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Related Manuals for Riello RS 410/EV FGR
Summary of Contents for Riello RS 410/EV FGR
- Page 1 Installation, use and maintenance instructions Forced draught gas burners Modulating operation CODE MODEL TYPE 20162652 RS 410/EV FGR S029T2 20162653 RS 510/EV FGR S030T2 20162655 RS 610/EV FGR S031T2 20162733 (2) - 08/2021...
- 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 Burner start-up ................................31 FGR commissioning..............................32 Air / fuel adjustment ..............................33 6.5.1 Air adjustment for maximum output ...........................33 6.5.2 Air/fuel adjustment and output modulation system ....................33 6.5.3 Burner adjustment..............................33 6.5.4 Output upon ignition ..............................33 6.5.5 Maximum output ................................33 6.5.6 Minimum output .................................33 Final adjustment of the pressure switches .........................34 6.6.1 Air pressure switch..............................34...
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Page 5: Declarations
Such products are marked as follows: CE- 0123CU1034 (Class 4 prEN 676:2016) 0085 The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015. Legnago, 03.05.2021 Research & Development Director RIELLO S.p.A. - Burner Department Mr. F. Maltempi 20162733... -
Page 6: 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 at- is an integral and essential part of the product and must not mosphere may be present. -
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 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 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 Burner designation Range: Fuel: Natural gas Gas oil Gas oil / Methane Heavy oil Size Adjustment: Two stage (light oil) / Proportional valve (gas) Electronic cam Electronic cam with variable speed (with Inverter) Proportional air/gas valve Mechanical cam C01 - ... -
Page 10: Models Available
“Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in EN ISO 3746. In order to reduce the nitrogen oxides NOx in case of FGR system, the maximum burner capacity ob- tained, changes within the limits agreed with the Riello Technical Dept. for the specific application. WARNING 20162733... -
Page 11: Electrical Data
Technical description of the burner Electrical data Model RS 510/EV FGR RS 510/EV FGR RS 610/EV FGR Main electrical supply 3N ~ 400V +/-10% 50 Hz 2930 2920 2920 230/400 400/690 400/690 Fan motor IE3 28.6 - 16.5 21 - 12.2 27 - 15.6 V1 - V2 230 V - 1 x 8 kV... -
Page 12: Maximum Dimensions
Technical description of the burner Maximum dimensions The maximum dimensions of the burner are given in Fig. 1. Bear in mind that inspection of the combustion head requires the * The gas adaptor is set also for DN 80 bore. burner to be opened and the rear part turned on the hinge. -
Page 13: Firing Rates
The MAXIMUM OUTPUT is chosen from within the diagram area (Fig. 2). Pre-calibration of the combustion head only for The MINIMUM OUTPUT must not be lower than the minimum the burner model RS 410/EV FGR: limit of the diagram: If the maximum burner output of the burner falls WARNING... -
Page 14: Test Boiler
Stud bolts M16X60 to fix the gas elbow to the pipe coupling . .No. 1 Internal shutter (RS 410/EV FGR) ....No. 1 Instructions . -
Page 15: Burner Description
Technical description of the burner 4.10 Burner description ASSEMBLY VIEW 20165354 Fig. 4 Lifting rings 28 UV sensor 29 Servomotor for flue gas Fan motor 30 Air cooling intake Air damper servomotor 31 Rpm sensor Combustion head gas pressure test point Combustion head The burner can be opened to the right or to the left Ignition electrode... -
Page 16: Electrical Panel Description
Technical description of the burner 4.11 Electrical panel description 20165363 Fig. 5 Earth terminal Supply cables and external connections passage Main terminal supply board Auxiliary circuits fuse (includes a spare fuse) Air pressure switch Ignition transformer Free contact relay Electronic cam “0/AUTO”... -
Page 17: Control Box For The Air/Fuel Ratio (Lmv51
To avoid accidents, material or environmental damage, observe the following instructions! The LMV51... is a safety device! Avoid opening or WARNING modifying it, or forcing its operation. Riello S.p.A. cannot assume any responsibility for damage re- sulting from unauthorised interventions! Risk of explosion! - Page 18 Technical description of the burner Electrical connection of flame detector 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 signal. –...
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Page 19: 4.13 Servomotor
Technical description of the burner 4.13 Servomotor Warnings To avoid accidents, material or environmen- tal damage, observe the following instruc- tions! WARNING Avoid opening, modifying or forcing the ac- tuators. All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ... -
Page 20: 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 21: Operating Position
For boilers with front flue passes 1)(Fig. 11) or flame inversion chamber, a protection in refractory material 5) must be inserted between the boiler fettling 2) and the blast tube 4). RS 410/EV FGR The refractory can have a conical shape (minimum 60°). RS 510/EV FGR... -
Page 22: Access To Head Internal Part
Installation Access to head internal part The burner leaves the factory set for opening to the left, therefore maintaining the pin 1)(Fig. 12) in the housing. To open the burner towards the left, proceed as follows: A disconnect the plug/socket 9)(Fig. 12) of the maximum gas pressure switch;... -
Page 23: Probe-Electrode Position
Check that the probe and the electrode are placed as in Fig. 13, according to the dimensions indicat- WARNING RS 510-610/EV FGR 20164331 RS 410/EV FGR Fig. 13 Gas butterfly valve If necessary, replace the gas butterfly valve. The correct position is shown in Fig. 14. -
Page 24: Combustion Head Adjustment
Fig. 16 Max burner output (kW) The combustion head can be adjusted within the following ranges: RS 410/EV FGR: 5 - 14; WARNING RS 510/EV FGR: 4 - 16; RS 610/EV FGR: 0 - 4. The adjustment cannot be carried out outside these ranges. -
Page 25: Fgr Duct System
Installation 5.11 FGR duct system – Normally the duct would connect to the stack as shown in There must be sufficient condensate drip legs and catch Fig. 17, with a 45° cut facing the flue gas flow and with the space (volume of drip legs) to prevent the condensation from centre of the cut centred in the stack. -
Page 26: 5.11.1 Flue Gas Recirculation Line Sizing
Installation 5.11.1 Flue gas recirculation line sizing Maximum allowed pipe length (considering smooth steel pipes) is specified for every burner and pipe diameter. The Tab. J can be helpful to correctly size the FGR pipes taking To prepare the Tab. J a flue gas maximum temperature of 260°C flue gases from boiler stack base up to the burner intake port. -
Page 27: Gas Pressures
Installation 5.12 Gas pressures 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 the fuel interception tap is closed be- fore performing any operation on the burner. The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws. -
Page 28: 5.12.2 Gas Train
Installation 5.12.2 Gas train Approved according to standard EN 676 and provided separately Make sure that the gas train is properly installed from the burner. by checking for any fuel leaks. 5.12.3 Gas train installation The operator must use the required equipment during installation. -
Page 29: 5.12.4 Gas Pressure
Add this value to the estimated pressure in the combustion 5301 chamber. 5850 Example for RS 410/EV FGR with G20 natural gas: Tab. L Required burner maximum output operation: 2745 kW Gas pressure at an output of 2745 kW = 20.0 mbar... -
Page 30: Electrical Wiring
Installation 5.13 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 31: Supply Cables And External Connections Passage
Installation 5.13.1 Supply cables and external connections 20165369 passage All the cables to be connected to the burner must be threaded through cable grommets. The use of the cable grommets can take various forms; by way of example see Fig. 23. Key (Fig. -
Page 32: 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 33: Burner Start-Up
Start-up, calibration and operation of the burner Burner start-up Feed electricity to the burner via the disconnecting switch on the boiler panel. Close the thermostats/pressure switches. Turn the switch to position “AUTO” (Fig. 25). Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present. -
Page 34: Fgr Commissioning
Start-up, calibration and operation of the burner FGR commissioning The flue gas recirculation (FGR) function is used to reduce the First time FGR set up NOx content of flue gases. This is accomplished by feeding a cer- Modify the factory preset: FGR-Mode = time (Auxiliary actuator 3 tain proportion of the flue gas back to the combustion chamber, is held in the ignition position until an adjustable time is reached). -
Page 35: Air / Fuel Adjustment
Start-up, calibration and operation of the burner Air / fuel adjustment 6.5.4 Output upon ignition Air/fuel synchronisation is carried out with the relevant air and gas servomotors by logging a calibration curve by using the elec- Ignition must occur at a lower output than the max. operation out- tronic cam. -
Page 36: 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 Adjust the air pressure switch (Fig. 26) after performing all other burner adjustments with the air pressure switch set to the start of the scale. -
Page 37: 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 38: Safety Components
Maintenance Gas filter 7.2.4 Safety components Change the gas filter when it is dirty. The safety components should be replaced at the end of their life cycle indicated in the following table. Combustion The specified life cycles do not refer to the warranty terms indi- If the combustion values measured before starting maintenance cated in the delivery or payment conditions. -
Page 39: Voltage On The Qri Sensor
Maintenance 7.2.5 Voltage on the QRI sensor 7.2.7 Checking the air and gas pressure on the combustion head Minimum value for correct operation: 3.5V DC (value on AZL dis- play at about 50%). To carry out this operation it is necessary to use a pressure gauge to measure the air and gas pressure at the combustion head, as If the value is lower, it could be due to: shown in Fig. -
Page 40: Opening The Burner
Maintenance Opening the burner Disconnect the electrical supply from the burner by means of the main system switch. DANGER Turn off the fuel interception tap. DANGER Wait for the components in contact with heat sources to cool down completely. To open the burner, use the same procedure set out in “Access to head internal part”... -
Page 41: Faults - Probable Causes - Solutions
Faults - Probable causes - Solutions Faults - Probable causes - Solutions If faults arise in ignition or operations, the burner performs a In the event of a burner lockout, more than two “safety stop”, which is signalled by the red burner lockout LED. consecutive burner reset operations could cause The display visualises alternately the lockout code and the rela- damage to the installation. -
Page 42: A Appendix - Accessories
Inverterkit (VSD) Line Motor Output Inverter Output Burner Code voltage (kW) (kW) RS 410/EV FGR 400V 20163093 RS 510/EV FGR 400V 20163096 RS 610/EV FGR 400V 20163096 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 people and damage to property. -
Page 43: B Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Single-wire output layout Functional layout Functional layout LMV 51... Functional layout LMV 51... Functional layout LMV 51... Functional layout LMV 51... Functional layout LMV 51... Functional layout LMV 51... - Page 44 Appendix - Electrical panel layout 20162733...
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- Page 56 Appendix - Electrical panel layout Wiring layout key Control box Display for control box Probe with output under current Device with output undercurrent, for modifying remote set-point Load indicator with input under current Device with output under current for remote modulation Pressure probe Pressure probe Probe Pt1000, 2 wires...
- Page 60 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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