Riello RS 160/E BLU Installation, Use And Maintenance Instructions
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Riello RS 160/E BLU Installation, Use And Maintenance Instructions

Riello RS 160/E BLU Installation, Use And Maintenance Instructions

Forced draught gas burners
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Progressive two-stage or modulating operation
CODE
20089525
20134899
20169809
MODEL
RS 160/E BLU
RS 200/E BLU
RS 200/E BLU
20067467 (10) - 03/2022

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Summary of Contents for Riello RS 160/E BLU

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two-stage or modulating operation CODE MODEL RS 160/E BLU 20089525 RS 200/E BLU 20134899 RS 200/E BLU 20169809 20067467 (10) - 03/2022...
  • 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

    Declarations Declarations Declaration of Conformity in accordance with ISO / IEC 17050-1 These products are in compliance with the following Technical Standards: • EN 12100 • EN 676 According to the European Directives: 2006/42/EC Machine Directive 2014/35/EU Low Voltage Directive EMC 2014/30/EU Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.

  • 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

    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 10: Models Available

    Technical description of the burner Models available Designation Voltage Code RS 160/E BLU TC FS2 3 ~ 400V - 50Hz 20089525 RS 200/E BLU TL FS2 3 ~ 400V - 50Hz 20134899 RS 200/E BLU TC FS2 3 ~ 400V - 50Hz 20169809 Tab.

  • Page 11: 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 160/E BLU 373-503 1442-1587 2” RS 200/E BLU...

  • Page 12: Firing Rates

    25. refers to the operation with fuel G20 - G25. In case G31 is used, the minimum output goes CAUTION from 550 to 630 kW. RS 160/E BLU S8831 Thermal power RS 200/E BLU 20127184 Thermal power Fig.

  • 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

    Technical description of the burner Test boiler The firing rates were obtained in special test boilers, according to The coupling is ensured when the boiler is EC type-approved; for EN 676 regulations. boilers or ovens with combustion chambers of very different di- mensions compared to those shown in the diagram of Fig.

  • Page 15: Burner Description

    Technical description of the burner 4.10 Burner description 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 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

    CO. D455 Fig. 14 5.5.2 Boring the boiler plate Drill holes in the plate shutting off the combustion chamber, as il- RS 160/E BLU 325-368 M 16 lustrated in Fig. 14. RS 200/E BLU 325-368 M 16 The position of the threaded holes can be marked using the ther- Tab.

  • 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  pull back the burner on the guides 5) by about 100 mm;  disconnect the probe and electrode leads, then unthread the Provide an adequate lifting system of the burner. burner completely from the guides. Once this operation has been carried out: ...

  • Page 27: Pre-Calibrating The Combustion Head

    Two adjustments of the head are foreseen: – external air R1 – central gas/air R2 (only for RS 160/E BLU) – central air R3 (only for RS 200/E BLU) 20135196 Max burner output Fig. 19...

  • Page 28: Burner Closing

    To facilitate adjustment, loosen the screw 6), adjust and then lock. WARNING (R 2) Central gas/air R2 adjustment (for RS 160/E BLU)  Loosen the 3 screws 1)(Fig. 20) and rotate the ring nut 2) until the notch you have found corresponds with the index 3).

  • 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

    – Read the corresponding output on the left. WARNING Ensure that the maximum pressure to the burner Example with natural gas G 20 for RS 160/E BLU: is within the calibration range of the pressure reg- Maximum output operation ulator.
  • Page 31 Installation Example with natural gas G 20 for RS 160/E BLU: Required burner maximum output operation: 1600 kW Gas pressure at output of 1600 kW 13.0 mbar Pressure in combustion chamber 3.0 mbar 13.0 + 3.0 16.0 mbar pressure required at test point 1)(Fig. 27).

  • 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: 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 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 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 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. 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 37: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 6.5.3 Minimum gas pressure switch The purpose of the minimum gas pressure switch is to prevent the burner from operating in an unsuitable way due to too low gas pressure. Adjust the minimum gas pressure switch (Fig. 34) after having adjusted the burner, the gas valves and the gas train stabiliser.

  • 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 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 39: 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 40: 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 46.

  • Page 41: 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 42 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. 36) shows how the fuel modulation curve is modified if the values of point “ P5 ” are changed. Nine adjustment/calibration points (P1 ÷...

  • Page 43: 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 44 Start-up, calibration and operation of the burner Press the button “ + ”: the display visualises the flashing “ P1 ” indi- way, parameter “ 546 ” will automatically be assigned the value of cator and proposes the same settings as for point “ P0” . 100% and parameter “...

  • Page 45: 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 46: 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 47 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 48: 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 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. Baud Rate for Modbus Values set: Modification Service mode 0 = 9600 1 = 19200 Parity for Modbus 0 = none...
  • 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. Gas: selection of flame sensor 0 = QRB.../ QRC Modification Service mode 1 = ION / QRA Gas: Selection of the pre-purging function 0 = deactivated...
  • 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. Position of the fuel servomotor in absence of flame Index 0 = standby position (°) Modification 0°...

  • Page 52: 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 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- ...

  • Page 54: 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 55: Safety Components

    Maintenance Flame inspection window 7.2.4 Safety components Clean the glass of the flame inspection window. The safety components must be replaced at the end of their life cycle indicated in Tab. U. The specified life cycles do not refer to Boiler the warranty terms indicated in the delivery or payment Clean the boiler as indicated in its accompanying instructions in...

  • Page 56: Measuring The Ionisation Current

    Maintenance 7.2.5 Measuring the ionisation current The burner is fitted with an ionisation system to check that a flame is present. The minimum current for control box operation is 4 µA. The Op- erator Panel visualises “30%” (see "Parameter list" at page 46, parameter no.

  • Page 57: 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 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

    Appendix - Accessories Appendix - Accessories Long head kit Standard head length Extended head length Burner Code (mm) (mm) RS 160/E BLU 3010442 RS 200/E BLU 3010474 Spacer kit Burner Thickness (mm) Code RS 160-200/E BLU 3000722 Continuous purging kit...
  • Page 68 Appendix - Accessories Software interface kit (ACS410 + OCI410.30) - Service Level Burner Code RS 160-200/E BLU 3010436 Modbus interface kit Burner Model Code RS 160-200/E BLU OCI412 3010437 Gas trains in compliance with EN 676 Please refer to manual. 20067467...

  • Page 69: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references REC37... operational layout REC37... operational layout REC37... operational layout Electrical connection set by installer Electrical connection for RWF kit Indication of references / 1 . A 1 Sheet no.
  • Page 70 Appendix - Electrical panel layout 20067467...
  • Page 71 Appendix - Electrical panel layout 20067467...
  • Page 72 Appendix - Electrical panel layout 20067467...
  • Page 73 Appendix - Electrical panel layout 20067467...
  • Page 74 Appendix - Electrical panel layout 20067467...
  • Page 75 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio XPGM Maximum gas pressure switch connector Operator panel XPGMin Minimum gas pressure switch connector Burner components XPGVP Gas pressure switch connector for valve leak detec- tion control device Boiler components XRWF Terminal board for output power regulator RWF...
  • Page 76 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...

This manual is also suitable for:

Rs 200/e blu200895252013489920169809

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