Riello RS 300/E BLU Quick start guide

Installation, use and maintenance instructions

Gas burners

Modulating operation

2543947 (2) - 06/2007

CODE MODEL TYPE

3809098 RS 300/E BLU 09098 D

3809097 RS 400/E BLU 09097 D

3809099 RS 500/E LN 09099 D

CONTENTS

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of available models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Description of panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Blast tube length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 7

Accessibility to the interior of the combustion head . . . . . . . . . . . 7

Position of electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rotation of fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Adjustment before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Combustion air adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Air adjustment for maximum output . . . . . . . . . . . . . . . . . . . . . . .11

Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maximum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Air/fuel control and power modulation system . . . . . . . . . . . . . . 15

Appendix

Layout of electrical panel board . . . . . . . . . . . . . . . . . . . . . . . . . 16

Key to electrical layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

TECHNICAL DATA

(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394 “WC - Altitude 329 ft a.s.l.

(2) Pressure at pressure switch test point 20)(A)p.4 with zero pressure in the combustion chamber and maximum burner output.

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

(4) Values referred to Gross calorific Value (GCV).

(5) Values referred to Net calorific Value (NCV).

ACCESSORIES (optional)

•PRESSURE/TEMPERATURE CONTROL PROBE

•KIT SOFTWARE INTERFACE: code 3010388

Note.

Riello S.p.a. declines all responsibility for the addition of safety devices not provided for herein.

MODEL RS 300/E BLU RS 400/E BLU RS 500/E BLU

TYP 09098 D 09097 D 09099 D

OUTPUT (1) HIGH MBtu/hr (4) 5112 ÷ 14390 6817 ÷ 17043 9468 ÷ 19580

kW (5) 1350 ÷ 3800 1800 ÷ 4500 2500 ÷ 5170

LOW MBtu/hr (4) 1893 3030 3787

kW (5) 500 800 1000

FUEL Natural gas

Gas pressure at maximum delivery. (2) “ w.c. 7 / 10.2 13 / 15.2 15 / 22

OPERATION Continuous / Intermittent

STANDARD APPLICATIONS Boilers: water, steam, diathermic oil

AMBIENT TEMPERATUR °F 32 - 104 (0 - 40 °C)

COMBUSTION AIR TEMPERATURE °F max 140 (60 °C)

MAIN POWER SUPPLY (+/- 10%) V/Ph/Hz 460 / 3 / 60

AUXILIARY SUPPLY V/Ph/Hz 110-120 / 3 / 60

FAN MOTOR

(star-delta starting for RS400 and RS500)

rpm

3410

460

7,5

3410

460/795

13 - 8

3410

460/795

16 - 13

IGNITION TRANSFORMER V1 - V2

I1 - I2

120 V - 1 x 7 kV

1.6 A - 23 mA

ELECTRICAL POWER CONSUMPTION HP - kW max 8 - 6 13.5 - 10 15 - 11

ELECTRICAL PROTECTION NEMA 3

NOISE LEVELS (3) dBA 82 85 88

PARAMETER TO BE CHECKED PROBE

Range Type Code

Temperature - 148...+ 932°F (- 100...+ 500°C) PT 100 3010110

Pressure 0...36.3 PSI (0...2,5 bar)

0...232 PSI (0...16 bar)

Output probe

4...20 mA

3010213

3010214

DESIGNATION OF BURNER SERIES RS

Series : R

Size

Fuel : S

Natural gas

Light oil

Light oil / Methane

Setting : E Electronic cam

EV Variable speed (with Inverter)

Head : TC Standard head

TL Extended head

Flame control system :

FS1

FS2

Standard (1 stop every 24 h)

Continuos working (1 stop every 72 h)

Electrical supply to the system :

3/400/50

3/230/50

Auxiliary voltage :

230/50/60

110/50/60

R S 300 ETC

Emission : ... Class 1 EN267 - EN676

MZ Class 2 EN267 - EN676

BLU Class 3 EN267 - EN676

MX Class 1 EN267

Class 3 EN676

FS1 3/400/50 230/50/60

BASIC DESIGNATION

EXTENDED DESIGNATION

Designation Electrical supply Starting Code

RS 300/E BLU TC 460V-60Hz Direct 3809098

RS 400/E BLU TC 460V-60Hz Star/Delta 3809097

RS 500/E BLU TC 460V-60Hz Star/Delta -

RS 500/E LN TC 460V-60Hz Star/Delta 3809099

3N / 400V / 50Hz

3 / 230V / 50Hz

230V / 50-60Hz

110V / 50-60Hz

N Heavy oil

P Air/gas proportioning valve

LIST OF AVAILABLE MODELS

LN Class LOW NOx US

BURNER DESCRIPTION (A)

1 Lifting eyebolts

2Fan

3 Fan motor

4 Air gate valve servomotor

5 Gas pressure test point

6 Combustion head

7 Ignition pilot

8 Flame stability disk

9 Electric panel board - cover

10 Servomotor for gas butterlfy valve

11 Air inlet to fan

12 Manifold

13 Thermal insulation screen for securing

burner to boiler

14 Gas butterfly valve

15 Shutter

16 Lever for movement of combustion head

17 Gears for movement of air damper

18 Air pressure switch (differential operating

type)

19 Air pressure test point

20 Maximum gas pressure switch with pressure

test point

21 QRI infrared sensor

22 Hinge for opening burner

23 Air pressure test point pressure test point “+”

24 Air pressure test point pressure test point “-”

The burner can be opened either on the right or

left sides, irrespective of the side from which

fuel is supplied.

When the burner is closed, the hinge can be re-

positioned on the opposite side.

DESCRIPTION OF PANEL BOARD (B)

1 Auxiliary terminal strip

2 Relay outlet - clean contacts

3 Electronic cam transformer

4 Electronic cam setting device

5 Ignition transformer

6 Stop push-button

7 Dial for O - AUTO

8 Signal light for power on

9 Signal light for fan motor overload

10 Signal light for burner failure and lock-out

reset button

11 Display AZL

12 Star-powered/delta-powered starter (RS

400/E BLU - RS 500/E BLU only)

13 Timer

14 Main supply terminal strip

15 Entry for power cables and external leads

N.B.

Two types of burner failure may occur:

Flame control lockout: light 12)(B) on the

panel comes on to report burner lockout.

To reset, press pushbutton 12)(B).

Motor trip: release by pressing the push button

on thermal.

Key to layout (C)

1Electrical supply

2Auxiliary electrical supply

3Fan motor

4Triggering / Safety devices

5Gas train

6Adjustment probes

7Available

(A)

2 3 4 5

12 13

78 9

9 1 17 116 19 615

10 22

13 512 24 4

ENTRY FOR POWER CABLES AND EXTERNAL LEADS

D3793

5557 1

34447

D3801

(C)

(B)

PACKAGING - WEIGHT (A) - Approximate

measurements

• The burners stands on a wooden base which

can be lifted by fork-lifts. Outer dimensions of

packaging are indicated in (A).

• The weight of the burner complete with pack-

aging is indicated in Table (A).

STANDARD EQUIPMENT

1 - Flange gasket

4 - Flange fixing screws M 16 x 50

1 - Thermal insulation screen

4 - Screws to secure the burner flange to the

boiler: M 18 x 70

2 - Spacers (see Fig. C page 8)

1 - Pressure switch (for leak detection control)

1 - Instruction booklet

1 - Spare parts list

MAX. DIMENSIONS (B) -Approximate

measurements

The maximum dimensions of the burner are

given in (B). Bear in mind that inspection of the

combustion head requires the burner to be

opened by rotating the rear part on the hinge.

The overall dimensions of the burner when open

are indicated by L and R.

(A)

inch A B C lbs

RS 300/E BLU 7711/64“37

1/64“38

3/16“496

RS 400/E BLU 7711/64“37

1/64“38

3/16“520

RS 500/E BLU 7711/64“37

1/64“38

3/16“551

inch A B C D E F G H L R S

RS 300/E BLU 523/16“20

1/2“6

7/16“12

5/16“23

5/32“DN80 2811/32“34

9/64“46

1/4“41

17/32“12

19/32“

RS 400/E BLU 523/16“20

1/2“6

7/16“12

5/16“23

5/32“DN80 301/2“34

9/64“46

1/4“41

17/32“12

19/32“

RS 500/E BLU 523/16“20

1/2“6

7/16“14

17/32“23

5/32“DN80 301/2“34

9/64“46

1/4“41

17/32“12

19/32“

(B)

D3099

D36

FIRING RATES (A)

MAXIMUM OUTPUT must be selected in the

hatched area of the diagram.

MINIMUM OUTPUT must not be lower than the

minimum limit shown in the diagram:

Important: The FIRING RATE area values have

been obtained considering a surrounding tem-

perature of 68°F (20°C), and an atmospheric

pressure of 394 “WC (approx. 329 ft above sea

level) and with the combustion head adjusted as

shown on page 8.

MODEL NCV GCV

RS 300/E BLU 500 kW 1893 MBtu/hr

RS 400/E BLU 800 kW 3030 MBtu/hr

RS 500/E BLU 1000 kW 3787 MBtu/hr

(A) D3775

mbar

MBtu/h

w.c.

MBtu/h

0 5000 10000 15000 17500

0 56005200

mbar

4800440040003600320028002400200016001200800400

05600

5200

4800

4400

400036003200

2800

2400

20001600

1200

800

400

0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000

6000

NCV

GCV

RS 500/E BLU

RS 400/E BLU

RS 300/E BLU

RS 400/E BLU

RS 500/E BLU

MBtu/hr

W.C. W.C.

GCV

NCV

mbar

Combustion chamber pressureCombustion chamber pressure

Burner power output (referred to NCV)

Burner power output (referred to GCV)

0 2000 6000 80004000 12000 1400010000 16000 18000 20000

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.

For boilers with front flue passes 1) or flame

inversion chambers, protective fettling in refrac-

tory material 5) must be inserted between the

boiler fettling 2) and the blast tube 4).

This protective fettling must not compromise the

extraction of the blast tube.

For boilers having a water-cooled front the

refractory fettling 2)-5)(B) is not required unless

it is expressly requested by the boiler manufac-

turer.

SECURING THE BURNER TO THE

BOILER (B)

• Create a suitable hoisting system by hooking

onto the rings 3)(B), removing the fastening

screws 7) securing the cover 8) first.

• Slip the thermal protection (standard equip-

ment) onto the blast tube 4) (B).

• Place entire burner on the boiler hole

(arranged previously, see fig. (A), and fasten

with the screws given as standard equipment.

The coupling of the burner-boiler must be air-

tight.

ACCESSIBILITY TO THE INTERIOR OF

THE COMBUSTION HEAD (C)

• Open burner at hinge as illustrated in fig. C

after releasing the tie rod of the head move-

ment lever 1) and removing the 4 fastening

screws 2).

• Disconnect the wire 3) from the electrode.

Disconnect the tube of ignition pilot 6).

• Unscrew the under part of the elbow 4) until it

comes free of its slot.

• Extract the internal part 5) of the combustion

head.

36 4

inch A B C

RS 300-400/E BLU 1325/32“17

51/64“45/64W

RS 500/E BLU 153/4“17

51/64“45/64W

(A)

(B)

(C)

D455

D3090

D3819

POSITION OF ELECTRODES (A)

Make sure that the electrode and the ignition

pilot are positioned as shown in figure (A).

COMBUSTION HEAD SETTING (B)

In addition to varying air flow depending on the

output requested, the air gate valve servomotor

4)(A) pag. 4 - by means of a lifting assembly -

varies the setting of the combustion head.

This system allows an optimal setting even at a

minimum firing rate.

For the same servomotor rotation, combustion

head opening can be varied by moving the tie

rod onto holes 1-2-3, fig. (B).

The choice of the hole (1-2-3) to be used is de-

cided on the basis of diagram (D) against the re-

quired maximum output.

Setting is pre-arranged in the plant for the maxi-

mum run (hole 3).

When dealing with boilers featuring a strong

back pressure, if air delivery is insufficient even

with the damper fully open, you can use a differ-

ent setting to that illustrated in diagram (D) - do

this by moving the tie rod onto the next highest

hole numerically speaking, thus increasing the

combustion head’s opening and hence air deliv-

ery.

If combustion requirements require you to move

spacer (1) fig. (C) onto the 1st or 2nd hole of the

gear and, at the same time, the hinge is on the

right, you need to fit the spacers (4) fig. (C)

supplied with the burner.

Proceed as follows (fig. C):

- first unscrew nuts (2), remove tie rod (3),

unscrew spacer (1) and position it on the hole

you want,

- screw the spacers (4) onto spacer (1) and

screw (5) respectively,

- once done, refit the tie rod and nuts.

For operation on flame-reversal

boilers, gas pipes must be adjusted

to hole position 4, see Fig. (E).

ROTATION OF FAN MOTOR

Look at the fan motor's cooling fan from the front

and make sure it turns anticlockwise.

D3409

D3777

MBtu/h

NCV

19694

17743

18179

16378

16664

15012

15150

13648

13635

12283

12120

10919

10605

9554

9090

8189

7575

6824

6060

5459

4545

40953412

3787

2730

3030

GCV

4545 6060 7575 9090 10605 12120 13635 15150 16664

4095 5459 6824 8189 9554 10919 12283 13648 15012

NCV

GCV MBtu/h

N° Hole

(A)

D3802

(C)

D3093

(D)

D3803

(B)

Max burner output

N° Hole

NCV

GCV

NCV

GCV

MBtu/hr

RS 500/E BLU

RS 400/E BLU

RS 300/E BLU

MBtu/hr

Ignition pilot Electrode

(E)

GAS LINE (A)

The gas train is to be connected on the right of

the burner, by flange 1) (A).

If it is necessary to connect it on the left of the

burner, loosen nuts and screws 3) and 4),

remove blind flange 2) together with its gasket

and fit them to flange 1) tightening the nuts and

screws.

Note

Once assembled the gas train, check for leaks.

GAS TRAIN (B)

It must be type-approved according to Stand-

ards and is supplied separately from the burner.

KEY TO LAYOUT (B)

1 - Gas input pipe for main burner

2 - Manual valve

3 - Low gas pressure switch

4 - Safety shut-off valve with SKP10

5 - NO vent valve

6 - Regulating shut off valve with SKP20

7 - Gas input pipe for pilot

8 - Gas adjustment butterfly valve

9 - Burner

10- High gas pressure switch

11- Manual valve (for seal control)

12- Pilot regulator

IMPORTANT

The pressure at the head of the burner from

table (C) - refers to zero in the combustion

chamber; to obtain true pressure, measured by

a U-type manometer, (see fig. (A) page 10) add

the counter-pressure of the boiler.

Note

See the accompanying instructions for the

adjustment of the gas train.

(A)

(B)

Main

gas supply

Vent

Pilot

gas supply

212

Vent

NCV

Combustion

Head

mbar

Gas

butterfly +

Adaptor

mbar

GCV

MBtu/hr

Combustion

Head

“WC

Gas

butterfly +

Adaptor

“WC

RS 300/E BLU

1350 8.4 1.6 5112 3.3 0.63

1500 9.4 2.0 5680 3.7 0.79

2000 12.4 3.5 7574 4.9 1.38

2500 13.7 5.4 9467 5.4 2.13

3000 15.0 7.8 11361 5.9 3

3500 20.2 10.6 13254 7.9 4.2

3800 23.0 13.0 14390 9 5.1

RS 400/E BLU

1800 5.8 2.8 6816 2.3 1.1

2000 7.6 3.5 7574 3 1.38

2500 11.9 5.4 9467 4.7 2.13

3000 16.3 7.8 11361 6.4 3

3250 18.5 9.2 12307 7.3 3.62

3500 21.1 10.6 13254 8.3 5.17

4000 27.6 13.9 15148 10.8 5.47

4500 33.0 18.0 17042 13 7

RS 500/E BLU

2500 11.2 4.6 9467 4.4 1.81

3000 15.4 6.7 11361 62.64

3500 19.5 9.1 13254 7.7 3

4000 24.7 11.8 15148 9.7 3.82

4500 30.0 15.0 17042 11.8 4.64

5000 35.9 18.5 18935 14.1 5.55

5200 38.0 20.0 19692 15 5.9

(C)

D3095

D3776

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