Riello RS 190/M Installation, Use And Maintenance Instructions
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Riello RS 190/M Installation, Use And Maintenance Instructions

Forced draught gas burners
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Low-high-low or modulating operation
CODE
MODEL
20166104 - 20166105 - 20166106
RS 190/M
20160742 (6) - 03/2022

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Summary of Contents for Riello RS 190/M

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Low-high-low or modulating operation CODE MODEL 20166104 - 20166105 - 20166106 RS 190/M 20160742 (6) - 03/2022...
  • Page 2 Original instructions...

  • Page 3: Table Of Contents

    Contents Information and general instructions ..............3 Information about the instruction manual .
  • Page 4 Contents Notes on safety for the first start-up............. . . 26 Adjustments before first firing .

  • Page 5: Information And General Instructions

    Information and general instructions Information and general instructions Information about the instruction manual 1.1.1 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 be away from moving mechanical parts;...

  • Page 6: Delivery Of The System And The Instruction Manual

    Information and general instructions 1.1.4 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 7: Safety And Prevention

    Safety and prevention Safety and prevention Introduction The burners have been designed and built in compliance with cur- the type and pressure of the fuel, the voltage and frequency of the rent regulations and directives, applying the known technical rules electrical power supply, the minimum and maximum deliveries for of safety and envisaging all the potential danger situations.

  • Page 8: Technical Description Of The Burner

    Technical description of the burner Technical description of the burner Burner models designation Model Riello Code RBNA Code Voltage Flame safeguard RS 190/M TC FS1 20166104 208-230/3/60 Burner mounted 20160257 RS 190/M TC 20166105 460/3/60 Burner mounted RS 190/M TC FS1...

  • Page 9: Electrical Data

    Technical description of the burner Electrical data Model RS 190/M Control circuit power supply V/Ph/Hz 120/1/60 Main electrical supply (+/- 10%) V/Ph/Hz 208-220/3/60 460/3/60 575/3/60 Fan motor IE3/EPACT 3500 3500 3500 HP - kW 7.5 - 5.5 7.5 - 5.5 7.5 - 5.5...

  • Page 10: Burner Dimensions

    Bear in mind that inspection of the combustion head requires the burner to be opened by withdrawing the rear part on the slide bars. 20161124 Fig. 1 inch 29” 12” 2” RS 190/M 25 /32 “ 13 /64 “ 31 /32 “ 3 /4 “...

  • Page 11: Firing Rates

    Model MBtu/hr different to the standard values (328 ft above sea level, 68 °F)” RS 190/M 1781 on page 10 for operation at different ambient temperatures and/or altitudes. The firing rate area values have been obtained con- sidering an ambient temperature of 68 °F, and an...

  • Page 12: Procedure To Refer Burner Operating Condition At An Altitude And/Or At A Combustion Supporter Air Temperature Different To The Standard Values (328 Ft Above Sea Level, 68 °F)

    Technical description of the burner 3.6.1 Procedure to refer burner operating condition at an altitude and/or at a combustion supporter air temperature different to the standard values (328 ft above sea level, 68 °F) AIR TEMPERATURE Altitude Altitude bar. press. bar. press. °C ft a.s.l.

  • Page 13: Burner Description

    Technical description of the burner Burner description 20161406 23 8 9 10 Fig. 4 Key (Fig. 4) Combustion head 11 Terminal strip 12 Pilot burner attachment Ignition electrode 13 Control box Screw for combustion head adjustment 14 Flame inspection window High gas pressure switch 15 Low air pressure switch (differential operating type) Sleeve...

  • Page 14: Rfgo-A13 Control Box

    The control box 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!  All interventions (assembly and installation operations, assis- tance, etc.) must be carried out by qualified personnel.

  • Page 15: Servomotor Sqm41

    Technical description of the burner 3.10 Servomotor SQM41 ... Warnings To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying or forcing the ser- WARNING vomotor.  All interventions (assembly and installation operations, assis- tance, etc.) must be carried out by qualified personnel. ...

  • Page 16: Installation

    20150238 Drill the combustion chamber mounting plate as shown in Fig. 7. The position of the threaded holes can be marked using the head gasket supplied with the burner. Ø inch RS 190/M - 14 16“ 16“ 2“ Fig. 7...

  • Page 17: Blast Tube Length

    Model  For boilers having a water-cooled front, the insulation 13)-14) (short blast tube) is not required unless it is required by the boiler manufacturer. RS 190/M 32“ D2434 Fig. 8 Securing the burner to the boiler Prepare a suitable lifting system.

  • Page 18: Combustion Head Setting

    Installation Combustion head setting Installation operations are now at the stage where the blast tube and sleeve are secured to the boiler as shown in Fig. 9 and Fig. 10. It is now a very simple matter to set up the combustion head, as this depends solely on the MAX output developed by the burner.

  • Page 19: Ignition Pilot Adjustment

    Installation Make sure that the combustion characteristics are satisfactory and free of pulsations. D2442 Once you have finished setting up the head:  refit the burner to the slide bars 3)(Fig. 12) at approximately 4” from the sleeve 4) - burner positioned as shown in Fig. 8, page 15 - insert the flame rod cable and the ignition electrode cable and then slide the burner up to the sleeve so that it is positioned as shown in Fig.

  • Page 20: Electrical Connections

    Installation 4.7.1 Electrical connections S9810 Fig. 15 20160742...

  • Page 21: Gas Supply

    Installation Gas supply Explosion danger due to fuel leaks in the presence 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 22: Gas Pressure

    Installation 4.8.3 Gas pressure D3190 The Fig. 18 is used to calculate manifold pressure taking into ac- count combustion chamber pressure. Gas manifold pressure measured at test point 1)(Fig. 19), with: • combustion chamber at 0 “WC; • burner operating at maximum output; •...

  • Page 23: 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 carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination.

  • Page 24: Supply Cables And External Connections Passage

    Installation 4.9.2 Supply cables and external connections Cable grommets used in factory: A - Fan motor passage B - Maximum gas pressure switch All the cables to be connected to the burner are fed through the C - Air/Gas servomotor grommets.

  • Page 25: Thermal Relay Calibration

    Installation 4.10 Thermal relay calibration Depending on the burner type, there are two different thermal re- 4.10.2 Electronic thermal relay lays:  To reset, in the case of an intervention of the thermal relay, – electro-mechanical thermal relay (used for single phase mo- press the button “RESET”...

  • Page 26: Motor Connection At 208-230 Or 460V

    Installation 4.11 Motor connection at 208-230 or 460V WARNING: the motors, manufactured for 208-230/460 IE3 NEMA Premium Efficiency voltage, have the same connection than IE2/Epact motors, but different connection than IE1 motors no more star/delta but star/double star. Please, pay attention to the indications in case of modification of voltage, maintenance, or substitution. IE2/Epact - IE3 NEMA Premium Efficiency S8380 S8379...

  • Page 27: Burner Operation

    Installation 4.14 Burner operation 4.14.1 Burner starting Key for the times Pre-purge time with air damper open • Operating closes. First safety time Fan motor starts (A Fig. 30). Pre-ignition time, short (ignition transformer on terminal 16) Interval between main fuel piloted valve and release to modu- •...

  • 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, com- by qualified personnel, as indicated in this manual mand and safety devices.

  • Page 29: Servomotor

    Start-up, calibration and operation of the burner Servomotor The servomotor (Fig. 36) provides simultaneous adjustment for the 20162481 gas butterfly valve, by means of the adjustable profile cam and the air damper: 1)(Fig. 35 and Fig. 36). It rotates by 130° in approx. 36 s. To open the servomotor and release the mechanical cam and the gas butterfly valve, see procedure (Refer to paragraph “Servomo- tor adjustment”...

  • Page 30: Servomotor Adjustment

    Start-up, calibration and operation of the burner Servomotor adjustment 20161833 Fig. 37 5.4.1 Disengage the gears of the servomotor 5.4.2 Cams adjustment For adjusting the cams, see A) (Fig. 37). Switch off the burner using the switch 1)(Fig. 38), OFF position. Proceed with care and without forcing.

  • Page 31: Final Calibration Of The Pressure Switches

    Start-up, calibration and operation of the burner Final calibration of the pressure switches 5.6.1 Air pressure switch Adjust the air pressure switch after having performed all other burn- er adjustments with the air pressure switch set to the start of the scale (Fig.

  • Page 32: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 5.6.3 Minimum gas pressure switch The purpose of the minimum gas pressure switch is to prevent the burner from operating in an unsuitable way due to too low gas pres- sure. Adjust the minimum gas pressure switch (Fig. 42) after having ad- justed the burner, the gas valves and the gas train stabiliser.

  • Page 33: Burner Calibration

    Start-up, calibration and operation of the burner Burner calibration The optimum calibration of the burner requires an analysis of the 5.8.3 Minimum burner output flue gases at the boiler outlet. Minimum output must be selected within the “Firing rates” range Adjust successively: shown at page 9.

  • Page 34: Intermediate Outputs

    Start-up, calibration and operation of the burner 5.8.4 Intermediate outputs Adjustment of gas delivery When the adjustment is complete, switch off the burner using the switch 1)(Fig. 38, page 28), OFF position, release the mechanical No adjustment of gas delivery is required. cam 8)(Fig.

  • Page 35: Final Checks (With The Burner Working)

    Start-up, calibration and operation of the burner 5.10 Final checks (with the burner working)   Open the control limit operation The burner must stop  Open the high limit operation  Rotate the maximum gas pressure switch knob to the mini- ...

  • Page 36: Maintenance

    Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, safe- Before carrying out any maintenance, cleaning or checking opera- ty, yield and duration of the burner. tions: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.

  • Page 37: Flame Presence Check

    Maintenance Flame inspection window D709 Clean the flame inspection window (Fig. 47). Burner Check for excess wear or loose screws in the mechanisms con- trolling the air damper and the gas butterfly valve. Also make sure that the screws securing the electrical leads in the burner connections are fully tightened.

  • Page 38: Opening The Burner

    Maintenance Opening the burner To open the burner proceed as follows:  remove screws 1)(Fig. 49) and withdraw the cover 2); Disconnect the electrical supply from the burner by  disconnect the swirler joint 7) to the graduate sector; means of the main system switch. DANGER ...

  • Page 39: 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 position- Open...

  • Page 40: 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 Open Closed Modulation Ignition Flame Status LED ● = ON damper damper Icon S9740 S9741 S9742 S9743 S9744 S9745 S9746 Power OFF/ON...

  • Page 41: 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 indicate Thermal unit’s operation, maintenance the cause of the stop. troubleshooting interventions must be carried out The terminal T3 is not powered.
  • Page 42 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 43 Problems - Causes - Remedies signalled by LED indicators Faults LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Supervisor processor timeout ● ● ● ● Off-specification mains voltage ● ● ● ● Off-specification mains voltage ●...
  • Page 44 Problems - Causes - Remedies signalled by LED indicators Fault explanation Faults Cause Solution Initial power diagnostics fault Post-diagnostics fault Make sure that the status of inlets and outlets Check T12, T13 and T14 is correct upon ignition The user started the manual reset or the reset Local reset Check T21 inlet or reset for normal operation switch is faulty...
  • Page 45 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution Unexpected flame (false or parasitic flame) False flame in stand-by mode Check flame sensor or interference detected during the Stand-by status Not used Internal processor timeout Internal fault Replace the control device Internal processor timeout Internal fault...

  • Page 46: A Appendix - Spare Parts

    Appendix - Spare parts Appendix - Spare parts 20160742...
  • Page 47 Appendix - Spare parts CODE DESCRIPTION • • 20073610 AIR DAMPER ASSEMBLY • • 3013683 PROTECTION • • 3013682 SOUND DAMPING • • 3012976 • • 3003763 INSPECTION WINDOW • • 3013001 U BOLT • • 3012983 PILOT TUBE • •...
  • Page 48 Appendix - Spare parts CODE DESCRIPTION • • 3012049 SCREW • • 3012639 ADJUSTMENT ASSEMBLY • • 20049844 FRONT PIECE • • 3013698 SQUARE • • 3013699 FLAME FUNNEL • • 3012560 SHUTTER • • 3003322 CONNECTOR • • 3013687 BAR EXTENSION •...

  • Page 49: B Appendix - Accessories

    • Kit for LPG operation The kit allows the burner to operate on LPG. Burner Output Code RS 190/M 1761 - 8673 MBtu/hr 20080781 • Gas train according to UL Standards The installer is responsible for the supply and instal- lation of any required safety device(s) not indicated in this manual.

  • Page 50: Appendix - Burner Start Up Report

    Appendix - Burner start up report Appendix - Burner start up report Model number: Serial number: Project name: Start-up date: Installing contractor: Phone number: GAS OPERATION : Low Fire Gas Supply Pressure: High Fire : Low Fire Main Power Supply: High Fire Control Power Supply: CO: Low Fire...
  • Page 52 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.com RIELLO BURNERS NORTH AMERICA http://www.riello.ca 35 Pond Park Road 2165 Meadowpine Blvd Hingham, Massachusetts, Mississauga, Ontario U.S.A. 02043 1-800-4-RIELLO Canada L5N 6H6 Subject to modifications...

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