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Installation, use and maintenance instructions

20123781 (1) - 02/2017

Forced draught gas burners

Modulating operation

CODE

MODEL

TYPE

20116496

RS 1000/EV BLU

1133 T2

20116498

RS 1200/EV BLU

1134 T2

Содержание RS 1000/EV BLU

Страница 1: ...Installation use and maintenance instructions 20123781 1 02 2017 Forced draught gas burners Modulating operation CODE MODEL TYPE 20116496 RS 1000 EV BLU 1133 T2 20116498 RS 1200 EV BLU 1134 T2 GB ...

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

Страница 3: ...4 14 Flame sensor FFS 06 15 4 15 Servomotors 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 18 5 7 Securing the burner to the boiler 19 5 8 Access to head internal part 19 5 9 Electrodes...

Страница 4: ...29 6 6 4 PVP pressure switch kit 29 6 7 Final checks with burner operating 30 7 Maintenance 31 7 1 Notes on safety for the maintenance 31 7 2 Maintenance programme 31 7 2 1 Maintenance frequency 31 7 2 2 Checking and cleaning 31 7 2 3 Positioning the rpm sensor 32 7 3 Opening the burner 32 7 4 Closing the burner 32 8 Faults Probable causes Solutions 33 A Appendix Accessories 34 B Appendix Electric...

Страница 5: ...etic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 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 draught gas burners 1133 T2 RS 1000...

Страница 6: ... 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 symbol...

Страница 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...

Страница 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...

Страница 9: ...ystem 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 R S 1000 SV TC Emission C01 or Class 1 EN676 BLU or BLU Class 3 EN676 FS2 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION BLU 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam SV Electronic cam with variable speed with Inverter P Proportional air gas valve BP Two stage light oil Proportional va...

Страница 10: ...ab C Model RS 1000 EV BLU RS 1200 EV BLU Type 1133 T2 1134 T2 Power 1 Output 1 min max kW 1100 4000 10100 1500 5500 11100 Fuels Natural gas G20 methane gas 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 Continuous min 1 stop in 72 hours Modulating Standard applications Boilers water steam diathermic oil Ambient tempera...

Страница 11: ... 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 E Country 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 Fig 1 20061119 mm A B C D E F G H I L R RS 1000 EV BLU 1637 669 200 413 88...

Страница 12: ...the diagram consult the manufac turer The 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 7000 kW diameter 120 cm length 6 m 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...

Страница 13: ...nt lever 18 Minimum air pressure switch differential operating type 19 Combustion head air pressure test point 20 Maximum gas pressure switch with pressure test point 21 Flame sensor 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 M12x25 screws supplied as standard 1 1 12 4 9 13 5 15 8 23 14 ...

Страница 14: ...use 17 Air servomotor plug socket 18 Air servomotor plug socket 19 Filter NOTE Two types of burner failure may occur Control box lockout switching on of button 13 Fig 5 red led signals that the burner is in lockout Release by press ing the push button on the display 6 Fig 5 Motor lockout see inverter manual 4 11 Burner equipment Gasket for gas train flange No 1 Thermal insulation screen No 1 M12x2...

Страница 15: ...box is perfectly dry Static charges must be avoided since they can damage the control box s electronic components when touched Electrical wiring of the flame detectors It is important for signal transmission to be almost totally free of any disturbances or loss Always separate the detector cables from the other cables Line capacitance reduces the magnitude of the flame sig nal Use a separate cable...

Страница 16: ...g terminals Use adequate ferrules Arrange the HV ignition cables separately as far as possible from the control box and the other cables The burner manufacturer must protect unused AC 230V ter minals with dummy plugs refer to sections Suppliers of other accessory items When wiring the unit make sure that AC 230V mains voltage cables are run strictly separate from extra low voltage cables to avoid ...

Страница 17: ...evice used respectively from the allocation of the ETAMATIC terminals Fig 10 The connection cable has an additional measuring wire pink that can be used to measure the signal voltage via a hand held digital multimeter according to EN 61010 input impedance 5 M The voltage is measured between the earth potential blue wire and the additional measurement wire pink wire of the connec tion cable to dete...

Страница 18: ...VAC section of the servomotor is completely separated from the low voltage section The static torque is reduced when the 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 cases make sure that dust or dirt does not penetrate inside the actuator The top side of the board carries a cove...

Страница 19: ...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...

Страница 20: ...last tube 4 This 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 16 is not necessary unless expressly requested by the boiler manufacturer Tab H WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 13 Installation 1 is preferable as it is the only one that allows the maintenance ...

Страница 21: ...17 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 16 WARNING The seal between burner and boiler must be airtight 3 8...

Страница 22: ...s determined based on the maximum output requested as illustrated in Tab I In the factory the adjustment is adjusted for the maximum stroke hole 10 Fig 19 Tab I WARNING Position the electrodes according to the dimen sions shown in Fig 18 Fig 18 Diffuser Electrodes D11587 Fig 19 20061124 Leverage hole Output kW From A RS 1000 5 1100 4000 5 4000 6600 8 6600 8100 10 8100 10100 RS 1200 5 1500 5500 5 5...

Страница 23: ...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 pres ence of a flammable source Precaution...

Страница 24: ...sure measured at test point 1 Fig 26 Find inTab J 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 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 ...

Страница 25: ...meter To calculate the required gas pressure at test point 1 Fig 26 set the maximum modulating output required from the burner op eration find the nearest output value in Tab J for the burner in ques tion read on the right column 1 the pressure at the test point 1 Fig 26 Add this value to the estimated pressure in combustion chamber Example RS 1000 EV BLU with G20 natural gas Operation at maximum ...

Страница 26: ...he 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 to the wiring diagrams The electrical safety of 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...

Страница 27: ... casing by tightening the 4 screws 1 Fig 28 5 12 3 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...

Страница 28: ...solenoids to check the exact moment in which voltage 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 6 2 1 Rpm sensor This is located inside the motor cover and measures the rpm us ing the reading plate The rpm sensor is factory set 6 Start up calibration and operation of the burner WARNING The first ...

Страница 29: ...vant control box manual 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 connections When the limit thermostat TL closes the burner begins the starting cycle 1 EMERGENCY STOP 0 AUTO AUXILIARY DEVICE ON BURNER LOCKOUT FAN MOTO...

Страница 30: ...uel through positioning using direct servo commands 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 sequen...

Страница 31: ...ch Adjust the maximum gas pressure switch after having performed all the other burner adjustments with the maximum gas pressure switch set at the end of the scale Fig 35 With the burner operating at maximum output lower the adjust ment pressure by slowly turning the relative knob anticlockwise until the burner locks out Turn the knob clockwise by 0 2 kPa 2 mbar and repeat the start up of the burne...

Страница 32: ...ob 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 Obscure the flame sensor The burner must stop in lockout due to ignition failure WARNING Make sure that the mechanical locking systems on th...

Страница 33: ...nying 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 pipe between the gas meter and the burner Gas filter Change the gas filter when it is dirty Combustion In case the combustion values found at the beginning of the inter vention do not ...

Страница 34: ...he gas servomotor Remove the screws 3 At this point it is possible to open the burner on the hinge 7 4 Closing the burner Refit following the steps described but in reverse order refit all burner components as they were originally assembled WARNING In the event the rpm sensor is malfunctioning or needs replacing check reset its position inside the fan motor cover Fig 39 20087860 DANGER Turn off th...

Страница 35: ...e red LED goes out and the con trol box is reset 8 Faults Probable 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 interventions mus...

Страница 36: ... 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 EV BLU RS 1200 EV BLU 3010401 Burner Code RS 1000 EV BLU RS 1200 EV BLU 3010344 Burner Code All models Box LT2 20044983 Burner Code All models Box LT2 with probe 20043847 Burner Code All models Box LT2 with display 20020436 PT 100 pr...

Страница 37: ...Hz 22 kW 3090913 RS 1200 EV BLU 3Ph 400V 50Hz 30 kW 20030338 WARNING The use of inverters other than those indicated by the Manufacturer may lead to burner failure and in extreme cases a potential risk of harm to peo ple and damage to property The Manufacturing company shall not be liable for any such damage arising from non observance of the requirements contained in this manual ...

Страница 38: ...Indication of references 3 Single wire output layout 4 Functional layout 5 Functional layout 6 Functional layout 7 Functional layout 8 Electrical wiring that the installer is responsible for 9 Electrical wiring that the installer is responsible for 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Страница 39: ...37 20123781 GB Appendix Electrical panel layout 001 2 2 001 001 34 001 34 5 34 34 6 34 6 7 001 34 6 34 34 5 5 5 8 6 2 8 5 5 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 555 5 555 5 555 5 555 5 0 0 0 ...

Страница 40: ...20123781 38 GB Appendix Electrical panel layout 0 0 0 0 0 1 0 0 2 3 0 3 0 0 4 4 4 5 4 6 4 4 4 4 4 4 4 74 7 7 4 4 5 4 89 9 0 ...

Страница 41: ...39 20123781 GB Appendix Electrical panel layout ...

Страница 42: ...20123781 40 GB Appendix Electrical panel layout 0 0 1 0 0 0 0 0 2 2 2 0 0 0 0 345 6 78 6 9 68 6 0 995 36 68 6 6 85 9 68 6 3 6 853 4 85 A 538 6 58 36B 3 3 3 ...

Страница 43: ...41 20123781 GB Appendix Electrical panel layout 0 1 2 2 2 0 3 4 56 789 ...

Страница 44: ...20123781 42 GB Appendix Electrical panel layout 0 1 0 2 3 2 4 4 5 5 2 3 6 0 6 2 7 7 1 8 8 1 8 9 8 0 8 8 8 8 8 8 8 38 3 3 8 8 9 8 ...

Страница 45: ...43 20123781 GB Appendix Electrical panel layout 0 1 0 1 222 3 3 3 4 3 3 3 3 3 3 3 3 3 3 3 4 3 ...

Страница 46: ...cts output relay for fan 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 device S1 Emergency stop button S2 Service selector S4 Automatic off selector SM1 Air servomotor SM2 Gas servomotor R Input in current DC 4 20 mA TA Ignition transformer TL Limit thermostat pres...

Страница 47: ......

Страница 48: ...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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