Riello RS 160/M BLU Instruction Manual
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Riello RS 160/M BLU Instruction Manual

Forced draught gas burners
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Progressive two-stage or modulating operation
CODE
20168492
20169219
MODEL
RS 160/M BLU
RS 160/M BLU
TYPE
843 T
843 T
20168488 (2) - 07/2020

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  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 20168492 RS 160/M BLU 843 T 20169219 RS 160/M BLU 843 T 20168488 (2) - 07/2020...
  • Page 2 Translation of the original instructions...

  • Page 3: Table Of Contents

    Contents Declarations....................................3 Information and general warnings............................5 Information about the instruction manual ........................5 2.1.1 Introduction.................................. 5 2.1.2 General dangers................................5 2.1.3 Other symbols ................................5 2.1.4 Delivery of the system and the instruction manual...................... 6 Guarantee and responsibility............................6 Safety and prevention................................
  • Page 4 Contents 6.5.4 Minimum output .................................28 6.5.5 Intermediate outputs ..............................29 Final adjustment of the pressure switches .........................30 6.6.1 Air pressure switch..............................30 6.6.2 Maximum gas pressure switch...........................30 6.6.3 Minimum gas pressure switch............................30 Burner operation ................................31 6.7.1 Burner start-up ................................31 6.7.2 Steady state operation ...............................31 6.7.3 Ignition failure................................31 6.7.4...

  • Page 5: Declarations

    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. BImSchV revision 26.01.2010”. Product...
  • Page 6 Ridlerstrase, 65 80339 München DEUTSCHLAND Values measured: Max. CO: 5 mg/kWh Max. NOx: 61 mg/kWh 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 20168488...

  • Page 7: Information And General Warnings

    Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction DANGER: EXPLOSION The instruction manual supplied with the burner: This symbol signals places where an explosive  is an integral and essential part of the product and must not atmosphere may be present.

  • Page 8: 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 9: Safety And Prevention

    Safety and prevention Safety and prevention Introduction 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 safety rules and envisaging all the potential danger situations.

  • Page 10: Technical Description Of The Burner

    Technical description of the burner Technical description of the burner Burner designation Series: Fuel: Natural gas Light oil Light oil / Methane Heavy oil Size Adjustment: Electronic cam Electronic cam and variable speed (with Inverter) Mechanical cam Proportional air/gas valve Emission: C01 or ...

  • Page 11: Models Available

    Technical description of the burner Models available Designation Power supply voltage Start-up Code RS 160/M BLU 3 ~ 400V - 50Hz Diretto 20168492 RS 160/M BLU 3 ~ 400V - 50Hz Diretto 20169219 Tab. B Technical data Model RS 160/M BLU...

  • Page 12: Maximum Dimensions

    Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the slide bars. D1702 Fig. 1 RS 160/M BLU 373-503 1442-1587 Tab. E (1) Blast tube: short-long Firing rates The maximum output is to be chosen within area A of the diagram (Fig.

  • Page 13: Test Boiler

    Technical description of the burner Test boiler The firing rates were obtained in special test boilers, according to Although combination is guaranteed when boiler has a CE type- EN 676 regulations. approval, preliminary tests are recommended for boilers or furnaces having a combustion chamber size much different than In Fig.

  • Page 14: Burner Description

    Technical description of the burner 4.10 Burner description 20169167 15 12 Fig. 4 Combustion head Ignition electrode Screw for combustion head adjustment Maximum gas pressure switch Pipe coupling with flange for boiler fixing Servomotor controlling the gas butterfly valve and the air damper, by means of a variable profile cam mechanism.

  • Page 15: Electrical Panel Description

    Technical description of the burner 4.11 Electrical panel description 20158313 Fig. 5 Plug-socket on ionisation probe cable Motor contactor and thermal relay with reset button A switch for: automatic-manual-off operation A button for: output increase - decrease Terminal board Cable grommets for electrical wiring (to be carried out by the installer) Minimum air pressure switch (differential type) Ignition transformer...

  • Page 16: 4.12 Control Box Rfgo-A22

    Technical description of the burner 4.12 Control box RFGO-A22 Important notes To avoid accidents, material or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening ATTENTION or modifying it, or forcing its operation. The Manufacturer cannot assume any responsibility for damage resulting from unauthorised work! ...

  • Page 17: Servomotor (Sqn31

    Technical description of the burner 4.13 Servomotor (SQN31...) Important notes To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying forcing ATTENTION actuators.  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ...

  • Page 18: 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 19: Operating Position

    The boiler front door maximum thickness A)(Fig. 10), complete with refractory, must not exceed: Blast tube A (mm) RS 160/M BLU D1079 Tab. H ) A kit for reducing CO is available for boilers with flame Fig. 10 inversion chambers, if necessary See Accessories.

  • Page 20: Blast Tube Length

    For boilers with a water-cooled front piece, a refractory lining 11)- Blast tube Short (mm) Long (mm) 12)(Fig. 14) is not necessary, unless expressly requested by the RS 160/M BLU boiler manufacturer. Tab. J Positioning the probe - electrode Before securing the burner to the boiler, check...

  • Page 21: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler  disconnect the probe and electrode cables, then completely unthread the burner from the slide bars. Provide an adequate lifting system of the burner. As soon as this operation is completed (if necessary): ...

  • Page 22: Closing The Burner

     Loosen the 3 screws 1)(Fig. 16) and rotate the ring nut 2) Continuing the example above, you understand that for until the notch you have found corresponds with the RS 160/M BLU burner having a power of 1500 kW, pressure must indicator 3). be 5.0 at outlet 6)(Fig. 16).

  • Page 23: Gas Supply

    Installation 5.10 Gas supply Explosion danger due to fuel leaks in the MBC “threaded” presence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure the fuel shut-off valve 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 24: 5.10.2 Gas Train

    Installation 5.10.2 Gas train Type-approved in accordance with EN 676 and supplied separately from the burner. To select the correct gas train model, refer to the manual "Burner- gas train combination" supplied with the unit. 5.10.3 Gas train installation Disconnect the power supply using the system main switch.
  • Page 25 Installation To calculate the approximate output at which the burner operates: – subtract the combustion chamber pressure from the gas pressure measured at test point 1)(Fig. 23). – Find in Tab. K related to the burner concerned, the pressure value closest to the result of the subtraction. –...

  • Page 26: Electrical Connections

    Installation 5.11 Electrical connections 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 27: Calibration Of The Thermal Relay

    Installation 5.12 Calibration of the thermal relay The thermal relay (Fig. 25) serves to avoid damage to the motor due to an excessive absorption increase or if a phase is missing. For calibration 2), refer to the table indicated in the electrical layout (electrical wiring by the installer).

  • Page 28: 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, by qualified personnel, as indicated in this manual command and safety devices.

  • Page 29: Servomotor Adjustment

    Start-up, calibration and operation of the burner Servomotor adjustment The servomotor provides simultaneous adjustment of the air damper, by means of the variable profile cam and the gas butterfly valve. The servomotor rotates by 130° in 42 s. Do not alter the factory setting for the 5 cams; just check that they are as specified below: ATTENTION 130°.

  • Page 30: Maximum Output

    Start-up, calibration and operation of the burner In order to measure the ignition output: Key (Fig. 30) disconnect the plug-socket 1)(Fig. 5 on page 13) on the Servomotor  Servomotor 1) - cam 4): fastened ionisation probe cable (the burner will ignite and then go Servomotor 1) - cam 4): unfastened into lockout after the safety time has elapsed);...

  • Page 31: Intermediate Outputs

    Start-up, calibration and operation of the burner 6.5.5 Intermediate outputs Adjustment of gas delivery No adjustment is required Air adjustment After adjusting the maximum and minimum output of the burner, carry out air adjustment on higher intermediate positions of the servomotor.

  • Page 32: Final Adjustment Of The Pressure Switches

    Start-up, calibration and operation of the burner Final adjustment of the pressure switches 6.6.1 Air pressure switch 6.6.2 Maximum gas pressure switch Adjust the air pressure switch (Fig. 32) after performing all other Adjust the maximum gas pressure switch (Fig. 33) after burner adjustments with the air pressure switch set to the start of performing all other burner adjustments with the maximum gas the scale.

  • Page 33: Burner Operation

    Start-up, calibration and operation of the burner Burner operation 6.7.1 Burner start-up • The burner locks out when the heat request is less than the heat supplied by the burner at MIN output, (section G-H). • Control remote control TL closes. The TL remote control opens, and the servomotor returns to Fan motor start-up.

  • Page 34: 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 safety, yield and duration of the burner. operations: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.

  • Page 35: Safety Components

    Maintenance Flame inspection window Combustion Clean the glass of the flame inspection window (Fig. 37). Carry out an analysis of the combustion flue gases. Significant differences with respect previous measurements indicate the points where most care should be exercised during maintenance. If the combustion values measured before starting maintenance do not comply with applicable Standards or do not indicate efficient combustion, consult the table below or contact our...

  • Page 36: Opening The Burner

    Maintenance Opening the burner  Loosen the 4 screws 1)(Fig. 39) and remove the hood 2).  Disengage the articulated coupling 7) from the graduated Disconnect the electrical supply from the burner sector 8). by means of the system main switch. ...

  • Page 37: Led Indicator And Special Function

    LED indicator and special function LED indicator and special function Description of LED lamps It turns on when the fan motor is powered (T6) and blinks when RUN/CHECK switch is set to “CHECK” during damper movement phases, PTFI AND MTFI. S9740 It blinks when the air damper is moving towards the maximum opening position until the Damper...

  • Page 38: Led Lamps: Burner Operating Status

    LED indicator and special function LED lamps: burner operating status OPERATING STATUSES INDICATED BY LEDS DURING NORMAL OPERATION AND CHECK MODE Operation Damper Damper Modulation Ignition Flame Status LED ● = ON open closed Icon S9740 S9741 S9742 S9743 S9744 S9745 S9746 Power OFF/ON...

  • Page 39: Problems - Causes - Remedies Signalled By Led Indicators

    Problems - Causes - Remedies signalled by LED indicators Problems - Causes - Remedies signalled by LED indicators When an emergency stop occurs, the control device LEDs Thermal unit’s operation, maintenance and indicate the cause of the stop. troubleshooting interventions must be carried out The terminal T3 is not powered.
  • Page 40 Problems - Causes - Remedies signalled by LED indicators Error / RFGO LED lock-out codes Faults LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Operation Open Closed Auto Ignition Flame Status LED ● = ON damper damper Icon...
  • Page 41 Problems - Causes - Remedies signalled by LED indicators Faults LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 UV: Internal fault ● ● Supervisor processor fault ● ● ● Main processor fault ● ● ●...
  • Page 42 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution UV: no flame at the end of the Inspect the system, check the gas pressure, check the flame sensor, check the wiring, No flame at the end of the 2 safety time safety time (MTFI) etc.
  • Page 43 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution UV: false flame during operation False flame detected before ignition Check the flame sensor FR: false flame during operation Check the wiring False flame detected before ignition Check the flame sensor Make sure that earthing is appropriate T8 inlet fault The system detected the presence of...

  • Page 44: A Appendix - Accessories

    20099657 0 ÷ 16 bar 4 ÷ 20 mA 3010214 Extended head kit Extended head Burner Standard head length (mm) Code length (mm) RS 160/M BLU 3010442 Soundproofing box kit Burner Type dB(A) Code RS 160/M BLU C4/5 3010404 Spacer kit...

  • Page 45: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Functional layout RFGO-A22 Functional layout RFGO-A22 Electrical wiring that is the responsibility of the installer Functional layout RWF50 Indication of references / 1 . A 1 Sheet no.
  • Page 46 Appendix - Electrical panel layout 20168488...
  • Page 47 Appendix - Electrical panel layout 20168488...
  • Page 48 Appendix - Electrical panel layout 20168488...
  • Page 49 Appendix - Electrical panel layout 20168488...
  • Page 50 Appendix - Electrical panel layout Wiring layout key Electrical control box Filter to protect against radio disturbance RWF50 output power regulator Current input DC 4...20mA Current input DC 4...20mA for remote setpoint change Pressure probe Pressure probe Remote setpoint potentiometer Thermocouple probe Probe Pt100, 2 wires Probe Pt100, 3 wires...
  • Page 52 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...

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