Riello RS BLU Series Installation, Use And Maintenance Instructions
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Riello RS BLU Series Installation, Use And Maintenance Instructions

Forced draught gas burner
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Installation, use and maintenance instructions
Forced draught gas burner
GB
Progressive two-stage or modulating operation
CODE
MODEL
TYPE
20094341
RS 160/EV BLU TC
94341X
20095002 (3) - 08/2015

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Summary of Contents for Riello RS BLU Series

  • Page 1 Installation, use and maintenance instructions Forced draught gas burner Progressive two-stage or modulating operation CODE MODEL TYPE 20094341 RS 160/EV BLU TC 94341X 20095002 (3) - 08/2015...
  • Page 2 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 Burner start-up ................................31 Burner adjustment..............................32 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 Maximum gas pressure switch...........................33 6.5.3 Minimum gas pressure switch............................33 Visualisation and programming mode........................34 6.6.1 Normal mode ................................34 6.6.2...

  • Page 5: Declarations

    The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001. Legnago, 21.05.2015 Executive General Manager Research & Development Director RIELLO S.p.A. - Burner Department RIELLO S.p.A. - Burner Department Mr. U. Ferretti Mr. F. Comencini...

  • 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

    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 C01 or ...

  • Page 10: 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 11: 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 I. Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the guides. D1206 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 Seen from A 20096721 Fig. 5 Combustion head 19 Minimum air pressure switch (differential operating type) Ignition pilot 20 Slide bars for opening the burner and inspecting the com- Screw for combustion head adjustment bustion head Maximum gas pressure switch...

  • Page 15: Control Box For The Air/Fuel Ratio (Rec 37.400A2)

    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 Technical data Control box Mains voltage AC 230 V -15 % / +10 % Mains frequency 50 / 60 Hz ±6 % Power absorption < 30 W (normal) Safety class I, with components in compliance with II and III, ac- cording to DIN EN 60730-1 Load on ‘input’...
  • Page 17 Technical description of the burner Cross-sections of They should be sized for rated currents as per the pri- the power supply mary external fuse and the fuse of the internal unit. lines – Min. cross-section (max. 6.3 AT) – Fuses used inside the control box F1 0.75 mm²...

  • Page 18: Operation Sequence Of The Burner

    Technical description of the burner 4.12 Operation sequence of the burner Operation Checking Start up Shutdown of seal TSA1 Phase number 0.6 s Timer - Resolution - Ratio 27 s 30 s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max. phase time RAST plug Input signals PIN number...

  • 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: Inverter

    To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying or forcing the inverter. WARNING Riello S.p.A. cannot assume any responsibility for damage resulting from unauthorised interven- tions! Operators must be aware of the fact that incorrect- ly setting the inverter risks causing dangerous conditions while the burner is operating.

  • Page 23: 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 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. 14). rect operation of the appliance.  Installation 1 is preferable, as it is the only ...

  • Page 25: Blast Tube Length

    Installation 5.5.3 Blast tube length For boilers with front flue passes 13)(Fig. 19 at page 24), or flame inversion chambers, a protection in refractory material 11) must The length of the blast tube must be selected according to the in- be inserted between the boiler refractory 12) and the blast tube dications provided by the manufacturer of the boiler, and in any 10).

  • Page 26: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler Once this operation has been carried out:  fix the flange 9) to the boiler plate, interposing the insulating Provide an adequate lifting system of the burner. gasket 8) supplied.  Use the 4 screws supplied, with a tightening torque of 35 - 40 Nm, after protecting their thread with anti-seize products.

  • Page 27: Combustion Head Adjustment

    Installation Combustion head adjustment At this point of the installation, the combustion head is fixed to the Two adjustments of the head are foreseen: boiler as shown in Fig. 18. It is therefore especially easy to adjust, – external air R1 and this adjustment depends only on the maximum output of the –...

  • Page 28: Burner Closing

    Installation Burner closing  connect the socket of the maximum gas pressure switch; Once the combustion head adjustment is completed:  reassemble the burner on the guides 3) at about 100 mm  refit the screws 2) on the guides 3); ...

  • Page 29: 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 30: 5.10.4 Gas Pressure

    Installation The values shown in Tab. N refer to: – Natural gas G 20 NCV 9.45 kWh/Sm (8.2 Mcal/Sm Beware of train movements: danger of crushing of – Natural gas G 25 NCV 8.13 kWh/Sm (7.0 Mcal/Sm limbs. Column 1 Make sure that the gas train is properly installed Load loss at combustion head.

  • 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: 5.11.2 Motor Cable Shield

    Installation 5.11.2 Motor cable shield It is important to shield the motor cable 1) as indi- cated in Fig. 30. WARNING D12115 Fig. 30 Key (Fig. 30) Power supply cable (from the inverter). Single-phase power supply cable. Connecting cable between inverter REC 37.400A2 electronic cam The connection from the inverter to the...

  • 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 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. 34) 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 Normal mode 6.6.1.4 Error state message, display of the errors and information The Normal mode is the standard operation mode visualised on the operator panel display. It is the main level of the menu. The display visualises alternately the error code (in the example ...
  • Page 37 Start-up, calibration and operation of the burner 6.6.1.5 Reset procedure 6.6.1.7 Manual operation procedure The burner is in lockout when the red indicator light on the oper- After the adjustment of the burner and the setting of the points on ator panel is lit up, and the display visualises the lockout code (in the modulation curve, it is possible to manually check the opera- the example alongside c: 4 ) and the relative diagnostics (in the...

  • Page 38: Info Mode

    Start-up, calibration and operation of the burner 6.6.2 Info mode 6.6.3 Service mode The Info mode ( InFo ) visualises general system information. To The Service mode ( SEr ) visualises the error log and certain access this level you must: technical information about the system.

  • Page 39: Parameters Mode

    Start-up, calibration and operation of the burner 6.6.4 Parameters Mode The password must only be communicated to the The Parameters Mode ( PArA ) displays and allows you to modi- qualified personnel or the Technical Assistance fy/programme the parameters list on page 45. Service, and must be kept in a safe place.

  • Page 40: Parameter Modification Procedure

    Start-up, calibration and operation of the burner Parameter modification procedure After accessing the level and group of parameters, the display To insert or adjust a point, proceed as follows. visualises the number of the parameter (flashing) on the left, and Using the keys “+”...

  • Page 41: Calc Function

    Start-up, calibration and operation of the burner 6.7.2 CALC function 6.7.3 Modification of parameter “acceleration / deceleration ramp” The diagram (Fig. 37) shows how the fuel modulation curve is modified if the values of point “ P5 ” are changed. The burner leaves the factory with the parameters 522 (acceler- By keeping the “+”...

  • Page 42: Start-Up Procedure

    Start-up, calibration and operation of the burner Start-up procedure Check that the operator panel display shows the heat request Phase 24: and “OFF Upr” : this means it is necessary to set the modulation The burner goes to the pre-purging position, the air servomotor curve of the burner.
  • Page 43 Start-up, calibration and operation of the burner Solve the problem, referring to the paragraph "Ignition failure" Halfway through the procedure (i.e. around point P4 or P5 ), you on page 49. are advised to measure gas delivery and check that the output is about 50% of the maximum output.

  • Page 44: Backup / Restore Procedure

    Start-up, calibration and operation of the burner Backup / Restore procedure At the end of the "Start-up procedure" it is wise to carry out a We suggest that this operation be carried out at backup, creating a copy of the data memorised on the REC, in the end of any intervention that involves modifica- the RDI 21 display panel.

  • Page 45: Restore

    Start-up, calibration and operation of the burner NOTE: It is advisable to perform a backup every time If an error occurs during the backup process, the display that a parameter is changed, after checking screen shows a negative value. that the modification carried out is correct. Refer to diagnostic code 137 to determine the cause of the WARNING error (see section "Error codes list"...
  • Page 46 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 47: 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 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. Baud Rate for Modbus Set values: Modification Service Mode 0 = 9600 1 = 19200 Parity for Modbus 0 = none...
  • 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. Gas: Selection of the pre-purging function 0 = deactivated Modification Service Mode 1 = activated Maximum repeats of minimum gas pressure switch intervention...
  • Page 50 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. 0°; 100°; VSD control curve ratio (only curve setting) (°) Modification 20° 100°...

  • Page 51: 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. Result of the sampling of the contact (codified in bits) Bit 0.0 = 1: Minimum pressure switch Bit 0.1 = 2: Maximum pressure switch Bit 0.2 = 4: Pressure switch control valves Bit 0.3 = 8: Air pressure switch...

  • Page 52: Stopping Of The Burner

    Start-up, calibration and operation of the burner 6.13 Stopping of the burner The burner can be stopped by: Panel, after loosening the relative screw, and using the  intervening on the disconnecting switch of the electrical sup- panel itself according to "Manual lockout procedure" on 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, 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 54: Checking The Air And Gas Pressure On The Combustion Head

    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 Checking combustion (consult the table below), contact the Technical As- gas pressure sistance Service for the necessary adjustments. Air excess EN 676 Max.

  • Page 55: Opening The Burner

    Maintenance Opening the burner  Loosen the 4 screws 1)(Fig. 41) and remove the hood 2).  Disconnect the plug 7) and unscrew the cable grommet 8). Disconnect the electrical supply from the burner  Disconnect the socket from the maximum gas pressure by means of the main system switch.

  • Page 56: 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 57 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 58 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 59 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code The motor has not reached a stable speed after acceleration. 1. The VSD train times are not shorter than those of the standard unit (parameters 522, 523).
  • Page 60 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code The speed was not reached because the curve was too steep. 1. With a train REC3... of 20 s, the speed variation between 2 points of the curve (in modulating mode) cannot exceed 10%.
  • Page 61 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Bit 3 The slope of the curve can correspond to a maximum position Curve too steep in terms of train ratio Valence  8 modification of 31°...
  • Page 62 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 Voltage monitoring test internal error control box Insufficient mains voltage. Low level of power supply Conversion of the diagnostic code --->...
  • Page 63 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 252 (-4) After restoration, the pages are still in INTERRUPTION Repeat the reset and backup 253 (-3) The restoration cannot currently be carried out Repeat the reset and backup 254 (-2) Interruption owing to transmission error...
  • Page 64 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 Carry out a reset;...

  • Page 65: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Long head kit Standard head length Extended head length Burner Code (mm) (mm) RS 160/EV BLU 3010442 Spacer kit Burner Thickness (mm) Code RS 160/EV BLU 3000722 Continuous purging kit Burner Code RS 160/EV BLU 3010094 Soundproofing chamber kit Burner...
  • Page 66 Appendix - Accessories Software interface kit (ACS410 + OCI410.30) - Service Level Burner Code RS 160/EV BLU 3010436 Modbus interface kit Burner Model Code RS 160/EV BLU OCI412 3010437 Inverter kit (variable speed drive) Burner Max output (kW) Code RS 160/EV BLU 20062679 Kit PVP (Pressure Valve Proving) Burner...

  • Page 67: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output REC37... operational layout REC37... operational layout REC37... operational layout REC37... operational layout Electrical connection set by installer Electrical connection set by installer Indication of references / 1 .
  • Page 68 Appendix - Electrical panel layout 20095002...
  • Page 69 Appendix - Electrical panel layout 20095002...
  • Page 70 Appendix - Electrical panel layout 20095002...
  • Page 71 Appendix - Electrical panel layout 20095002...
  • Page 72 Appendix - Electrical panel layout 20095002...
  • Page 73 Appendix - Electrical panel layout 20095002...
  • Page 74 Appendix - Electrical panel layout 20095002...
  • Page 75 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio Electronic burner control box User interface Burner components Boiler components Electromagnetic Compliance filter Output regulator RWF50 Fuel meter 4...20mA active current output probe 4...20mA active current output remote setpoint adjust 4...20mA 2-wires pressure probe 0..10V pressure probe Remote setpoint potentiometer...
  • 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 160/ev blu tc

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