Riello 835 T80 Quick start guide

Installation, use and maintenance instructions

Instrucciones de Instalación, Funcionamiento y Mantenimiento

Instruções de Instalação, Funcionamento e Manutenção

Forced draught gas burners

Quemadores de gas

Queimadores a gás

2916014 (9) - 09/2013

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3785820 RS 190 835 T80

20011699 RS 190 835 T80

Progressive two-stage operation

Funcionamiento a dos llamas progresivas

Funcionamento a duas chamas progressivas

CONTENTS

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2

Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 6

Setting the combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Adjustments before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Burner calibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 - Firing output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 - 2nd stage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 - 1st stage output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 - Intermediates outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 - Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6 - Minimum gas pressure switch. . . . . . . . . . . . . . . . . . . . . . . . 15

Flame present check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . 18

Resetting the control box and using diagnostics. . . . . . . . . . . 18

Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 19

Normal operation / flame detection time. . . . . . . . . . . . . . . . . . . 20

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

N.B.

Figures mentioned in the text are identified as follows:

1)(A) =part 1 of figure A, same page as text;

1)(A)p.3 =part 1 of figure A, page number 3.

TECHNICAL DATA

(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m s.l.m.

(2) Pressure at test point 17)(A)p.3, with zero pressure in the combustion chambre, with open gas ring 2)(B)p.7 an maximum burner output

(3) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.

ELECTRICAL DATA

Motor IE1

Motor IE2

GAS CATEGORY VARIANTS

MODEL RS 190

CODE 3785820 20011699

OUTPUT (1) 2nd stage kW

Mcal/h

1279 - 2290

1100 - 1970

min. 1st stage kW

Mcal/h

470

405

FUEL NATURAL GAS: G20 - G21 - G22 - G23 - G25

G20 G25

- net calorific value kWh/Sm3

Mcal/Sm3

9.45

8.2

8.13

7.0

- absolute density kg/Sm30.71 0.78

- max. delivery Sm3/h 230 267

- pressure at max. delivery mbar 15 22

OPERATION • On-Off (1 stop min each 24 hours).

• Two-stage (high and low flame) and single stage (all - nothing)

STANDARD APPLICATIONS Boilers: water, steam, diathermic oil

AMBIENT TEMPERATUR °C 0 - 40

COMBUSTION AIR TEMPERATURE °C max 60

IN CONFORMITY WITH EEC DIRECTIVES 2004/108 - 2006/95 - 2006/42

NOISE LEVELS (2) dBA 83.1

MODEL RS 190

ELECTRICAL SUPPLY V

380 ~ +/-10%

60 - three-phase

220 ~ +/-10%

60 - three-phase

AUXILIARY CIRCUITS SUPPLY V 220

ELECTRIC MOTOR rpm

3430

4000

380

3430

4000

220

Running current A 9.1 15.8

IGNITION TRANSFORMER V1 - V2

I1 - I2

230 V - 1 x 8 kV

1 A - 20 mA

ELECTRICAL POWER CONSUMPTION W max 5500

ELECTRICAL PROTECTION IP 44

MODEL RS 190

ELECTRICAL SUPPLY V

380 ~ +/-10%

60 - three-phase

220 ~ +/-10%

60 - three-phase

AUXILIARY CIRCUITS SUPPLY V 220

ELECTRIC MOTOR rpm

3540

4000

220-380

3540

4000

220

Running current A 13.8 / 8 13.8 / 8

IGNITION TRANSFORMER V1 - V2

I1 - I2

230 V - 1 x 8 kV

1 A - 20 mA

ELECTRICAL POWER CONSUMPTION W max 5000

ELECTRICAL PROTECTION IP 44

COUNTRY CATEGORY

IT - AT - GR - DK - FI - SE

ES - GB - IE - PT

LU - PL

II2H3B / P

II2H3P

II2L3B / P

II2Er3P

II2ELL3B /P

I2E(R)B, I3P

II2E 3B/P

Model Code Power supply

electrical

RS 190 3785820 380 V

RS 190 20011699 220 V

BURNER DESCRIPTION (A)

1 Combustion head

2 Ignition electrode

3 Screw for combustion head adjustment

4Sleeve

5 Servomotor controlling the gas butterfly

valve and of air gate valve (by means of a

variable profile cam mechanism).

When the burner is stopped the air gate

valve will be completely closed to reduce

heat loss due to the flue draught, which

tends to draw air from the fan air inlet.

6 Plug-socket on ionisation probe cable

7 Extension for slide bars 16)

8 Motor contactor and thermal cut-out reset

button

9 Flame stability disk

10 Terminal strip

11 Fairleads for electrical connections by installer

12 Two switches:

- one “burner off-on”

- one for “1st - 2nd stage operation”

13 Control box with lock-out pilot light and lock-

out reset button

14 Flame inspection window

15 Minimum air pressure switch

(differential operating type)

16 Slide bars for opening the burner and

inspecting the combustion head

17 Gas pressure test point and head fixing screw

18 Air pressure test point

19 Flame sensor probe

20 Air gate valve

21 Air inlet to fan

22 Screws securing fan to sleeve

23 Gas input pipework

24 Gas butterfly valve

25 Boiler mounting flange

Two types of burner failure may occur:

•Control box lock-out: if the control box

13)(A) pushbutton (red led) lights up, it indi-

cates that the burner is in lock-out.

To reset, hold the pushbutton down for

between 1 and 3 seconds.

•Motor trip: release by pressing the pushbut-

ton on thermal cutout 8)(A).

PACKAGING - WEIGHT (B)

Approximate measurements

• The burner stands on a wooden base which

can be lifted by fork-lifts.

Outer dimensions of packaging are indicated

in (B).

• The weight of the burner complete with pack-

aging is indicated in Table (B).

MAX. DIMENSIONS (C)

Approximate measurements

The maximum dimensions of the burner are

given in (C).

Bear in mind that inspection of the combustion

head requires the burner to be opened by with-

drawing the rear part on the slide bars.

The maximum dimension of the burner when

open is give by measurement I.

STANDARD EQUIPMENT

1 - Gas train flange

1 - Flange gasket

6 - Flange fixing screws M 10 x 30

1 - Thermal insulation screen

4 - Screws to secure the burner flange to the

boiler: M 12 x 35

1 - Instruction booklet

1 - Spare parts list

(A)

(B)

(C)

D7861

D36

D731

mm A B C kg

RS 190 1250 725 785 82

mm ABCDEFGH I LMN O

RS 190 681 366 315 555 872 372 222 430 1328 246 150 186 2”

FIRING RATES (A)

The RS 190 model burner can work in two way:

one-stage and two-stage.

MAXIMUM OUTPUT must be selected in area

MINIMUM OUTPUT must not be lower than the

minimum limit shown in the diagram.

RS 190 = 470 kW

Important

The FIRING RATE area values have been ob-

tained considering a surrounding temperature of

20 °C, and an atmospheric pressure of 1013

mbar (approx. 0 m above sea level) and with the

combustion head adjusted as shown on page 7.

TEST BOILER (B)

The firing rates were set in relation to special

test boilers, according to EN 676 regulations.

Figure (B) indicates the diameter and length of

the test combustion chamber.

Example:

Output 756 kW:

diameter = 60 cm; length = 2 m.

COMMERCIAL BOILERS

The burner/boiler combination does not pose

any problems if the boiler is CE type-approved

and its combustion chamber dimensions are

similar to those indicated in diagram (B).

If the burner must be combined with a commer-

cial boiler that has not been CE type-approved

and/or its combustion chamber dimensions are

clearly smaller than those indicated in diagram

(B), consult the manufacturer.

(A)

(B) D715

D1262

RS 190

pressure mbar

Combustion chamber

length m

Combustion chamber

GAS PRESSURE

The adjacent table shows minimum pressure

losses along the gas supply line depending on

the burner output in 2nd stage operation.

Column 1

Pressure loss at combustion head.

Gas pressure measured at test point 1)(B), with:

• Combustion chamber at 0 mbar

• Burner operating in 2nd stage

• Combustion head adjusted as indicated in

diagram (C)p. 7.

Column 2

Pressure loss at gas butterfly valve 2)(B) with

maximum opening: 90°.

Column 3

Pressure loss of gas train 3)(B) includes: adjust-

ment valve VR, safety valve VS (both fully

open), pressure governor R, filter F.

The values shown in the table refer to:

natural gas G 20 NCV 9.45 kWh/Sm3

(8,2 Mcal/Sm3)

With:

natural gas G 25 NCV 8,13 kWh/Sm3

(7,0 Mcal/Sm3) multiply tabulated values:

- column 1 - 2: by 1.5

- column 3: by 1.35.

Calculate the approximate 2nd stage output of

the burner thus:

- Subtract the combustion chamber pressure

from the gas pressure measured at test point

1)(B).

- Find the nearest pressure value to your result

in column 1 of the table (A).

- Read off the corresponding output on the left.

Example:

• 2nd stage operation

• Natural gas G 20 NCV 9.45 kWh/Sm3

• Gas pressure at test point 1)(B) = 11 mbar

• Pressure in combustion chamber = 3 mbar

11 - 3= 8 mbar

A 2nd stage output of 1600 kW shown in Table

(A) corresponds to 8 mbar pressure, column 1.

This value serves as a rough guide, the effective

delivery must be measured at the gas meter.

To calculate the required gas pressure at test

point 1)(B), set the output required from the

burner in 2nd stage operation:

- Find the nearest output value in the table (A).

- Read off the pressure at test point 1)(B) on

the right in column 1.

- Add this value to the estimated pressure in

the combustion chamber.

Example:

• Required burner output in 2nd stage opera-

tion: 1600 kW

• Natural gas G 20 NCV 9.45 kWh/Sm3

• Gas pressure at burner output of 1600 kW,

taken from table (A), column 1 = 8 mbar

• Pressure in combustion chamber = 3 mbar

8 + 3 = 11 mbar

pressure required at test point 1)(B).

(A)

RS 190 p (mbar)

kW 1 2

3970181

3970182

3970221

3970225

3970222

3970226

3970223

3970227

1280 7.0 1.3 28.6 10.3 7.2 4.8

1400 7.3 1.6 33.5 12.1 8.2 5.2

1500 7.6 1.8 37.7 13.6 9.0 5.5

1600 8.0 2.1 41.8 15.2 9.9 5.8

1700 8.7 2.4 46.0 16.7 10.7 6.1

1800 9.3 2.7 50.2 18.2 11.6 6.5

1900 10.2 3.0 54.3 19.8 12.5 6.8

2000 11.3 3.3 59.3 21.6 13.6 7.3

2100 12.5 3.6 64.4 23.5 14.8 7.7

2290 15.0 4.3 74.1 27.1 17.0 8.6

(B)

D3734

MB 420

MBC 1200

MBC 1900

MBC 3100

INSTALLATION

BOILER PLATE (A)

Drill the combustion chamber locking plate as

shown in (A). The position of the threaded holes

can be marked using the thermal screen sup-

plied with the burner.

BLAST TUBE LENGTH (B)

The length of the blast tube must be selected

according to the indications provided by the

manufacturer of the boiler, and in any case it

must be greater than the thickness of the boiler

door complete with its fettling. The length avail-

able, L (mm), is 372 mm.

For boilers with front flue passes 15) or flame

inversion chambers, protective fettling in refrac-

tory material 13) must be inserted between the

boiler fettling 14) and the blast tube 12).

This protective fettling must not compromise the

extraction of the blast tube.

For boilers having a water-cooled front the

refractory fettling 13)-14)(B) is not required

unless it is expressly requested by the boiler

manufacturer.

SECURING THE BURNER TO THE BOILER

(B)

Before securing the burner to the boiler, check

through the blast tube opening to make sure

that the flame sensor probe and the ignition

electrode are correctly set in position, as shown

in (C).

Now detach the combustion head from the

burner, fig.(B):

- Loosen the 4 screws 3) and remove the cover 1)

- Disengage the articulated coupling 7) from

the graduated sector 8).

- Remove the screws 2) from the slide bars 5).

- Remove the two screws 4) and pull the burner

back on slide bars 5) by about 100 mm.

Disconnect the wires from the probe and the

electrode and then pull the burner completely

off the slide bars.

Secure the flange 11)(B) to the boiler plate, inter-

posing the thermal insulating screen 9)(B) sup-

plied with the burner. Use the 4 screws, also

supplied with the unit, after first protecting the

thread with an anti-locking product.

The seal between burner and boiler must be air-

tight.

If you noticed any irregularities in positions of

the probe or ignition electrode during the check

mentioned above, remove screw 1)(D), extract

the internal part 2)(D) of the head and proceed

to set up the two components correctly.

Do not attempt to turn the probe. Leave it in the

position shown in (C) since if it is located too

close to the ignition electrode the control box

amplifier may be damaged.

(A)

(B)

(C)

(D)

PROBE ELECTRODE

D455

D3036

D1265

D1266

mm A B C

RS 190 230 325-368 M 16

SETTING THE COMBUSTION HEAD

Installation operations are now at the stage

where the blast tube and sleeve are secured to

the boiler as shown in fig. (B). It is now a very

simple matter to set up the combustion head, as

this depends solely on the output developed by

the burner in 2nd stage operation.

It is therefore essential to establish this value

before proceeding to set up the combustion

head.

There are two adjustments to make on the

head.

Air adjustment (B) See diagram (C).

Turn screw 4)(B) until the notch identified is

aligned with the front surface 5)(B) of the flange.

Gas adjustment (A)

When the burner is installed for an output in 2nd

stage 1300 Mcal/h (about 1500 kW) assemble

the supplied disks 1)-2)(A) removing the inner

pipe 3)(A). If there is little gas in the network, the

head may be left in standard configuration, limit-

ing the minimum modulation to 450 Mcal/h

(circa 520 kW).

Example

Burner output = 1593 kW (1370 Mcal/h).

If we consult diagram (C) we find that for this

output, air must be adjusted using notch 3, as

shown in fig. (B).

Continuing with the previous example, page 5

indicates that for burner with output of 1593 kW

(1370 Mcal/h) a pressure of approximately 8

mbar is necessary at test point 6)(B).

Once you have finished setting up the head, refit

the burner to the slide bars 3)(D) at approxi-

mately 100 mm from the sleeve 4)(D) - burner

positioned as shown in fig. (B)p. 6 - insert the

flame detection probe cable and the ignition

electrode cable and then slide the burner up to

the sleeve so that it is positioned as shown in

fig. (D).

Refit screws 2) on slide bars 3).

Secure the burner to the sleeve by tightening

screw 1).

Reconnect the articulation 7) to the graduated

sector 6).

Important

When fitting the burner on the two slide bars, it

is advisable to gently draw out the high tension

cable and flame detection probe cable until they

are slightly stretched.

(A)

(C)

(B)

(D)

Burner output in 2nd stage operation

Nr. Notches

D1267

D1268

D3037

GAS LINE

• The gas train can enter the burner from the

right or left side, depending on which is the

most convenient.

• Gas valves must be as close as possible to the

burner to ensure gas reaches the combustion

head within the safety time range of 3 s.

• Make sure that the pressure governor calibra-

tion range (colour of the spring) comprises the

pressure required by the burner.

GAS TRAIN (A)

It is type-approved according to EN 676 Stand-

ards and is supplied separately from the burner

with the code indicated in Table (B).

KEY (A)

1 - Gas input pipe

2 - Manual valve

3 - Vibration damping joint

4 - Pressure gauge with pushbutton cock

5 - Filter

6A - Threaded” Multibloc including:

- filter (replaceable)

- functioning valve

- pressure governor

6B - Flanged” Multibloc including:

- safety valve

- functioning valve

- pressure governor

7 - Minimum gas pressure switch

8 - Gas valve leak detection control device.

In accordance with EN 676 Standards,

gas valve leak detection control devices

are compulsory for burners with maximum

outputs of more than 1200 kW.

9 - Gasket

10 - Standard issue burner gasket

11 - Gas adjustment butterfly valve

12 - Maximum gas pressure switch

13 - Gas train/burner adaptor

- supplied with burner

- supplied on requested separately with the

gas ramp for flanged versions

P1 - Pressure at combustion head

P2 - Up-line pressure valve/adjuster

P3 - Pressure up-line from the filter

L - Gas train supplied separately with the code

indicated in Table (B)

L1 - The responsibility of the installer

KEY TO TABLE (B)

C.T.= Gas valves leak detection control devic-

es:

- = Gas train without gas valve leak de-

tection control device; device that can

be ordered separately and assem-

bled subsequently (see column 8).

= Gas train with assembled VPS valve

leak detection control device.

8 = VPS valve leak detection control de-

vice.

Supplied separately from gas train on

request.

13 = Gas train/burner adaptor.

Supplied separately from gas train on

request.

Note

See the accompanying instructions for the ad-

justment of the gas train.

(B)

56B

123

L1 L

BURNERS AND RELEVANT GAS TRAINS APPROVED ACCORDING TO EN 676

GAS TRAINS - L 8 13

Code Model Ø C.T. Code Code

3970181 MBD 420 2” - 3010123 -

3970182 MBD 420 CT 2” --

3970221 MBC-1200-SE-50 2” - 3010123 -

3970225 MBC-1200-SE-50 CT 2” --

3970222 MBC-1900-SE-65 FC DN 65 - 3010123 3000825

3970226 MBC-1900-SE-65 FC CT DN 65 - 3000825

3970223 MBC-3100-SE-80 FC DN 80 - 3010123 3000826

3970227 MBC-3100-SE-80 FC CT DN 80 - 3000826

(A) D3735

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