Riello GAS 3 P/M Installation, Use And Maintenance Instructions
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Riello GAS 3 P/M Installation, Use And Maintenance Instructions

Forced draught gas burner
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Two stage progressive or modulating operation
CODE
20159096
20159118
20159126
20159129
20159133
MODEL
GAS 3 P/M
GAS 4 P/M
GAS 5 P/M
GAS 6 P/M
GAS 7 P/M
TYPE
533 T1
534 T1
535 T1
536 T1
537 T1
20159111 (3) - 02/2022

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Summary of Contents for Riello GAS 3 P/M

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Two stage progressive or modulating operation CODE MODEL TYPE 20159096 GAS 3 P/M 533 T1 20159118 GAS 4 P/M 534 T1 20159126 GAS 5 P/M 535 T1 20159129 GAS 6 P/M...
  • 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 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 adjustment..............................29 6.6.1 Ignition output ................................29 6.6.2 Preliminary calibrations, if necessary.........................29 6.6.3 MAX output ................................30 6.6.4 MIN output .................................30 6.6.5 Intermediate outputs ..............................31 Pressure switch adjustment ............................32 6.7.1 Air pressure switch..............................32 6.7.2 Maximum gas pressure switch...........................32 6.7.3 Minimum gas pressure switch............................33 6.7.4 Flame presence check ...............................33 Burner operation ................................34...

  • Page 5: Declarations

    Electromagnetic Compatibility Such products are marked as indicated below: CE-0085AQ0707 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 20159111...

  • 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 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 / 50-60Hz 110/50/60 110V / 50-60Hz 3/230-400/50 230/50/-60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code GAS 3 P/M 1/230/50 Direct 20159096 GAS 4 P/M 1/230/50 Direct 20159118 GAS 5 P/M 3/230-400/50 Direct 20159126 GAS 6 P/M...

  • Page 10: Burner Categories - Countries Of Destination

    2ELL (43.46 ÷ 45.3 MJ/m (0°C)) 2L - 2E - 2E(R)B LU - PL Technical data MODEL GAS 3 P/M GAS 4 P/M GAS 5 P/M GAS 6 P/M GAS 7 P/M TYPE 533 T1 534 T1 535 T1 536 T1...

  • Page 11: Electrical Data

    Technical description of the burner Electrical data MODEL GAS 3 P/M GAS 4 P/M TYPE 533 T1 534 T1 ELECTRICAL POWER SUPPLY 230 ~ +/- 10% 50 - single-phase ELECTRICAL MOTOR 2750 2800 0,250 0,370 F MOTOR CAPACITOR 12.5 450/500...

  • Page 12: Maximum Dimensions

    The maximum dimension of the burner, without casing, when open is given by measurement I. Note that to inspect the combustion head the burner must be moved backward and turned upward. Fig. 1 GAS 3 P/M Rp 1 1/2 GAS 4 P/M Rp 1 1/2 GAS 5 P/M...

  • Page 13: Firing Rates

     The MINIMUM OUTPUT (MIN) is to be chosen from within the range of values indicated on diagrams. Example: for GAS 3 P/M, it can be chosen from 80 and 175 kW (equivalent to 69 and 150 Mcal/h) It is not required to know the pressure in combustion chamber in 1st stage.

  • Page 14: 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. 4). If the burner must be combined with a boiler that has not been EC 4.9.1 Commercial boilers...

  • Page 15: Burner Description

    Technical description of the burner 4.10 Burner description 20159978 Fig. 5 Slide bars for opening the burner and inspecting the combustion head Combustion head Closed air damper in stand-by to reduce heat losses Air pressure switch Air damper control lever Gas butterfly valve control rod Control box with lockout pilot light and reset button Air-gas control servomotor...

  • Page 16: Electrical Panel Description

    Technical description of the burner 4.11 Electrical panel description Capacitor (in GAS 3-4 P/M models) Motor contactor and thermal relay (in GAS 5-6-7 P/M models) Terminal board Cable grommets for electrical wiring (to be carried out by the installer) Plug-socket on ionisation probe cable 20159979 Plug-socket on servomotor cable Control box base...

  • Page 17: 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 18: 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 19: 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 20: Operating Position

    The range of lengths available, L (mm), is as follows: GAS 3 P/M Blast tube GAS 3 GAS 4...

  • Page 21: Securing The Burner To The Boiler

    Installation 5.5.3 Securing the burner to the boiler Provide an adequate lifting system.  Remove blast tube 6)(Fig. 12) from the burner as follows: – Remove screws 1) from the two slide bars 2). – Remove the screws 3) retaining the blast tube to the burner.

  • Page 22: Combustion Head Adjustment

    Fig. 15 Example: D1113 The GAS 3 P/M burner is installed in a 240 kW boiler. Considering an efficiency of 89%, the burner must supply around 270 kW. The diagram (Fig. 15) shows that the gas and air adjustments for this output are carried out on notch 4.5.

  • Page 23: Gas Supply

    Installation 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: Gas Train

    Installation 5.8.2 Gas train 5.8.4 Gas pressure Type-approved in accordance with EN 676 and supplied Tab. H indicates the pressure drops of the combustion head and separately from the burner. gas butterfly valve, on the basis of the burner operating output. 1 p (mbar) 5.8.3 Gas train installation...
  • Page 25 Installation The values shown in Tab. H refer to: – Natural gas G 20 NCV 10 kWh/Sm (8.6 Mcal/Sm – Natural gas G 25 NCV 8.6 kWh/Sm (7.4 Mcal/Sm Column 1 Combustion head pressure drop. Gas pressure measured at test point 11)(Fig. 5 a pag. 13), with: –...

  • Page 26: Electrical Connections

    Installation 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 carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination.
  • Page 27 Installation The use of the cable grommets and the pre-blanked holes can be 20159533 done in different manners; for example: GAS 3-4 P/M GAS 3-4 P/M 1 - single-phase power supply Pg 13.5 TR or RWF remote control Pg 13.5 (the pipe union is not required in the 2nd case) TL or probe (RWF) remote control Pg 13.5...

  • Page 28: Calibration Of The Thermal Relay

    Installation 5.10 Calibration of the thermal relay The thermal relay (Fig. 22) 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 29: 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 by qualified personnel, as indicated in this manual Before starting up the burner, refer to section and in compliance with the standards and "Safety test - with no gas supply”...

  • Page 30: Servomotor Adjustment

    Start-up, calibration and operation of the burner Servomotor adjustment SQM 40 servomotor provides simultaneous adjustment of the air damper by means of the variable profile cam and the gas butterfly valve. It performs a 130° rotation in 45 s. It is equipped with three adjustable cams that activate as many contacts, factory set as follows: RED cam 130°...

  • Page 31: Burner Adjustment

    Start-up, calibration and operation of the burner Burner adjustment The optimum adjustment of the burner requires an analysis of flue gases at the boiler outlet. Adjust in sequence: 1 - Output upon ignition 2 - Preliminary calibrations, if necessary 3 - MAX output 4 - MIN output 5 - Intermediate outputs between Min.

  • Page 32: Max Output

    Start-up, calibration and operation of the burner – Reconnect the articulated coupling 4) to the lever 8).  Lengthen the tie-rod 4)(Fig. 26) of the gas butterfly valve to – Lift the cam profile 2) from its initial part by tightening a few reduce the delivery, shorten the tie-rod to increase it.

  • Page 33: Intermediate Outputs

    Start-up, calibration and operation of the burner 6.6.5 Intermediate outputs (especially necessary for modulating operation) No adjustment is required The adjustment is carried out by working on the profile cam adjustment intermediate screws 1)(Fig. 28 a pag. 30), paying attention not to move those related to the minimum and maximum delivery.

  • Page 34: Pressure Switch Adjustment

    Start-up, calibration and operation of the burner Pressure switch adjustment 6.7.1 Air pressure switch Adjust the air pressure switch after performing all other burner adjustments with the air pressure switch set to the start of the scale (Fig. 30). With the burner operating in 1st stage, increase adjustment pressure by slowly turning the relevant knob clockwise until the burner locks out.

  • Page 35: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 6.7.3 Minimum gas pressure switch 6.7.4 Flame presence check The purpose of the minimum gas pressure switch is to prevent The burner is fitted with an ionisation system to check that a the burner from operating in an unsuitable way due to too low gas flame is present.

  • Page 36: Burner Operation

    Start-up, calibration and operation of the burner Burner operation 6.8.1 Burner start-up STANDARD IGNITION (no. = seconds from instant 0) 20156545 Control remote control TL closes. Fan servomotor start-up. Servomotor start-up: turn to the right by 130°. The air damper is positioned to MAX output. 51s: Pre-purging stage with MAX output air delivery.

  • Page 37: Final Checks (With Burner Operating)

    Start-up, calibration and operation of the burner Final checks (with burner operating)  Disconnect a wire of the minimum gas pressure switch   Open the thermostat/pressure switch TL The burner must stop  Open the thermostat/pressure switch TS  Disconnect the P shared wire of the maximum gas pressure switch ...

  • Page 38: 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 39: Combustion Control (Gas)

    Maintenance Combustion 7.2.5 Safety components Carry out an analysis of the combustion flue gases. The safety components should be replaced at the end of their life Significant differences with respect previous cycle indicated in the following table. The specified life cycles do measurements indicate the points where most care should be not refer to the warranty terms indicated in the delivery or exercised during maintenance.

  • Page 40: Opening The Burner

    Maintenance Opening the burner Disconnect the electrical supply from the burner Wait for the components in contact with heat by means of the system main switch. sources to cool down completely. DANGER  Disengage the articulated coupling 1)(Fig. 36) of the air damper control lever;...

  • Page 41: 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 42: 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 43: 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 44 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 45 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 46 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 47 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution Internal processor fault Internal fault Replace the control device 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...

  • Page 48: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Extended head kit L = standard head L1 = extended head obtainable with the kit MODEL CODE GAS 3 P/M 3000605 L = 185 L1 = 320 mm GAS 4 P/M 3000606 L = 187...
  • Page 49 Appendix - Accessories Output regulator kit for modulating operation With modulating operation, the burner continuously adjusts its • output regulator to be installed to the burner; output to the heat request, thereby ensuring a great stability of • probe to be installed to the heat generator the controlled parameter: temperature or pressure.

  • Page 50: Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Functional layout RFGO-A22 Functional layout Electrical wiring that is the responsibility of the installer Electrical wiring that is the responsibility of the installer Functional layout RWF 50 Indication of references / 1 .
  • Page 51 Appendix - Electrical panel layout 20159111...
  • Page 52 Appendix - Electrical panel layout 20159111...
  • Page 53 Appendix - Electrical panel layout 20159111...
  • Page 54 Appendix - Electrical panel layout 20159111...
  • Page 55 Appendix - Electrical panel layout 20159111...
  • Page 56 Appendix - Electrical panel layout 20159111...
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  • Page 58 Appendix - Electrical panel layout 20159111...
  • Page 59 Appendix - Electrical panel layout 20159111...
  • Page 60 Appendix - Electrical panel layout 20159111...
  • Page 61 Appendix - Electrical panel layout WIRING DIAGRAM 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 modification Pressure probe Pressure probe Remote setpoint potentiometer Thermocouple probe Probe Pt100, 2 wires Probe Pt100, 3 wires...
  • Page 64 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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