...

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

Page 3: ... 22 14 4 Installation 15 4 1 Notes on safety for the installation 15 4 2 Handling 15 4 3 Preliminary checks 15 4 4 Operating position 16 4 5 Preparing the boiler 16 4 5 1 Boring the boiler plate 16 4 5 2 Blast tube length 16 4 5 3 Securing the burner to the boiler 16 4 6 Access to head internal part 17 4 7 Positioning the probe electrode 17 4 8 Combustion head adjustment 18 4 8 1 Air adjustment 18...

Page 4: ...ner flame goes out during operation 30 5 8 Stopping of the burner 30 5 9 Final checks with burner operating 30 5 9 1 Checking the air and gas pressure on the combustion head 30 6 Maintenance 31 6 1 Notes on safety for the maintenance 31 6 2 Maintenance programme 31 6 2 1 Maintenance frequency 31 6 2 2 Safety test with gas feeding closed 31 6 2 3 Checking and cleaning 31 6 2 4 Combustion control ga...

Page 5: ...ied 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 CRUS...

Page 6: ...t 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 appliance use of the burner with safety devices that are faulty incor rectly applied and o...

Page 7: ...hose parts envisaged by the manufacturer can be replaced 2 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 in...

Page 8: ...1 stop every 24 h Continuous working 1 stop every 72 h Electrical supply of the system 1 230 50 3 230 400 50 3 230V 50Hz Auxiliary voltage 230 50 60 R 150 TC Emission C01 or Class 1 EN676 BLU or BLU Class 3 EN676 FS1 3 400 50 1 230 50 BASIC DESIGNATION EXTENDED DESIGNATION 1 230V 50Hz 3N 400V 50Hz 230V 50 60Hz Two stage M Modulating 1 one stage Head TC Standard head TL Extended head C02 or MZ Clas...

Page 9: ... in EN ISO 3746 3 4 Electrical data Tab C MODEL RS 150 POWER 1 2nd stage kW 900 1850 Mcal h 774 1591 min 1st stage kW 300 Mcal h 258 FUEL NATURAL GAS G20 G25 G20 G25 Gas pressure at max output 2 Gas G20 G25 mbar 24 9 36 6 Operation Intermittent 1 stop min each 24 hours Two stage high and low flame and one stage all nothing Standard applications Boilers water steam diathermic oil Ambient temperatur...

Page 10: ...ithout cover is given by measurement I Tab D 1 Blast tube short long 3 6 Burner equipment Flange for gas train No 1 Gasket for flange No 1 Flange fixing screws M 10 x 35 No 4 Thermal insulation screen No 1 Screws to fix the burner flange to the boiler M 12 x 35 No 4 Instruction booklet No 1 Spare parts list No 1 B T T 1 D E N F P C L M G H U U 1 Fig 1 20152197 mm B C D E F G H L M N P T T 1 U U 1 ...

Page 11: ... firing rates were set in relation to special test boilers accord ing to EN 676 regulations In Fig 3 you can see the diameter and length of the test combus tion chamber Example Output 756 kW diameter 60 cm length 2 m WARNING The firing rate value Fig 2 has been obtained considering an ambient temperature of 20 C an atmospheric pressure of 1013 mbar approx 0 m a s l and with the combustion head adj...

Page 12: ...ons The burner boiler match is assured where the boiler is EC type approved for boilers and furnaces with combustion chambers featuring dimensions differing considerably from those given in the diagram Fig 4 it is advisable to perform preliminary tests The maximum depth of the boiler door is referred to dimension I Fig 1 on page 8 NOTE For flame inversion boilers a kit is available to reduce CO em...

Page 13: ...lity disc 9 Boiler fixing flange 10 Gas butterfly valve 11 Gas input pipe 12 Control box with lockout pilot light and lockout reset button 13 Flame inspection window 14 Screw securing fan to pipe coupling 15 Slide bars for opening the burner and inspecting the com bustion head 16 Gas pressure test point and head fixing screw 17 Air pressure test point 18 Flame sensor probe 19 Air damper Two types ...

Page 14: ...reset button 3 Two switches one for on off burner one for 1st 2nd stage 4 Terminal board for electric connection 5 Cable grommets for electrical wiring to be carried out by the installer 6 Minimum air pressure switch differential type 7 Ignition transformer 8 Control box base 9 Filter to protect against radio disturbance 10 Relay 1 2 9 4 8 6 10 3 5 7 Fig 6 20189977 ...

Page 15: ... 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 Technical data Mechanical structure The control box is made of plastic to resist knocks heat and flame propagation The control box contains the following comp...

Page 16: ...e servomotor and connecting the damp er the gears can be disengaged by means of a lever allow ing the drive shaft to be easily adjusted in both directions of rotation Technical data Tab E WARNING To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the actua tors The servomotor contains electric and electronic components that mus...

Page 17: ... air inside the boiler must 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 ...

Page 18: ...ressly requested by the boiler manufacturer 4 5 3 Securing the burner to the boiler Separate the combustion head from the rest of the burner Fig 12 loosen the 4 screws 3 and remove the hood 1 disengage the articulated coupling 7 from the graduated sector 8 remove the screws 2 from the two slide bars 5 remove the two screws 4 and pull the burner back on the slide bars 5 by about 100 mm disconnect t...

Page 19: ...he screw 1 Fig 13 take out the inner part 2 Fig 13 of the head and then cali brate them 1 2 Fig 13 D8689 WARNING Before securing the burner to the boiler check through the opening of the blast tube that the probe and electrode are correctly positioned as in Fig 14 WARNING Do not rotate the probe leave it as in Fig 14 since if it is located too close to the ignition electrode the control box amplif...

Page 20: ...as shown in Fig 12 insert the flame detection probe cable and the ignition electrode cable and then slide the burner up to the sleeve so that it is positioned as shown in Fig 17 Refit screws 2 on slide bars 3 Fig 17 Secure the burner to the sleeve by tightening screw 1 Fig 17 Reconnect the articulation 7 to the graduated sector 6 Fig 17 WARNING The diagrams show an optimum adjustment for a type of...

Page 21: ...0 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 avoid knocking attrition sparks and heat Make sure that the fue...

Page 22: ...f the corresponding output on the left Example with natural gas G20 Operation at maximum modulating output Gas pressure at test point 1 Fig 23 11 7 mbar Pressure in combustion chamber 3 mbar 11 7 3 8 7 mbar A pressure of 8 7 mbar column 1 corresponds in Tab H to an output of 1300 kW This value serves as a rough guide the effective output must be measured at the gas meter To calculate the required ...

Page 23: ...ion Example with natural gas G20 Operation at maximum modulating output Gas pressure at an output of 1300 kW 8 7 mbar Pressure in combustion chamber 3 mbar 8 7 3 11 7 mbar pressure required at test point 1 Fig 23 Fig 23 D3734 ...

Page 24: ...een type approved 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 t...

Page 25: ...rner is fitted with an ionisation system to check that a flame is present The minimum current for control box operation is 6 µA The burner provides a much higher current so controls are not normally required If it is necessary however to measure the ionisation current dis connect the plug socket 2 Fig 26 on the ionisation probe cable and insert a direct current microammeter 1 Fig 26 with a base sc...

Page 26: ...d valves VR and VS to check the exact moment at which volt age is supplied This operation is unnecessary if each of the two solenoid valves is equipped with a pilot light that signals voltage pass ing through 5 Start up calibration and operation of the burner WARNING The first start up of the burner must be carried out by qualified personnel as indicated in this manual and in compliance with the s...

Page 27: ...imultaneously adjusts the air damper by means of the variable profile cam and the gas butterfly valve The servomotor rotates by 130 in 17 seconds Cam I 130 Limits rotation toward maximum position When the burner is at MAX output the gas butterfly valve must be fully open 90 Cam II 0 Limits rotation toward minimum position When the burner is shut down the air damper and gas butterfly valve must be ...

Page 28: ...e formula for ts 3s Vg volume supplied in ignitions carried out Sm3 Qa ignition delivery Sm3 h n number of ignitions 10 ts safety time sec Example for gas G20 9 45 kWh Sm3 ignition output 150 kW corresponding to 15 87 Sm3 h After 10 ignitions with lockout the output read on the meter must be equal to or less than 5 6 2 Output in 2nd stage MAX output must be selected within the firing rate range sh...

Page 29: ...held in place beneath the servomotor with the aid of a magnet Air adjustment Progressively adjust the initial profile of the cam 4 Fig 31 on page 26 by turning the screws 5 5 6 4 Intermediate outputs Adjustment of gas delivery No adjustment of gas delivery is required Air adjustment Switch off the burner by means of the switch 1 Fig 28 on page 25 release the cam 4 Fig 31 on page 26 from the servom...

Page 30: ...air pressure switch con nected in absolute mode Note the presence of a T connection 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 a second tube between the air pressure switch and the fan suction line mouth 5 6 6 M...

Page 31: ...cycle is completed the servomotor command moves on to the TR remote control that controls the pressure or temperature in the boiler point D The control box still continues to check the presence of the flame and the correct position of the air pressure switch When the temperature or pressure increases and opens the TR the servomotor closes the gas butterfly valve and air damper and the burner goes ...

Page 32: ...ssure on the burner pipe coupling install the relative pressure gauges as shown in Fig 37 Carry out all the operations then reassemble the hood and all the burner safety and protection de vices Open the thermostat pressure switch TL Open the thermostat pressure switch TS The burner must stop Turn the air pressure switch to the maximum end of scale position The burner must stop in lockout Turn off ...

Page 33: ...f a tester some valves are fitted with light signals or closure opening position indicators that are activated when the electrical supply arrives 6 2 3 Checking and cleaning Combustion head Open the burner and make sure that all components of the combustion head are in good condition not deformed by the high temperatures free of impurities from the surroundings and correctly positioned Gas filter ...

Page 34: ...t is avoided that a small decalibration for example a variation in the tension could cause a combustion with an air defect and with the subse quent formation of CO CO It should not exceed 100 mg kWh 6 2 5 Safety components The safety components should be replaced at the end of their life cycle indicated in Tab K The specified life cycles do not refer to the warranty terms indicated in the delivery...

Page 35: ...r to approximately 100 mm from the pipe coupling Reconnect the cables and slide in the burner until it comes to a stop Replace the screws 3 and carefully pull the probe and elec trode cables outwards until they are slightly taut Reconnect the articulated coupling 7 to the graduated sec tor 8 DANGER Disconnect the electrical supply from the burner by means of the main system switch DANGER Close the...

Page 36: ...ot switch on and the lock out appears Air pressure switch in operating position Adjust or replace The burner switches on but then stops in 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 switc...

Page 37: ...ace The burner continues to repeat the start up cy cle 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 pres sure switch itself the valve immediately closes and the burner comes to a halt Pressure increas es again the pressure switch closes aga...

Page 38: ...it is available as an interface between the control box and the burner DN80 gas flange kit Gas trains in compliance with EN 676 Please refer to manual A Appendix Accessories Burner Standard head length mm Extended head length mm Code RS 150 280 415 20052186 Burner Type Reduction of noise average Code RS 150 C4 5 10 dB A 3010404 Burner Thickness mm Code RS 150 135 3010129 Burner Code RS 150 3010094...

Page 39: ...al panel layout B Appendix Electrical panel layout Index of layouts 2 Indication of references 3 Operational layout 4 Operational layout 5 Electrical connections set by installer 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Page 40: ...3 38 GB Appendix Electrical panel layout 0 0 1 2 2 2 32 2 2 2 4 556 7 8 9 7 7 7 7 7 9 7 8 2 2 0 0 0 2 2 1 3 2 3 2 A 0 B 0 2 2 0 2 2 2 2 2 2 2 2 2 2 2 2 2 3 2 3 2 2 2 0 2 2 2 0 2 2 0 2 2 2 3 2 0 3 2 A 2 2 2 2 0 ...

Page 41: ...39 20191053 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 4 ...

Page 42: ...20191053 40 GB Appendix Electrical panel layout 0 1 1 23 4 4 5 1 6 7 8 23 7 8 5 9 7 0 ...

Page 43: ...itch ION Ionisation probe MV Fan motor PA Air pressure switch PGmin Minimum gas pressure switch Q1 Three phase line switch disconnecting switch Q2 Single phase line disconnecting switch S1 On Off and 1st 2nd stage SM Servomotor TA Ignition transformer TL Limit pressure switch thermostat TR Adjustment thermostat pressure switch TS Safety pressure switch thermostat VR Regulation valve VS Safety valv...

Page 44: ...Legnago VR Tel 39 0442 630111 http www riello it http www riello com Manufacturing site Riello Heating Equipment Shanghai CO LTD No 388 Jinbai Road Jinshan Industrial Zone 201506 Shanghai CHINA 生产场所 Riello Heating Equipment Shanghai CO LTD 利雅路热能设备上海有限公司上海市金山工业区金百路 388 号 ...

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