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Riello RS 310/E ULX Installation, Use And Maintenance Instructions

Forced draught gas burners
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Modulating operation
CODE
20204449
20204450
MODEL
RS 310/E ULX
RS 510/E ULX
TYPE
S045T1
S046T1
20205048 (3) - 09/2023

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Summary of Contents for Riello RS 310/E ULX

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Modulating operation CODE MODEL TYPE 20204449 RS 310/E ULX S045T1 20204450 RS 510/E ULX S046T1 20205048 (3) - 09/2023...
  • Page 2 Translation of the original instructions...

  • Page 3: Table Of Contents

    Contents Information and general warnings............................3 Information about the instruction manual ........................3 1.1.1 Introduction.................................. 3 1.1.2 General dangers................................3 1.1.3 Other symbols ................................3 1.1.4 Delivery of the system and the instruction manual ...................... 4 Guarantee and responsibility............................4 Safety and prevention................................
  • Page 4 Contents Adjustments prior to ignition............................29 Burner start-up ................................30 Air / fuel adjustment ..............................31 5.4.1 Air adjustment for maximum output ...........................31 5.4.2 Air/fuel adjustment and output modulation system ....................31 5.4.3 Burner adjustment..............................31 5.4.4 Output upon ignition ..............................31 5.4.5 Maximum output ................................31 5.4.6 Minimum output .................................32 Final adjustment of the pressure switches .........................33...

  • Page 5: Information And General Warnings

    Information and general warnings Information and general warnings Information about the instruction manual 1.1.1 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 6: Delivery Of The System And The Instruction Manual

    Information and general warnings 1.1.4 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 7: 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 8: Technical Description Of The Burner

    Technical description of the burner Technical description of the burner Burner designation Range: R Fuel: Natural gas Light Oil Light Oil/Natural gas Heavy Oil Size: Adjustment: Two stage (light oil / proportional valve (gas) Mechanical cam Electronic Cam Electronic cam and variable speed (with Inverter) Electronic cam with integrated Inverter Electronic cam and suitable for Oxygen Control (O Electronic cam and variable speed (with Inverter) and suitable for Oxygen Control O...

  • Page 9: Models Available

    Technical description of the burner Models available Designation Voltage Start-up Code RS 310/E ULX 3N/400/50 Direct 20204449 RS 510/E ULX 3N/400/50 Star/Delta 20204050 Tab. A Technical data Model RS 310/E ULX RS 510/E ULX Type S045T1 S046T1 Power Min. - Max.

  • Page 10: Burner Equipment

    Bear in mind that inspection of the combustion head requires the fractory thickness of the boiler door. burner to be opened and the rear part turned on the hinge. 20208259 Fig. 1 RS 310/E ULX 1015 518 DN65 480 290 1104 886 RS 510/E ULX...

  • Page 11: Firing Rates

    The maximum output must be higher than the following values If the chosen maximum output is lower than the following va- (Tab. E): lues (Tab. F): Model Model RS 310/E ULX 1250 RS 310/E ULX 1860 RS 510/E ULX 1900...

  • Page 12: 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 13: Burner Description

    Technical description of the burner Burner description 20198246 Fig. 4 Lifting rings Wait for the components in contact with heat Fan motor sources to cool down completely. Air damper servomotor Combustion head gas pressure test point Combustion head The burner can be opened to the right or to the left Ignition electrodes without links to the fuel supply side.

  • Page 14: Electrical Panel Description

    Technical description of the burner 3.10 Electrical panel description 20197930 Fig. 5 Earth terminal Supply cables and external connections passage Main terminal supply board Auxiliary circuits fuse (includes a spare fuse) Air pressure switch Ignition transformer Free contact relay Direct start up line contactor Star/delta start-up line contactor 10 Thermal relay (with reset button) 11 Delta contactor (star/delta start up)

  • Page 15: Flame Control For The Air/Fuel Ratio (Rec 27

    To avoid accidents, material and/or environmental D8266 damage, observe the following instructions! The flame control is a safety device! Avoid open- ing or modifying it, or forcing its operation. Riello WARNING S.p.A. cannot assume any responsibility for dam- age resulting from unauthorised interventions!
  • Page 16 Technical description of the burner Technical data Flame control 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 flame control (can be inspected)

  • Page 17: Operation Sequence Of The Burner

    Technical description of the burner 3.12 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: 3.12.1 List Of Phases

    Technical description of the burner 3.12.1 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: 3.13.2 Description Of The Buttons

    Technical description of the burner 3.13.2 Description of the buttons Button Button Function Button F To adjust the fuel servomotor (keep pressed and adjust the value by pressing Button A To adjust the air servomotor (keep pressed and adjust the value by pressing Buttons A and F change mode...

  • Page 20: Servomotor (Sqm33

    Technical description of the burner 3.14 Servomotor (SQM33..) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Do not open, modify or force the actuators.  All interventions (assembly and installation WARNING operations, assistance, etc.) must be carried out by qualified personnel.

  • Page 21: 3.15 Calibration Of The Thermal Relay

    Technical description of the burner 3.15 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

    4).  The refractory can have a conical shape (minimum 60°). This protective fettling must not compromise the extraction of the RS 310/E ULX blast tube. RS 510/E ULX For boilers with a water-cooled front piece, a refractory lining 2)- Tab.

  • Page 24: Access To Head Internal Part

    Installation Access to head internal part The burner leaves the factory set for opening to the right, there- fore maintaining the pin 1)(Fig. 16) in the housing. To open the burner towards the right, proceed as follows: disconnect the plug/socket 6)(Fig. 16) of the maximum gas pressure switch;...

  • Page 25: Combustion Head Adjustment

    3200 3400 3600 3800 following ranges: Max burner output (kW) RS 310/E ULX: 0 - 10 WARNING RS 510/E ULX: 0 - 10 RS 510/E ULX The adjustment cannot be carried out outside these ranges. No. Notches (air = gas)

  • Page 26: Central Gas Adjustment

    20201341 4.10.1 Central gas setting The factory setting for the central gas is with the following passa- ge holes (Fig. 21). RS 310/E ULX Central hole + 2 open holes RS 510/E ULX Central hole + 2 open holes If necessary, modify as indicated in “Firing rates” on page 9: ...

  • Page 27: Gas Feeding

    Installation 4.11 Gas feeding Explosion danger due to fuel leaks in the pres- The fuel supply line must be installed by qualified ence of a flammable source. personnel, in compliance with current standards and laws. Precautions: avoid knocking, attrition, sparks and WARNING heat.

  • Page 28: 4.11.4 Gas Pressure

    Natural gas G 20 NCV 9.45 kWh/Sm (8.2 Mcal/Sm RS 310/E ULX S10334 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 Burner output –...
  • Page 29 Installation To calculate the required gas pressure at test point P1)(Fig. 24), 20198299 set the MAX output required from the burner operation: – find the nearest output value. – Read the pressure at the test point P1)(Fig. 23). – Add this value to the estimated pressure in the combustion chamber.

  • Page 30: Electrical Wiring

    Installation 4.12 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 31: 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 32: Burner Start-Up

    Start-up, calibration and operation of the burner Burner start-up Electrically power the burner using the disconnecting switch on the boiler panel. Close the thermostats/pressure switches and set the switch of Fig. 27 to “1/ON”. Make sure that the lights or testers connected to the solenoids, or the pilot lights on the solenoids themselves, indicate that no voltage is present.

  • Page 33: Air / Fuel Adjustment

    Start-up, calibration and operation of the burner Air / fuel adjustment 5.4.4 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 34: Minimum Output

    Start-up, calibration and operation of the burner 5.4.6 Minimum output Indication for the burner ignition The MIN output must be set within the firing rate (Fig. 2 on In Tab. K the calibrations of the air and gas servomotors at the page 9).

  • Page 35: Final Adjustment Of The Pressure Switches

    Start-up, calibration and operation of the burner Final adjustment of the pressure switches 5.5.1 Air pressure switch Adjust the air pressure switch (Fig. 28) after performing all other burner adjustments with the air pressure switch set to the start of the scale.

  • Page 36: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 5.5.3 Minimum gas pressure switch Adjust the minimum gas pressure switch (Fig. 30) after having adjusted the burner, the gas valves and the gas train stabiliser. With the burner operating at maximum output: –...

  • Page 37: Control And Display

    Control and display Control and display Visualisation and programming mode 7.1.1 Normal mode The Normal mode is the standard operation mode visualised on the operator panel display. It is the main level of the menu.  Visualises the operation conditions and allows you to modify the operation point of the burner manually.

  • Page 38: Info Mode

    Control and display To exit manual mode, press the keys “+” and “-” (ESC) simulta- neously for 3 seconds: the burner will work in Automatic mode and the output will depend on the thermostat/adjustment pres- sure switch (TR). min s To reset, press the “i/reset”...

  • Page 39: Service Mode

    Control and display 7.1.3 Service mode 7.1.4 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 44. must: The factory-set parameters are not visible.

  • Page 40: Parameter Modification Procedure

    Control and display Parameter The password must only be communicated to the 100: ParA General parameters qualified personnel or the Technical Assistance Information and identification data of the system. Service, and must be kept in a safe place. WARNING 200: ParA Checks on the burner Type of operation, intervention and safety times Once the access procedure has been carried out, the display will...
  • Page 41 Control and display positioned on the values shown on the display and which corre- spond to the point previously set. D7908 It is now possible to insert/modify the position by degrees. The set value does not require confirmation. original curve WARNING CALC+ For the fuel servomotor, keep the key “F”...

  • Page 42: Start-Up Procedure

    Control and display Start-up procedure Check that the operator panel display shows the heat request and “OFF Upr”: this means it is necessary to set the modulation curve of the burner. The values shown in the figure are purely for indi- cation purposes.
  • Page 43 Control and display Press the button “+”: the display visualises the indicator “P1” If you want to make the burner work on the entire modulation flashing and proposes the same settings as point “P0”. curve, press the “+” and “-” (ESC) keys simultaneously: in this Press button “+”...

  • Page 44: Backup / Restore Procedure

    Control and display 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 45: Restore

    Control and display It is advisable to perform a backup every time NOTE: that a parameter is changed, after checking If an error occurs during the backup process, the display that the modification carried out is correct. screen shows negative value.

  • Page 46: List Of Parameters

    Control and display The value 1 appears on the display screen: NOTE: When the restore process is successfully completed, the 0 value shown display screen. Err C information: 136 D: 1 (restore process initialised) is displayed for a brief moment. At the end of the restore process, it is neces- h min s sary to check the sequence of functions and...
  • Page 47 Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Eliminate visualisation error chronology To eliminate the visualisation, set the parameter to 1, then to 2 Modification Service Mode Answer 0: process successful...
  • Page 48 Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Burner operation mode (fuel supply line, modulating/ stage, servomotors, etc.) -- = not defined (eliminate curves) 1 = Gmod 2 = Gp1 mod 3 = Gp2 mod...
  • Page 49 Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Gas: Valve leak detection test 0 = test deactivated 1 = valve leak detection test at start up Modification Service Mode 2 = valve leak detection test at shutdown...

  • Page 50: Operation

    Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment • Error chronology: 701-725.03.Error class Reading only Info mode • Error chronology: 701-725.04.Phase Reading only Info mode •...

  • Page 51: Motor Lockout

    Control and display Motor lockout If the motor does not start, it could be because of a thermal relay intervention due to its incorrect calibration or problems with the motor or the main power supply, to release press the button of the thermal relay, see “Calibration of the thermal relay”...

  • Page 52: 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 53: Safety Components

    Maintenance 8.2.5 Measuring the ionisation current Boiler Clean the boiler as indicated in its accompanying instructions in The burner is fitted with an ionisation system to check that a fla- order to maintain all the original combustion characteristics in- me is present. tact, especially the flue gas temperature and combustion cham- The minimum current for flame control operation is 4 μA.

  • Page 54: Opening The Burner

    Maintenance Opening the burner Disconnect the electrical supply from the burner Wait for the components in contact with heat by means of the main system switch. sources to cool down completely. DANGER To open the burner, use the same procedure set out in “Access to head internal part”...

  • Page 55: 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 56 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code The diagnostics covers the period between the closure of the fuel  3…255 Flame loss during TÜV test (flame loss test) valve to the point the flame loss is detected (resolution 0.2 s value 5 = 1 s).
  • Page 57 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Safety circuit open /Burner flange open, extraneous light - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light, air pressure, fuel pressure - Alarm lockout at start Safety circuit /Burner flange open, POC - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light,...
  • Page 58 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Reference error of a servomotor The reference of the fuel servomotor was not successful. It was not possible to reach the reference point. Reference error of the fuel servomotor 1.
  • Page 59 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Relay supervision error Check the contacts: 1. flame control connected to the power supply: the fan output must be without voltage. 2. Disconnect the power supply. Disconnect the fan. The The safety relay contacts have joined together or the safety resistive connection between the fan output and the neutral wire relay has been powered by an external power supply...
  • Page 60 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Carry out a reset, repeat and check the last setting of the EEPROM reading access internal error parameters. If the error arises repeatedly, replace the flame control.
  • Page 61 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code The TÜV test can only be started in phase 60 1 (-1) Invalid phase (operation) The output of the TÜV test must be lower than the minor output 2 (-2) The TÜV test default output is too low limit...
  • Page 62 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code The selected operating mode is not released for the Select an operating mode released for the standard unit standard unit Carry out a reset; if the error arises repeatedly, replace the Internal error flame control Carry out a reset;...

  • Page 63: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Kit for modulating operation Burner Output regulator Code All models RWF 50.2 3-POINT OUTLET 20085417 RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441 RWF 55.6 COMPLETE WITH RS-485/PROFIBUS INTERFACE 20074442 Burner Probe Adjustment field Code All models PT 100 temperature - 100...+ 500°C...

  • Page 64: 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 Layout of unifilar output Layout of unifilar output Operational layout Operational layout Operational layout Electrical connections for power regulator (internal) Electrical connections set by installer Electrical connections set by installer Inputs/outputs power regulator...
  • Page 65 Appendix - Electrical panel layout 20205048...
  • Page 66 Appendix - Electrical panel layout 20205048...
  • Page 67 Appendix - Electrical panel layout 20205048...
  • Page 68 Appendix - Electrical panel layout & & 20205048...
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  • Page 75 Appendix - Electrical panel layout 20205048...
  • Page 76 Appendix - Electrical panel layout 20205048...
  • Page 77 Appendix - Electrical panel layout Wiring layout key Flame control 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 Pressure probe Pressure probe Remote setpoint potentiometer Thermocouple probe Probe Pt100, 2 wires Probe Pt100, 3 wires...
  • 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...

This manual is also suitable for:

Rs 510/e ulxS045t1S046t1

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