Riello RS 68/EV BLU Installation, Use And Maintenance Instructions
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Riello RS 68/EV BLU Installation, Use And Maintenance Instructions

Forced draught gas burners progressive two-stage or modulating operation
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Progressive two-stage or modulating operation
CODE
20013995
20010976 - 20014609
20010988 - 20015253
20006982 - 20015254
MODEL
RS 68/EV BLU
RS 120/EV BLU
RS 160/EV BLU
RS 200/EV BLU
TYPE
846 T2
847 T2
843 T2
1106 T2
20068463 (8) - 03/2021

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Summary of Contents for Riello RS 68/EV BLU

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 20013995 RS 68/EV BLU 846 T2 20010976 - 20014609 RS 120/EV BLU 847 T2 20010988 - 20015253 RS 160/EV BLU 843 T2 20006982 - 20015254...
  • 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 Burner adjustment..............................33 6.4.1 Firing output ................................33 6.4.2 Maximum output ................................33 6.4.3 Minimum output .................................33 Final calibration of the pressure switches ........................34 6.5.1 Air pressure switch..............................34 6.5.2 Maximum gas pressure switch...........................34 6.5.3 Minimum gas pressure switch............................35 6.5.4 PVP pressure switch kit .............................35 Visualisation and programming mode........................36 6.6.1 Normal mode ................................36...

  • Page 5: Declarations

    The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015. 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 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 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

    3/400/50 230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RS 68/EV BLU 3 ~ 400V - 50Hz Direct 20013995 RS 120/EV BLU 3 ~ 400V - 50Hz Direct 20010976 RS 120/EV BLU 3 ~ 400V - 50Hz...

  • Page 10: Burner Categories

    ES, GB, IE, PT II2H3P (43.46 ÷ 45.3 MJ/m (0°C)) 2L - 2E - Tab. B Technical data Model RS 68/EV BLU RS 120/EV BLU Output Max. 350 ÷ 860 600 ÷ 1300 Mcal/h 301 ÷ 740 516 ÷ 1118 Min.

  • Page 11: Electrical Data

    Technical description of the burner Electrical data Model RS 68/EV BLU RS 120/EV BLU Main electrical supply 3 ~ 400V +/-10% 50Hz 3 ~ 400V +/-10% 50Hz Control circuit power supply 1N ~ 230V +/-10% 50Hz 1N ~ 230V +/-10% 50Hz...

  • Page 12: Firing Rates

    The minimum output must not be lower than the minimum limit level), with the combustion head adjusted as WARNING of the diagram. shown at page 25. RS 68/EV BLU RS 120/EV BLU D9600 Thermal power Thermal power RS 200/EV BLU...

  • Page 13: 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 14: Test Boiler

    Screws M12 x 35 to fix the burner flange to the boiler ..No. 4 PVP kit for leak detection (except RS 68/EV BLU) ..No. 1 Instruction manual ....... No. 1 Spare parts list .

  • Page 15: Burner Description

    Technical description of the burner 4.10 Burner description 20079526 Seen from A Fig. 5 Combustion head 23 Flame sensor probe Ignition electrode 24 Air damper Screw for combustion head adjustment 25 Fan air inlet Maximum gas pressure switch 26 Screws to secure fan to pipe coupling Pipe coupling 27 Gas input pipe Gas servomotor...

  • Page 16: 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 17 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 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 Start up Shutdown of seal TSA1 Phase number Timer - Resolution - Ratio 0.6 s 27 s 30 s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max. phase time RAST plug Input signals PIN number...

  • 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 (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 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

    With the kit, this second group of tubes is substituted so that all the tubes are the same. D455 After assembling the kit, check its efficiency by measuring Fig. 14 the flue gases and CO. RS 68/EV BLU 275-325 M 12 5.5.2 Boring the boiler plate RS 120/EV BLU...

  • Page 25: Blast Tube Length

    Installation 5.5.3 Blast tube length For boilers with front flue passes 13)(Fig. 17 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 Before fixing the burner to the boiler, check for the model RS 120/EV BLU, if its maximum output is Provide an adequate lifting system of the burner. included in area A or B of the firing rate (Fig. 2 at page 10).

  • Page 27: Pre-Calibrating The Combustion Head

    Installation Pre-calibrating the combustion head The head must be pre-calibrated for model RS 120/EV BLU only, if its maximum output is within area B of the firing rate (Fig. 2 at page 10). WARNING Proceed as follows:  remove the 8 screws 2)(Fig. 18); ...

  • Page 28: Burner Closing

    3).  Block the 3 screws 1). Example: RS 68/EV BLU, burner output = 500 kW. 2 (R 3) The diagram of (Fig. 19) shows that the adjustments for this po- tential are: –...

  • Page 29: Gas Feeding

    Installation 5.11 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: 5.11.2 Gas Train

    Installation 5.11.2 Gas train 5.11.4 Gas pressure Type-approved in accordance with EN 676 and supplied sepa- Tab. O indicates the pressure drop of the combustion head and rately from the burner. the gas butterfly valve depending on the operating output of the burner.
  • Page 31 Installation To know the approximate output at which the burner is operating at its maximum: – Subtract the combustion chamber pressure from the gas pressure measured at test point 1)(Fig. 27). – Find, in the Tab. O relating to the burner concerned, column 1, the pressure value closest to the result you want.

  • Page 32: Electrical Wiring

    Installation 5.12 Electrical wiring Notes on safety for the electrical wiring  The electrical wiring must be carried out with the electrical supply disconnected.  Electrical wiring must be made in accordance with the regulations currently in force in the country of destination and by qualified personnel.

  • Page 33: 5.12.2 Motor Cable Shield

    Installation 5.12.2 Motor cable shield It is important to shield the motor cable 1) as indi- cated in Fig. 29. WARNING D12115 Fig. 29 Key (Fig. 29) 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 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 Check the correct working of the adjustment, com- by qualified personnel, as indicated in this manual mand and safety devices.

  • Page 35: Burner Start-Up

    Start-up, calibration and operation of the burner Burner start-up Feed electricity to the burner via the disconnecting switch on the Follow the "Start-up procedure" on page 42. boiler panel. Close the thermostats/pressure switches and turn the switch of Fig. 33 to position “1”. Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present.

  • Page 36: 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 37: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 6.5.3 Minimum gas pressure switch Adjust the minimum gas pressure switch (Fig. 36) after having performed all 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 locks out.

  • Page 38: 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 39 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 40: 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 41: 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 47. Service, and must be kept in a safe place.

  • Page 42: 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 43: 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. 38) 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 44: 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 45 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 51. are advised to measure gas delivery and check that the output is about 50% of the maximum output.

  • Page 46: 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 47: 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 48 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 49: 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 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. Baud Rate for Modbus Set values: Modification Service Mode 0 = 9600 1 = 19200 Parity for Modbus 0 = none...
  • Page 51 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 52 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 53: 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 54: 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 55: 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 56: Measuring The Ionisation Current

    Maintenance Gas leaks Carefully check the polarities! Make sure that there are no gas leaks on the pipes between the gas meter and the burner. WARNING Gas filter Replace the gas filter when it is dirty. 7.2.5 Checking the air and gas pressure on the Flame inspection window combustion head Clean the glass of the flame inspection window.

  • Page 57: Opening The Burner

    Maintenance Opening the burner  Loosen the 4 screws 1)(Fig. 42) and remove the hood 2).  Assemble the two extensions supplied on the slide bars 4) Disconnect the electrical supply from the burner (TL versions). by means of the main system switch. ...

  • Page 58: 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 59 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 60 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 61 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 62 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 63 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 64 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 65 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 66 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 37.100A2 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 67: A Appendix - Accessories

    3010214 RWF55 20099905 0 ÷ 25 bar 4 ÷ 20 mA 3090873 Head kit for flame inversion boiler Burner Code RS 68/EV BLU 3010247 RS 120/EV BLU 3010248 RS 160/EV BLU 3010249 RS 200/EV BLU 20035848 Kit for LPG operation...
  • Page 68 Code RS 68-120/EV BLU OCI412 3010437 RS 160-200/EV BLU Inverter kit (variable speed drive) Burner Max output (kW) Code RS 68/EV BLU 20063532 RS 120/EV BLU 20063533 RS 160-200/EV BLU 20062679 Kit PVP (Pressure Valve Proving) Burner Gas train type...

  • Page 69: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output Operational layout REC37..Operational layout REC37..Operational layout REC37..Electrical connection set by installer Operational layout RWF50... Indication of references / 1 .
  • Page 70 Appendix - Electrical panel layout 20068463...
  • Page 71 Appendix - Electrical panel layout 20068463...
  • Page 72 Appendix - Electrical panel layout 20068463...
  • Page 73 Appendix - Electrical panel layout 20068463...
  • Page 74 Appendix - Electrical panel layout 20068463...
  • Page 75 Appendix - Electrical panel layout 20068463...
  • Page 76 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio XPGVP Gas pressure switch connector for valve leak detection control device Operator panel XRWF Terminal board for output power regulator RWF Burner components Gas adjustment valve + gas safety valve Boiler components Filter to protect against radio disturbance Output regulator RWF...
  • Page 80 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...

This manual is also suitable for:

Rs 120/ev bluRs 160/ev bluRs 200/ev blu200139952001097620014609 ... Show all

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