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Riello RS 810/E BLU Modulating Operation

Forced draught gas burner
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Installation, use and maintenance instructions
Forced draught gas burner
GB
Modulating operation
CODE
MODEL
TYPE
20160126
RS 810/E BLU
S032T1
20160897 (5) - 06/2021

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Summary of Contents for Riello RS 810/E BLU

  • Page 1 Installation, use and maintenance instructions Forced draught gas burner Modulating operation CODE MODEL TYPE 20160126 RS 810/E BLU S032T1 20160897 (5) - 06/2021...
  • Page 2 Translation of the original instructions...

  • 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 ........................28 Notes on safety for the first start-up ...........................28 Adjustments prior to ignition............................28 Burner start-up ................................28 Air / fuel adjustment ..............................29 6.4.1 Air adjustment for maximum output ...........................29 6.4.2 Air/fuel adjustment and output modulation system ....................29 6.4.3 Burner adjustment..............................29 6.4.4...

  • Page 5: Declarations

    The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015. 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 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 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

    3N / 400V / 50Hz 3/230/50 3 / 230V / 50Hz Voltage of auxiliaries: 230/50/60 230V / 50-60Hz 110/50/60 110V / 50-60Hz FS1/FS2 3/400/50 230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RS 810/E BLU 3/400/50 Star/Delta 20160126 Tab. A 20160897...

  • Page 10: Burner Categories - Countries Of Destination

    Gas category Destination country 2ELL AT-BG-CH-CZ-DK-EE-ES-FI-GB-GR-HU-HR-IE-IS-IT-LT-LV-NO- PT-RO-SE-SI-SK-TR LU - PL 2E(R) Tab. B Technical data Model RS 810/E BLU Power 1200/3500 ÷ 8000 Output Fuels Natural gas: G20 (methane gas) - G25 Gas pressure at max. output mbar 49.7/73 Gas: G20/G25 FS1: Intermittent (min.

  • Page 11: Burner Equipment

    Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part turned on the hinge. The l position is reference for the refractory thickness of the boiler door. 20162256 Fig. 1 RS 810/E BLU 1197 DN80 1345 1055 Tab. E Burner equipment Thermal insulation screen .

  • Page 12: Firing Rates

    Technical description of the burner Firing rates The MAXIMUM OUTPUT is chosen from within the diagram area The firing rate value (Fig. 2) has been obtained (Fig. 2). considering an ambient temperature of 20C, an The MINIMUM OUTPUT must not be lower than the minimum atmospheric pressure of 1013 mbar (approx.

  • Page 13: Burner Description

    Technical description of the burner 4.10 Burner description 20162260 Fig. 4 Lifting rings The burner can be opened to the right or to the left Cover for electrical panel without links to the fuel supply side. Lever for combustion head movement When the burner is closed, the hinge can be refit- Air pressure test point for combustion head CAUTION...

  • Page 14: Electrical Panel Description

    Technical description of the burner 4.11 Electrical panel description 20162606 Fig. 5 Electrical control box ON/OFF selector Output regulator Earth terminal Supply cables and external connections passage. See sec- tion “Electrical wiring” on page 26 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 15: 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 16 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)

  • Page 17: Operation Sequence Of The Burner

    Technical description of the burner 4.13 Operation sequence of the burner Operation Checking of Start-up Switching off seal TSA1 Phase number Timer - Resolution - Ratio 0.6s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max. phase time RAST plug Input signals PIN number Thermostat/pressure switch...

  • Page 18: 4.13.1 List Of Phases

    Technical description of the burner 4.13.1 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 19: 4.14.2 Description Of The Buttons

    Technical description of the burner 4.14.2 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 20: Servomotor (Sqm33

    Technical description of the burner 4.15 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 21: 4.16 Calibration Of The Thermal Relay

    Technical description of the burner 4.16 Calibration of the thermal relay The thermal relay serves to avoid damage to the motor due to an excessive absorption increase or if a phase is missing. For calibration 2), see the table in the wiring diagram. To reset, in case of an intervention of the thermal relay, press the “RESET”...

  • Page 22: Installation

    Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner will The installation of the burner must be carried out be installed, and arranging the correct lighting of the environ- by qualified personnel, as indicated in this manual ment, proceed with the installation operations.

  • Page 23: 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 24: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler 20162275 Prepare a suitable lifting system using rings 3)(Fig. 16).  Fit the heat insulation supplied onto the blast tube 4)(Fig. 16).  Fit the entire burner onto the boiler hole prepared previously (Fig.

  • Page 25: Combustion Head Adjustment

    Installation 5.10 Combustion head adjustment In order to optimise performance, the burner is equipped with a variable geometry combustion head which operates on the basis 20162133 of the delivered output. According to the same rotation of the air servomotor, it is possible to change the combustion head opening by moving the lever 2)(Fig.

  • Page 26: Gas Feeding

    Installation 5.11 Gas feeding 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 that the fuel interception tap is closed before performing any operation on the burner. The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws.

  • Page 27: 5.11.2 Gas Train

    – read the corresponding output on the left. Disconnect the electrical power using the main Example for RS 810/E BLU with G20 natural gas: system switch. Maximum output operation DANGER Gas pressure at test point P1)(Fig. 25) 27.6 mbar...

  • Page 28: Electrical Wiring

     Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man- ual.  The RS 810/E BLU burners equipped with REC 37... can operate in FS1 or FS2 mode. See the specific REC 37... manual for continuous/intermittent operation (FS2/FS1). Refer to the following notes for the type of operation that has been set.

  • Page 29: 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. 26. Key (Fig.

  • Page 30: 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 31: 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 32: Final Adjustment Of The Pressure Switches

    In this case also, the pressure gauge must be connected in differ- 20163262 ential mode, as shown in Fig. 29. On RS 810/E BLU burners the air pressure switch is fitted in an Fig. 29 “absolute” mode, that is, connected only to the pressure test point “+”...

  • Page 33: Minimum Gas Pressure Switch

    6.5.3 Minimum gas pressure switch Adjust the minimum gas pressure switch (Fig. 31) after perform- ing all the other burner adjustments with the pressure switch set to the start of the scale. With the burner operating at maximum output, increase adjust- ment pressure by slowly turning the relative knob clockwise until the burner stops.

  • Page 34: Visualisation And Programming Mode

    Visualisation and programming mode 6.6.1 Normal mode 6.6.1.4 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 35: Info Mode

    Start-up, calibration and operation of the burner 6.6.1.5 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 36: Service Mode

    Start-up, calibration and operation of the burner 6.6.3 Service mode 6.6.4 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 41.

  • Page 37: Parameter Modification Procedure

    Start-up, calibration and operation of the burner 6.6.4.2 Assigning parameter levels The password must only be communicated to the The parameters level is subdivided into groups as shown in Tab. qualified personnel or the Technical Assistance Service, and must be kept in a safe place. WARNING Parameter 100: ParA...
  • Page 38 Start-up, calibration and operation of the burner 6.7.0.1 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.

  • Page 39: Start-Up Procedure

    Start-up, calibration and operation of the burner Start-up procedure Check that the operator panel display shows the heat request Otherwise, modify the ignition point (see the sectionProcedure and “OFF Upr”: this means it is necessary to set the modulation for inserting and adjusting points on the modulation curve. curve of the burner.
  • Page 40 Start-up, calibration and operation of the burner Press the button “+”: the display visualises the indicator “P1” If you want to make the burner work on just a part of the modula- flashing and proposes the same settings as point “P0”. tion curve, modify the parameters “546”...

  • Page 41: Backup / Restore Procedure

    Start-up, calibration and operation of the burner 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 42: 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 parameters).

  • Page 43: List Of Parameters

    Start-up, calibration and operation of the burner The value 1 appears on the display screen: NOTE: When the restore process is successfully completed, the 0 value is shown on the display screen. Err C information: 136 D: 1 (restore process initialised) is displayed for a brief moment.
  • Page 44 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Default output for TÜV test: Not valid for TÜV test when output is activated Modification / 100% 0.1%...
  • Page 45 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Stopping of the program 0 = deactivated 1 = pre-purging (Ph24) Modification Service Mode 2 = Ignition (Ph36)
  • Page 46 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Oil: selection transformer ignition phase TA 0 = brief pre-ignition (Ph38) Modification Service Mode 1 = long pre-ignition (with fan)(Ph22)

  • Page 47: Operation

    Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Relay request status (coded in bits) Bit 0 = 1: Alarm Bit 1 = 2: Safety valve Bit 2 = 4: Ignition Reading only...

  • Page 48: Stopping Of The Burner

    Start-up, calibration and operation of the burner 6.14 Stopping of the burner The burner can be stopped by: There are now two possibilities:  intervening on the disconnecting switch of the electrical sup- – using the operator panel according to the manual lockout pro- ply line, located on the boiler panel;...

  • Page 49: Maintenance

    Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, Before carrying out any maintenance, cleaning or checking oper- safety, yield and duration of the burner. ations: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.

  • Page 50: Measuring The Ionisation Current

    Maintenance 7.2.4 Measuring the ionisation current Air excess The burner is fitted with an ionisation system to check that a EN 676 Max. output Min. output flame is present.  1.2  1.3 The minimum current for control box operation is 4 µA. The oper- % Calibration theoretic ator panel displays “30%”...

  • Page 51: 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 52 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 53 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 54 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 55 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 56 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 57 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 58 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 59 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.

  • Page 60: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Kit for modulating operation Burner Output regulator Code RWF 50.2 3-POINT OUTLET 20085417 RS 810/E BLU RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441 RWF 55.6 COMPLETE WITH RS-485/PROFIBUS INTERFACE 20074442 Burner Probe Adjustment field...

  • Page 61: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output Layout of unifilar output REC 37... operational layout REC 37... operational layout REC 37... operational layout Electrical connections for power regulator (internal) Electrical connections set by installer Electrical connections set by installer Inputs/outputs power regulator...
  • Page 62 Appendix - Electrical panel layout 20160897...
  • Page 63 Appendix - Electrical panel layout & & 20160897...
  • Page 64 Appendix - Electrical panel layout 20160897...
  • Page 65 Appendix - Electrical panel layout 20160897...
  • Page 66 Appendix - Electrical panel layout 20160897...
  • Page 67 Appendix - Electrical panel layout 20160897...
  • Page 68 Appendix - Electrical panel layout 20160897...
  • Page 69 Appendix - Electrical panel layout 20160897...
  • Page 70 Appendix - Electrical panel layout 20160897...
  • Page 71 Appendix - Electrical panel layout Wiring layout key Electronic cam Display and calibration unit Output regulator RWF50 internal Fuel meter Probe with output under current Device with output under current, for modifying re- mote setpoint Modulation control 4-20mA Pressure probe Pressure probe Remote setpoint potentiometer Thermocouple probe...
  • Page 72 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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