Riello RS 310/E MZ FS1 Installation, Use And Maintenance Instructions

Forced draught gas burners

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Installation, use and maintenance instructions

Forced draught gas burners

Modulating operation

CODE

20068349 - 20068353

20068026

20068358 - 20068363

20067961

20068028

20067963

20074260 - 20074261

20074264

20074262 - 20074263

20074265

20074266

20074267

MODEL

RS 310/E MZ FS1

RS 410/E MZ FS1

RS 510/E MZ FS1

RS 610/E MZ FS1

RS 310/E MZ FS2

RS 410/E MZ FS2

RS 510/E MZ FS2

RS 610/E MZ FS2

TYPE

1142T1

1143T1

1144T1

1145T1

1150T1

1151T1

1152T1

20079029 (4) - 03/2015

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Summary of Contents for Riello RS 310/E MZ FS1

Page 1 Installation, use and maintenance instructions Forced draught gas burners Modulating operation CODE MODEL TYPE 20068349 - 20068353 RS 310/E MZ FS1 1142T1 20068026 20068358 - 20068363 RS 410/E MZ FS1 1143T1 20067961 20068028 RS 510/E MZ FS1 1144T1 20067963 RS 610/E MZ FS1...
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 Start-up, calibration and operation of the burner ........................33 Notes on safety for the first start-up ...........................33 Adjustments prior to ignition............................33 Burner start-up ................................33 Air / fuel adjustment ..............................34 6.4.1 Air adjustment for maximum output ...........................34 6.4.2 Air/fuel adjustment and output modulation system ....................34 6.4.3 Burner adjustment..............................34 6.4.4...
Page 5: Declarations
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001. Manufacturer's Declaration RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BIm- SchV revision 26.01.2010”.
Page 6: Information And General Warnings
Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction DANGER: EXPLOSION The instruction manual supplied with the burner: This symbol signals places where an explosive at-  is an integral and essential part of the product and must not mosphere may be present.
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 Gas oil Gas oil / Methane Heavy oil Size Adjustment : Two stage (light oil) / Proportional valve (gas) Electronic cam Electronic cam with variable speed (with Inverter) Proportional air/gas valve Mechanical cam C01 - ...
Page 10: Models Available
Technical description of the burner Models available Version FS1 Designation Voltage Start-up Code RS 310/E MZ FS1 3/230/50 Direct 20068349 3/400/50 Direct 20068353 3/400/50 Star/Triangle 20068026 RS 410/E MZ FS1 3/230/50 Direct 20068358 3/400/50 Direct 20068363 3/400/50 Star/Triangle 20067961 RS 510/E MZ FS1...
Page 11: Technical Data
Technical description of the burner Technical data Model RS 310/E MZ RS 410/E MZ RS 510/E MZ RS 610/E MZ 1142T1 1143T1 1144T1 1145T1 Type 1150T1 1151T1 1152T1 1153T1 Power min - max kW 600/1300 - 3900 800/2000 - 4900 802/2200 - 5520 820/2400 - 6300 Delivery...
Page 12: Burner Weight
Technical description of the burner DIRECT START UP Model RS 310/E MZ RS 410/E MZ RS 310/E MZ RS 410/E MZ 20068349 - 20068353 20068358 - 20068363 Code 20074260 - 20074261 20074262 - 20074263 Main electrical supply 3 ~ 230/400V +/-10% 50 Hz Fan motor IE3 2900 2920...
Page 13: Maximum Dimensions
Technical description of the burner Maximum dimensions The maximum dimensions of the burner are given in Fig. 2. * The gas adaptor is set also for DN 80 bore. Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part turned on the hinge.
Page 14: Firing Rates
Technical description of the burner Firing rates The MAXIMUM OUTPUT is chosen from within the diagram area The firing rate value (Fig. 3) has been obtained (Fig. 3). considering an ambient temperature of 20 °C, an The MINIMUM OUTPUT must not be lower than the minimum atmospheric pressure of 1013 mbar (approx.
Page 15: Test Boiler
Technical description of the burner Test boiler The burner/boiler combination does not pose any problems if the The firing rates were set in relation to special test boilers, accord- boiler is EC approved and its combustion chamber dimensions ing to EN 676 regulations. are similar to those indicated in the diagram (Fig.
Page 16: Burner Description
Technical description of the burner 4.11 Burner description ASSEMBLY VIEW 20072087 Fig. 5 Lifting rings The burner can be opened to the right or to the left without links to the fuel supply side. Fan motor Air damper servomotor Combustion head gas pressure test point To open the burner see section “Access to head Combustion head internal part”...
Page 17: Electrical Panel Description
Technical description of the burner 4.12 Electrical panel description 20069487 Fig. 6 Electrical control box ON/OFF selector Output regulator Earth terminal Supply cables and external connections passage. See sec- tion “Electrical wiring” on pag. 31 Bracket for applying the kits Main terminal supply board Relay with clean contacts for signalling the burner is in lock- Relay with clean contacts for signalling the burner is operat-...
Page 18: Control Box For The Air/Fuel Ratio (Rec 27
To avoid accidents, material and/or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening or modifying it, or forcing its operation. Riello WARNING S.p.A. cannot assume any responsibility for dam- age resulting from unauthorised interventions!
Page 19 Technical description of the burner Technical data Control box Mains voltage AC 230 V -15% / +10% Mains frequency 50 / 60 Hz ±6% Power absorption < 30 W Safety class I, with components in compliance with II and III, ac- cording to DIN EN 60730-1 Load on Fuse on the control box (can be inspected)
Page 20: Operation Sequence Of The Burner
Technical description of the burner 4.14 Operation sequence of the burner Operation Checking of Start-up Switching off 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 21: 4.14.1 List Of Phases
Technical description of the burner 4.14.1 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 22: 4.15.2 Description Of The Buttons
Technical description of the burner 4.15.2 Description of the buttons Button Button Function Button F To adjust the fuel servomotor (keep pressed and adjust the value by pressing Button A To adjust the air servomotor (keep pressed and adjust the value by pressing Buttons A and F To change the mode setting parameter P VSD function...
Page 23: Servomotor (Sqm33
Technical description of the burner 4.16 Servomotor (SQM33..) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Do not open, modify or force the actuators.  All interventions (assembly and installation WARNING operations, assistance, etc.) must be carried out by qualified personnel.
Page 24: 4.17 Calibration Of The Thermal Relay
Technical description of the burner 4.17 Calibration of the thermal relay The thermal relay serves to avoid damage to the motor due to an excessive absorption increase or if a phase is missing. For calibration 2), see the table in the wiring diagram. To reset, in case of an intervention of the thermal relay, press the "RESET"...
Page 25: 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 26: Operating Position
Installation Operating position  The burner is designed to operate only in positions 1, 2, 3 and 4 (Fig. 14).  Installation 1 is preferable, as it is the only WARNING one that allows the maintenance operations as described in this manual. ...
Page 27: Access To Head Internal Part
Installation Access to head internal part The burner leaves the factory set for opening to the left, therefore maintaining the pin 1)(Fig. 17) in the housing. To open the burner towards the left, proceed as follows: A Disconnect the plug/socket 9)(Fig. 17) of the maximum gas pressure switch;...
Page 28: Gas Butterfly Valve
Installation Gas butterfly valve If necessary, replace the gas butterfly valve. The correct position is shown in Fig. 19. Fig. 19 20078516 5.10 Combustion head adjustment Rotate the screw 1) until the notch you have found corresponds with the front surface of the screw itself. The combustion head is opened by turning the screw 1) anti- clockwise.
Page 29 Installation Below is a diagram (Fig. 22) that shows the recommended ad- NOTE: justment of the combustion head. Depending on the specific application, the adjustment can be modified. 20078016 No. Setpoint (air = gas) Max. burner output (kW) Fig. 22 20079029...
Page 30: Gas Pressures
Installation 5.11 Gas pressures Explosion danger due to fuel leaks in the pres- MBC “threaded” ence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure the fuel interception tap is closed be- fore performing any operation on the burner. The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws.
Page 31: 5.11.2 Gas Train
Installation 5.11.2 Gas train Pay attention when handling the train: danger of Approved according to standard EN 676 and provided separately crushing of limbs. from the burner. To select the correct gas train model, refer to the supplied "Burn- er-gas train combination" manual. Make sure that the gas train is properly installed by checking for any fuel leaks.
Page 32: Gas Pressure
Installation 5.11.4 Gas pressure 1 p (mbar) 2 p (mbar) Tab. N indicates the minimum pressure drops along the gas sup- G 20 G 25 G 20 G 25 ply line, depending on the maximum burner output. 1300 The values shown in Tab. N refer to: –...
Page 33: 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 34: Supply Cables And External Connections Passage
Installation 5.12.1 Supply cables and external connections passage All the cables to be connected to the burner must be threaded through cable grommets. The use of the cable grommets can take various forms; by way of example see Fig. 28. Key (Fig.
Page 35: 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 36: Air / Fuel Adjustment
Start-up, calibration and operation of the burner Air / fuel adjustment 6.4.4 Output upon ignition Air/fuel synchronisation is carried out with the relevant air and gas servomotors by logging a calibration curve by using the elec- Ignition must occur at a lower output than the max. operation out- tronic cam.
Page 37: Final Adjustment Of The Pressure Switches
Start-up, calibration and operation of the burner Final adjustment of the pressure switches 6.5.1 Air pressure switch Adjust the air pressure switch (Fig. 31) after performing all other burner adjustments with the air pressure switch set to the start of the scale.
Page 38: 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. 33) after perform- ing all the other burner adjustments with the pressure switch set to the start of the scale. With the burner operating at maximum output, increase adjust- ment pressure by slowly turning the relative knob clockwise until the burner stops.
Page 39: Visualisation And Programming Mode
Start-up, calibration and operation of the burner Visualisation and programming mode 6.6.1.4 Error state message, display of the errors and 6.6.1 Normal mode 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 40: Info Mode
Start-up, calibration and operation of the burner 6.6.1.5 Reset procedure The burner is in lockout when the red indicator light on the oper- ator panel is lit up, and the display visualises the lockout code (in the example alongside c: 4) and the relative diagnostics (in the example d: 3) alternately.
Page 41: Service Mode
Start-up, calibration and operation of the burner 6.6.3 Service mode 6.6.4 Parameters Mode The Service mode (SEr) visualises the error log and certain The Parameters Mode (PArA) displays and allows you to modi- technical information about the system. To access this level you fy/programme the parameters list on pag.
Page 42: Parameter Modification Procedure
Start-up, calibration and operation of the burner 6.6.4.2 Assigning parameter levels The password must only be communicated to the The parameters level is subdivided into groups as shown in qualified personnel or the Technical Assistance Tab. Q. Service, and must be kept in a safe place. WARNING Parameter 100: ParA...
Page 43 Start-up, calibration and operation of the burner 6.7.0.1 Procedure for inserting and adjusting points on 6.7.0.2 CALC function the modulation curve The diagram (Fig. 35) shows how the fuel modulation curve is modified if the values of point “P5” are changed. Nine adjustment/calibration points (P1 ÷...
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 and “OFF Upr”: this means it is necessary to set the modulation curve of the burner. The values shown in the figure are purely for indi- cation purposes.
Page 45: Backup / Restore Procedure
Start-up, calibration and operation of the burner Press “+” until point “P9” is reached. Once the calibration of point “P1” is completed, confirm by press- Once point“P9” is reached wait for the display to show the flash- ing the keys “+” and “-” (ESC) simultaneously: parameter “546” ing indicator “P9”...
Page 46: Restore
Start-up, calibration and operation of the burner Confirm with the key "i/reset": NOTE: If an error occurs during the backup process, the display screen shows a negative value. Refer to diagnostic code 137 to determine the cause of the error (see section “List of parameters” on pag. 46). /reset It is advisable to perform a backup every time that a parameter is changed, after checking...
Page 47 Start-up, calibration and operation of the burner The parameter bAC_UP appears on the display screen: 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 48: List Of Parameters
Start-up, calibration and operation of the burner 6.9.3 List of parameters Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment INTERNAL PARAMETERS Start backup/restore process via RDI21... / PC TOOL (set the parameter to 1) Index 0 = create backup Modification...
Page 49 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Peripheral address for Modbus Set values: Modification Service Mode 1 ... 247 Baud Rate for Modbus Set values: Modification...
Page 50 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Maximum repeats of safety circuit 1 = No repetition Modification Service Mode 2...15 = Number of repetitions 16 = Constant repetitions Gas: selection of flame sensor...
Page 51 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Checking fuel servomotor 0°; 0°; 15°; (°) Modification 0° 90° 0.1° Service Mode (only setting of the curve) Not defined...
Page 52: Operation
Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Relay request status (coded in bits) Bit 0 = 1: Alarm Bit 1 = 2: Safety valve Bit 2 = 4: Ignition Reading only...
Page 53: 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- The burner must stop in lockout ...
Page 54: Maintenance
Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, Disconnect the electrical supply from the burner safety, yield and duration of the burner. by means of the main system switch. It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.
Page 55: Safety Components
Maintenance 7.2.3 Safety components 7.2.4 Measuring the ionisation current The safety components should be replaced at the end of their life The burner is fitted with an ionisation system to check that a cycle indicated in the following table. flame is present. The specified life cycles do not refer to the warranty terms indi- The minimum current for control box operation is 4 µA.
Page 56: Opening The Burner
Maintenance Opening the burner Disconnect the electrical supply from the burner by means of the main system switch. DANGER Turn off the fuel interception tap. DANGER Wait for the components in contact with heat sources to cool down completely. To open the burner, use the same procedure set out in “Access to head internal part”...
Page 57: Faults - Possible Causes - Solutions
Faults - Possible causes - Solutions Faults - Possible causes - Solutions If faults arise in ignition or operations, the burner performs a In the event the burner stops, in order to prevent "safety stop", which is signalled by the red burner lockout LED. any damage to the installation, do not unblock the The display of the operator panel visualises alternately the lock- burner more than twice in a row.
Page 58 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Leak test Check if the valve on the side of the burner has any leaks. V2 leaks Check if the pressure switch for the leak test (PGVP) is closed when gas pressure is not present.
Page 59 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Safety circuit open /Burner flange, air pressure, fuel pressure, POC - Alarm lockout at start Safety circuit open /Burner flange, extraneous light, air pressure, fuel pressure, POC - Alarm lockout at start Carry out a reset;...
Page 60 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Air servomotor error It was not possible to reach the target position within the Position error requested tolerance range. 1. Check if the servomotor is blocked or overloaded. Circuit open shown on the servomotor connection.
Page 61 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 0 Min. pressure switch 1 Max. pressure switch 2 Valve operation test pressure switch 3 Air pressure 4 Load controller open 5 Load controller on/off Can be caused by capacitive loads or presence of DC voltage 6 Load controller closed Blocked upon irregularity...
Page 62 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Backup – the data comparison between the internal 243 (-13) Repeat the reset and backup microprocessors is irregular The backup data are incompatible with the current version of 244 (-12) The backup data are incompatible the software;...
Page 63 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Selection of internal operation mode Redefine the operation mode (parameter 201) Redefine the operation mode (parameter 201) Internal error Carry out a reset; if the error arises repeatedly, replace the control box Phase number Program stop...
Page 64: Appendix - Accessories
Appendix - Accessories Appendix - Accessories Kit for modulating operation Burner Output regulator Code All models RWF 50.2 3-POINT OUTLET 20085417 All models RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441 All models RWF 55.6 COMPLETE WITH RS-485/PROFIBUS INTERFACE 20074442 Burner Probe Adjustment field Code...
Page 65: B Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Single line output diagram (RS 310/E MZ 230 V - Direct Start Up - FS1/FS2) Single line output diagram (RS 310/E MZ 400 V - Direct Start Up - FS1/FS2) Single line output diagram (RS 410/E MZ 230 V - Direct Start Up - FS1/FS2) Single line output diagram (RS 410/E MZ 400 V - Direct Start Up - FS1/FS2) Single line output diagram (RS 310/E MZ 400 V - Star/Triangle Start Up - FS1/FS2)
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Page 85 Appendix - Electrical panel layout Wiring layout key Electronic cam Display and calibration unit Output regulator RWF40 internal Output regulator RWF40 external Probe with output under current Device with output undercurrent, for modifying re- mote setpoint Pressure probe Pressure probe Remote setpoint potentiometer Thermocouple probe Probe Pt100, 2 wires...
Page 88 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...

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