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Riello RS 280, Installation, Use And Maintenance Instructions

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Riello RS 280 Installation, Use And Maintenance Instructions Download Page 2

Original instructions

Summary of Contents for RS 280

Page 1: ...se and maintenance instructions Forced draught gas burners Progressive two stage or modulating operation CODE MODEL 20125096 20125099 20125100 RS 280 E 20125102 20125104 RS 310 E 20125105 20125106 RS 410 E 20125107 20125109 RS 510 E GB ...

Page 2: ...Original instructions ...

Page 3: ...el ratio LMV37 4 16 3 11 Actuators SQM33 5 19 4 Installation 20 4 1 Notes on safety for the installation 20 4 2 Handling 20 4 3 Preliminary checks 20 4 4 Operation position 20 4 5 Preparing the boiler 21 4 5 1 Boring the boiler plate 21 4 5 2 Blast tube length 21 4 6 Securing the burner to the boiler 21 4 6 1 Accessibility to the interior of the combustion head 22 4 7 Electrode and ignition pilot ...

Page 4: ...e switch 31 5 7 3 Minimum gas pressure switch 31 5 7 4 Steady state operation 32 5 8 Firing failure 32 5 9 Flame signal measurement 32 5 10 Final checks with the burner working 32 6 Maintenance 33 6 1 Notes on safety for the maintenance 33 6 2 Maintenance programme 33 6 2 1 Maintenance frequency 33 6 2 2 Checking and cleaning 33 6 3 Opening the burner 34 6 4 Closing the burner 34 A Appendix Spare ...

Page 5: ...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 lethal 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 ...

Page 6: ...e event of damage to things or injury to peo ple 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 incorrectly applied...

Page 7: ...aintenance Only those parts envisaged by the manufacturer can be replaced 2 2 Personnel training The user is the person body or company that has acquired the ma chine and intends to use it for the specific purpose He is responsi ble for the machine and for the training of the people working around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel...

Page 8: ... 20121852 460 3 60 Star Delta Burner mounted 20125106 20122574 575 3 60 RS 510 E 20125107 20121863 460 3 60 Star Delta Burner mounted 20125109 20122576 575 3 60 Model RS 280 E RS 310 E Output delivery 1 High kW 762 3 077 2 770 1 026 3 986 3 587 Mbtu hr 4 2 600 10 500 9 450 3 500 13 600 12 240 Low kW 308 403 Mbtu hr 4 1 050 1 375 Fuel Natural gas Gas max delivery SCFH 10 396 13 465 Gas pressure at ...

Page 9: ...operating on test boiler and at maximum rated output 4 Equivalent Btu values based on 1 USGPH 140 000 Btu hr Model RS 410 E RS 510 E Output delivery 1 High kW 1 172 4 719 4 247 1 465 5 627 5 064 Mbtu hr 4 4 000 16 100 14 490 5 000 19 200 17 280 Low kW 479 586 Mbtu hr 4 1 635 2 000 Fuel Natural gas Gas max delivery SCFH 15 941 19 010 Gas pressure at max delivery 2 WC 26 0 32 6 Operation Low high or...

Page 10: ...r consumption W 4500 4530 8320 8320 Electrical control circuit consumption W max 750 Total electrical consumption W 5250 5280 9070 9070 Electrical protection NEMA 3 Model RS 410 E RS 510 E Control circuit power supply V Ph Hz 120 1 60 Main power supply 10 V Ph Hz 460 3 60 575 3 60 460 3 60 575 3 60 Fan motor rpm HP V A 3545 12 4 460 14 5 3545 12 4 575 11 6 3535 14 8 460 17 7 3535 14 8 575 14 2 Ign...

Page 11: ...e packaging are shown in the Tab E The weight of the burner complete with its packaging is shown in Tab E Tab E 3 5 Standard equipment Flange gasket No 1 Flange fixing screws M18 x 60 No 4 Gas train flange No 1 Gas train flange gasket No 2 Gas train flange fixing screws M16x70 No 8 Instruction manual No 1 inch A B C lbs RS 280 E 71 45 435 16 550 RS 310 E 80 45 471 4 575 RS 410 E 80 45 471 4 575 RS...

Page 12: ...nd R Tab F I B A D E N C F G M H F O R L R L Fig 2 20126330 inch A B C D E F G H I L M N O R RS 280 E 49 3 4 19 9 32 6 11 16 10 5 8 20 1 2 ANSI 3 19 7 8 31 14 43 25 32 13 1 2 155 8 12 19 32 38 RS 310 E 49 3 4 20 23 64 6 11 16 12 21 64 20 1 2 ANSI 3 20 1 4 31 14 11 16 43 25 32 15 3 4 15 5 8 12 19 32 38 RS 410 E 49 3 4 20 23 64 6 11 16 12 21 64 20 1 2 ANSI 3 22 1 4 31 14 11 16 43 25 32 15 3 4 15 5 8...

Page 13: ...pection window 17 Gas butterfly valve 18 Combustion head air pressure test point 19 Air pressure test point 20 Max gas pressure switch with pressure test point 21 Flame detector 22 Indication for checking the fan motor rotation 23 Gas servomotor 24 Reset button 25 Transparent protection 26 Pilot gas train attachment 2 12 13 19 21 23 3 18 14 26 22 16 22 4 20 6 7 15 5 1 10 1 9 8 24 25 11 17 Fig 3 20...

Page 14: ...xiliary alarm relay 23 K5 auxiliary burner lock out relay 24 Fan motor direct start up contactor 25 K2 auxiliary remote position relay 26 Fan motor thermal relay with reset button 27 Earth terminal 28 Fan motor sheath 29 Available for step down transformer 30 Available 31 Timer for Star Triangle Start up 32 Star Triangle Start up line contactor 33 Fan motor thermal relay with reset button 34 Trian...

Page 15: ... 68 F and an atmospheric pressure of 394 WC and with the combustion head adjusted as shown on page 23 Model MBtu hr RS 280 E 2 600 RS 310 E 3 500 RS 410 E 4 000 RS 510 E 5 000 Fig 5 0 2 4 6 8 10 12 14 16 18 20 mbar 8 7 6 5 4 3 2 0 1 w c 0 5600 5200 4800 4400 4000 3600 3200 2800 2400 2000 1600 1200 800 400 0 6000 MBtu hr kW 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22 RS 510 E Burner ...

Page 16: ...cted Capacity 5090 5113 2 5101 5 MBtu hr Corrected Pressure 4 41 4 87 2 4 64 WC Reference conditions Ambient temperature 68 F 20 C Barometric pressure 394 WC 1000 mbar Altitude 328 ft a s l 100 m a s l CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE Altitude Rated Capacity m a s l 0 100 305 610 915 1220 1525 1830 2135 2440 ft a s l 0 328 1000 2000 3000 4000 5000 6000 7000 8000 1000 995 1000 1011 1...

Page 17: ...4 41 4 87 5 35 5 86 2 5 3 67 3 56 3 67 3 9 4 25 4 63 5 04 5 47 5 93 6 41 6 92 3 56 4 72 4 61 4 72 4 95 5 3 5 68 6 09 6 52 6 98 7 46 7 97 4 61 5 78 5 67 5 78 6 01 6 36 6 74 7 15 7 58 8 04 8 52 9 03 5 67 6 83 6 72 6 83 7 06 7 41 7 79 8 2 8 63 9 09 9 57 10 08 6 72 7 89 7 78 7 89 8 12 8 47 8 85 9 26 9 69 10 15 10 63 11 14 7 78 8 94 8 83 8 94 9 17 9 52 9 9 10 31 10 74 11 2 11 68 12 19 8 83 10 9 89 10 1...

Page 18: ...rcuits via which it is possible to easily identify any causes of malfunctioning Mechanical design The following system components are integrated in the LMV37 4 basic unit Burner control with gas valve proving system Electronic air fuel ratio control Control frequency converter air fan Modbus interface Installation notes Always run high voltage ignition cables separately while ob serving the greate...

Page 19: ...inal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 cos 0 4 Alarm output Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 A cos 0 4 Ignition transformer Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 or 250 VA ignition load declaration to UL372 cos 0 2 Fuel valves Nominal v...

Page 20: ...P T P 10 Shutdown Operation Startup Valve proving OUTPUTS INPUTS Phase number Fuel Actuator 2 Air Actuator 1 Actuators Safety limit thermostat STB Control thermostat or pressurestat R Flame signal FS Air pressure switch LP Pressure switch min Pmin Pressure switch max Pmax Valve proving leakage test P LT POC alternative to Pmax No load position Ignition load Postpurge position Nominal load Low fire...

Page 21: ...s can be seen on the dis play of the Operator Panel Index 0 for fuel actuator index 1 for air actuator Installation notes Always run the high voltage ignition cables separate from the unit and other cables while observing the greatest possible dis tance The holding torque is reduced when the actuator is disconnect ed from power Technical data Tab H WARNING To avoid injury to persons damage to prop...

Page 22: ...oride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently WARNING The handling operations for the burner can be high ly dangerous if not carried out with the greatest at tention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also that the area in which you are working is empty an...

Page 23: ... protective fettling must not compromise the extraction of the blast tube For boilers with a water cooled front piece a refractory lining 2 5 Fig 18 on page 23 is not necessary unless expressly request ed by the boiler manufacturer Tab I 4 6 Securing the burner to the boiler Fit the heat insulation supplied onto the blast tube 4 Fig 12 Fit the entire burner onto the boiler hole prepared previously...

Page 24: ...e combustion head 4 7 Electrode and ignition pilot adjustment RS 280 E model Place the pilot and electrodes as shown in Fig 15 4 8 Electrode and ignition pilot adjustment RS 310 410 510 E model Place the electrode and the ignition pilot observing the dimensions in Fig 15 4 9 Gas butterfly valve If necessary replace the gas butterfly valve The correct position is shown in Fig 17 on page 23 WARNING ...

Page 25: ...ment can be modified WARNING The burner leaves the factory with the combustion head adjusted to notch 0 Fig 18 This adjustment allows you to secure the moving parts when the burner is being transported WARNING The combustion head can be adjusted within the fol lowing fields RS 280 E 0 12 RS 310 E 0 11 RS 410 E 0 8 RS 510 E 0 11 No adjustment can be made outside these intervals 2000 4000 6000 8000 ...

Page 26: ...fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel interception tap is closed before performing any operation on the burner WARNING The fuel supply line must be installed by qualified personnel in compliance with current standards and laws 10 2 3 4 5 6 11 2 12 5 4 7 9 8 1 4 D3776 Fig 19 WARNING See the accompanying instructions ...

Page 27: ...ration Gas pressure at test point 1 Fig 20 11 7 WC Pressure in combustion chamber 2 WC 11 7 2 9 7 WC An output of 10500 MBtu hr shown in Tab J corresponds to 9 7 WC pressure column 1 This value serves as a rough guide the effective delivery must be measured at the gas meter Tab J Fig 20 20086798 MBtu hr GCV 1 p WC 2 p WC RS280 2 600 1 2 0 01 3 500 2 2 0 02 4 500 3 6 0 03 5 500 6 5 0 07 6 500 9 1 0...

Page 28: ...the device is obtained only when it is correctly connected to an efficient earthing system made according to current standards It is necessary to check this fundamental safety requirement In the event of doubt have the electrical system checked by qualified personnel Do not use the gas tubes as an earthing system for electrical devices The electrical system must be suitable for the maximum input p...

Page 29: ...or ground terminals A Fan motor B Maximum gas pressure switch C UV sensor D Air servomotor E Fuel servomotor F Air pressure switch G Motor earth cable 4 13 Thermal relay calibration 4 13 1 Electronic thermal relay To reset in the case of an intervention of the thermal relay press the button RESET Fig 22 There are two different solution to test the electronic thermal relay Device test Fig 23 Push s...

Page 30: ...tors manufactured for 208 230 460 IE3 NEMA Premium Efficiency voltage have the same connection than IE2 Epact motors but differ ent connection than IE1 motors no more star delta but star double star D3686 IE1 IE2 Epact IE3 NEMA Premium Efficiency U2 V2 W2 U3 V3 W3 U1 V1 W1 S8379 U2 V2 W2 U3 V3 W3 U1 V1 W1 S8380 460V 208 230V 460V 208 230V Fig 25 WARNING the motors manufactured for 575V IE3 NEMA Pr...

Page 31: ... indicated in the previous heading the pilot of the burner should fire If the motor starts but the flame does not appear and the flame safeguard goes into lock out reset and wait for a new firing at tempt Pilot adjustment has been illustrated on Fig 15 on page 22 Having adjusted the pilot reconnect the main valve and ignite the main flame it might require several attempts to purge the air from the...

Page 32: ...arameters with the air servomotor and store the maximum combustion point complete the procedure slowly synchronizing the combustion with the two servomotors and storing the different setting points DANGER Make sure that the lamps or testers connected to the solenoids or indicator lights on the solenoids themselves show that no voltage is present If volt age is present stop the burner immediately a...

Page 33: ...le bit more 5 7 2 Maximum gas pressure switch Adjust the maximum gas pressure switch after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale Fig 31 With the burner operating at MAX output reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out Then turn the dial clockwise by 0 8 WC an...

Page 34: ...ner will lock out in 1 s 5 9 Flame signal measurement Check the flame signal through the parameter 954 as indicated in Fig 33 The displayed value is expressed in percentage The value during the operation must be higher than 24 If at the burner start up the value is higher or equal of 18 the burner locks out due to the extraneous light For further and specific information please refer to the specif...

Page 35: ...scanner proceed as follows extract the UV scanner 2 clean the glass cover from any dust that may have accumu lated Flame inspection window Clean the flame inspection window 1 Fig 34 Fan Check to make sure that no dust has accumulated inside the fan or on its blades as this condition will cause a reduction in the air flow rate and provoke polluting combustion 6 Maintenance DANGER The maintenance in...

Page 36: ...tion contact the Technical Assis tant and have him carry out the necessary adjustments Gas leaks Make sure that there are no gas leaks on the pipework between the gas meter and the burner Gas filter Change the gas filter when it is dirty 6 3 Opening the burner See Accessibility to the interior of the combustion head on page 22 6 4 Closing the burner Refit following the steps described but in rever...

Page 37: ...Appendix Spare parts 35 20122392 GB A Appendix Spare parts ...

Page 38: ...IEWING PORT 18 3006723 CONNECTOR C 19 3020191 O RING SEAL B 20 3013328 FLANGE GASKET A 21 20075037 END CONE B 21 3013314 END CONE B 22 20073781 CYLINDER C 23 20075041 SHUTTER C 23 20074988 SHUTTER C 24 20075043 SQUARE 24 20073784 SQUARE 25 20075916 SCREW 26 20052434 CONNECTOR C 27 3007077 SEAL B 28 3005447 CONNECTOR C 29 20075022 JOINT C 30 20073817 DISC A 31 3013937 JOINT C 32 20008601 SERVOMOTOR...

Page 39: ...C 48 20114124 FAN C 49 3012794 INSPECTION WINDOW 50 3013682 SOUND DAMPING 50 20073811 SOUND DAMPING 51 3014079 SPACER 52 3012841 BASE C 53 20096592 POWER REGULATOR C 54 20031413 HORN 55 20014366 FUSE HOLDER 56 20010969 RELAY C 57 3013926 DISPLAY 58 20086561 COVER B 59 20056809 AIR DAMPER 59 20073813 AIR DAMPER 60 3013683 PROTECTION 60 20073814 PROTECTION 61 3012795 BEARING C 62 3012956 TRANSFORMER...

Page 40: ...ncy Low Fire High Fire Low Fire Flame Signal Overfire Draft High Fire Flame Signal OIL OPERATION Oil supply pressure CO2 Low Fire High Fire Oil suction pressure O2 Low Fire High Fire Control Power Supply CO Low Fire High Fire Burner Firing Rate NOX Low Fire High Fire Low Fire Flame Signal Net Stack Temp Low Fire High Fire High Fire Flame Signal Comb Efficiency Low Fire High Fire Low Fire Nozzle Si...

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Page 44: ...BURNERS NORTH AMERICA 35 Pond Park Road http www riello ca 2165 Meadowpine Blvd Hingham Massachusetts Mississauga Ontario U S A 02043 1 800 4 RIELLO Canada L5N 6H6 RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello com ...

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