Riello RS 25/E BLU Series Installation, Use And Maintenance Instructions
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Riello RS 25/E BLU Series 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
3910710
3910701 - 3910711
3910810
3910801 - 3910811
3910840
3910831 - 3910841
MODEL
RS 25/E BLU
RS 25/E BLU
RS 35/E BLU
RS 35/E BLU
RS 35/E BLU
RS 35/E BLU
TYPE
878 T
878 T
879 T
879 T
879 T
879 T
20068118 (2) - 09/2016

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  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 3910710 RS 25/E BLU 878 T 3910701 - 3910711 RS 25/E BLU 878 T 3910810 RS 35/E BLU 879 T 3910801 - 3910811 RS 35/E BLU 879 T 3910840...
  • 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 ............................
  • Page 4 Contents 6.4.1 Firing output ................................32 6.4.2 Maximum output .................................32 6.4.3 Minimum output ................................32 Final calibration of the pressure switches........................33 6.5.1 Air pressure switch ..............................33 6.5.2 Minimum gas pressure switch ............................33 6.5.3 PVP pressure switch kit ..............................33 Visualisation and programming mode ........................34 6.6.1 Normal mode ................................34 6.6.2...

  • Page 5: Declarations

    14 mg/kWh CO max: 1 mg/kWh NOx max: 72 mg/kWh NOx max: 56 mg/kWh Legnago, 01.12.2015 Executive General Manager Research & Development Director RIELLO S.p.A. - Burner Department RIELLO S.p.A. - Burner Department Mr. U. Ferretti Mr. F. Comencini 20068118...
  • Page 6 Declarations 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”. Product Type Model Power 878T RS 25/E BLU 45 - 370 kW Forced draught gas burners...

  • Page 7: Information And General Warnings

    Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction WARNING: MOVING PARTS The instruction manual supplied with the burner: This symbol indicates that you must keep limbs  is an integral and essential part of the product and must not away from moving mechanical parts;...

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

    Information and general warnings  The system supplier must carefully inform the user about: 2.1.4 Delivery of the system and the instruction – the use of the system; manual – any further tests that may be required before activating the When the system is delivered, it is important that: system;...

  • Page 9: Safety And Prevention

    Safety and prevention Safety and prevention 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 Burner designation Range : Fuel : Natural gas Light oil Light oil Natural gas Heavy oil Size Adjustment Electronic cam Electronic cam and variable speed (with Inverter) Mechanical cam Proportional air/gas valve Emission Class 1 EN676 Class 2 EN676...

  • Page 11: Burner Categories

    Technical description of the burner Burner categories Country of destination Gas category I2E(R) CY, MT I3B/P LU, PL II2E3B/P II2ELL3B/P II2Er3P 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.

  • Page 12: Maximum Dimensions

    Technical description of the burner Maximum dimensions The dimensions of the burner are shown in Fig. 1. The dimensions of the open burner are indicated by position O. Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the guides. Fig.

  • Page 13: Firing Rate On Basis Of Air Density

    Technical description of the burner If H3 is greater than H1)(Fig. 3), the burner can produce the de- 4.7.1 Firing rate on basis of air density 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 14: 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 15: Burner Description

    Technical description of the burner 4.10 Burner description 20052390 Fig. 5 Combustion head 19 Guides for opening the burner and inspecting the combus- Ignition electrode tion head Screw for combustion head adjustment 20 Gas pressure test point and head fixing screw Pipe coupling 21 Air pressure socket Gas servomotor...

  • Page 16: 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 17 Technical description of the burner trocution; it must be protected against any accidental con- Electrical connection of flame detector 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 18 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 19: 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 20: 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 21: 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 22: Servomotors (Sqn13

    Technical description of the burner 4.14 Servomotors (SQN13...) Introduction The servomotors that equip the burners of the RS range work di- rectly on the air damper and the gas butterfly valve, without me- chanical leverages but via the interposition of an elastic coupling. They are commanded by the control box, which constantly checks their position by means of a return signal from the optic sensor inside the servomotor.

  • Page 23: Installation

    In the event of doubt, do not GAS-KAASU use the burner; contact the supplier. GAZ-AEPIO CAUTION RIELLO S.p.A. I-37045 Legnago (VR) The packaging elements (wooden cage or card- board box, nails, clips, plastic bags, etc.) must not 0085 be abandoned as they are potential sources of danger and pollution;...

  • Page 24: Operating Position

    Installation Operating position  The burner is designed to operate only in  Any other position could compromise the cor- positions 1, 2, 3 and 4 (Fig. 12). rect operation of the appliance.  Installation 1 is preferable, as it is the only ...

  • Page 25: 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 Fig. 16. WARNING If, in the previous check, the position of the probe or electrode was not correct, is necessary: ...

  • Page 26: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler  pull back the burner on the guides 5) by about 100 mm;  disconnect the probe and electrode leads, then unthread the Provide an adequate lifting system of the burner. burner completely from the guides 5). ...

  • Page 27: Burner Closing

    Installation Air adjustment Rotate the screw 4)(Fig. 19) until the notch you have found cor- responds with the front surface 5) of the flange. To facilitate the adjustment, loosen the screw 6)(Fig. 19), adjust, then block. WARNING Example: RS 35/E BLU, burner output = 270 kW. From diagram (Fig.

  • Page 28: Gas Feeding

    Installation 5.10 Gas feeding Explosion danger due to fuel leaks in the presence 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 29: 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 Disconnect the electrical power using the main D3839 system switch.
  • Page 30 Installation Example with natural gas G 20 for RS 35/E BLU: Maximum output operation Gas pressure at test point 1)(Fig. 27) 11.3 mbar Pressure in combustion chamber 2.0 mbar 11.3 - 2.0 9.3 mbar A maximum output of 360 kW shown in Tab. K corresponds to 9.3 mbar pressure, column 1.

  • Page 31: 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 32: Supply Cables And External Connections Passage

    Installation 5.11.1 Supply cables and external connections passage All cables to connect to the burner are connected to the appropri- ate sockets on the side of the burner (Fig. 28), (use the supplied plugs for the connections). The use of the cable grommets can take various forms. By way of example we indicate the following mode: RS 25-35/E BLU single phase 7 pole socket for single phase power supply, thermostat/...

  • Page 33: 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 34: Burner Adjustment

    Start-up, calibration and operation of the burner Only for RS 35/E BLU three-phase 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 35: 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. 33) 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 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 Releasing the key “F” the standard visualisation appears, with the 6.6.1.5 Reset procedure 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 Select another point, or exit this area by pressing the keys “+” 6.7.0.1 Procedure for inserting and adjusting points on 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 Simultaneously press the keys “+” and “-” (ESC) twice, the dis- the points “P0” and “P1” to points “P2” to “P8”. play will show the position of the current load. The purpose is to reach the point “P9”...

  • 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 the of each intervention that modifies what has been 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 7.2.3 Measuring the ionisation current The burner is fitted with an ionisation system to check that a flame is present. The minimum current for control box operation is 4 μA. The Op- erator Panel visualises “30%” (see "Parameter list" at page 44, parameter no.

  • Page 54: Opening The Burner

    Maintenance Opening the burner  Loosen the screw 1)(Fig. 40) and remove the cover 2).  Remove the nuts 2)(Fig. 17 at page 24) fit them on the sup- Disconnect the electrical supply from the burner plied extensions and screw them on guides 3)(TL versions). 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. Conversion of the diagnostic code Low level of power supply 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 Refer to the Modbus User Documentation (A7541) Time-out of the system automation interface 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 25/E BLU 3010430 RS 35/E BLU 3010431 Spacer kit Burner Thickness (mm) Code RS 25-35/E BLU 3010095 Soundproofing chamber kit Burner Type dB(A)
  • Page 63 Appendix - Accessories Software interface kit (ACS410 + OCI410.30) - Service Level Burner Code RS 25-35/E BLU 3010436 Modbus interface kit Burner Model Code RS 25-35/E BLU OCI412 3010437 Kit for LPG operation Blast tube length Burner Code (mm) RS 25/E BLU 230 - 365 3010423 RS 35/E BLU...

  • 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 Electrical connections for kit Electrical connections for external RWF... kit Indication of references / 1 .
  • Page 65 Appendix - Electrical panel layout 20068118...
  • Page 66 Appendix - Electrical panel layout 20068118...
  • Page 67 Appendix - Electrical panel layout 20068118...
  • Page 68 Appendix - Electrical panel layout 20068118...
  • Page 69 Appendix - Electrical panel layout 20068118...
  • Page 70 Appendix - Electrical panel layout 20068118...
  • Page 71 Appendix - Electrical panel layout 20068118...
  • Page 72 Appendix - Electrical panel layout 20068118...
  • Page 73 Appendix - Electrical panel layout 20068118...
  • Page 74 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio 9 pole plug Operator panel Connector for output power regulator kit RWF Filter to protect against radio disturbance 4 pole socket Burners components 5 pole socket Boiler components 6 pole socket Output regulator RWF...
  • Page 76 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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Rs 35/e blu series

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