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Installation, use and maintenance instructions
Forced draught gas burners
GB
Progressive two-stage or modulating operation
CODE
3897432 - 3897433
3897632 - 3897633
3788032 - 3788033
3899810 - 3899811
3899840
MODEL
RS 68/E BLU
RS 120/E BLU
RS 160/E BLU
RS 200/E BLU
RS 200/E BLU
TYPE
846 T1
847 T1
843 T1
1106 T1
1106 T1
20068435 (8) - 07/2021
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Table of Contents
Related Manuals for Riello RS 68/E BLU
Summary of Contents for Riello RS 68/E BLU
- Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 3897432 - 3897433 RS 68/E BLU 846 T1 3897632 - 3897633 RS 120/E BLU 847 T1 3788032 - 3788033 RS 160/E BLU 843 T1...
- Page 2 Translation of the original instructions...
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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 Burner adjustment..............................36 6.4.1 Firing output ................................36 6.4.2 Maximum output ................................36 6.4.3 Minimum output .................................36 Final calibration of the pressure switches ........................37 6.5.1 Air pressure switch..............................37 6.5.2 Maximum gas pressure switch...........................37 6.5.3 Minimum gas pressure switch............................38 6.5.4 PVP pressure switch kit .............................38 Visualisation and programming mode........................39 6.6.1 Normal mode ................................39...
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Page 5: Declarations
Legnago, 03.05.2021 Research & Development Director RIELLO S.p.A. - Burner Department Mr. F. Maltempi 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... - Page 6 L.D. dated January 8, 2004 and July 17, 2009. Type of product: Forced draught gas burners Model: RS 68/E BLU Regulation applied: EN 676 and A.R. dated January 8, 2004 - July 17, 2009 Control body: TÜV Industrie Service GmbH TÜV SÜD Gruppe...
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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 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 : C01 or ... -
Page 11: Burner Categories
(0°C)) 2L - 2E - Tab. A Models available Designation Voltage Start-up Code RS 68/E BLU 3 ~ 400 / 230V - 50Hz Direct 3897432 RS 68/E BLU 3 ~ 400 / 230V - 50Hz Direct 3897433 RS 120/E BLU... -
Page 12: Technical Data
Technical description of the burner Technical data Model RS 68/E BLU RS 120/E BLU RS 160/E BLU Type 846 T1 847 T1 843 T1 Output Max. 350 ÷ 860 600 ÷ 1300 930 ÷ 1860 Mcal/h 301 ÷ 740 516 ÷ 1118 800 ÷... -
Page 13: Electrical Data
Technical description of the burner Electrical data Model RS 68/E BLU RS 120/E BLU Type 846 T1 847 T1 Main electrical supply 3 ~ 230/400V +/-10% 50Hz 3 ~ 230/400V +/-10% 50Hz Control circuit power supply 1N ~ 230V +/-10% 50Hz... -
Page 14: Maximum Dimensions
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. 1 RS 68/E BLU 255-390 1161-1296 2” RS 120/E BLU... -
Page 15: 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 28. RS 68/E BLU RS 120/E BLU D9600 Thermal power Thermal power RS 200/E BLU... -
Page 16: 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 17: Test Boiler
Screws M12 x 35 to fix the burner flange to the boiler ..No. 4 PVP kit for leak detection (except RS 68/E BLU) ..No. 1 Instruction manual ....... No. 1 Spare parts list . -
Page 18: Burner Description
Technical description of the burner 4.10 Burner description D7923 Seen from A Fig. 5 Vista da "A" Combustion head 22 Air pressure socket Ignition electrode 23 Flame sensor probe Screw for combustion head adjustment 24 Air damper Maximum gas pressure switch 25 Fan air inlet Pipe coupling 26 Screws to secure fan to pipe coupling... -
Page 19: 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 20 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 21 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) –...
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Page 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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/E BLU 275-325 M 12 5.5.2 Boring the boiler plate RS 120/E BLU... -
Page 28: Blast Tube Length
Installation 5.5.3 Blast tube length For boilers with front flue passes 13)(Fig. 17 at page 27), 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 29: 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/E BLU, if its maximum output is in- Provide an adequate lifting system of the burner. cluded in area A or B of the firing rate (Fig. 2 at page 13). -
Page 30: Pre-Calibrating The Combustion Head
Installation Pre-calibrating the combustion head The head must be pre-calibrated for model RS 120/E BLU only, if its maximum output is with- in area B of the firing rate (Fig. 2 at page 13). WARNING Proceed as follows: remove the 8 screws 2)(Fig. 18); ... -
Page 31: Burner Closing
3). Block the 3 screws 1). Example: RS 68/E BLU, burner output = 500 kW. 2 (R 3) The diagram of (Fig. 19) shows that the adjustments for this po- tential are: –... -
Page 32: 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 33: 5.11.2 Gas Train
Installation 5.11.2 Gas train Tab. P indicates the pressure drop of the combustion head and the gas butterfly valve depending on the operating output of the Type-approved in accordance with EN 676 and supplied sepa- burner. rately from the burner. 1 ... - Page 34 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. P relating to the burner concerned, column 1, the pressure value closest to the result you want.
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Page 35: 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 36: Calibration Of The Thermal Relay
Installation 5.13 Calibration of the thermal relay The thermal relay is used to avoid damage to the motor owing to a strong increase in absorption or the lack of a phase. For the calibration 2)(Fig. 29), refer to the table given in electrical layout. If the minimum value of the scale of the thermal relay is greater than the rating absorption of the motor, protection is still ensured. -
Page 37: 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 38: 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" at page 44. boiler panel. Close the thermostats/pressure switches and turn the switch of Fig. 31 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 39: Final Calibration Of The Pressure Switches
Start-up, calibration and operation of the burner Final calibration of the pressure switches 6.5.1 Air pressure switch Adjust the air pressure switch (Fig. 32) after having performed all other burner adjustments with the air pressure switch set to the start of the scale. With the burner working at MIN output, insert a combustion analyser in the stack, slowly close the suction inlet of the fan (for example, with a piece of cardboard) until the CO value does not... -
Page 40: 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 after performing all the other burner adjustments with the pressure switch set to the start of the scale (Fig. 25). With the burner operating at maximum output, increase adjust- ment pressure by slowly turning the relative knob clockwise until the burner locks out. -
Page 41: 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 Condition error 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 42: Info Mode
Start-up, calibration and operation of the burner 6.6.1.5 Reset procedure Releasing the key “ F ” the standard visualisation appears, with the current load percentage flashing: this means that the burner is The burner is in lockout when the red indicator light on the oper- working in Manual mode (any outside adjustment is excluded and ator panel is lit up, and the display visualises the lockout code (in only the safety devices are active). -
Page 43: 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 49. -
Page 44: 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 45 Start-up, calibration and operation of the burner 6.7.0.1 Procedure for inserting and adjusting points on Select another point, or exit this area by pressing the keys “+” and “-” ( ESC ) simultaneously. the modulation curve Nine adjustment/calibration points (P1 ÷ P9) can be inserted in the control box for each servomotor, varying their position by de- grees and, consequently, the quantity of air and fuel introduced.
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Page 46: 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 47 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.
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Page 48: Backup / Restore Procedure
Start-up, calibration and operation of the burner Backup / Restore procedure At the end of the "Start-up procedure" it is opportune to make a We suggest carrying out this operation at the end backup, creating a copy of the data memorised on the REC, in of each intervention that modifies what has been the display panel RDI 21. -
Page 49: 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 50 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.
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Page 51: 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 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. Baud Rate for Modbus Values set: Modification Service mode 0 = 9600 1 = 19200 Parity for Modbus 0 = none...
- Page 53 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 54 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°...
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Page 55: 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 56: 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 57: 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 58: Measuring The Ionisation Current
Maintenance Gas leaks Make sure that there are no gas leaks on the pipes between the gas meter and the burner. Gas filter Replace the gas filter when it is dirty. Flame inspection window Clean the glass of the flame inspection window. Boiler D7894 Clean the boiler as indicated in its accompanying instructions in... -
Page 59: Safety Components
Maintenance 7.2.6 Safety components The safety components must be replaced at the end of their life cycle indicated in Tab. X. The specified life cycles do not refer to the warranty terms indicated in the delivery or payment conditions. Safety component Life cycle 10 years or 250,000 Flame control... -
Page 60: Opening The Burner
Maintenance Opening the burner Loosen the 4 screws 1)(Fig. 40) and remove the hood 2). Assemble the two extensions supplied on the guides 4) (ver- Disconnect the electrical supply from the burner sions TL). by means of the main system switch. ... -
Page 61: 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 62 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 63 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 64 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 65 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Insufficient mains voltage. Low level of power supply Conversion of the diagnostic code Voltage value (230 V AC : 1,683) Error code for the carrying out of a reset in the event of power Reset power supply voltage supply restoration (absence of error) Carry out a reset;...
- Page 66 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 254 (-2) Interruption owing to transmission error Repeat the reset and backup 255 (-1) Interruption owing to time-out during the restoration Carry out a reset, check the connections and repeat the backup Time-out of the system automation interface Refer to the Modbus User Documentation (A7541) Modbus time-out...
- Page 67 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.
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Page 68: A Appendix - Accessories
3010214 RWF55 20099905 0 ÷ 25 bar 4 ÷ 20 mA 3090873 Head kit for flame inversion boiler Burner Code RS 68/E BLU 3010247 RS 120/E BLU 3010248 RS 160/E BLU 3010249 RS 200/E BLU 20035848 Kit for LPG operation... - Page 69 Burner Model Code RS 68-120/E BLU OCI412 3010437 RS 160-200/E BLU Kit PVP (Pressure Valve Proving) Burner Gas train type Code RS 68/E BLU MB - CB 3010344 Gas trains in compliance with EN 676 Please refer to manual. 20068435...
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Page 70: 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 connection set by installer Electrical connection set by installer RWF50 operational layout Indication of references / 1 . - Page 71 Appendix - Electrical panel layout 20068435...
- Page 72 Appendix - Electrical panel layout 20068435...
- Page 73 Appendix - Electrical panel layout 20068435...
- Page 74 Appendix - Electrical panel layout 20068435...
- Page 75 Appendix - Electrical panel layout 20068435...
- Page 76 Appendix - Electrical panel layout 20068435...
- Page 77 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio XPGVP Gas pressure switch connector for valve leak detec- tion 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...