Riello GI/EMME 1400 Installation, Use And Maintenance Instructions

Dual fuel light oil/ gas burners

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Manual (80 pages)

Installation, use and maintenance instructions (49 pages)

Installation, use and maintenance manual (44 pages)

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Installation, use and maintenance instructions

Dual fuel light oil/ gas burners

Two stage progressive or modulating operation

CODE

20163249

20163312

20163313

20163264

20160903

20162382

20162388

20162385

20162391

20160912

MODEL

GI/EMME 1400

GI/EMME 2000

GI/EMME 3000

GI/EMME 4500

TYPE

680T1

681T1

682T1

683T1

20160907 (3) - 09/2021

Table of Contents

Summary of Contents for Riello GI/EMME 1400

Page 1 Installation, use and maintenance instructions Dual fuel light oil/ gas burners Two stage progressive or modulating operation CODE MODEL TYPE 20163249 GI/EMME 1400 680T1 20163312 GI/EMME 2000 681T1 20163313 GI/EMME 2000 681T1 20163264 GI/EMME 2000 681T1 20160903 GI/EMME 3000 682T1...
Page 2 Translation of the original instructions...
Page 3: Table Of Contents
Contents Declarations....................................3 Information and general warnings............................4 Information about the instruction manual ........................4 Guarantee and responsibility............................5 Safety and prevention................................6 Introduction.................................. 6 Personnel training ............................... 6 Technical description of the burner ............................7 Burner designation ..............................7 Models available................................
Page 4 Contents Combustion air adjustment ............................31 Ignition output of the burner ............................32 6.10 Air / fuel adjustment ..............................32 6.11 Pressure switch adjustment ............................34 6.12 Burner operation ................................36 6.13 Final checks (with burner operating) ..........................37 Maintenance ....................................38 Notes on safety for the maintenance .........................38 Maintenance programme ............................38 Opening the burner ..............................41 Closing the burner..............................41...
Page 5: Declarations
Class 1 (EN 267) - Class 1 (EN 676) 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 20160907...
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: Guarantee And Responsibility
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 safety rules and envisaging all the potential danger situations.
Page 9: Technical Description Of The Burner
230V / 50Hz 110/50/60 110V / 50-60Hz GI/EMME 2000 3/400/50 230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code  GI/EMME 1400 230/400/50 Direct 20163249  GI/EMME 2000 230/400/50 Direct 20163312  GI/EMME 2000 230/400/50 Direct 20163313 ...
Page 10: Burner Categories - Countries Of Destination
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO 2ELL (43.46 ÷ 45.3 MJ/m (0°C)) 2E(R)B LU - PL Tab. B Technical data Model GI/EMME 1400 GI/EMME 2000 GI/EMME 3000 GI/EMME 4500 Type 680 T1 681 T1 682 T1 683 T1...
Page 11: Electrical Data
L2* Short head blast tube length burner to be opened and the rear part drawn back (see "Lifting L2** Long head blast tube length points” on page 17). D1373 Fig. 1 L2** MODEL GI/EMME 1400 1090 GI/EMME 2000 1090 GI/EMME 3000 1320 GI/EMME 4500 1320 Tab.
Page 12: Firing Rates
1013 mbar (approx. 0 m limit of the diagram: a.s.l.), and with the combustion head adjusted as ATTENTION GI/EMME 1400 = 407 kW shown on page 19. GI/EMME 2000 = 581 kW GI/EMME 3000 = 872 kW...
Page 13: Burner Description
Technical description of the burner Burner description 20161915 Fig. 4 Output modulator (for modulating version only) 20161981 Air pressure switch Gas butterfly valve control rod Control box reset button with lockout signal Head drive rod Servomotor Air adjustment cam Maximum gas pressure switch Pipe coupling gas pressure test point 10 Gas regulator 11 Pressure adjustment eccentric on return line...
Page 14: Electrical Panel Description
Burner equipment Flange (for GI/EMME 1400) ......No. 1 Seal for gas train ....... . No. 1 Screws (for GI/EMME 1400) .
Page 15: 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 16: 4.13 Servomotor Sqm40
Technical description of the burner 4.13 Servomotor SQM40 ... Important notes To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying forcing ATTENTION servomotor.  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ...
Page 17: 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 18: Operating Position
The position of the threaded holes can be marked using the case it must be greater than the thickness of the boiler door thermal insulation screen supplied with the burner. complete with its fettling. D1366 Model Code GI/EMME 1400 20163249 GI/EMME 2000 20163312 20163313 20163264 GI/EMME 3000...
Page 19: Lifting Points
Fig. 12 shows how to apply the burner to a boiler with a headpiece that is not cooled. The refractory wall must not extend beyond the end of the combustion head of the burner. GI/EMME 1400 GI/EMME 2000 GI/EMME 3000 M A X - M I N GI/EMME 4500 Tab.
Page 20: Nozzle Installation
Fluidics: 70 - 80 - 90 - 100 - 115 - 130 - 145 - 160 - 180 - 200 recommended and/or alternative nozzles specified by Riello in - 225 - 250 - 275 - 300 - 330 - 360 - 400 - 450 the Instruction and warning booklet should be used.
Page 21: Combustion Head Adjustment
Installation 5.10 Combustion head adjustment The combustion head moves together with the eccentric 8), the If a more consistent reduction is needed, act as follows: variable profile cams and the gas butterfly valve. The head  with servomotor at 0°, loosen the screws 5) and push, in the positioning can be seen on cylinder 2) (Fig.
Page 22: Light Oil Supply
Installation 5.11 Light oil supply When the tank is at a level lower than the burner, the return line Explosion danger due to fuel leaks in the should terminate at the same level as the suction line. presence of a flammable source. In this case a non-return valve is not required.
Page 23: Hydraulic Operation Diagram
It triggers the lockout condition of the burner in case of too much counter-pressure on the fuel return line. Recommended calibration (recommended values with return line resistance in tank of 0.5 bar): GI/EMME 1400: 1.5 ÷ 2.0 bar GI/EMME 2000: 2.0 ÷ 2.5 bar GI/EMME 3000: 3.0 ÷...
Page 24: Pump
Installation 5.14 Pump 5.14.1 Technical data G/M 1400 G/M 2000 G/M 3000 G/M 4500 Pump TA2C TA3C TA4C TA5C Min. delivery rate at 40 bar pressure kg/h 1000 Delivery pressure range 7 - 40 7 - 40 7 - 40 7 - 40 Max.
Page 25: Gas Supply
Installation 5.15 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 26 Installation 5.15.2 Gas train 5.15.4 Gas pressure Type-approved in accordance with EN 676 and supplied Tab. L indicates the pressure drops of the combustion head and separately from the burner. gas butterfly valve depending on the burner operating output. 1 p (mbar) 5.15.3 Gas train installation G 20 G 25...
Page 27 Installation The values shown in Tab. L refer to: 20167883 – Natural gas G 20 NCV 9.45 kWh/Sm (8.2 Mcal/Sm – Natural gas G 25 NCV 8.13 kWh/Sm (7.0 Mcal/Sm Column 1 Combustion head pressure drop. Gas pressure measured at test point 2)(Fig. 27), with: •...
Page 28: Electrical Connections
Installation 5.16 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 29: Calibration Of The Thermal Relay
Installation 5.17 Calibration of the thermal relay The thermal relay (Fig. 29) serves to avoid damage to the motor due to an excessive absorption increase or if a phase is missing. D8685 For calibration 2), refer to the table indicated in the electrical layout (electrical wiring by the installer).
Page 30: 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 31: Adjustments Prior To Ignition (Gas)
Start-up, calibration and operation of the burner Adjustments prior to ignition (gas) In addition, the following adjustments must also be made: Before starting up the burner, it is good practice to  slowly open the manual valves situated upstream of the gas adjust the gas train so that ignition takes place in train.
Page 32: Servomotor Adjustment
Start-up, calibration and operation of the burner Servomotor adjustment The servomotor adjusts simultaneously, through driving gears, the output and pressure of the air and the delivery of the fuel in use. It performs a 130° rotation in 45s. After the adjustment made in the factory to its 6 cams to allow an initial ignition.
Page 33: Combustion Air Adjustment
Start-up, calibration and operation of the burner Combustion air adjustment The fuel/combustion synchronization is made by means of a The values indicated in Tab. M and Tab. N can be a reference for servomotor connected to two variable profile cams, which act on a good combustion calibration.
Page 34: Ignition Output Of The Burner
Start-up, calibration and operation of the burner Ignition output of the burner According to EN 676 standard This quantity must be equal to or lower than the quantity given by the formula: Burners with MAX output above 120 kW. Ignition must occur at a lower output than the max. operation /h (max.
Page 35 Start-up, calibration and operation of the burner 6.10.2 Burner calibration procedure  Install the nozzle suitable to achieve the maximum desired output.  Verify that the eccentricity of the oil cam is such to make a travel of about 8 mm on the shaft of oil modulator. Normally, with a shaft stroke of 8 mm, the pressure variation needed for the modulation of the minimum to maximum output is obtained.
Page 36: Pressure Switch Adjustment
Start-up, calibration and operation of the burner 6.11 Pressure switch adjustment 6.11.1 Air pressure switch The air pressure switch is set after all other adjustments have been made. Begin with the switch at the start of the scale. With the burner operating, increase adjustment pressure by slowly turning the relevant knob clockwise until the burner stops.
Page 37 Start-up, calibration and operation of the burner 6.11.4 Minimum oil pressure switch The minimum oil pressure switch is calibrated in the factory at 16- 18 bar. If the oil pressure falls below this value in the delivery line, the pressure switch stops the burner. The burner restarts automatically if the pressure goes above bar value set after the burner starts.
Page 38: Burner Operation
Start-up, calibration and operation of the burner 6.12 Burner operation 6.12.1 Burner start-up Burner flame goes out during operation If the flame should accidentally go out during operation, the (gas trains in compliance with EN 676) burner will lock out within 1s. : Control remote control TL closes.
Page 39: Final Checks (With Burner Operating)
Start-up, calibration and operation of the burner 6.13 Final checks (with burner operating)   Open the thermostat/pressure switch TL The burner must stop  Open the thermostat/pressure switch TS  Turn the knob of the gas maximum pressure switch to the ...
Page 40: 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 41 Maintenance Burner 7.2.4 Safety components Check that there is no excess wear or loosen screws, especially The safety components should be replaced at the end of their life on cams 3)(Fig. 32 on page 30). cycle indicated in the following table. Clean the outside of the burner.
Page 42 Maintenance LIGHT OIL OPERATION GAS OPERATION Pump Gas leaks The delivery pressure must comply with the graph on page 18. Make sure that there are no gas leaks on the pipe between the The depression must be less than 0.45 bar. gas meter and the burner.
Page 43: Opening The Burner
Maintenance Opening the burner Disconnect the electrical supply from the burner by means of the system main switch. DANGER D1375 Close the fuel shut-off valve. DANGER Wait for the components in contact with heat sources to cool down completely.  To separate the burner from the combustion head, proceed as follows (Fig.
Page 44: 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 45: 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 46: 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 47 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 48 Problems - Causes - Remedies signalled by LED indicators Faults LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Off-specification mains voltage ● ● ● ● ● UV: Internal fault ● ● Supervisor processor fault ●...
Page 49 Problems - Causes - Remedies signalled by LED indicators Fault explanation Faults Cause Solution Post-diagnostics fault Initial power diagnostics fault Make sure that the status of inlets and Check T12, T13 and T14 outlets is correct upon ignition Local reset The user started the manual reset or the Check T21 inlet or reset for normal reset switch is faulty...
Page 50 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution Not used Internal processor timeout Internal fault Replace the control device Internal processor timeout Internal fault Replace the control device Combustion air check timeout The system could not perform verification tests of the combustion air during the burner Check the wiring or the air pressure switch sequence...
Page 51: A Appendix - Accessories
Output probe 3010213 Pressure RWF55.5 20101965 0...16 bar 4...20 mA 3010214 Potentiometer kit Burner Code GI/EMME 1400 - 2000 3010021 GI/EMME 3000 - 4500 Spacer kit Thickness Burner Code (mm) GI/EMME 1400 - 2000 3000722 GI/EMME 3000 - 4500 3000751...
Page 52: Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Single-wire output layout Functional layout star/triangle starter Functional layout RFGO-A22 Functional layout RFGO-A22 Functional layout RFGO-A22 Functional layout RFGO-A22 Electrical wiring kit RWF50 internal Electrical wiring that is the responsibility of the installer Electrical wiring that is the responsibility of the installer Functional layout RWF50...
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Page 79 Appendix - Electrical panel layout Wiring layout key Electrical control box Oil return valve Filter to protect against radio disturbance Oil return valve Oil safety valve RWF50 output power regulator Current input DC 4...20mA Oil operation valve Current input DC 4...20mA for remote setpoint change XPGM Maximum gas pressure switch connector Pressure probe...
Page 80 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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Riello GI/EMME 1400 Installation, Use And Maintenance Instructions

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