Riello RS 1000/E C01 Installation, Use And Maintenance Instructions Download

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Installation, use and maintenance instructions

20061994 (5) - 12/2014

Forced draught gas burners

Modulating operation

CODE

MODEL

TYPE

20062014

RS 1000/E C01

1139 T1

20061950

RS 1200/E C01

1140 T1

Summary of Contents for RS 1000/E C01

Page 1: ...Installation use and maintenance instructions 20061994 5 12 2014 Forced draught gas burners Modulating operation CODE MODEL TYPE 20062014 RS 1000 E C01 1139 T1 20061950 RS 1200 E C01 1140 T1 GB ...

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

Page 3: ...ox for the air fuel ratio LMV51 13 4 13 Servomotor 15 5 Installation 16 5 1 Notes on safety for the installation 16 5 2 Handling 16 5 3 Preliminary checks 16 5 4 Operating position 17 5 5 Removal of the locking screws from the shutter 17 5 6 Preparing the boiler 17 5 6 1 Boring the boiler plate 17 5 6 2 Blast tube length 17 5 7 Securing the burner to the boiler 18 5 8 Access to head internal part ...

Page 4: ...O 27 6 6 2 Maximum gas pressure switch 27 6 6 3 Minimum gas pressure switch 27 6 6 4 PVP pressure switch kit 27 6 7 Final checks with burner operating 28 7 Maintenance 29 7 1 Notes on safety for the maintenance 29 7 2 Maintenance programme 29 7 2 1 Maintenance frequency 29 7 2 2 Checking and cleaning 29 7 3 Opening the burner 30 7 4 Closing the burner 30 8 Faults Probable causes Solutions 31 A App...

Page 5: ...EMC 2004 108 EC Electromagnetic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BIm SchV revision 26 01 2010 Product Type Model Output Forced draugh...

Page 6: ...h risks CAUTION This symbol indicates operations which if not 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 le thal consequences DANGER FLAMMABLE MATERIAL This symbol indicates the presence of flammable materials DANGER BURNING This symbo...

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: ...ance 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 under...

Page 9: ...1 stop every 24h Continuous operation 1 stop every 72h Electrical supply of the system 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 R S 1000 E TC Emission C01 or Class 1 EN676 BLU 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 oil E Electronic cam EV Electronic cam with variable speed w...

Page 10: ... G21 G22 G23 G25 Gas pressure at max output 2 Gas G20 G25 mbar 64 5 92 7 80 5 114 Operation Intermittent min 1 stop in 24 hours Modulating Standard applications Boilers water steam diathermic oil Ambient temperature C 0 50 Combustion air temperature C max 60 Noise levels 3 Sound pressure Sound power dB A 85 99 89 3 99 7 Weight Kg 460 500 Model RS 1000 E C01 RS 1200 E C01 Electrical supply 3N 400V ...

Page 11: ... 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 Country of destination Gas category SE FI AT GR DK ES GB IT IE PT IS CH NO I2H DE I2ELL NL I2L FR I2Er BE I2E R B LU PL I2E I B A E D C F H G R L R 20089867 Fig 1 mm A B C D E F G H I L R RS 1000 E C01 1637 538 200 413 885 ...

Page 12: ...ted in the diagram consult the manufac turer The firing rates were obtained in special test boilers according to EN 676 regulations In Fig 3 you can see the diameter and length of the test combus tion chamber Example Output 7000 kW diameter 120cm length 6m MODULATING RATIO The modulating ratio obtained in test boilers in accordance with standard EN 676 is 7 1 WARNING The firing rate value Fig 2 ha...

Page 13: ...ever 18 Air pressure switch differential operating type 19 Combustion head air pressure test point 20 Maximum gas pressure switch with pressure test point 21 QRI cell 22 Pressure test point for air pressure switch 23 Gas butterfly valve servomotor 24 Locking screws of the shutter during the transport replace them with the screws M12x25 supplied with the burner 25 Pilot gas train 9 1 4 12 13 5 15 8...

Page 14: ...me sensor plug sensor socket 18 Main terminal supply board 19 Air pressure switch 20 Supply cables external connections and kits 21 Auxiliary circuits fuse 22 Plug socket servomotor NOTE Two types of burner lockout may occur Control box lockout if the pushbutton 13 Fig 5 red led lights up it indicates that the burner is in lockout release by pressing the pushbutton 13 Fig 5 Motor lockout release b...

Page 15: ...st 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 and e...

Page 16: ...V Oil pump magnetic clutch nominal voltage Nominal current Power factor 2A cosϕ 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cosϕ 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 Si...

Page 17: ... 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 pro...

Page 18: ...ust 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 t...

Page 19: ...ast tube 4 This protection must not compromise the extraction of the blast tube For boilers with a water cooled frontpiece a refractory lining 2 5 Fig 12 is not necessary unless expressly requested by the boiler manufacturer Tab I WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 9 Installation 1 is preferable as it is the only one that allows the maintenance operations a...

Page 20: ...13 proceed as follows disconnect the gas servomotor socket 1 disconnect the head movement leverage 2 remove the 4 fixing screws 3 open the burner on the hinge disconnect the electrode cables 4 remove the screw gas pressure socket 5 of the head pull out the inner part of the head 6 Prepare a suitable lifting system using rings 3 Fig 12 WARNING The seal between burner and boiler must be airtight 1 1...

Page 21: ...of the combustion head moving the tie rod on the holes 5 6 7 8 10 Fig 15 The selection of the hole to be used is determined based on the maximum output requested as illustrated in Tab J In the factory the adjustment is adjusted for the maximum stroke hole 10 Fig 15 Tab J WARNING Place the electrode on the ignition pilot observing the dimensions specified in Fig 14 Fig 14 18 5 0 2 71 5 1 Electrode ...

Page 22: ...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 23: ...rom the gas pressure measured at test point 1 Fig 21 Find in Tab K related to the burner concerned the pressure value closest to the result of the subtraction Read off the corresponding output on the left 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 properl...

Page 24: ...e RS 1000 E C01 with G20 natural gas Maximum modulating output operation Gas pressure at an output of 9000 kW 49 2 mbar Pressure in combustion chamber 10 mbar 49 2 10 59 2 mbar Pressure required at test point 1 Fig 21 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 o...

Page 25: ...op 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 according...

Page 26: ...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 27: ...eration is unnecessary if each of the two solenoid valves is equipped with a pilot light that signals voltage pass ing through 6 3 Burner start up Close the remote controls and position the selector 1 Fig 27 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 burn...

Page 28: ...1 The dosage of the air and fuel through positioning 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 opera...

Page 29: ...re 6 6 2 Maximum gas pressure switch Adjust the maximum gas pressure switch after performing all oth er burner adjustments with the maximum gas pressure switch set to the end of the scale Fig 29 With the burner operating at maximum output lower the adjust ment pressure by slowly turning the relative knob anticlockwise until the burner locks out Now turn the knob clockwise by 2 mbar and repeat the ...

Page 30: ... 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 wire The burner must stop in lockout due to ignition failure WARNING Make sure that the mechanical locking systems on ...

Page 31: ...e of the burner Boiler Clean the boiler as indicated in its accompanying instructions in order to maintain all the original combustion characteristics in tact especially the flue gas temperature and combustion cham ber pressure Gas leaks Make sure that there are no gas leaks on the pipes between the gas meter and the burner Gas filter Replace the gas filter when it is dirty Combustion If the combu...

Page 32: ...e hinge 7 4 Closing the burner Refit following the steps described but in reverse order refit all burner components as they were originally assembled DANGER Disconnect the electrical supply from the burner by means of the main system switch DANGER Close the fuel interception tap Wait for the components in contact with heat sources to cool down completely 2 1 3 3 3 3 4 Fig 33 20089875 Carry out all...

Page 33: ...ontrol box manual supplied When the burner starts again the red LED goes out and the con trol box is reset 8 Faults Probable causes Solutions WARNING In the event of a burner lockout more than two consecutive burner reset operations could cause damage to the installation On the third lockout contact the Aftersales Service DANGER If further lockouts or burner faults occur interven tions must only b...

Page 34: ...d 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 RS 1000 E C01 RS 1200 E C01 3010388 Burner Code RS 1000 E C01 RS 1200 E C01 3010401 Burner Code RS 1000 E C01 RS 1200 E C01 3010469 Burner Code ...

Page 35: ...unctional layout 6 LMV51 functional layout 7 LMV51 functional layout 8 LMV51 functional layout 9 LMV51 functional layout 10 LMV51 functional layout 11 LMV51 functional layout 12 Electrical wiring that the installer is responsible for 13 Electrical wiring that the installer is responsible for 14 Electrical wiring that the installer is responsible for 1 2 Sheet no 1 A1 Co ordinates Indication of ref...

Page 36: ...J6M 6 7 5 6 8 31 DD2A 1 8M 2 1 2 5 5 AF E 1CB BC A C F 5 B B B J6M B J7M J6M2 0 3 W 3 J 3 J 3 J 23 W AC J 2 J C A J 4 2AD E W F 2 C J E C J X23 J F F W A J FA J A1 J FAY A W AC C J A J AC3F J AC1 4 W 2 C J 4 1 J 2 J CFW 2A2 C J CA2 F J CA2 F J CA2 F 1W C 11C J C 1 J C 1 J C 11 FEW FA F C J FA E J FA J FA23 B W AC 2 J B J AC J AC 2 F W CAC J FC J CA J FC 1ZW 13A 4 J 13AZ3C J 13AZ3C J 13A 23 AW 2AF ...

Page 37: ...50 50 0 1 6 6 2 4 4 A E5 A E5 A E5 51 0 1 A2E6 2 3 60 A E6 F2 F3 3 4 9 8 47 7 G G 4 4 AFE71 A0E7 3 A2E5 A0E7 5 H 5 A 5 8 A 5 8 A 5 4 5 H 8 A 5 46 A A 6 I4 D8 H B 4 A D8 I A J4 8 A B8 5 B H 8 78 A B 88 A 8 A B K 7 H A 87 A B8 A I H 5 4 6 A I 8 A 5 4 6 A I8 BH 4 4 6 A 4 B8 A 4 B8 A 4 B8 H 8 A 8 A 8 A 8 BDH B B A B 8D A B A B 4 C H 4 A C A 8 A 4 B7H A B 7 A A B 7 LH 6 8 8 A L 8 A L 8 A 5 4 H 4 B8 A 8...

Page 38: ...C0 5 4 7 E2B6 E2B6 7 E2B6 4 J 4 E 4 7 E 4 7 E 4 4H J 7C E 4 5H E C E 59G C D7 J F E D7 G E K 7 E F7 4 F J A7C67 E FC77 E A7C0 E FCL C6 J C E C76 E C F7 E C 0 G9 J 4 5 E G9 07 E 4 5 E G7 FJ C 5 E C F7 E C F7 E C F7 A0J A 700 E A 70 E A 70 E A 700 FDJ FC F E FC7D E FC E FC HJ C E H E C 7 E C F6J C E F 6 E C E F 6 0MJ 0 C597 7 E 0 CM 7 E 0 CM 7 E 0 CH 4 CJ CF7 0 E A7C E CF7 0 E 47C F D7J F EA7C67 E D...

Page 39: ...012 0Q O B R GB M GB M G B M G B S R C IF M G S M CFEI M A6 ID K R 1E GGF M K GGF6 M T BC M 1 G 1C R 5 I M 1I C M 5 IJ M 1IUC I R IF F M I M IFB1 M IFJ 6A R E C F M 6AEJ M G C M 6 E F1R I C EF M FI C1 M FI C1 M FI C1 5JR 5EFG JJF M 5EFG J M 5EFG J M 5EFG JJ 1KR 1IE1EF M 1I K M 1IE M 1I B 0SR IF M 0ECS M IF M IF 1 R FIF M 1FG M FI M 1FG JVR JBI A M JBIVBFE M JBIVBFE M JBISE G B IR I1 CJF M EG5 I M ...

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Page 41: ...6 9 6 7 9 94 60 1 02 60 6 7 1 02 0 2 1 02 0 H1E 02 0 00 9 2 0 D C I 0 J99 670 67 J99 0 7 0 7 9 M 9D H 9D H 9D H 9D 94 M FC H 9D 4 H CBF H 58 FA 3 M IB DDC H 3 DDC8 H N H I D9 I M 6 F H IF H 6 FG H IFO F M FC C H F H FC I H FCG 85 M 9B C H 85BG H 9D H 8 B CIM F BC H CF I H CF I H CF I 6GM 6BCD GGC H 6BCD G H 6BCD G H 6BCD GG I3M IFBIBC H IF 3 H IFB H IF 74M FC H 7B 4 H FC H FC I M CFC H ICD H CF H ...

Page 42: ...8 2A72 DC 5 C 4 8 H9F 2A72 CA 9 9 P D H D 7 H D7 H D 5 P A72C H D 5 H AC32 H I 2B G7 P J3 DDC H G7DDCI H Q A7 H J7D JA P E72 7 H J277A H E724 H J2RA 2 P 2C C H 27 H 2C J7 H 2C4 I P 3 A C H I 347 H D A H I73 CJP 2 A 3C H C2 AJ7 H C2 AJ7 H C2 AJ7 E4P E3CD744C H E3CD74 H E3CD74 H E3CD744 JGP J23J3C H J27G H J23 H J2 65P 2C H 63A5 H 2C 7 H 2C J P C2C H JCD H C2 H JCD 41P 4 2 7 7 H 4 21 C3 7 H 4 21 C3 ...

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Page 44: ...C 9 1 N 1B G 1B 9 G 1B9 G 1B 1O N 9EA G 1B 7O G A E G 7 E F9 N M BBA G F9BBA G P 9 G M9B1 M N 39E89 G ME99 G 39E2 G MEQ E8 N EA A G E98 G EA M9 G EA2 N 1 7A G 29 G 1B 7 G 9 AMN E 7 A G AE M9 G AE M9 G AE M9 32N 3 AB922A G 3 AB92 G 3 AB92 G 3 AB922 MFN ME M A G ME9F G ME G ME DON EA G D O G EA 9 G EA M8N AEA G MAB8 G AE G MAB8 2RN 2 E7 9 9 G 2 ER A 9 G 2 ER A 9 G 2 EO 1B EN EM9 2A G B39E G EM9 2 G ...

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Page 46: ...T18 1 L0753F8 N 418 793 16 C 2L5 0 C U 0C 2L5 C C U C 8 2L5 1 1 C 1L0V 1 168 18 60 1F 00F9P 8 78 18 60 7 1 551 7 C 0 F 56 578 6 F06 6 70 1 11 578 5 7F 01 W L 5G 0 F8 41 97 7 L075 G1 96QF1 7 1 07 4 I L07557 1 9657 H W L 5G 0 F8 41 L 1881 L075 1 L F01F J LF 81 0753 7F D C K L07557 L F56 7 1 I L 1881 168 L F01F 18 9 5G1 7 61 578 5 7 1 F 8 N 168378 3 1 LF 81 78 L F56 7 1 68 F8O6781 C LF X L0F L0F1 L01...

Page 47: ... 9 67 B97 A7337 28 2B9L7 8 37 A L 7 6L5L676 9 8973 3 DDD 5J6 8 767 8 78 98E78 3 95 7 03 8 8E7E7 78 2 95 27 8372 98E 3 DDD 7K9E K9 87 78 C D A A C D C D C D C D57 C D DDD DDD P A A C D C D C D C D C D57 C D A DDD P A DDD C D C D C D A 6 6 0 07 A 07 DDDD P C D57 C D C D C D C D57 C D A DDD P A DDD C D C D C D C D C D57 C D57 C D A DDD P C D C D57 C D 8 E8 M B 7C 0 DDDD C D C D C D C D57 C D 9 Q 39 M...

Page 48: ... contactor KST1 Star triangle starter timer k1 Clean contacts output relay for fan ON k2 Clean contacts output relay for motor lockout k3 Clean contacts output relay for burner lockout k6 Clean contacts output relay for burner on MV Fan motor PA Air pressure switch PE Burner earth PGMax Maximum gas pressure switch PGMin Minimum gas pressure switch PGVP Pilot valves gas pressure switch QRI Flame se...

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Page 52: ...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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