Riello GAS 3 Installation, Use And Maintenance Instructions
Forced draught gas burners
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Summary of Contents for Riello GAS 3
- Page 1 Installation, use and maintenance instructions Forced draught gas burners One stage operation CODE MODEL TYPE 3751918 GAS 3 519 T1 3751617 GAS 4 516 T1 3751717 GAS 5 517 T1 3751817 GAS 6 518 T1 20144819 (3) - 01/2019...
- Page 2 Translation of the original instructions...
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Page 3: Table Of Contents
Contents Declarations....................................3 Information and general warnings............................4 Information about the instruction manual ........................4 2.1.1 Introduction.................................. 4 2.1.2 General dangers................................4 2.1.3 Other symbols ................................4 2.1.4 Delivery of the system and the instruction manual...................... 5 Guarantee and responsibility............................5 Safety and prevention................................ - Page 4 Contents 6.6.3 Flame presence check ...............................24 Burner operation ................................25 6.7.1 Burner start-up ................................25 6.7.2 Steady state operation ...............................25 6.7.3 Ignition failure................................25 Burner start-up cycle diagnostics ..........................26 6.8.1 Resetting of control box and diagnostics use ......................26 6.8.2 Control box reset................................26 6.8.3 Visual diagnostics ..............................26 6.8.4 Software diagnostics ..............................26...
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Page 5: Declarations
Quality is ensured by means of a quality and management system that is certified ISO 9001:2015. Legnago, 21.04.2018 General Manager Research and Development Director RIELLO S.p.A. - Burners Department RIELLO S.p.A. - Burners Department Eng. U. Ferretti Eng. F. Comencini... -
Page 6: Information And General Warnings
Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction WARNING: MOVING PARTS The instruction manual supplied with the burner: This symbol indicates that you must keep limbs is an integral and essential part of the product and must not away from moving mechanical parts;... -
Page 7: Delivery Of The System And The Instruction Manual
Information and general warnings 2.1.4 Delivery of the system and the instruction The system supplier must carefully inform the user about: - the use of the system; manual - any further tests that may be required before activating the When the system is delivered, it is important that: system;... -
Page 8: Safety And Prevention
Safety and prevention Safety and prevention Background The burners have been designed and built in compliance with the type and pressure of the fuel, the voltage and frequency of the current regulations and directives, applying the known technical electrical power supply, the minimum and maximum deliveries for rules of safety and envisaging all the potential danger situations. -
Page 9: Technical Description Of The Burner
Technical description of the burner Technical description of the burner Models available Designation Voltage Start-up Code GAS 3 1/230/50 Direct 3751918 GAS 4 1/230/50 Direct 3751617 GAS 5 3/230-400/50 Direct 3751717 GAS 6 3/230-400/50 Direct 3751817 Burner categories - Countries of destination... -
Page 10: Electrical Data
Technical description of the burner Electrical data MODEL GAS 3 GAS 4 GAS 5 GAS 6 Type 519 T1 516 T1 517 T1 518 T1 Electrical supply 1 PH 1N ~ 230V 50 Hz Electrical supply 3 PH 3 ~ 230 - 400V +/- 10% 50 Hz... -
Page 11: Firing Rates
1,013 mbar (approx. 0 m Example: WARNING a.s.l.), and with the combustion head adjusted as for GAS 3 the area is delimited by: shown on page 16. • the axis of the 130 - 350 kW outputs The burner can also operate with the combustion chamber in de- pression. -
Page 12: Test Boiler
Technical description of the burner Test boiler The burner/boiler combination does not pose any problems if the Example: boiler is EC approved and its combustion chamber dimensions Output 1500 Mcal/h: diameter 80 cm - length 2.5 m. are similar to those indicated in the diagram (Fig. 3). If the burner must be combined with a boiler that has not been EC 4.8.1 Commercial boilers... -
Page 13: Burner Description
Combustion head Manual damper for adjusting the air Air pressure switch Capacitor (in GAS 3-4 models) Motor contactor and thermal relay (in GAS 5-6 models) Terminal board Cable grommets (for electrical wiring to be carried out by the... -
Page 14: 4.10 Control Box Rmg88
The control box RMG88... is a safety device! WARNING Avoid opening or modifying it, or forcing its opera- tion. Riello S.p.A. cannot assume any responsibil- ity for damage resulting from unauthorised interventions! All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. -
Page 15: Installation
Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner is to The installation of the burner must be carried out be installed, and arranging for the environment to be illuminated by qualified personnel, as indicated in this manual correctly, proceed with the installation operations. -
Page 16: Operating Position
The range of lengths available, L, is as fol- lows: GAS 3 Blast tube GAS 3 GAS 4... -
Page 17: Securing The Burner To The Boiler
Installation 5.5.3 Securing the burner to the boiler Finally, put back the fan 4)(Fig. 9) on the slide bars 3), put back the screws 2) and, with the burner open, proceed to the adjustment of the combustion head. Provide an adequate lifting system. ... -
Page 18: Combustion Head Adjustment
WARNING Example: The GAS 3 burner is installed in a 240 kW boiler. Considering an efficiency of 89%, the burner should deliver about 270 kW. The diagram (Fig. 13) shows that the gas and air adjustments for this burner output are carried out on notch 4.5. -
Page 19: Gas Feeding
Installation Gas feeding Explosion danger due to fuel leaks in the pres- MBC “threaded” ence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure that the fuel interception tap is closed before performing any operation on the burner. The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws. -
Page 20: Gas Train
Installation 5.8.2 Gas train 5.8.4 Gas pressure Approved according to standard EN 676 and provided separately Tab. F indicates the pressure drops of the combustion head and from the burner. gas butterfly valve, on the basis of the burner operating output. 1 p (mbar) To select the correct gas train model, refer to the supplied "Burn- Model... - Page 21 Find in Tab. F related to the burner concerned, the pressure value closest to the result of the subtraction. Fig. 18 Read the corresponding output on the left. Example GAS 3 with natural gas G20: Pressure of the gas at the socket = 10.3 mbar Pressure in combustion chamber 2 mbar 10.3 - 2...
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Page 22: Electrical Wiring
Installation Electrical wiring Notes on safety for the electrical wiring The electrical wiring must be carried out with the electrical supply disconnected. Electrical wiring must be made in accordance with the regulations currently in force in the country of destination and by qualified personnel. -
Page 23: Calibration Of The Thermal Relay (Only 3Ph Versions)
Installation The fairleads and hole press-outs can be in various ways; by way of example we indicate the following mode: D995 Fig. 19 GAS 3 and GAS 4 CABLE SECTIONS Pg 13,5 Single-phase power supply GAS 5 GAS 6 Pg 13,5... -
Page 24: Start-Up, Calibration And Operation Of The Burner
Start-up, calibration and operation of the burner Start-up, calibration and operation of the burner Notes on safety for the first start-up The first start-up of the burner must be carried out Check the correct working of the adjustment, com- by qualified personnel, as indicated in this manual mand and safety devices. -
Page 25: Burner Adjustment
Start-up, calibration and operation of the burner Burner adjustment 6.5.2 Maximum burner output The optimum adjustment of the burner requires an analysis of flue gases at the boiler outlet. MAX gas adjustment Adjust in sequence: Ignition output Measure the gas flow rate. Maximum burner output -If you need to reduce it, close the 2nd stage gas valve a little. -
Page 26: Pressure Switch Adjustment
Start-up, calibration and operation of the burner Pressure switch adjustment 6.6.1 Air pressure switch 6.6.2 Minimum gas pressure switch Adjust the air pressure switch after performing all other burner Adjust the minimum gas pressure switch after performing all the adjustments with the air pressure switch set to the start of the other burner adjustments with the pressure switch set to the start scale (Fig. -
Page 27: Burner Operation
Start-up, calibration and operation of the burner Burner operation 6.7.1 Burner start-up 6.7.3 Ignition failure (with gas train in compliance with EN 676) If the burner does not fire, it goes into lockout within 3s from the opening of the gas valve and 43 s from the closure of the TL re- •... -
Page 28: Burner Start-Up Cycle Diagnostics
Start-up, calibration and operation of the burner Burner start-up cycle diagnostics 6.8.1 Resetting of control box and diagnostics use During start-up, indication is according to the colour code table (Tab. H). The control box features a diagnostics function through which any causes of malfunctioning are easily identified (indicator: RED Sequences Colour code... -
Page 29: Maintenance
Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, Before carrying out any maintenance, cleaning or checking oper- safety, yield and duration of the burner. ations: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time. -
Page 30: Combustion Control (Gas)
Maintenance Combustion 7.2.5 Safety components The optimum calibration of the burner requires an analysis of the The safety components should be replaced at the end of their life flue gases. cycle indicated in the following table. Significant differences with respect to the previous measure- The specified life cycles do not refer to the warranty terms indi- ments indicate the points where more care should be exercised cated in the delivery or payment conditions. -
Page 31: Opening The Burner
Maintenance Opening the burner Disconnect the electrical supply from the burner by means of the main system switch. DANGER D202 Close the fuel interception tap. DANGER Wait for the components in contact with heat sources to cool down completely. Remove the screws 1) fixing the fan 3) to the pipe coupling 4); ... -
Page 32: Faults - Possible Causes - Solutions
Faults - Possible causes - Solutions Faults - Possible causes - Solutions In the event the burner stops, in order to prevent In the event there are further lockouts or faults any damage to the installation, do not unblock the with the burner, the maintenance interventions burner more than twice in a row. - Page 33 Faults - Possible causes - Solutions Signal Problem Possible cause Recommended remedy 10 blinks The burner does not Incorrect electrical wiring Check switch on, and the lock- out appears The burner goes into Defective control box Replace lockout Presence of electromagnetic disturbances in the Filter or eliminate thermostat lines Presence of electromagnetic disturbance...
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Page 34: A Appendix - Accessories
Extended head kit L = standard head L1 = extended head obtainable with the kit COD. 3000605 L = 185 L1 = 320 mm • GAS 3 COD. 3000606 L = 187 L1 = 320 mm • GAS 4 COD. 3000607... - Page 35 Continuous purging kit It is composed of a small three-way solenoid valve to be installed COD. 3010030 • GAS 3-4-5-6 between the air pressure switch and the fan. It allows the burner, which has remained in continual purging following a flame cut- out, to fire again.
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Page 36: B Appendix - Electrical Panel Layout
Electrical system carried out by the factory burner GAS 5 - 6 THREE-PHASE (DIAGRAM A) Electrical system external connections without valve leak control burners GAS 3 - 4 SINGLE-PHASE (DIAGRAM B) Electrical system external connections with valve leak control burners GAS 5 - 6 THREE-PHASE (DIAGRAM B) - Page 37 Appendix - Electrical panel layout 20144819...
- Page 38 Appendix - Electrical panel layout 20144819...
- Page 39 Appendix - Electrical panel layout 20144819...
- Page 40 Appendix - Electrical panel layout 20144819...
- Page 41 Appendix - Electrical panel layout 20144819...
- Page 42 Appendix - Electrical panel layout 20144819...
- Page 43 Appendix - Electrical panel layout WIRING DIAGRAM KEY DIAGRAM (A) DIAGRAM (B) Electric connection without gas valves leak detection con- Capacitor trol device Motor contactor Filter to protect against radio disturbance Electrical connection with gas valves leak detection control device Relay Burner manual stop switch Control box...
- Page 44 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...