Riello RS 45/M C05 Installation, Use And Maintenance Instructions Download Page 2 | Manualshive

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Translation of the original instructions

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Summary of Contents for RS 45/M C05

Page 1: ...allation use and maintenance instructions 20159575 1 03 2019 Forced draught gas burners Progressive two stage or modulating operation CODE MODEL TYPE 20159209 RS 45 M C05 S028T 20159210 RS 45 M C05 S028T GB ...

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

Page 3: ...on 13 5 1 Notes on safety for the installation 13 5 2 Handling 13 5 3 Preliminary checks 13 5 4 Operating position 14 5 5 Preparing the boiler 14 5 5 1 Boring the boiler plate 14 5 5 2 Blast tube length 14 5 5 3 Securing the burner to the boiler 14 5 6 Access to head internal part 15 5 7 Positioning the probe electrode 15 5 8 Combustion head adjustment 16 5 9 Gas supply 17 5 9 1 Gas feeding line 1...

Page 4: ...1 Control box reset 26 6 10 2 Visual diagnostics 26 6 10 3 Software diagnostics 26 6 11 Normal operation flame detection time 27 7 Maintenance 28 7 1 Notes on safety for the maintenance 28 7 2 Maintenance programme 28 7 2 1 Maintenance frequency 28 7 2 2 Safety test with no gas supply 28 7 2 3 Checking and cleaning 28 7 2 4 Combustion control gas 29 7 2 5 Safety components 29 7 3 Opening the burne...

Page 5: ... and according to the European Directives GAR 2016 426 EU Gas Appliances 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 21 04 2018 General Manager RIELLO S p A Burners Depart...

Page 6: ...rried out correctly may cause damage to the machine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not carried 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 CRUSH...

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 incorrectly applied an...

Page 8: ...enance 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 responsible 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 under...

Page 9: ...s Continuous working 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 45 TC Emission C1 or Class 1 EN676 C02 or MZ Class 2 EN676 C03 or BLU Class 3 EN676 3 230 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam EV Electronic cam and variable speed with In...

Page 10: ...untry 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 C05 Type S028T Output 1 2nd stage kW 190 570 164 491 Mcal h 1st stage min kW Mcal h 90 78 Fuel Natural gas G20 G25 G31 Gas pressure at max output 2 Gas G20 G25 mbar 18 27 Operation Intermittent min 1 stop in 24 hours Progressive two sta...

Page 11: ...burners RS 45 M C05 can work in two ways one stage or two stage The MAXIMUM OUTPUT is chosen within area A The MINIMUM OUTPUT must not be lower than the minimum limit of the diagram RS 45 M C05 90 kW mm B C D E E1 F H L N P T T 1 U RS 45 M C05 164 108 140 352 367 11 2 474 476 168 580 192 327 810 Fig 1 L H T 1 T F C N D E E 1 P B U 20151007 ATTENTION The firing rate value Fig 2 has been obtained co...

Page 12: ...ns In Fig 3 you can see the diameter and length of the test combustion chamber Example Output 400 kW diameter 50 cm length 1 5 m 4 9 1 Commercial boilers The burner is suitable for operating on both flame inversion boil ers as well as on boilers 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 thicknes...

Page 13: ...aught which tends to draw air from the fan air inlet 11 Areas for passage of electric cables 12 Air inlet to fan 13 Gas input pipework 14 Gas butterfly valve 15 Boiler mounting flange 16 Flame stability disc 17 Flame inspection window 18 Power switch for automatic manual off Button for power increase power reduction 19 Suppressor 20 Relay 21 Control box with lockout pilot light and lockout reset b...

Page 14: ...rried out by qualified personnel in compliance with the standards and regulations of the laws in force Electrical supply AC 220 240V 10 15 Frequency 50 60 Hz 6 Internal fuse T6 3H250V Operation below the nominal value of electrical supply Minimum operation value on reduction of electrical supply below nominal value approx AC 160 V Minimum operation value on increase in electrical supply towards no...

Page 15: ...nside the boiler must be free from hazardous mixes e g chloride fluoride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently ATTENTION Burner handling operations can be highly dangerous if not carried out with the greatest attention distance unauthorised personnel check integrity and suitability of the means available Check also that the area in which ...

Page 16: ...nless expressly requested by the boiler manufacturer 5 5 3 Securing the burner to the boiler Separate the combustion head from the rest of the burner Fig 11 Remove the cover Disengage the articulated coupling 4 from the graduated sector 5 Remove the screws 2 from the two slide bars 3 Remove the screw 1 and draw the burner back on the slide bars 3 by about 100mm Disconnect the probe and electrode c...

Page 17: ...ler must be airtight 5 7 Positioning the probe electrode If in the previous check the position of the probe or electrode was not correct remove the screw 1 Fig 12 extract the inner part 2 Fig 12 of the head and adjust them Fig 12 D501 ATTENTION 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 13 ATT...

Page 18: ...g 14 until notch shown on the diagrams Fig 15 and Fig 16 In order to carry out this operation unscrew the screws 5 Fig 14 and rotate the ring nuts 4 and 7 Fig 14 At the end tighten the screws 5 Fig 14 again Once you have finished adjusting the head reassemble the burner 4 Fig 17 on the guides 3 Fig 17 at about 100mm from the pipe coupling 5 Fig 17 burner in the position shown in Fig 11 insert the ...

Page 19: ...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 presence of a flammable source Precautions...

Page 20: ...t Tab F The values shown in refer to Natural gas G 20 NCV 9 45 kWh Sm3 8 2 Mcal Sm3 Natural gas G 25 NCV 8 13 kWh Sm3 7 0 Mcal Sm3 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 ...

Page 21: ... pressure at test point 1 Fig 23 17 0 mbar Pressure in combustion chamber 2 0 mbar 17 0 2 0 15 0 mbar A pressure of 15 0 mbar column 1 corresponds in Tab F to output of 463 kW This value serves as a rough guide the effective output must be measured at the gas meter To calculate the required gas pressure at test point 1 Fig 23 set the maximum modulating output required from the burner operation fin...

Page 22: ...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 23: ...e 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 butterfly valve must be fully open 90 Cam II 0 Limits rotation toward minimu...

Page 24: ... ignition 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 5 on page 11 on the ionisation probe cable...

Page 25: ...u 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 the output re duction key To adjust cam III remove the snap action cover 1 Fig 29 re move the relative key 2 from inside and insert it into the notch of cam III Air adjustment Progressively adjust the beginning...

Page 26: ...ating in 2nd stage increase adjustment pressure by slowly turning the relevant knob clockwise until the burner stops Then turn the knob anticlockwise by 0 2 kPa 2 mbar and repeat burner start up to ensure it is operating regularly If the burner locks out again turn the knob again anticlockwise by 0 1 kPa 1 mbar 6 7 3 Flame presence check The burner is fitted with an ionisation system to check that...

Page 27: ...perature 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 28: ...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 29: ...ses will identify the DETECTION TIME of the probe since the opening of gas valves according to Tab H Tab H This is updated in every burner start up Once read the burner repeats the start up cycle by briefly press ing the control box button Pressing the button Control box status From 1 to 3 seconds Reset of the control box without visualisation of the visual diagnostics More than 3 seconds Visual d...

Page 30: ... or closing opening position indicators that activate as soon as they are powered 7 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 Change the gas filter when it is dirty Burner Check that there a...

Page 31: ...ion for example a variation in the tension could cause a combustion with an air defect and with the subsequent formation of CO CO It should not exceed 100 mg kWh 7 2 5 Safety components The safety components must be replaced at the end of their life cycle indicated in Tab J The specified life cycles do not refer to the warranty terms indicated in the delivery or payment conditions Tab J EN 676 Air...

Page 32: ...he screw 8 7 4 Closing the burner Proceed as follows Fig 36 remove the split pin 9 and push the burner up to approxi mately 100 mm from the pipe coupling Reconnect the leads and slide in the burner until it comes to a stop Replace the screw 5 and split pin 9 and carefully pull the probe and electrode cables outwards until they are slightly taut Re couple the articulated coupling 3 to the graduated...

Page 33: ...es 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 ...

Page 34: ... 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 35: ...05 229 354 In progress Burner Type dB A Code RS 45 M C05 C1 3 10 3010403 Burner Probe Adjustment field Code RS 45 M C05 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 C05 RWF50 20082208 RWF55 20099657 Burner Signal converter Code RS 45 M C05 0 2 10V 0 4 20mA 3010390 Burner Potentiometer Code RS 45 M C05...

Page 36: ...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 37: ...35 20159575 GB Appendix Electrical panel layout 0 1 2344 567 4 1 2 8 9 1 65 31 4 2 1 264 1 5 3 0 6 6 6 3 3 A B B B C B D B B B B B B B B B B C B ...

Page 38: ...20159575 36 GB Appendix Electrical panel layout ...

Page 39: ...7 20159575 GB Appendix Electrical panel layout 0 1 2 3 45 6 7 7 7 6 7 7 7 8 6 7 8 7 9 7 6 7 7 7 6 7 7 7 8 6 7 8 7 7 8 6 7 7 7 6 7 7 7 6 7 7 7 6 7 7 7 6 7 7 7 6 7 7 7 6 7 7 7 6 7 7 87 7 9 7 7 7 6 7 8 7 7 ...

Page 40: ...20159575 38 GB Appendix Electrical panel layout 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 1 0 2 3 4 5 6 6 ...

Page 41: ...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...

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Page 44: ...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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