Riello RX 1800 S/E Installation, Use And Maintenance Instructions
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Riello RX 1800 S/E Installation, Use And Maintenance Instructions

Riello RX 1800 S/E Installation, Use And Maintenance Instructions

Premix gas burners, progressive two-stage or modulating operation with pilot flame ignition
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Installation, use and maintenance instructions
Premix gas burners
GB
Progressive two-stage or modulating operation
with pilot flame ignition
CODE
20148880
20148881
20148882
CODE
20151520
20151274
20151483
MODEL
RX 1800 S/E
RX 2500 S/E
RX 3000 S/E
COMBUSTION HEAD ASSEMBLY
TYPE
S023
S024
S025
RX 1800 S/E
RX 2500 S/E
RX 3000 S/E
20152087 (5) - 06/2019

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Summary of Contents for Riello RX 1800 S/E

  • Page 1 Installation, use and maintenance instructions Premix gas burners Progressive two-stage or modulating operation with pilot flame ignition CODE MODEL TYPE 20148880 RX 1800 S/E S023 20148881 RX 2500 S/E S024 20148882 RX 3000 S/E S025 CODE COMBUSTION HEAD ASSEMBLY 20151520...
  • 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 Start-up, calibration and operation of the burner ........................32 Notes on safety for the first start-up ...........................32 Adjustments prior to ignition............................32 Burner start-up ................................32 Burner adjustment..............................33 Ignition pilot adjustment .............................33 Air / fuel adjustment ..............................33 6.6.1 Air adjustment for maximum output ...........................33 6.6.2 Air/fuel adjustment and output modulation system ....................33 Final adjustment of the pressure switches .........................34...

  • Page 5: Declarations

    RIELLO S.p.A. - Burner Department RIELLO S.p.A. - Burner Department Mr. U. Ferretti Mr. F. Comencini 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”. Product Type Model...
  • Page 6 NOx max: 77 mg/kWh RX 3000 S/E CO max: 2 mg/kWh NOx max: 73 mg/kWh Legnago, 21.04.2018 Executive General Manager Research & Development Director RIELLO S.p.A. - Burner Department RIELLO S.p.A. - Burner Department Mr. U. Ferretti Mr. F. Comencini 20152087...

  • 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 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 9: 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 10: Technical Description Of The Burner

    Technical description of the burner Technical description of the burner Models available Designation Voltage Start-up Code RX 1800 S/E 3N/400/50 Direct 20148880 RX 2500 S/E 3N/400/50 Direct 20148881 RX 3000 S/E 3N/400/50 Direct 20148882 Tab. A Burner categories - Countries of destination...

  • Page 11: Electrical Data

    The weight of the burner complete with its packaging is shown in 20123805 Tab. E. Model RX 1800 S/E (pos. 1 Fig. 1) RX 2500 S/E (pos. 1 Fig. 1) RX 3000 S/E (pos. 1 Fig. 1) Model Combustion head assembly RX 1800 S/E (pos.

  • Page 12: Maximum Dimensions

    The l position is reference for the refractory thickness of the boiler door. 20122705 Fig. 2 RX 1800 S/E 1015 520 DN65 830 1178 1080 RX 2500 S/E 1015...

  • Page 13: Burner Description

    Technical description of the burner Burner description 20122708 Fig. 4 Lifting rings The burner can be opened to the right or to the left Fan motor without links to the fuel supply side. Air damper servomotor Combustion head gas pressure test point Combustion head To open the burner see section “Access to head Ignition electrode...

  • Page 14: Electrical Panel Description

    Technical description of the burner Electrical panel description 20153648 Fig. 5 Electrical control box 12 Ignition transformer ON/OFF selector 13 Air filter pressure switch Output regulator 14 Operator panel with LCD display Earth terminal 15 Light signalling burner lockout Supply cables and external connections passage. See sec- 16 Reset button tion “Electrical wiring”...

  • Page 15: Firing Rates

    RX 1800 S/E = 300 kW limit of the diagram (Fig. 6). RX 2500 S/E = 365 kW RX 1800 S/E = 1960 kW - with filter RX 3000 S/E = 635 kW RX 1800 S/E = 2160 kW - without filter The firing rate (Fig.

  • Page 16: Commercial Boilers

    Technical description of the burner 4.10.1 Commercial boilers The burner-boiler combination does not pose any problems if the boiler is EC type-approved. If, however, the burner is to be used with a commercial boiler that has not been EC approved and/or its combustion chamber di- mensions are distinctly smaller, consult the manufacturer.

  • Page 17: Control Box For The Air/Fuel Ratio (Rec 27

    To avoid accidents, material and/or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening ATTENTION 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...

  • Page 19: Operation Sequence Of The Burner

    Technical description of the burner 4.13 Operation sequence of the burner Operation Start-up Shutdown Valve proving Phase number Timer-Resolution-Relationship 30 s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = phase max. time RAST plug Function PIN number X3-04 Pin 1/2 R (ON) X5-03 Pin1/4 X10-05...

  • Page 20: 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 21: 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...

  • Page 22: Servomotor (Sqm33

    Technical description of the burner 4.15 Servomotor (SQM33..) Important Notes To avoid accidents, material or environmental damage, observe the following instructions! Do not open, modify or force the actuators. ATTENTION  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel.

  • Page 23: 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 24: 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 25: Operating Position

    The available length is shown in Fig. 17. Fig. 16 The burners cannot be used on flame inversion boilers. ATTENTION RX 1800 S/E 22.5 RX 2500 S/E 22.5 RX 3000 S/E 22.5 Tab. K 20129430 Fig.

  • Page 26: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler Prepare a suitable lifting system using the rings 3)(Fig. 19), after removing the fixing screws 7) of the casing 8).  Prepare a suitable lifting system using the rings 3)(Fig. 191) of the head assembly. ...

  • Page 27: 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. 21) in the housing. To open the burner towards the left, proceed as follows: disconnect the plug/socket 9)(Fig. 21) of the maximum gas pressure switch;...

  • Page 28: Position Of Electrode - Flame Sensor

    Installation Position of electrode - flame sensor Check that the electrode is positioned as in Fig. 24, respecting the indicated dimensions. ATTENTION The burner is equipped with a flame sensor 1)(Fig. 25). This is fixed on an adaptor 2) with glass 3) and gasket 4). The pipe 5) allows to cool the fixing area of the sensor.

  • Page 29: Gas Line

    Installation 5.10 Gas line 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 Precautions: avoid knocking, attrition, sparks and and laws. ATTENTION heat.

  • Page 30: Gas Train

    4)(Fig. 29). RX 1800 S/E 1 p (mbar) 5.10.2 Gas train installation Disconnect the electrical power using the main 1050 switch.
  • Page 31 Installation Example RX 1800 S/E with natural gas G20: 20123545 Maximum output operation Gas pressure at test point 4)(Fig. 29) 9 mbar Pressure in combustion chamber 5 mbar 9 - 5 4 mbar A pressure of 4 mbar, (column 1, corresponds in to an output of 1450 kW.

  • Page 32: 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 33: Supply Cables And External Connections Passage

    Installation 5.11.1 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. 30. Key (Fig.

  • Page 34: 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 35: Burner Adjustment

    Start-up, calibration and operation of the burner Burner adjustment The optimum adjustment of the burner requires an analysis of 3 - MIN output flue gases at the boiler outlet. 4 - Intermediate outputs between Min. and Max. 5 - Air pressure switch Adjust in sequence: 6 - Maximum gas pressure switch 1 - Pilot flame...

  • Page 36: Final Adjustment Of The Pressure Switches

    Start-up, calibration and operation of the burner Final adjustment of the pressure switches 6.7.1 Air pressure switch Adjust the air pressure switch (Fig. 34) after performing all other burner adjustments with the air pressure switch set to the start of the scale.

  • Page 37: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 6.7.3 Minimum gas pressure switch Adjust the minimum gas pressure switch (Fig. 36) 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 38: Visualisation And Programming Mode

    Start-up, calibration and operation of the burner Visualisation and programming mode 6.8.1 Normal mode 6.8.1.4 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 39: Info Mode

    Start-up, calibration and operation of the burner 6.8.1.5 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 40: Service Mode

    Start-up, calibration and operation of the burner 6.8.3 Service mode 6.8.4 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 45.

  • Page 41: Parameter Modification Procedure

    Start-up, calibration and operation of the burner 6.8.4.2 Assigning parameter levels The password must only be communicated to the The parameters level is subdivided into groups as shown in Tab. P. qualified personnel or the Technical Assistance Parameter Service, and must be kept in a safe place. ATTENTION 100: ParA General parameters...
  • Page 42 Start-up, calibration and operation of the burner 6.9.0.1 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 43: Start-Up Procedure

    Start-up, calibration and operation of the burner 6.10 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 44 Factory settings Burner Value After adjusting point “P9” keep the “-” key on the display aria 1.0° pressed for about 5 seconds, “CALC” appears for a few sec- RX 1800 S/E onds. 13.5° aria 2.0° RX 2500 S/E 14.0° aria 7.5°...

  • Page 45: Backup / Restore Procedure

    Start-up, calibration and operation of the burner 6.11 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: 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.

  • Page 47: 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 48 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 49 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 50 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 51: 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 52: Stopping Of The Burner

    Start-up, calibration and operation of the burner 6.16 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 53: 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 54: Electrical Current To Flame Sensor

    Maintenance Boiler Optimum calibration values Clean the boiler as indicated in its accompanying instructions in MIN output MAX output order to maintain all the original combustion characteristics in- tact, especially: the flue gas temperature and combustion cham- Methane ber pressure. Tab.

  • Page 55: Flame Sensor

    Maintenance 7.2.6 Flame sensor To access the flame detector (Fig. 46), proceed as follows:  unscrew the sensor;  clean the glass 1) from any dust that may have accumu- lated;  pay attention to the gasket 2) and thermal insulator 3). Be extremely careful while troubleshooting the detector;...

  • Page 56: Safety Components

    Maintenance 7.2.8 Safety components Safety component Life cycle The safety components should be replaced at the end of their life 10 years or 250,000 Flame control cycle indicated in the following table. operation cycles The specified life cycles do not refer to the warranty terms indi- Flame sensor appross.

  • Page 57: 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 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 - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Safety circuit open /Burner flange open, fuel pressure, POC - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light, air pressure, POC - Alarm lockout at start Safety circuit open /Burner flange, air pressure, fuel pressure, POC - Alarm lockout at start...
  • Page 60 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code It was not possible to reach the target position within the Position error requested tolerance range. 1. Check if the servomotor is blocked or overloaded. Circuit open shown on the servomotor connection.
  • Page 61 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 0 Min. pressure switch 1 Max. pressure switch 2 Valve operation test pressure switch 3 Air pressure 4 Load controller open 5 Load controller on/off Can be caused by capacitive loads or presence of DC voltage 6 Load controller closed Blocked upon irregularity...
  • Page 62 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 242 (-14) Backup – the backup carried out is contradictory The backup is irregular and cannot be transferred again Backup – the data comparison between the internal 243 (-13) Repeat the reset and backup microprocessors is irregular...
  • Page 63 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Selection of internal operation mode Redefine the operation mode (parameter 201) Redefine the operation mode (parameter 201) Internal error Carry out a reset; if the error arises repeatedly, replace the control box Phase number Program stop...

  • Page 64: A Appendix - Accessories

    Appendix - Accessories Kit for modulating operation Burner Output regulator Code RWF 50.2 3-POINT OUTLET 20085417 RX 1800 S/E RX 2500 S/E RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441 RX 3000 S/E RWF 55.6 COMPLETE WITH RS-485/PROFIBUS INTERFACE 20074442 Burner...

  • Page 65: 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 27... operational layout REC 27... operational layout REC 27... operational layout Electrical connections for output power regulator (internal) Electrical connections set by installer Electrical connections set by installer Input/output of the output power regulator...
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  • Page 84 Appendix - Electrical panel layout Wiring layout key Electronic cam XPGMin Minimum gas pressure switch connector Display and calibration unit XPGVP Gas pressure switch connector for valve leak detec- tion control device Suppressor XRWF Terminal board for output power regulator RWF50 Output power regulator RWF50 internal Ignition transformer connector Fuel level measurer...
  • Page 88 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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