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Riello RX 500 S/PV Modulating Operation

Premix gas burner
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Installation, use and maintenance instructions
Premix gas burner
GB
Modulating operation
CODE
MODEL
TYPE
20136698
RX 500 S/PV
852T3
20138630 (2) - 09/2018

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Summary of Contents for Riello RX 500 S/PV

  • Page 1 Installation, use and maintenance instructions Premix gas burner Modulating operation CODE MODEL TYPE 20136698 RX 500 S/PV 852T3 20138630 (2) - 09/2018...
  • Page 2 Translation of the original instructions...

  • Page 3: Table Of Contents

    Contents Declarations....................................3 Information and general warnings............................5 Information about the instruction manual ........................5 2.1.1 Introduction.................................. 5 2.1.2 General dangers................................5 2.1.3 Other symbols ................................5 2.1.4 Delivery of the system and the instruction manual...................... 6 Guarantee and responsibility............................6 Safety and prevention................................
  • Page 4 Contents 6.10 Final checks (with burner operating) ..........................34 Maintenance ....................................35 Notes on safety for the maintenance .........................35 Maintenance programme ............................35 7.2.1 Maintenance frequency..............................35 7.2.2 Safety test - with gas feeding closed .........................35 7.2.3 Checking and cleaning...............................35 7.2.4 Safety components ..............................37 Opening and closing the burner ..........................37 Recommended preventive maintenance programme ....................38 Operation, indications, diagnostic ............................39...

  • Page 5: Declarations

    Class 3 (EN 676) Quality is ensured by means of an ISO 9001:2015 certified quality and management system. Legnago, 21.04.2018 General Manager Research and Development Director RIELLO S.p.A. - Burners Department RIELLO S.p.A. - Burners Department Eng. U. Ferretti Eng. F. Comencini 20138630...
  • Page 6 TÜV SÜD Gruppe Controlling organisation: Ridlerstrase, 65 80339 München DEUTSCHLAND Manufacturer's Declaration RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BImSchV revision 26.01.2010”. Product Type Model Output Pre-mixed gas burner...

  • Page 7: Information And General Warnings

    Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 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 away from moving mechanical parts;...

  • Page 8: Delivery Of The System And The Instruction Manual

    Information and general warnings  The system supplier must carefully inform the user about: 2.1.4 Delivery of the system and the instruction – 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 9: Safety And Prevention

    Safety and prevention Safety and prevention Background 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 standard technical electrical power supply, the minimum and maximum deliveries for rules of safety and envisaging all the potential danger situations.

  • Page 10: Technical Description Of The Burner

    Models available Designation Voltage Code External modulation (*) RX 500 S/PV 230V - 50-60 Hz 20136698 3 points (*) FACTORY SETTING. To change the external modulation parameter it is necessary to access the password-protected list of parameters using the AZL 21... display kit (page 48).

  • Page 11: Technical Data

    Technical description of the burner Technical data Model RX 500 S/PV Type 852T3 Power min - max 80 - 490 Delivery min - max Mcal/h 69 - 422 Fuels Natural gas: G20 (methane), G25 - LPG: (G31) 17 - 65 (G20)

  • Page 12: Maximum Dimensions

    The maximum dimensions of the burner are given in Fig. 1. Bear in mind that, in order to inspect the combustion head, the burner must be removed from the boiler door. 20149948 Fig. 1 RX 500 S/PV Tab. D RX 500 S/PV 1280 Tab. E Fig.

  • Page 13: Burner Description

    Technical description of the burner Burner description 20136770 Fig. 3 Combustion head Burner lockout may occur. Ignition electrode CONTROL BOX LOCKOUT: Flame sensor probe The lockout signal is indicated on the display of the Gas valve WARNING control box with “LOC” and the error code. To un- Air/gas mixer in the suction line circuit lock, press the button 13) (Fig.

  • Page 14: Firing Rate

    The firing rate (Fig. 4) has been obtained at an limit of the diagram (Fig. 4). ambient temperature of 20°C, at a barometric RX 500 S/PV = 490 kW pressure of 1013 mbar (about 0 m a.s.l.). WARNING The minimum output must not be lower than the minimum limit of the diagram (Fig.

  • Page 15: Output Supplied

    Example: For an exact reading of the number of revs there is a kit for inter- facing with the control box. operation with Premix RX 500 S/PV natural gas G20 PCI 9.45 kWh/Sm NOTE: pressure on point 1 = - 5.2 mbar (See 2nd Chart).

  • Page 16: Burner Controls (Lme71

    The LME71... are safety devices! Avoid opening WARNING or modifying it, or forcing its operation. Riello S.p.A. cannot assume any responsibility for damage resulting from unauthorised interven- tions! Also the safety notes contained in other chapters of this document must be respected! The installation and operation of the machine should be carried out only by qualified personnel.
  • Page 17 Technical description of the burner Installation notes Description of displays and buttons  Arrange the high voltage ignition cables separately, as far as possible from the control box and the other cables.  Do not confuse the powered conductors with the neutral ones.
  • Page 18 Technical description of the burner Technical data Burner controls Mains voltage AC 230 V Mains frequency 50 / 60 Hz +- 6% LME71... Power absorption <10 W, normally Primary external fuse Max. 6.3 A (slow) Safety class I, with components in compliance with II and III, ac- cording to DIN EN 60730-1 "Input"...
  • Page 19 Technical description of the burner Program sequence Standby Startup Operation Shutdown Valve proving if parameter P241 =1 (ON) Can be parameterized t11 t10 t12 t3 t3n t11 t8 td4 td1 td3 td2 Phase number oP: xx (actual load in %) 242 243 244 245 Operating unit parameter number LED permanent...
  • Page 20 Technical description of the burner Key Fig. 9: Times Alarm device Safety time Standby time Auxiliary output Pre-purging time Lead connection Spark pre-ignition time Reset button (info button) Post-ignition time (P257 +0.3 seconds) (EK1) /reset Interval: end of safety time - fuel valve 1 ON (depending on Interval: end of safety time - fuel valve 2 ON Remote reset button...

  • Page 21: 4.10.1 Indication Of The Diagnostic Mode

    Technical description of the burner Phases key (Fig. 9 on page 17): 4.10.1 Indication of the diagnostic mode Phase The reset button (info button) is the key element Function number for resetting the burner control and activating/de- activating the diagnostic functions. Switching off phase lockout Stand-by, awaiting heat request The multi-colour indicator lamp is the key indica-...

  • Page 22: Installation

    2R 3R CAUTION AT BE CH CY CZ DE DK EE ES FI FR GB GR HU RIELLO S.p.A. / I-37045 Legnago(VR) IE IS IT LT LU LV MT NL NO PL PT SE SI SK ..The packaging elements (wooden cage or card- 20120446 board box, nails, clips, plastic bags, etc.) must not...

  • Page 23: Operating Position

    Pierce the closing plate of the combustion chamber, as in Fig. 12. D X 2 The position of the threaded holes can be marked using the ther- mal insulation screen supplied with the burner. RX 500 S/PV 45° Tab. L 5.5.2 Head length Fig.

  • Page 24: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler Provide an adequate lifting system. 6 mm The burners are supplied with the combustion head and elec- trodes already assembled. The seal between burner and boiler must be airtight. 20047399 WARNING Before fixing the burner to the boiler, make sure the probe and electrodes are positioned correctly as in Fig.

  • Page 25: Fuel Supply

    Installation Fuel supply Explosion danger due to fuel leaks in the pres- Refer to the accompanying instructions for the ad- ence of a flammable source. justment of the gas train. Precautions: avoid knocking, attrition, sparks and WARNING heat. The operator must use appropriate tools for instal- Make sure the fuel interception tap is closed be- lation.

  • Page 26: Gas Train

    Installation 5.7.1 Gas train Gas valve adjustment This has been type-approved together with the burner, in accord- The adjustment of the output of gas is achieved by using the two ance with regulation EN 676, and is supplied as standard with the screws V1 and V2.

  • Page 27: Electrical Connections

    Installation Electrical connections 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 28: Opening Sequence Of The Fuse-Holder

    Installation 5.9.2 Opening sequence of the fuse-holder In the event of a fault or control of the fuse-holder, proceed as fol- Close the component side (Fig. 22). lows to remove or change the fuse: Disconnect the electrical supply from the burner by means of the main system switch.

  • Page 29: 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 Before igniting the burner, see the paragraph by qualified personnel, as indicated in this manual “Safety test - with gas feeding closed”...

  • Page 30: Burner Start-Up

    Start-up, calibration and operation of the burner Burner start-up The burner can operate in two different modes: To return to manual mode, press button "A" together with the "+" manual operation (to be used for the initial start-up): in this or "-"...
  • Page 31 Start-up, calibration and operation of the burner MANUAL MODULATION PROCEDURE Press for the current position relative to the actuator or the current speed relative to the PWM fan. The indicator light blinks green. The display shows .oP. Press (1…3 seconds) to display the current position or current speed. The indicator light blinks green.
  • Page 32 Start-up, calibration and operation of the burner • Pressing button "A" and button "+" increases the fan speed Eventual modifications to the parameters and the and therefore the burnt output. Slowly increase the speed of settings should be set and saved in the memory the fan checking the appearance of the flame, if possible, and on-board the unit.

  • Page 33: Manual Backup

    Start-up, calibration and operation of the burner Manual Backup Press together for >1 second (Esc) to start the manual backup procedure. Parameter PrC is displayed. Display: PrC > 1s Press to display parameter bAC. Display: bAC 1...3 s Run appears during the download (backup procedure) in the program sequence. The display shows End and bAC alternately.

  • Page 34: Burner Adjustment

    Start-up, calibration and operation of the burner Burner adjustment The optimum adjustment of the burner requires an analysis of 6.6.1 Optimum calibration values flue gases at the generator outlet. MIN output MAX output The burner application at the generator, the adjustment and the testing must be carried out in compliance with the instruction Methane manual of the generator itself, including the control of the concen-...

  • Page 35: Switching Off The Burner

    Start-up, calibration and operation of the burner Switching off the burner Press the button in position 0 to turn off the burner. Disable the electrical supply. If the burner is turned off for long pe- riods, close the manual gas gates. Turning off the burner during post-purging, the control box goes into lockout after a few seconds 20138621...

  • Page 36: Combustion Head

    Start-up, calibration and operation of the burner Combustion head The combustion head comprises a highly heat resistant cylinder This allows modulating ratios as high as 6:1, avoiding the danger whose surface features numerous holes, encased in a metal of flashback when modulating is at its minimum. "mesh".

  • Page 37: 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 38 Maintenance Boiler Flame control Clean the boiler as indicated in its accompanying instructions in Displayed value: order to maintain all the original combustion characteristics in- 1 µA = 20% tact, especially: the flue gas temperature and combustion cham- 40 µA = 100% ber pressure.

  • Page 39: Safety Components

    Maintenance 7.2.4 Safety components The safety components should be replaced at the end of their life cycle indicated in Tab. W. The specified life cycles do not refer to the warranty terms indicated in the delivery or payment condi- tions. Safety component Life cycle 10 years or 250,000...

  • Page 40: Recommended Preventive Maintenance Programme

    Maintenance Recommended preventive maintenance programme The use and maintenance instructions are meant for general ap- plications. For specific use and maintenance instructions, contact the manufacturer of the control box. Test/Inspection Frequency Checking components, monitor and indicators DAILY Checking adjustments of instruments and control boxes DAILY Checking burner flame DAILY...

  • Page 41: Operation, Indications, Diagnostic

    Operation, indications, diagnostic Operation, indications, diagnostic Control sequence in the event of a fault In the event of a lockout, the outlets for fuel valves, burner motor and ignition devices should be immediately deactivated (<1 sec- ond). Causes Answer Mains voltage interruption Restart Voltage below the undervoltage threshold Safety switch off...

  • Page 42: Error Code List With Operation Via The Control Box Control Panel

    Operation, indications, diagnostic Error code list with operation via the control box control panel Error Clear text Possible cause code bAC Er3 Programme module compatibility fault with the base unit dur- The program sequence of the program module is not com- ing the back-up process patible with the base unit Err PrC...

  • Page 43: Resetting Of Burner Control

    Operation, indications, diagnostic Resetting of burner control When a lockout occurs, the burner control can be immediately re- leased by pressing the “RESET” button. NOTE: For the meaning of the diagnostic codes and errors, see the chapter“Error code list with operation via the control box control panel”...

  • Page 44: Before Starting With A New Program Module Or When The Program Module Is Replaced

    Operation, indications, diagnostic 8.3.2 Before starting with a new program module or when the program module is replaced The display shows rSt and PrC alternately. The display shows the replacement of the program module. Alternatively The indicator light blinks alternately one red and two yellow. Press for >3 to start the download of the program module data.

  • Page 45: Manual Reset

    Operation, indications, diagnostic Manual reset Press contemporaneously for >1 second (Escape) to start the manual reset process. The parameter PrC appears. Display: PrC > 1s Press for the parameter rSt. Display: rSt 1..3 s run appears during the download (restore process) of the program sequence. At the end of the reset process, the unit is automatically in a lockout position (LOC 138) and Alternatively need to be released in order to work!

  • Page 46: Error During The Reset Process

    Operation, indications, diagnostic 8.4.1 Error during the reset process Alternatively with with The display shows rSt and Er1, Er2 or Er3. For the meaning of the possible cause, see the chapter “Error code list with operation via the control box control panel” on page 40 Tab.

  • Page 47: A List Of Parameters Pme71.901

    List of parameters PME71.901...) List of parameters PME71.901...) The following pages have the Menus and the list of parameters To display/change the parameters it is neces- for setting up the LCD AZL 2 ... Display for the LME 71 ... control sary to use the AZL 21 ...
  • Page 48 List of parameters PME71.901...) Parameter Value range Password Password Factory Set- reading Modification Resolution writing level ting level to Description Min. Max. to level level Ratio control 503.00 Speed without PWM fan flame: Standby speed Modification 0 rpm 9000 rpm 10 rpm 0 rpm Speed without PWM fan flame: Speed of impu-...
  • Page 49 List of parameters PME71.901...) Parameter Value range Password Password Factory Set- reading Modification Resolution writing level ting level to Description Min. Max. to level level Speed interval for constant time PT1: Upper 9000 rpm 680.00 Modification 800 rpm 10 rpm 4000 rpm speed interval threshold Speed interval for constant time PT1: Lower...

  • Page 50: Appendix - Accessories

    – the probe to be installed on the heat generator. Burner Output power regulator Code RX 500 S/PV RWF50.2 20095185 Burner Probe Adjustment field Code Temperature PT 100 - 100 ÷...

  • Page 51: C Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Functional layout Functional layout Functional layout Functional layout Electrical wiring that the installer is responsible for Functional layout Indication of references / 1 . A 1 Sheet no.
  • Page 52 Appendix - Electrical panel layout 20138630...
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  • Page 54 Appendix - Electrical panel layout 20138630...
  • Page 55 Appendix - Electrical panel layout 20138630...
  • Page 56 Appendix - Electrical panel layout 20138630...
  • Page 57 Appendix - Electrical panel layout 20138630...
  • Page 58 Appendix - Electrical panel layout Wiring layout key Control box LME7... Display for control box Noise reduction filter Input in current DC 4...20 mA Burners components Boiler components Pressure probe Pressure probe Probe Pt100, 2 wires Probe Pt100, 3 wires Probe Pt100, 3 wires Input in voltage DC 0...10V Output power regulator RWF50.2 internal...
  • Page 60 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...

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