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Summary of Contents for Riello RS 300/EV FGR
- Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two stage or modulating operation CODE MODEL C9171410 RS 300/EV FGR 20093003 RS 500/EV FGR 20122657 RS 650/EV FGR 20111981 - 20114092 RS 800/EV FGR 20109903 (9) - 09/2024...
- Page 2 Original instructions...
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Page 3: Table Of Contents
Contents Information and general instructions ..............3 Information about the instruction manual . - Page 4 Contents Burner firing ................. 33 Burner start-up.
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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 Technical data Model RS 300/EV FGR RS 500/EV FGR RS 650/EV FGR RS 800/EV FGR Output 1500 - 4220 (3834*) 2715 - 5740 (5217*) 3330 - 7270 (6543*) 3885 - 8990 (8172*) max. -
Page 9: Burner Models Designation
Technical description of the burner Burner models designation Model Riello Code RBNA code Voltage Starting Flame safeguard RS 300/EV FGR 20112410 C9171410 460/3/60 Inverter Burner mounted RS 500/EV FGR 20101163 20093003 460/3/60 Inverter Burner mounted RS 650/EV FGR 20120788 20122657... -
Page 10: Burner Dimensions
R. Bear in mind that inspection of the combustion head requires the burner to be opened by rotating the rear part on the hinge. 20092541 Fig. 2 inch RS 300/EV FGR ANSI 3” ANSI 4” 37” 16“ 2“ 16“... -
Page 11: Burner Description
Technical description of the burner Burner description 20114623 Fig. 3 Lifting eyebolts 20 Maximum gas pressure switch with pressure test point 21 QRI flame sensor Fan motor 22 Hinge for opening burner 23 Air pressure test point “+” Air gate valve servomotor Gas pressure test point 24 Air pressure test point “-”... -
Page 12: Electrical Panel Description
Technical description of the burner Electrical panel description 20114644 Fig. 4 Operator panel with LCD display Horn “K5” relay Terminal strip “XAUX” Flame control transformer “T1” Bracket for shielded cables Flame control for checking flame and air/fuel ratio Warning: used only to avoid a break in the cable’s shielding, Ignition transformer “TA1”... -
Page 13: Firing Rates
Firing rates Maximum output must be selected in the hatched area of the dia- Model MBtu/hr gram (Fig. 5 and Fig. 6). RS 300/EV FGR 1893 Minimum output must not be lower than the minimum limit shown RS 500/EV FGR 3787 in the diagram. -
Page 14: 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 D11425 RS 800/EV FGR RS 650/EV FGR MBtu/h 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000 Power output 1200 2400 3200 3600 4000 4800 5600 6000 6400 7200 7600 8000 8800... -
Page 15: Minimum Furnace Dimensions
Technical description of the burner 3.10 Minimum furnace dimensions The firing rates were set in relation to certified test boilers. Example for RS 500/EV FGR: Fig. 7 indicates the diameter and length of the test combustion Output 18500 MBtu/hr: diameter 39.4 inch - length 16.5 ft. chamber. -
Page 16: Flame Control (Lmv52
WARNING The LMV52... is a safety device! Do not open, in- terfere with or modify the unit. Riello S.p.A. will not assume responsibility for any damage resulting from unauthorized inter- ference! Risk of explosion! Incorrect configuration can lead to excessive... - Page 17 Technical description of the burner Electrical connection of ionization probe and flame detector • Observe the permissible cable lengths. • The ionization probe is not protected against electrical shock It is important to achieve practically disturbance- and loss-free hazard. The mainspowered ionization probe must be protected signal transmission: against accidental contact.
- Page 18 Technical description of the burner Operation sequence of the burner TSA1 Timer 1 Timer 2 TSA1 Fuel 1 (oil) Fuel selection Fuel 2 (gas) Controller - ON (internal + external) Air pressure switch (LP) Fan conductor contact (GSK) (CPI function with LMV52...) Start release - oil Ignition (Z) (alternative start signal)
- Page 19 Technical description of the burner Key to the sequence diagrams: Assignment of times: Depending on the parameter, valve proving takes place: Postpurge lockout position between phase 62 and phase 70 or/and Max. time safety phase between phase 30 and phase 32. Min.
- Page 20 Technical description of the burner Key to the sequence diagrams: Parameter: With / without pressure switch Permissible positioning range Parameter: Short / long preignition time for oil only Short / long oil pump – ON – time In Standby: actuator can travel within the permissible po- Delayed shutdown within TSA1 + TSA2 sitioning range, but is always driven to the home position.
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Page 21: Actuators
Technical description of the burner 3.12 Actuators Warning notes To avoid injury to persons, damage to property or the environment, the following warning notes should be observed! WARNING Do not open, interfere with or modify the actua- tors! All activities (mounting, installation and service work, etc.) must be performed by qualified staff. -
Page 22: Installation
Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner will be The installation of the burner must be carried out by installed, and arranging the correct lighting of the environment, pro- qualified personnel, as indicated in this manual and ceed with the installation operations. -
Page 23: Operation Position
Boiler plate Drill the combustion chamber mounting plate as shown in Fig. 13. The position of the threaded holes can be marked using the gasket supplied with the burner. inch RS 300/EV FGR coarse 32” 64” 4” RS 500/EV FGR coarse 32”... -
Page 24: Blast Tube Length
Installation 4.6.2 Blast tube length The length of the blast tube must be selected according to the indi- This protective fettling must not compromise the extraction of the cations provided by the manufacturer of the boiler, and in any case blast tube. -
Page 25: Electrode And Ignition Pilot Adjustment
Installation Electrode and ignition pilot adjustment Make sure that the electrode and the ignition pilot are positioned 2" as shown in Fig. 16. E LE CTR O DE PILO T 7/32" D9159 Fig. 16 4.10 Combustion head setting In addition to varying air flow depending on the output requested, the air gate valve servomotor 4)(Fig. -
Page 26: Adjustment At The Maximum Output
Installation RS 300/EV FGR 4545 6060 7575 9090 10605 12120 13635 15150 MBtu/hr Max burner output RS 500/EV FGR S9531 3030 18179 19694 MBtu/hr 4545 6060 7575 9090 10605 12120 13635 15149 16664 Max burner output RS 650 - 800/EV FGR... -
Page 27: Fgr Duct System
Installation 4.11 FGR duct system – Normally the duct would connect to the stack as shown in a condensate drip leg may be required on the bottom of the Fig. 21, with a 45° cut facing the flue gas flow and with the housing, to remove condensate. -
Page 28: Flue Gas Recirculation Line Sizing
Installation 4.11.1 Flue gas recirculation line sizing 4.11.2 Calculating the percentage of recirculated flue The Tab. M can be helpful to correctly size the FGR pipes taking flue gases from boiler stack base up to the burner intake port. As a general rule, recirculated flue gas quantity must be adjusted so as to recirculate the smallest quantity necessary to obtain the re- Maximum allowed pipe length (considering smooth steel pipes) is quired Nox rate. -
Page 29: Gas Feeding
Installation 4.12 Gas feeding Explosion danger due to fuel leaks in the presence The fuel supply line must be installed by qualified of a flammable source. personnel, in compliance with current standards Precautions: avoid knocking, attrition, sparks and and laws. WARNING heat. -
Page 30: Gas Train
Installation 4.12.2 Gas train 4.12.3 Gas pressure It must be type-approved according to UL Standards and is sup- The Tab. O shows minimum pressure losses along the gas supply plied separately from the burner. line depending on the maximum burner output operation. MBtu/hr (GCV) 1 p (“WC) 2 p (“WC) - Page 31 Installation Calculate the approximate maximum output of the burner as fol- lows: – subtract the combustion chamber pressure from the gas pres- sure measured at test point 1)(Fig. 24); – find, in the Tab. O relating to the burner concerned, the pres- sure value closest to the result of the subtraction;...
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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 carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination. -
Page 33: Cable Shielding
Installation 4.13.2 Cable shielding 4.13.3 Other connection The connection from the Inverter to LMV52..must be done It is very important to shield the motor cable 1) as as shown in Fig. 27. shown in Fig. 26. The connection from the speed sensor to LMV52..must be done as shown in Fig. -
Page 34: Inverter Connection
Installation 4.13.4 Inverter connection Treatment of cables Countermeasures against cable noise Following, it is reported an example how to con- nect the Inverter. The treatment of cables is the most important countermeasure. For further information, please refer to the relevant The machinery manufacturers are requested Inverter instruction manual. -
Page 35: 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 36: 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. Close the thermostats/pressure switches and turn the switch of Fig. 33 to position “LOCAL”. 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 37: Combustion Air Adjustment
Start-up, calibration and operation of the burner Combustion air adjustment Fuel/combustion air must be synchronized with the relevant servo- NOTE motors (air and gas) by storing a setting curve by means of the The first start-up and all further operations concerning internal set- electronic cam. -
Page 38: 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 (Fig. 34) after having performed all other burner adjustments with the air pressure switch set to the start of the scale. With the burner operating at min. -
Page 39: 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. 36) after having ad- justed the burner, the gas valves and the gas train stabiliser. -
Page 40: 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 41: Safety Components
Maintenance Burner Gas filter Clean the outside of the burner. Change the gas filter when it is dirty. Clean and grease the cam variable profile. Combustion Measurement of detector current In case the combustion values found at the beginning of the inter- vention do not respect the standards in force or, in any case, do not Measurement of the detector’s signal (Fig. -
Page 42: Adjustment Fan Motor Covering With External Rpm
Maintenance Adjustment fan motor covering with external rpm To calibrate the rpm sensor 6)(Fig. 38), proceed as follows: remove the cover 1) unscrewing the screws 2); unscrew or screw the nuts 3) - 5) and the rpm detection disc 4) so that its distance from the rpm sensor 6) is about 2 mm.;... -
Page 43: Opening The Burner
Maintenance Opening the burner Remove the tie rod 1)(Fig. 39) of the head movement lever, loosening nut 2); Disconnect the electrical supply from the burner by disconnect the gas servomotor test point 3); means of the main system switch. ... -
Page 44: A Appendix - Spare Parts
Appendix - Spare parts Appendix - Spare parts 20109903... - Page 45 Appendix - Spare parts CODE DESCRIPTION • • 20013113 GAS HEAD • 20121970 GAS HEAD • • 3013966 GAS HEAD • • 3013106 ELECTRODE • 20050435 ELECTRODE • • 20014076 ELECTRODE • • 20013159 ELECTRODE CONNECTION • 3013794 ELECTRODE CONNECTION •...
- Page 46 Appendix - Spare parts CODE DESCRIPTION • 20142775 LEVER ASSEMBLY • • 20114283 LEVER ASSEMBLY • • 20030725 • • • 20038375 • • 20030724 • • • 20038376 • 3013313 CYLINDER • 3013641 CYLINDER • 20026703 CYLINDER • • 3013959 CYLINDER •...
- Page 47 Appendix - Spare parts CODE DESCRIPTION • 20159557 PILOT BURNER SUPORT • 20033305 AIR DIFFUSOR • 20117057 FLANGE A DVISED PARTS = Spare parts for minimum fittings = Spare parts for basic safety fittings A+B+C = Spare parts for extended safety fittings 20109903...
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Page 48: B Appendix - Accessories
Appendix - Accessories Appendix - Accessories 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. WARNING 20109903... -
Page 49: 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: Model number: Serial number: Project name: Start-up date: Installing contractor: Phone number: GAS OPERATION : Low Fire Gas Supply Pressure: High Fire : Low Fire... - Page 52 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http://www.riello.it 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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