Riello RS 64/E MZ Installation, Use And Maintenance Instructions
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Riello RS 64/E MZ Installation, Use And Maintenance Instructions

Riello RS 64/E MZ Installation, Use And Maintenance Instructions

Forced draught gas burners
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Progressive two-stage or modulating operation
CODE
3789900 - 3789910
3789901 - 3789911
MODEL
RS 64/E MZ
RS 64/E MZ
TYPE
896 T
896 T
20068423 (2) - 05/2015

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Summary of Contents for Riello RS 64/E MZ

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 3789900 - 3789910 RS 64/E MZ 896 T 3789901 - 3789911 RS 64/E MZ 896 T 20068423 (2) - 05/2015...
  • 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 6.4.1 Firing output ................................31 6.4.2 Maximum output ................................31 6.4.3 Minimum output .................................31 Final calibration of the pressure switches ........................32 6.5.1 Air pressure switch..............................32 6.5.2 Maximum gas pressure switch...........................32 6.5.3 Minimum gas pressure switch............................32 6.5.4 PVP pressure switch kit .............................33 Visualisation and programming mode........................34 6.6.1 Normal mode ................................34...

  • 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 release 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  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 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

    230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RS 64/E MZ 3 ~ 400 / 230V - 50Hz Direct 3789900 - 3789910 RS 64/E MZ 3 ~ 400 / 230V - 50Hz Direct 3789901 - 3789911 Tab. A...

  • Page 10: Burner Categories

    AT, CH, CZ, DK, EE, FI, GR, HU, IS, IT, LT, NO, SE, SI, SK II2H3B/P ES, GB, IE, PT II2H3P II2L3B/P Tab. B Technical data Model RS 64/E MZ Output Max. 400 ÷ 850 Mcal/h 345 ÷ 730 Min. Mcal/h...

  • Page 11: Maximum Dimensions

    Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the guides. D3906 Fig. 1 RS 64/E MZ 250 - 385 2” Tab. E (1) Blast tube: short-long Firing rate The maximum output is chosen within area A (Fig.

  • Page 12: Firing Rate On Basis Of Air Density

    Technical description of the burner 4.7.1 Firing rate on basis of air density If H3 is greater than H1)(Fig. 3), the burner can produce the de- livery requested. The firing rate of the burner shown in the manual is valid for a If H3 is less than H1, it is necessary to reduce the output of the room temperature of 20°C and an altitude of 0m above sea level burner.

  • Page 13: Test Boiler

    Technical description of the burner Test boiler The firing rates were obtained in special test boilers, according to The coupling is ensured when the boiler is EC type-approved; for EN 676 regulations. boilers or ovens with combustion chambers of very different di- mensions compared to those shown in the diagram of Fig.

  • Page 14: Burner Description

    Technical description of the burner 4.10 Burner description Seen from A D8140 Fig. 5 Combustion head Ignition electrode Screw for combustion head adjustment Pipe coupling Gas servomotor Plug-socket on ionisation probe cable Motor relay Operation on/off switch Terminal board for electrical wiring 10 Operator panel with LCD display 11 Control box for checking flame and air/fuel ratio 12 Clean contact relay...

  • Page 15: Control Box For The Air/Fuel Ratio (Rec 27.100A2)

    To avoid accidents, material 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 Electrical connection of flame detector trocution; it must be protected against any accidental con- tact. It is important for signal transmission to be almost totally free  The grounding of the burner must be in compliance with the of any disturbances or loss: rules in force;...
  • Page 17 Technical description of the burner Cable lengths – Main line AC 230 V Max. 100 m (100 pF / m) – Display, BCI For installation under the casing of the burner or in the control panel max. 3 m (100 pF / m) –...

  • Page 18: Operation Sequence Of The Burner

    Technical description of the burner 4.12 Operation sequence of the burner Operation Checking of Start up Shutdown 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 19: 4.12.1 List Of Phases

    Technical description of the burner 4.12.1 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 20: 4.13.2 Buttons Description

    Technical description of the burner 4.13.2 Buttons description Button Button Function To regulate the fuel servomotor Button F (keep pressed and adjust the value by pressing To regulate the servomotor air Button A (keep pressed and adjust the value by pressing To modify the parameter for setting the P mode Button A and F VSD Function...

  • Page 21: Servomotors (Sqm33

    Technical description of the burner 4.14 Servomotors (SQM33..) Important notes To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying or forcing the servo- WARNING motor.  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ...

  • 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

    The lengths L available are: D455 Fig. 14 Blast tube Short (mm) Long (mm) RS 64/E MZ RS 64/E MZ 275 - 325 M 12 Tab. J Tab. K For boilers with front flue passes 13)(Fig. 17), a protection in re- fractory material 11) must be inserted between the boiler refrac- tory 12) and the blast tube 10).

  • Page 24: Positioning Probe - Electrode

    Installation Positioning probe - electrode Before fixing the burner to the boiler, check from the opening of the blast tube that the probe and the electrode are correctly positioned, as in WARNING Fig. 16. If, in the previous check, the position of the probe or electrode was not correct, is necessary: ...

  • Page 25: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler  disconnect the probe and electrode cables and remove the entire burner from the guides, after having removed the split Provide an adequate lifting system of the burner. pin from the guide 5). ...

  • Page 26: Burner Closing

    Installation Example: burner output = 500 Mcal/h. From diagram (Fig. 18) it can be seen that the air adjustment for this power is made on notch 7.5. NOTE: If the chamber pressure is equal to 0 mbar, the air adjustment is made referring to the dotted line of diagram.

  • Page 27: Gas Feeding

    Installation 5.10 Gas feeding Explosion danger due to fuel leaks in the pres- 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 28: 5.10.2 Gas Train

    Installation 5.10.2 Gas train Type-approved in accordance with EN 676 and supplied sepa- rately from the burner. To select the correct model of the gas train, refer to the “burner- gas train combination” manual supplied. 5.10.3 Gas train installation D505 Disconnect the electrical power using the main system switch.
  • Page 29 Installation Example with natural gas G 20: Maximum output operation Gas pressure at test point 1)(Fig. 27) 9.4 mbar Pressure in combustion chamber 2.0 mbar 9.4 - 2.0 7.4 mbar A maximum output of 700 kW shown in Tab. L corresponds to 7.4 mbar pressure, column 1.

  • Page 30: Electrical Wiring

    Installation 5.11 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: Calibration Of The Thermal Relay

    Installation 5.12 Calibration of the thermal relay The thermal relay is used to avoid damage to the motor owing to a strong increase in absorption or the lack of a phase. For the calibration, refer to the electrical wiring. If the minimum value of the scale of the thermal relay is greater than the rating absorption of the motor, protection is still ensured.

  • Page 32: 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 33: Burner Adjustment

    Start-up, calibration and operation of the burner As the burner is not fitted with a device to check the sequence of the phases, the motor rotation may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor and check it is rotating anticlockwise.

  • Page 34: Final Calibration Of The Pressure Switches

    Start-up, calibration and operation of the burner Final calibration of the pressure switches 6.5.1 Air pressure switch Adjust the air pressure switch (Fig. 32) after having performed all other burner adjustments with the air pressure switch set to the start of the scale. With the burner working at MIN output, insert a combustion analyser in the stack, slowly close the suction inlet of the fan (for example, with a piece of cardboard) until the CO value does not...

  • Page 35: Pvp Pressure Switch Kit

    Start-up, calibration and operation of the burner 6.5.4 PVP pressure switch kit Adjust the pressure switch for the valve leak detection control de- vice (PVP Kit)(Fig. 35), if present, according to the instructions supplied with the Kit itself. Fig. 35 D3855 20068423...

  • Page 36: Visualisation And Programming Mode

    Start-up, calibration and operation of the burner Visualisation and programming mode 6.6.1.4 Condition error message, display of the errors 6.6.1 Normal mode 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 37: Info Mode

    Start-up, calibration and operation of the burner 6.6.1.5 Reset procedure Releasing the key “ F ” the standard visualisation appears, with the current load percentage flashing: this means that the burner is The burner is in lockout when the red indicator light on the oper- working in Manual mode (any outside adjustment is excluded and ator panel is lit up, and the display visualises the lockout code (in only the safety devices are active).

  • Page 38: Service Mode

    Start-up, calibration and operation of the burner 6.6.3 Service mode 6.6.4 Parameter mode The Service mode ( SEr ) visualises the error log and certain The Parameters Mode ( PArA ) displays, and allows to be mod- technical information about the system. To access this level you ified/programmed, the list of parameters indicated on page 44.

  • Page 39: Parameter Modification Procedure

    Start-up, calibration and operation of the burner 6.6.4.2 Allocating the levels of the parameters 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 40 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 41: 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 section "Procedure and “OFF Upr” : this means it is necessary to set the modulation for inserting and adjusting points on the modulation curve"...
  • Page 42 Start-up, calibration and operation of the burner The control box will automatically report the same values set at the points “ P0 ” and “ P1 ” to points “ P2 ” to “ P8 ”. The purpose is to reach the point “ P9 ” to adjust/fix the maximum operating power.

  • Page 43: Backup / Restore Procedure

    Start-up, calibration and operation of the burner Backup / Restore procedure At the end of the "Start-up procedure" it is opportune to make a We suggest carrying out this operation at the end backup, creating a copy of the data memorised on the REC, in of each intervention that modifies what has been the display panel RDI 21.

  • Page 44: 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. the modification carried out is correct. To determine the cause of the error refer to diagnostic code WARNING 137 (see section "Error codes list"...
  • Page 45 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.

  • Page 46: Parameter List

    Start-up, calibration and operation of the burner 6.9.3 Parameter list Parameter Value range No. ele- Unit of Modifica- Degree of Default Acces mode ments measure tion accuracy setting Description Min. Max. INTERNAL PARAMETERS Start backup/restore process via RDI21... / PC TOOL (set the parameter to 1) Index 0 = create backup Modification...
  • Page 47 Start-up, calibration and operation of the burner Parameter Value range No. ele- Unit of Modifica- Degree of Default Acces mode ments measure tion accuracy setting Description Min. Max. Baud Rate for Modbus Values set: Modification Service mode 0 = 9600 1 = 19200 Parity for Modbus 0 = none...
  • Page 48 Start-up, calibration and operation of the burner Parameter Value range No. ele- Unit of Modifica- Degree of Default Acces mode ments measure tion accuracy setting Description Min. Max. Gas: selection of flame sensor 0 = QRB.../ QRC Modification Service mode 1 = ION / QRA Gas: Selection of the pre-purging function 0 = deactivated...
  • Page 49 Start-up, calibration and operation of the burner Parameter Value range No. ele- Unit of Modifica- Degree of Default Acces mode ments measure tion accuracy setting Description Min. Max. Position of the fuel servomotor in absence of flame Index 0 = standby position (°) Modification 0°...

  • Page 50: Steady-State Operation

    Start-up, calibration and operation of the burner Parameter Value range No. ele- Unit of Modifica- Degree of Default Acces mode ments measure tion accuracy setting Description Min. Max. /h, l, h, Actual output Reading only 6553.5 Info mode /h, gal/h Status of external modules and visualisation Reading only Info mode...

  • Page 51: Final Checks (With Burner Operating)

    Start-up, calibration and operation of the burner 6.14 Final checks (with burner operating)   Open the thermostat/pressure switch TL The burner must stop  Open the thermostat/pressure switch TS  Turn the gas maximum pressure switch knob to the mini- ...

  • 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: Measuring The Ionisation Current

    Maintenance Combustion If the combustion values found at the start of the intervention do not satisfy current standards or anyway indicate a poor state of combustion (consult the table below), contact the Technical As- sistance Service for the necessary adjustments. Air excess EN 676 Max.

  • Page 54: Opening The Burner

    Maintenance Opening the burner  Loosen the screws 1)(Fig. 41) and remove the cover 2).  Disconnect the plug 14)(Fig. 17 at page 23) and loosen the Disconnect the electrical supply from the burner cable grommet 15). by means of the main system switch. ...

  • Page 55: Faults - Probable Causes - Solutions

    Faults - Probable causes - Solutions Faults - Probable causes - Solutions If faults arise in ignition or operations, the burner performs a In the event of a burner lockout, more than two "safety stop", which is signalled by the red burner lockout LED. consecutive burner reset operations could cause The display of the operator panel visualises alternately the lock- damage to the installation.
  • Page 56 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code The valve leak detection is active, but the minimum gas Valve leak detection test not possible pressure switch is selected as input for X9-04 (check parameters 238 and 241) The valve leak detection is active, but no input has been Valve leak detection test not possible...
  • Page 57 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Carry out a reset; if the error arises repeatedly, replace the 50 ÷ 58 Internal error control box Carry out a reset; if the error arises repeatedly, replace the Internal error: no valid load checking device control box Carry out a reset;...
  • Page 58 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Overloading of the servomotor or servomotor subjected to mechanical torsion. Bit 4 Deviation of section compared with the last reference 1. Check if the servomotor is blocked in any point along its Valence ...
  • Page 59 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Insufficient mains voltage. Low level of power supply Conversion of the diagnostic code Voltage value (230 V AC : 1,683) Error code for the carrying out of a reset in the event of power Reset power supply voltage supply restoration (absence of error) Carry out a reset;...
  • Page 60 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 254 (-2) Interruption owing to transmission error Repeat the reset and backup 255 (-1) Interruption owing to time-out during the restoration Carry out a reset, check the connections and repeat the backup Time-out of the system automation interface Refer to the Modbus User Documentation (A7541) Modbus time-out...
  • Page 61 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 Tab.

  • Page 62: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Long head kit Standard head length Extended head length Burner Code (mm) (mm) RS 64/E MZ 3010427 Spacer kit Burner Thickness (mm) Code RS 64/E MZ 3010129 Continuous purging kit Burner Code RS 64/E MZ...
  • Page 63 Appendix - Accessories Software interface kit (ACS410 + OCI410.30) - Service Level Burner Code RS 64/E MZ 3010436 Modbus interface kit Burner Model Code RS 64/E MZ OCI412 3010437 Kit PVP (Pressure Valve Proving) Burner Gas train type Code RS 64/E MZ...

  • Page 64: Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references REC27... operational layout REC27... operational layout REC27... operational layout Electrical connections set by installer RWF50... operational layout Indication of references / 1 . A 1 Sheet no.
  • Page 65 Appendix - Electrical panel layout 20068423...
  • Page 66 Appendix - Electrical panel layout 20068423...
  • Page 67 Appendix - Electrical panel layout 20068423...
  • Page 68 Appendix - Electrical panel layout 20068423...
  • Page 69 Appendix - Electrical panel layout 20068423...
  • Page 70 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio 6 pin plug Operator panel 7 pin plug Filter to protect against radio disturbance Connector for operation without RWF output power regulator kit Burners components Connector for output power regulator kit RWF Boiler components 4 pole socket Output regulator RWF...
  • 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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