Riello 521T80 Quick start guide

2915865 (4) - 05/2012

Installation, use and maintenance instructions

Forced draught gas burner

Code Model Type

3752182 GAS 3/2 521T80

DECLARATION

Declaration of conformity in accordance with ISO / IEC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 7

37045 Legnago (VR)

Product: Forced draught gas burner

Model: GAS 3/2

These products are in compliance with the following Technical Standards:

EN 676

EN 12100

and according to the European Directives:

MD 2006/42/EC Machine Directive

LVD 2006/95/EC Low Voltage Directive

EMC 2004/108/EC Electromagnetic Compatibility

The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO

9001.

Legnago, 22.02.2010 Mr. G. Conticini

Burners Division Department

RIELLO S.p.A.

5865 1

TECHNICAL DATA

BURNER DESCRIPTION

OVERALL DIMENSIONS

Thermal output 2nd stage 130 - 340 kW - 112.000 - 292.000 kcal/h

Operation Two stages, high and low flame

Fuel Natural gas Pci 8 - 10 kWh/m3= 7000 - 8600 kcal/m3

Minimum gas pressure For maximum output 11.1 mbar are needed measured at the coupling with

nil pressure in the combustion chamber and gas with calorific value of

8600 kcal/m3

Maximum gas pressure 150 mbar

Electrical supply Single phase 220 V + 10% - 10% ~ 60Hz

Motor 1.85A / 220V

Capacitor 6.3 µF

Ignition transformer Primary: 1.8A / 220V - Secondary: 1 x 8 kV - 30 mA

Absorbed electrical power 0.4 kW

1– Air damper controlling motor

2– Control box re-set button

3– Fair leads

4– Wiring terminal block

5– Air pressure switch

6– Gas pressure test-point

Fig. 1

S7512

Boiler front-plate

drilling

*Length available with special blast tube to be separately required.

Burner

160

155 M10

410 610185

*320

397

292

165

ø 140

Rp 1 1/2

S7515 S7520

D1785

5865 2

STANDARDS EQUIPMENT

ACCESSORIES

• RADIO DISTURBANCE PROTECTION KIT code 3010386

If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10

V/m) owing to the presence of an INVERTER, or in applications where the length of the thermostat

connections exceeds 20 metres, a protection kit is available as an interface between the control box and the

burner.

FIXING TO THE BOILER

GAS SUPPLY

Quantity Description

1Flange

1Gasket

8 Screws

1 Flange gasket

Separate the combustion head from the

burner body by loosening the screws 1)

and 2) and withdrawing the group A) from

the holding bars 3).

Fix the group B) to the boiler front plate 4)

using the gasket 5) provided as accessory.

23 5 4

S7499

1- Gas pipe line 7- 1st stage gas shut off valve

2- Cock valve 8- 2nd stage gas shut off valve

3- Filter 9- Burner

4- Pressure stabilizer 10 - Gas safety shut off valve

5- Pressure test-point 11 - Isolator joint

6- Minimal gas pressure switch

710 5

431121

S7514

5865 3

WORKING RANGE

COMBUSTION CHAMBER PRESSURE 2nd STAGE OUTPUT

(in compliance with DIN 4788)

Min. output at 1st stage: 80 kW - 69.000 kcal/h.

MINIMUM GAS PRESSURE - OUTPUT

Pressure: detected at the pressure test-point 6) (fig. 1) with nil mbar into the combustion chamber.

Should the combustion chamber be pressurized, the pressure necessary will be that of the

graph plus the pressurization value.

Example: to obtain 270 kW it is necessary a gas pressure of 8 mbar and the combustion head set as

indicated at page 7.

If the combustion chamber is pressurized at 2 mbar, the pressure detected at the test-point

6) is: 8 + 2 = 10 mbar.

If this value is too high, for very low gas pipework pressures, the gas gear 6) (page 7) could

be more open.

Do not decrease the pressure at the coupling under the values shown in the diagram.

Output: the maximum value is obtainable with gas Pci 8600 kcal/m3.

CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

kcal/h

mbar

D1788

kcal/h

mbar

D1789

5865 4

BURNER ELECTRICAL WIRING

(carried out in the factory)

20052582

CCapacitor

F1 Protection against radio interference

K1 Relay

MB Burner terminal strip

MV Fan motor

PA Air pressure switch

RMG Control box

SO Ionisation probe

SM Servomotor

TA Ignition transformer

TB Burner earth

ATTENTION

In the case of phase-phase feed, a

bridge must be fitted on the control box

terminal board between terminal 6 and

the earth terminal.

5865 5

ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK

(to be carried out by the installer)

NOTICE

- Theelectricwiringcarriedoutbytheinstaller must bein compliancewiththerulesin forceintheCountry.

- Leads minimal section 1 mm2.

- Burners with non-stop operation. For safety reasons, this type of burner must be stopped every 24

hours of operation, by means of an hours-counter to be connected in series with the adjustment

devices.

FLAME MODULATION

The flame modulation is obtainable through the thermostat, controlling the second valve, connected

to the terminals 8 and 9.

FIXING OF THE ELECTRICAL WIRES

All the electrical wires, which are to be connected to the terminal block 4) (fig. 1) shall pass through

the fair leads 3) (fig. 1) as for this scheme.

1- Single phase supply : fair lead Pg 13.5

2- Adjustment thermostat : fair lead Pg 13.5

3- Safety thermostat : fair lead Pg 13.5

4- Gas train : fair lead Pg 13.5,

sheath ø 13

5-2nd stage thermostat : fair lead Pg 13.5

6 / 7 - Pre-sheared holes

Further prospective signals or controls can be connected to the burner wiring terminal board by

removing the metal weldnuts from the pre-sheared holes and inserting a commun fair lead for the

passage and the clamping of the leads.

NOTES

- Do not exchange the neutral wire with the phase (avoid the plug-pin connection).

- Carry out a safe earth connection.

- Check the stop of the burner, by opening the boiler thermostat and the burner lock-out, by

disconnecting the lead from the flame probe.

WARNING

When closing the burner on its slide-bars, pull towards the outside the high voltage cable and the

cable of the flame detection probe, till to little tension.

HRemote lock-out signal

MB Burner terminal strip

PG Minimum gas pressure swicth

TB Burner earth

TL Limit control device system

TR High-low mode load control system

TS Safety control device system

VS Gas safety shut off valve

V1 1° stage gas shut off valve

V2 2° stage gas shut off valve

D2660

S7523

5865 6

BURNER START-UP CYCLE

Air-purge: loosen the screw placed on the minimal gas pressure switch mounted on the gas train.

AIR PRESSURE SWITCH 5) (fig.1)

The air pressure switch setting shall be carried out after having

set all other adjustments of the burner and the air pressure

switch shall be at its lowest set-point.

When the burner is operating, increase the adjustment pressure

by turning - slowly - clockwise the knob till reaching the burner

lock-out.

Thereafter, turn the knob anticlockwise for 1 mbar and repeat the

burner start-up for checking the regularity: if lock-out intervenes

turn the knob anticlockwise for 0.5 mbar.

CAUTION:

do not turn the ionization probe, maintain the drawing position; should it be close to the ignition

electrode, damage may occur to the control box amplifier.

Screw

Plug for pressure measure

Pressure switch

S7506

1 ÷ 10

mbar

Adjustment knob

S7507

3 - 4 mm

2 - 4 mm

Probe position Ignition electrode position

S7524

5865 7

COMBUSTION HEAD ADJUSTMENT

Two separate adjustments have to be made: air and gas.

These adjustments can be carried out when the burner is still open, during the installation (see

page 2 - Fixing to the boiler).

Air setting

Loosen the two screws 1) and move the internal

part of the combustion head 2) so that its rear

edge 3) is coincident with the desired set-point

on the plate 4). Tighten the screws 1).

Gas setting

Loosen the screw 5), move the ring 6) so that

the pointer 7) is coincident with the desired set-

point 8). Tighten the screw 5).

Attention:

the set-point number is the same for air and gas

setting and is given by the following diagram.

Example:

the burner is installed on a boiler of 225 kW, assuming an efficiency of 90% the burner output

should be 250 kW.

From the diagram it can be seen that the air and gas settings for this rating should be no. 4.

134 7

S7510

kcal/h kW

Burner output

Set-point number = for air and gas

D1793

5865 8

ADJUSTMENT OF THE AIR DAMPER MOTOR

STOP - Blue lever

This lever leaves the factory vertically positioned and corresponds to the complete closing of the air

damper.

A partial opening of the air damper might be obtained by moving leftwards this lever (+ on the label).

The new position of the air damper is detectable when the burner is off.

Do not overcome the position of the orange lever for the 1st stage.

1st STAGE - Orange lever

The orange lever controls the air damper position for the first flame, it is adjustable both for opening and

closing.

2nd STAGE - Red and black levers

The red lever controls the air damper position for the second flame, it is adjustable both for closing and

opening.

The black lever controls the opening of the second oil valve and it must always anticipate - for a bit -

the red lever, but never the orange one.

OPERATIONAL DIAGRAM

S7525

Black lever

Red lever

Orange lever

Blue lever

Opening + –Closing

The black lever must

anticipate the red one

S7526

Output gas

Time

Pre-purge

1st stage valve energizing

2nd stage valve energizing

38 s

10 s

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