Table of Contents
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Modulating operation
CODE
20074268 - 20074269
20074270 - 20074271
20074272
20074273
MODEL
RS 310/EV BLU FS1/FS2
RS 410/EV BLU FS1/FS2
RS 510/EV BLU FS1/FS2
RS 610/EV BLU FS1/FS2
TYPE
1138T2
1135T2
1136T2
1137T2
20081753 (2) - 02/2015
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Table of Contents
Related Manuals for Riello RS 410/EV BLU FS1
Summary of Contents for Riello RS 410/EV BLU FS1
- Page 1 Forced draught gas burners Modulating operation CODE MODEL TYPE 20074268 - 20074269 RS 310/EV BLU FS1/FS2 1138T2 20074270 - 20074271 RS 410/EV BLU FS1/FS2 1135T2 20074272 RS 510/EV BLU FS1/FS2 1136T2 20074273 RS 610/EV BLU FS1/FS2 1137T2 20081753 (2) - 02/2015...
- Page 2 Translation of the original instructions...
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Page 3: Table Of Contents
Contents Declarations....................................3 Information and general warnings............................4 Information about the instruction manual ........................4 2.1.1 Introduction.................................. 4 2.1.2 General dangers................................4 2.1.3 Other symbols ................................4 2.1.4 Delivery of the system and the instruction manual...................... 5 Guarantee and responsibility............................5 Safety and prevention................................ - Page 4 Contents Start-up, calibration and operation of the burner ........................31 Notes on safety for the first start-up ...........................31 Adjustments prior to ignition............................31 Start-up procedure ..............................31 Air / fuel adjustment ..............................32 6.4.1 Air adjustment for maximum output ...........................32 6.4.2 Air/fuel adjustment and output modulation system ....................32 6.4.3 Burner adjustment..............................32 6.4.4...
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Page 5: Declarations
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001. Manufacturer's Declaration RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard "1. BIm- SchV revision 26.01.2010". -
Page 6: Information And General Warnings
Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction DANGER: EXPLOSION The instruction manual supplied with the burner: This symbol signals places where an explosive at- ➤ is an integral and essential part of the product and must not mosphere may be present. -
Page 7: Delivery Of The System And The Instruction Manual
Information and general warnings 2.1.4 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 8: 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 9: Technical Description Of The Burner
Technical description of the burner Technical description of the burner Burner designation Range: Fuel: Natural gas Gas oil Gas oil / Methane Heavy oil Size Adjustment: Two stage (light oil) / Proportional valve (gas) Electronic cam Electronic cam with variable speed (with Inverter) Proportional air/gas valve Mechanical cam C01 - ... -
Page 10: Models Available
Voltage Start-up Code 3/230/50 Inverter 20074268 RS 310/EV BLU FS1/FS2 3/400/50 Inverter 20074269 3/230/50 Inverter 20074270 RS 410/EV BLU FS1/FS2 3/400/50 Inverter 20074271 RS 510/EV BLU FS1/FS2 3/400/50 Inverter 20074272 RS 610/EV BLU FS1/FS2 3/400/50 Inverter 20074273 Tab. A Burner categories - Countries of destination... -
Page 11: Technical Data
Technical description of the burner Technical data Model RS 310/EV BLU RS 410/EV BLU RS 510/EV BLU RS 610/EV BLU Type (FS1/FS2*) 1138T2 1135T2 1136T2 1137T2 Power min - max 400/1200 - 3630 500/1500 ÷ 4450 680/1800 ÷ 5250 1000/2200 ÷ 6250 Delivery Fuels Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25... -
Page 12: Burner Weight
Technical description of the burner Burner weight The weight of the burner complete with its packaging is shown in Tab. E. Model RS 310/EV BLU RS 410/EV BLU RS 510/EV BLU RS 610/EV BLU Tab. E 20069483 Fig. 1 Maximum dimensions The maximum dimensions of the burner are given in Fig. -
Page 13: Firing Rates
Technical description of the burner Firing rates The MAXIMUM OUTPUT is chosen from within the diagram area The firing rate value (Fig. 3) has been obtained (Fig. 3). considering an ambient temperature of 20 °C, an The MINIMUM OUTPUT must not be lower than the minimum atmospheric pressure of 1013 mbar (approx. -
Page 14: Test Boiler
Technical description of the burner Test boiler The burner/boiler combination does not pose any problems if the The firing rates were set in relation to special test boilers, accord- boiler is EC approved and its combustion chamber dimensions ing to EN 676 regulations. are similar to those indicated in the diagram (Fig. -
Page 15: Burner Description
Technical description of the burner 4.11 Burner description ASSEMBLY VIEW Fig. 5 20081975 Lifting rings The burner can be opened to the right or to the left without links to the fuel supply side. Fan motor Air damper servomotor Combustion head gas pressure test point Combustion head To open the burner see section “Access to head Ignition electrode... -
Page 16: Electrical Panel Description
Technical description of the burner 4.12 Electrical panel description 20081976 Fig. 6 Electrical control box ON/OFF selector Output regulator Earth terminal Supply cables and external connections passage. See sec- tion “Electrical wiring” on page 29 Bracket for applying the kits Main terminal supply board Relay with clean contacts for signalling the burner is in lock- Relay with clean contacts for signalling the burner is operat-... -
Page 17: Control Box For The Air/Fuel Ratio (Rec37
To avoid accidents, material and/or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening WARNING or modifying it, or forcing its operation. Riello S.p.A. cannot assume any responsibility for dam- age resulting from unauthorised interventions! Risk of explosion! - Page 18 Technical description of the burner Technical data Control box Mains voltage AC 230 V -15% / +10% Mains frequency 50 / 60 Hz ±6% Power absorption < 30 W Safety class I, with components in compliance with II and III, ac- cording to DIN EN 60730-1 Load on Fuse on the control box (can be inspected)
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Page 19: Operation Sequence Of The Burner
Technical description of the burner 4.14 Operation sequence of the burner Operation Checking of Start-up Switching off seal Phase number 10 12 81 82 Timer - Resolution - Ratio 0,6 s 27 s 30 s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max. -
Page 20: 4.14.1 List Of Phases
Technical description of the burner 4.14.1 List of phases Phase Description Phase Description Ph44 t44 = interval time 1 Ph00 Lockout phase Ph60 Operation Ph02 Safety phase Ph62 The burner moves to the switching off position Ph10 Closing paused Ph70 t13 = post-combustion time Ph12 Standby... -
Page 21: 4.15.2 Description Of The Buttons
Technical description of the burner 4.15.2 Description of the buttons Button Button Function To adjust the fuel servomotor Button F (keep pressed and adjust the value by pressing To adjust the air servomotor Button A (keep pressed and adjust the value by pressing To change the mode setting parameter P Buttons A and F VSD function... -
Page 22: Servomotor (Sqm33
Technical description of the burner 4.16 Servomotor (SQM33..) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Do not open, modify or force the actuators. WARNING ➤ All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. -
Page 23: Installation
Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner is to The installation of the burner must be carried out be installed, and arranging for the environment to be illuminated by qualified personnel, as indicated in this manual correctly, proceed with the installation operations. -
Page 24: Operating Position
Installation Operating position ➤ The burner is designed to operate only in positions 1 , 2 , 3 and 4 (Fig. 13). ➤ Installation 1 is preferable, as it is the only one that allows the maintenance operations WARNING as described in this manual. ➤... -
Page 25: Access To Head Internal Part
Installation Access to head internal part The burner leaves the factory set for opening to the left, therefore maintaining the pin 1)(Fig. 16) in the housing. To open the burner towards the left, proceed as follows: A disconnect the plug/socket 9)(Fig. 16) of the maximum gas pressure switch;... -
Page 26: Probe-Electrode Position
Installation Probe-electrode position Check that the probe and the electrode are placed as in Fig. 17, according to the dimensions indicat- WARNING RS 410-510-610/EV BLU Probe Electrode Place in line with the hole RS 310/EV BLU Fig. 17 20071251 Gas butterfly valve If necessary, replace the gas butterfly valve. -
Page 27: Combustion Head Adjustment
Installation 5.10 Combustion head adjustment Rotate the screw 1) until the notch you have found corresponds with the front surface of the screw itself. The combustion head is opened by turning the screw 1) anti- clockwise. The combustion head is closed by turning the screw 1) clockwise (Fig. -
Page 28: Gas Pressures
Installation 5.11 Gas pressures Explosion danger due to fuel leaks in the pres- MBC "threaded" ence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure the fuel interception tap is closed be- fore performing any operation on the burner. The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws. -
Page 29: 5.11.2 Gas Train
Installation 5.11.2 Gas train Approved according to standard EN 676 and provided separately Pay attention when handling the train: danger of from the burner. crushing of limbs. To select the correct gas train model, refer to the supplied "Burn- er-gas train combination" manual. Make sure that the gas train is properly installed by checking for any fuel leaks. -
Page 30: Gas Pressure
Installation 5.11.4 Gas pressure 1 ∆p (mbar) 2 ∆p (mbar) G 20 G 25 G 20 G 25 Tab. L indicates the minimum pressure drops along the gas sup- 1200 23.1 34.5 ply line, depending on the maximum burner output. 1440 23.6 35.2... -
Page 31: Electrical Wiring
Installation 5.12 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 32: Supply Cables And External Connections Passage
Installation 5.12.1 Supply cables and external connections 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. 27. Key (Fig. -
Page 33: 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 34: Air / Fuel Adjustment
Start-up, calibration and operation of the burner Air / fuel adjustment 6.4.4 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 35: Final Adjustment Of The Pressure Switches
Start-up, calibration and operation of the burner Final adjustment of the pressure switches 6.5.1 Air pressure switch Adjust the air pressure switch (Fig. 30) after performing all other burner adjustments with the air pressure switch set to the start of the scale. -
Page 36: Pressure Switch Adjustment
Start-up, calibration and operation of the burner Pressure switch adjustment 6.6.1 Maximum gas pressure switch Adjust the maximum gas pressure switch (Fig. 31) after perform- ing all other burner adjustments with the maximum gas pressure switch set to the end of the scale. With the burner operating at maximum output, lower the adjust- ment pressure by slowly turning the relative knob anticlockwise until the burner locks out. -
Page 37: Visualisation And Programming Mode
Start-up, calibration and operation of the burner Visualisation and programming mode 6.7.1 Normal mode 6.7.1.4 Error state message, display of the errors and information The Normal mode is the standard operation mode visualised on the operator panel display. It is the main level of the menu. The display visualises alternately the error code (in the example ➤... -
Page 38: Info Mode
Start-up, calibration and operation of the burner 6.7.1.5 Reset procedure Releasing the "F" key, the standard visualisation appears, with the current load percentage flashing: this means that the burner The burner is in lockout when the red indicator light on the oper- is working in Manual mode (any outside adjustment is excluded ator panel is lit up, and the display visualises the lockout code (in and only the safety devices are active). -
Page 39: Service Mode
Start-up, calibration and operation of the burner 6.7.3 Service mode 6.7.4 Parameters Mode The Service mode ( SEr ) visualises the error log and certain The Parameters Mode ( PArA ) displays and allows you to modi- technical information about the system. To access this level you fy/programme the parameters list on page 46. -
Page 40: Parameter Modification Procedure
Start-up, calibration and operation of the burner 6.7.4.2 Assigning parameter levels The password must only be communicated to the The parameters level is subdivided into groups as shown in qualified personnel or the Technical Assistance Tab. O. Service, and must be kept in a safe place. WARNING Parameter 100: ParA... - Page 41 Start-up, calibration and operation of the burner 6.8.0.1 Procedure for inserting and adjusting points on Select another point, or exit this area by pressing the keys "+" and "-" ( ESC ) simultaneously. the modulation curve Nine adjustment/calibration points (P1 ÷ P9) can be inserted in the control box for each servomotor, varying their position by de- grees and, consequently, the quantity of air and fuel introduced.
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Page 42: Modify "Acceleration- Deceleration Train" Parameter
Start-up, calibration and operation of the burner 6.8.1 Modify "acceleration- deceleration train" 6.8.2 Modify the parameter for continuous/ parameter intermittent operation (FS2/FS1) The burner leaves the factory with the parameters 522 (acceler- The burner leaves the factory with parameter 239 set at "1" . This ation) and 523 (deceleration) already set. -
Page 43: Start-Up Procedure
Start-up, calibration and operation of the burner Start-up procedure Check that the operator panel display shows the heat request Phase 24: and "OFF Upr" : this means it is necessary to set the modulation The burner goes to the pre-purging position, the air servomotor curve of the burner. - Page 44 Start-up, calibration and operation of the burner Solve the problem, referring to the paragraph “Ignition failure” on Halfway through the procedure (i.e. around point P4 or P5 ), you page 50. are advised to measure gas delivery and check that the output is about 50% of the maximum output.
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Page 45: Backup / Restore Procedure
Start-up, calibration and operation of the burner 6.10 Backup / Restore procedure At the end of the "Start-up procedure" it is wise to carry out a We suggest that this operation be carried out at backup, creating a copy of the data memorised on the REC, in the end of any intervention that involves modifica- the RDI 21 display panel. -
Page 46: 6.10.2 Restore
Start-up, calibration and operation of the burner NOTE: It is advisable to perform a backup every time If an error occurs during the backup process, the display that a parameter is changed, after checking screen shows a negative value. that the modification carried out is correct. Refer to diagnostic code 137 to determine the cause of the WARNING error (see section “List of error codes”... - Page 47 Start-up, calibration and operation of the burner The value 1 appears on the display screen: h min s After approx 8 seconds (it depends on the duration of the pro- gramme), the 0 value appears on the display screen, this is to in- dicate that the restore process has been completed correctly.
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Page 48: 6.10.3 List Of Parameters
Start-up, calibration and operation of the burner 6.10.3 List of parameters Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment INTERNAL PARAMETERS Start backup/restore process via RDI21... / PC TOOL (set the parameter to 1) Index 0 = create backup Modification... - Page 49 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Parity for Modbus 0 = none Modification Service Mode 1 = odd 2 = even Selection of the burner operation during the interrup- tion of the switch-over with the system of remote man-...
- Page 50 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Maximum repeats of minimum gas pressure switch intervention 1 = No repetition Modification Service Mode 2...15 = Number of repetitions...
- Page 51 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Position of the fuel servomotor in absence of flame Index 0 = standby position (°) Modification 0°...
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Page 52: Operation
Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Result of the sampling of the contact (codified in bits) Bit 0.0 = 1: Minimum pressure switch Bit 0.1 = 2: Maximum pressure switch Bit 0.2 = 4: Pressure switch control valves Bit 0.3 = 8: Air pressure switch... -
Page 53: Burner Flame Goes Out During Operation
Start-up, calibration and operation of the burner 6.13 Burner flame goes out during operation If the flame should go out during operation, the burner will lockout within 1 s. 6.14 Stopping of the burner The burner can be stopped by: There are now two possibilities: ➤... -
Page 54: Maintenance
Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, safety, yield and duration of the burner. Disconnect the electrical supply from the burner It allows you to reduce consumption and polluting emissions and by means of the main system switch. -
Page 55: Safety Components
Maintenance 7.2.3 Safety components 7.2.4 Measuring the ionisation current The safety components should be replaced at the end of their life The burner is fitted with an ionisation system to check that a cycle indicated in the following table. flame is present. The specified life cycles do not refer to the warranty terms indi- The minimum current for control box operation is 4 µA. -
Page 56: Checking The Position Of The Rpm Sensor
Maintenance Checking the position of the rpm sensor To calibrate the rpm sensor, proceed as follows: loosen the screws 3) rest the sensor on the disc extension 2). Take the scale 4) as a reference, pull back the rpm sensor by about a notch so that the distance from the disc extension 2) is about 2 mm. -
Page 57: Faults - Possible Causes - Solutions
Faults - Possible causes - Solutions Faults - Possible causes - Solutions If faults arise in ignition or operations, the burner performs a In the event the burner stops, in order to prevent "safety stop", which is signalled by the red burner lockout LED. any damage to the installation, do not unblock the The display of the operator panel visualises alternately the lock- burner more than twice in a row. - Page 58 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code Leak test Check if the valve on the side of the burner has any leaks. V2 leaks Check if the pressure switch for the leak test (PGVP) is closed when gas pressure is not present.
- Page 59 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code Safety circuit open /Burner flange, air pressure, fuel pressure, POC - Alarm lockout at start Safety circuit open /Burner flange, extraneous light, air pressure, fuel pressure, POC - Alarm lockout at start Carry out a reset;...
- Page 60 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code The standard unit does not receive pulses from the speed sensor: 1. The motor does not turn. Speed sensor circuit open 2. The speed sensor is not connected. 3.
- Page 61 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code The speed was not reached because the curve was too steep. 1. With a train REC3... of 20 s, the speed variation between 2 points of the curve (in modulating mode) cannot exceed 10%.
- Page 62 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code Bit 3 The slope of the curve can correspond to a maximum position Curve too steep in terms of train ratio Valence ≥8 modification of 31°...
- Page 63 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code Carry out a reset; if the error arises repeatedly, replace the Voltage monitoring test internal error control box. Insufficient mains voltage. Low level of power supply Conversion of the diagnostic code --->...
- Page 64 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code 252 (-4) After restoration, the pages are still in INTERRUPTION Repeat the reset and backup. 253 (-3) The restoration cannot currently be carried out Repeat the reset and backup.
- Page 65 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code Carry out a reset; if the error arises repeatedly, replace the Internal error control box. Carry out a reset; if the error arises repeatedly, replace the Internal error control box.
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Page 66: A Appendix - Accessories
Appendix - Accessories Appendix - Accessories Kit for modulating operation Burner Output regulator Code All models RWF 50.2 3-POINT OUTLET 20085417 All models RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441 All models RWF 55.6 COMPLETE WITH RS-485/PROFIBUS INTERFACE 20074442 Burner Probe Adjustment field Code... - Page 67 Appendix - Accessories Modbus interface kit Burner Model Code All models OCI412 3010437 PVP kit (Seal control function - See gas train booklet) Burner Ramp type Code All models MB - CB 3010344 Gas trains in compliance with EN 676 Please refer to manual.
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Page 68: Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Single-wire output layout Single-wire output layout Functional layout REC 37... Functional layout REC 37... Functional layout REC 37... RWF50.2 output power regulator kit Electrical wiring that the installer is responsible for Electrical wiring that the installer is responsible for Output power regulator inputs/outputs Indication of references... - Page 69 Appendix - Electrical panel layout 20081753...
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- Page 75 Appendix - Electrical panel layout 20081753...
- Page 76 Appendix - Electrical panel layout 20081753...
- Page 77 Appendix - Electrical panel layout 20081753...
- Page 78 Appendix - Electrical panel layout Wiring layout key Electronic cam Main terminal supply board Display and calibration unit Plug for on board display Output regulator RWF40 internal Connector for output power regulator kit Output regulator RWF40 external XPGMax Maximum gas pressure switch connector Output probe in current XPGMin Minimum gas pressure switch connector...
- Page 80 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...