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Riello RS 68/E O2 ULX Installation, Use And Maintenance Instructions

Forced draught gas burners
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Modulating operation
CODE
20205457
20205459
20205460
20205462
MODEL
RS 68/E O2 ULX
RS 120/E O2 ULX
RS 160/E O2 ULX
RS 200/E O2 ULX
TYPE
S041T1
S042T1
S043T1
S044T1
20205911 (2) - 10/2023

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Summary of Contents for Riello RS 68/E O2 ULX

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Modulating operation CODE MODEL TYPE 20205457 RS 68/E O2 ULX S041T1 20205459 RS 120/E O2 ULX S042T1 20205460 RS 160/E O2 ULX S043T1 20205462 RS 200/E O2 ULX S044T1 20205911 (2) - 10/2023...
  • Page 2 Translation of the original instructions...

  • Page 3: Table Of Contents

    Contents Information and general warnings............................3 Information about the instruction manual ........................3 1.1.1 Introduction.................................. 3 1.1.2 General dangers................................3 1.1.3 Other symbols ................................3 1.1.4 Delivery of the system and the instruction manual ...................... 4 Guarantee and responsibility............................4 Safety and prevention................................
  • Page 4 Contents 5.4.2 Air/fuel adjustment and output modulation system ....................34 5.4.3 Burner adjustment..............................34 5.4.4 Output upon ignition ..............................34 5.4.5 Maximum output ................................34 5.4.6 Minimum output .................................35 Final calibration of the pressure switches ........................36 5.5.1 Air pressure switch..............................36 5.5.2 Maximum gas pressure switch...........................36 5.5.3 Minimum gas pressure switch............................37 5.5.4...

  • Page 5: Information And General Warnings

    Information and general warnings Information and general warnings 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 away from moving mechanical parts;...

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

    Information and general warnings 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 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 8: Technical Description Of The Burner

    Technical description of the burner Technical description of the burner Burner designation Range: R Fuel: Natural gas Light Oil LS Light Oil/Natural gas Heavy Oil Size: Adjustment: Two stage (light oil / proportional valve (gas) Mechanical cam Electronic Cam Electronic cam and variable speed (with Inverter) Electronic cam with integrated Inverter Electronic cam and suitable for Oxygen Control (O EV O...

  • Page 9: Models Available

    Technical description of the burner Models available Designation Voltage Start-up Code RS 68/E O2 ULX TL FS1 3 ~ 400V - 50Hz Direct 20205457 RS 120/E O2 ULX TL FS1 3 ~ 400V - 50Hz Direct 20205459 RS 160/E O2 ULX...

  • Page 10: Maximum Dimensions

    Technical description of the burner Maximum dimensions The dimensions of the burner are shown in Fig. 1. The dimensions of the open burner are indicated by position U. Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the guides. 20210872 Fig.

  • Page 11: Firing Rates

    The maximum output must be higher than the following values If the chosen maximum output is higher than the following va- (Tab. F): lues (Tab. G): Model Model RS 68/E O2 ULX RS 68/E O2 ULX RS 120/E O2 ULX RS 120/E O2 ULX 1175 RS 160/E O2 ULX...
  • Page 12 Technical description of the burner RS 160/E O2 ULX S10340 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 Thermal power - kW Fig. 4 RS 200/E O2 ULX S10341 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 Thermal power - kW 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 standard. In Fig. 6 you can see the diameter and length approval, preliminary tests are recommended for boilers or of the test combustion chamber.

  • Page 14: Burner Description

    Technical description of the burner 3.10 Burner description 20210878 Fig. 7 Lifting rings Wait for the components in contact with heat sources to cool down completely. Fan motor Air damper servomotor Combustion head gas pressure test point Combustion head Ignition electrodes Ionisation probe Electrical panel cover 10 Gas butterfly valve servomotor...

  • Page 15: Electrical Panel Description

    Technical description of the burner 3.11 Electrical panel description 20210883 Fig. 8 Flame control Transformer Display “ON/OFF” selector Air pressure switch Cable grommets for electrical connections Terminal board for electrical connections Earth screws Relay clean contacts 10 “EMERGENCY STOP” button Auxiliary fuses 12 “T1”...

  • Page 16: Flame Control (Lmv52

    The LMV52... flame control is a safety device! WARNING Avoid opening or modifying it, or forcing its opera- tion. Riello S.p.A. cannot assume any responsibil- ity for damage resulting from unauthorised interventions! Risk of explosion!
  • Page 17 Technical description of the burner Electrical connection of flame sensor It is important for signal transmission to be almost totally free – Line capacitance reduces the magnitude of the flame signal. of any disturbances or loss: – Use a separate cable. •...

  • Page 18: 3.13 Actuator

    Technical description of the burner 3.13 Actuator Warning notes To avoid injury to persons, damage to prop- erty or the environment, the following warn- ing notes should be observed! WARNING Do not open, interfere with or modify the ac- tuators! ...

  • Page 19: Pll52

    Technical description of the burner 3.14 PLL52... module (optional) Warnings To avoid accidents, material or environmen- tal damage, observe the following instruc- tions! WARNING Avoid opening, modifying or forcing the de- vice.  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ...

  • Page 20: Oxygen Sensor Qgo20

    Technical description of the burner 3.15 Oxygen sensor QGO20 ... (optional) Warnings To avoid accidents, material or environmen- S9895 tal damage, observe the following instruc- tions! WARNING Avoid opening, modifying or forcing the oxy- gen sensor.  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel.

  • Page 21: 3.15.1 Technical Data Qgo20

    Technical description of the burner 3.15.1 Technical data QGO20 Operating voltage of measuring cell’s: – QGO20.000D27 AC 230 V ±15 % – QGO20.000D17 AC 120 V °15 % (only with LMV52 ... with PLL52...) Mains frequency: 50...60 Hz ±6 % Power consumption: Max.

  • Page 22: Installation

    Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner will The installation of the burner must be carried out be installed, and arranging the correct lighting of the environ- by qualified personnel, as indicated in this manual ment, proceed with the installation operations.

  • Page 23: Operating Position

    This protective fettling must not compromise the extraction of the Ø blast tube. RS 68/E O2 ULX M 16 For boilers with a water-cooled front piece, a refractory lining 11)- 12)(Fig. 16) is not necessary, unless expressly requested by the...

  • Page 24: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler 20209164 Provide an adequate lifting system of the burner. Divide the combustion head from the rest of the burner, as shown in Fig. 16; you have to:  loosen the 4 screws 3) and remove the cover 1); ...

  • Page 25: Electrode Position

    Installation Electrode position 20188099 4 ± 0.5 ± 1 Before fixing the burner to the boiler, check the correct positioning of the electrodes as in Fig. 18. WARNING ±1 Fig. 18 Central gas adjustment As you can see in Fig. 19 the gas flows through the combustion head in two different ways: 20205150 ...

  • Page 26: Combustion Head Adjustment

    4.10 Combustion head adjustment At this point of the installation, the combustion head is fixed to the RS 68/E O2 ULX boiler as shown in Fig. 17 on page 22. It is therefore especially S10260 easy to adjust, and this adjustment depends only on the maxi- mum output of the burner.

  • Page 27: Closing The Burner

    Installation 4.11 Closing the burner Once the combustion head adjustment is completed: 20209347  reassemble the burner on the slide bars 3) at about 100 mm from the pipe coupling 4) burner in the position shown in Fig. 16 on page 22; ...

  • Page 28: Gas Feeding

    Installation 4.12 Gas feeding Explosion danger due to fuel leaks in the pres- The fuel supply line must be installed by qualified ence of a flammable source. personnel, in compliance with current standards and laws. Precautions: avoid knocking, attrition, sparks and WARNING heat.

  • Page 29: 4.12.4 Gas Pressure

    Installation 4.12.4 Gas pressure Example RS 200/E O2 ULX with G20 natural gas: Fixed Output operation Each diagram indicate the minimum pressure drops depending on the maximum burner output. Gas pressure at test point P1 108 mbar The values shown, refer to: Pressure in combustion chamber 8 mbar –...
  • Page 30 Installation RS 68/E O2 ULX S10342 1000 1050 1100 1150 1200 Burner output – kW Fig. 25 RS 120/E O2 ULX S10343 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 Burner output – kW Fig. 26 20205911...
  • Page 31 Installation RS 160/E O2 ULX S10353 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950 2000 Fig. 27 Burner output – kW RS 200/E O2 ULX S10354 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950 2000 2050 2100 2150 2200 2250 2300 2350 2400 2450 2500 Burner output –...

  • Page 32: Electrical Wiring

    Installation 4.13 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 33: Supply Cables And External Connections Passage

    Installation 4.13.1 Supply cables and external connections 20099843 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. 29. Key (Fig.

  • Page 34: 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 35: 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. 20209364 Close thermostats/pressure switches turn switch 4)(Fig. 8 on page 13) to position “(1) - ON”. Check that the lamps or testers connected to the solenoid valves, or the pilot lights on the solenoid valves, indicate that no voltage is present.

  • Page 36: Air / Fuel Adjustment

    Start-up, calibration and operation of the burner Air / fuel adjustment 5.4.4 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 37: Minimum Output

    Start-up, calibration and operation of the burner Indication for the burner ignition In Tab. N the calibrations of the air and gas servomotors at the ignition point for each model are summarized according to the change of the maximum burnt power. Ignition point - RS 68 ULX - Maximum power input (kW) 1050...

  • Page 38: Final Calibration Of The Pressure Switches

    Start-up, calibration and operation of the burner Final calibration of the pressure switches 5.5.1 Air pressure switch Adjust the air pressure switch (Fig. 33) after having performed all other burner adjustments with the air pressure switch set to the start of the scale. With the burner working at MIN output, insert a combustion analyser in the stack, slowly close the suction inlet of the fan (for example, with a piece of cardboard) until the CO value does not...

  • Page 39: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 5.5.3 Minimum gas pressure switch Adjust the minimum gas pressure switch (Fig. 35) after having adjusted the burner, the gas valves and the gas train stabiliser. With the burner operating at maximum output: –...

  • Page 40: Operation

    Start-up, calibration and operation of the burner Operation Once the start-up cycle is completed, the servomotor command  The burner stops when the heat request is less than the heat moves on to the thermostat/pressure switch TR that controls the supplied by the burner at MIN output.

  • Page 41: Stopping Of The Burner

    Start-up, calibration and operation of the burner 5.10 Stopping of the burner The burner can be stopped by:  intervening on the disconnecting switch of the electrical sup- ply line, located on the boiler panel;  using the switch “0-AUTO“ of Fig. 32 on page 33. 5.11 Final checks (with burner operating) ...

  • Page 42: Description Of O2 Trim Control (Optional)

    Start-up, calibration and operation of the burner 5.12 Description of O trim control (optional) A special feature of the LMV52… is control of the residual O content to increase the boiler’s efficiency. The LMV52… uses a QGO20…, an external PLL52…, and the standard components of the LMV51…...

  • Page 43: 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 44: Checking The Air And Gas Pressure On The Combustion Head

    Maintenance 6.2.4 Checking the air and gas pressure on the Gas leaks Make sure that there are no gas leaks on the pipes between the combustion head gas meter and the burner. To carry out this operation a pressure gauge must be used to measure the air and gas pressure at the combustion head, as Gas filter shown in Fig.

  • Page 45: Opening The Burner

    Maintenance Opening the burner  Loosen the 4 screws 1)(Fig. 39) and remove the cover 2);  assemble the two extensions supplied on the slide bars 4) Disconnect the electrical supply from the burner and tighten the screws 7); by means of the main system switch. ...

  • Page 46: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Kit for modulating operation Parameter to be checked Probe Adjustment field Type Code Temperature - 100 ÷ 500° C PT 100 3010110 0 ÷ 2.5 bar 4 ÷ 20 mA 3010213 Pressure 0 ÷ 16 bar 4 ÷...

  • Page 47: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Reference indication Layout of unifilar output LMV 52 ... operational layout LMV 52 ... operational layout LMV 52 ... operational layout LMV 52 ... operational layout LMV 52 ... operational layout LMV 52 ...
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  • Page 62 Appendix - Electrical panel layout Wiring layout key Electronic cam O2 module PLL.. type Display and calibration unit Output probe in current Device with output undercurrent, for modifying re- mote setpoint Load indicator Input in current DC 4...20 mA Pressure probe Pressure probe Probe Pt100, 3 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...

This manual is also suitable for:

Rs 120/e o2 ulxRs 160/e o2 ulxRs 200/e o2 ulxS041t1S042t1S043t1 ... Show all

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