Riello RX 1500 S/E Installation, Use And Maintenance Instructions
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Riello RX 1500 S/E Installation, Use And Maintenance Instructions

Riello RX 1500 S/E Installation, Use And Maintenance Instructions

Premix gas burner: progressive two-stage or modulating operation with pilot flame ignition
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Installation, use and maintenance instructions
Premix gas burner
GB
Progressive two-stage or modulating operation with pilot flame ignition
CODE
20148878
MODEL
RX 1500 S/E
TYPE
S022
20151518 (1) -05/2018

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Summary of Contents for Riello RX 1500 S/E

  • Page 1 Installation, use and maintenance instructions Premix gas burner Progressive two-stage or modulating operation with pilot flame ignition CODE MODEL TYPE 20148878 RX 1500 S/E S022 20151518 (1) -05/2018...
  • 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 Ignition pilot adjustment .............................27 Air / fuel adjustment ..............................27 6.6.1 Air adjustment for maximum output ...........................27 6.6.2 Air/fuel adjustment and output modulation system ....................27 Final adjustment of the pressure switches .........................28 6.7.1 Air pressure switch..............................28 6.7.2 Maximum gas pressure switch...........................28 6.7.3 Minimum gas pressure switch............................28 6.7.4...

  • Page 5: Declarations

    The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015. Legnago, 21.04.2018 Executive General Manager Research & Development Director RIELLO S.p.A. - Burner Department RIELLO S.p.A. - Burner Department Mr. U. Ferretti Mr. F. Comencini...

  • Page 6: Information And General Warnings

    Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction WARNING: MOVING PARTS The instruction manual supplied with the burner: This symbol indicates that you must keep limbs  is an integral and essential part of the product and must not away from moving mechanical parts;...

  • Page 7: Delivery Of The System And The Instruction Manual

    Information and general warnings 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 Models available Designation Voltage Start-up Code RX 1500 S/E 3/400/50 Direct 20148878 Tab. A Burner categories - Countries of destination Country of destination Gas category I2E(R) CY, MT I3B/P LU, PL...

  • Page 10: Burner Equipment

    The maximum dimensions of the open burner are indicated by position P. 20151254 Fig. 1 RX 1500 S/E 2” 1060 Tab. E RX 1500 S/E 2150...

  • Page 11: Firing Rate

    Technical description of the burner Firing rate The maximum output power must not be higher than the maxi- The firing rate (Fig. 3) was obtained considering a mum limit of the diagram (Fig. 3). room temperature of 20°C and an atmospheric The minimum output must not be lower than the minimum limit pressure of 1013 mbar (approx.

  • Page 12: Burner Description

    Technical description of the burner Burner description 20151569 Detail “A” Fig. 5 Lifting rings 32 ON/OFF selector Pilot pipe 33 Relay with clean contacts for signalling the burner is in lock- Fan motor Air damper servomotor 34 Supply cables and external connections passage. See sec- Combustion head gas pressure test point tion “Electrical wiring”...

  • Page 13: Control Box For The Air/Fuel Ratio (Rec 27

    To avoid accidents, material or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening ATTENTION 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 14 Technical description of the burner Electrical connection of flame detector  The grounding of the burner must be in compliance with the rules in force; the grounding of the boiler alone is not It is important for signal transmission to be almost totally free enough.
  • Page 15 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 16: Operation Sequence Of The Burner

    Technical description of the burner 4.11 Operation sequence of the burner Operation Start-up Shutdown Valve proving Phase number Timer-Resolution-Relationship 30 s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = phase max. time RAST plug Function PIN number X3-04 Pin 1/2 R (ON) X5-03 Pin1/4 X10-05...

  • Page 17: 4.11.1 List Of Phases

    Technical description of the burner 4.11.1 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 18: 4.12.2 Description Of The Buttons

    Technical description of the burner 4.12.2 Description of the buttons Button Button Function To adjust the fuel servomotor Button F (keep pressed and adjust the value by pressing To adjust the air servomotor Button A (keep pressed and adjust the value by pressing To change the mode setting parameter P...

  • Page 19: Servomotor (Sqm33

    Technical description of the burner 4.13 Servomotor (SQM33..) Important notes To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying or forcing the servo- ATTENTION motor.  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ...

  • Page 20: Installation

    Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner is to The installation of the burner must be carried out be installed, and arranging for the environment to be illuminated by qualified personnel, as indicated in this manual correctly, proceed with the installation operations.

  • Page 21: Operating Position

    The available length is shown in Fig. 14. The burners cannot be used on flame inversion Fig. 13 boilers. ATTENTION RX 1500 S/E 22.5° Tab. J 3 5 0 20132105 Fig. 14 20151518...

  • Page 22: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler The seal between burner and boiler must be Prepare a suitable lifting system. airtight. ATTENTION  Install the burner to the boiler 1)(Fig. 15) fastening the flange 5) to the door of the boiler, interposing the insulating After start-up of the burner check that there is no gasket 3) and tighten with the nuts 4).

  • Page 23: Electrode And Uv Flame Sensor Positioning

    Installation Electrode and UV flame sensor positioning The adaptor 2) allows to cool the fixing area of the sensor. Check that the electrode is positioned as in Fig. 17, respecting the indicated dimensions. Check the seal of the plate 6)(Fig. 17). ATTENTION ATTENTION The burner is equipped with a UV flame sensor 1)(Fig.

  • Page 24: Gas Line

    Installation Gas line Explosion danger due to fuel leaks in the pres- The fuel supply line must be installed by qualified ence of a flammable source. personnel, in compliance with current standards Precautions: avoid knocking, attrition, sparks and and laws. ATTENTION heat.

  • Page 25: Gas Pressure

    Installation The gas train can enter the burner from the right or left side, de- pending on which is the most convenient.  The gas train must be connected to the gas attachment 1)(Fig. 19) with the flange 2), the gasket 3) and the screws 4) supplied with the burner.

  • Page 26: Electrical Wiring

    Installation 5.10 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 27: Supply Cables And External Connections Passage

    Installation 5.10.1 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. 21. Key (Fig.

  • Page 28: 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 Before igniting the burner, see the paragraph by qualified personnel, as indicated in this manual “Safety test - with gas feeding closed”...

  • Page 29: Burner Adjustment

    Start-up, calibration and operation of the burner Burner adjustment The optimum adjustment of the burner requires an analysis of 3 - MIN output flue gases at the boiler outlet. 4 - Intermediate outputs between Min. and Max. 5 - Air pressure switch Adjust in sequence: 6 - Maximum gas pressure switch 1 - Pilot flame...

  • Page 30: Final Adjustment Of The Pressure Switches

    Start-up, calibration and operation of the burner Final adjustment of the pressure switches 6.7.1 Air pressure switch Adjust the air pressure switch (Fig. 26) after performing all other burner adjustments with the air pressure switch set to the start of the scale.

  • Page 31: Pvp Pressure Switch Kit

    Start-up, calibration and operation of the burner 6.7.4 PVP pressure switch kit Adjust the pressure switch for the leak detection control (PVP kit) (Fig. 29) according to the instructions supplied with the kit. 6.7.5 Air pressure switches The burner wiring diagram is complete with no. 2 air pressure switches, light indicators, relays and fuses that set up the air in- take filter (accessory to be ordered separately).

  • Page 32: Visualisation And Programming Mode

    Start-up, calibration and operation of the burner Visualisation and programming mode 6.8.1 Normal mode 6.8.1.4 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 33: Info Mode

    Start-up, calibration and operation of the burner 6.8.1.5 Reset procedure Releasing the “F” key, the standard visualisation appears, with the current load percentage flashing: this means that the burner The burner is in lockout when the red indicator light on the oper- is working in Manual mode (any outside adjustment is excluded ator panel is lit up, and the display visualises the lockout code (in and only the safety devices are active).

  • Page 34: Service Mode

    Start-up, calibration and operation of the burner 6.8.3 Service mode 6.8.4 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 page 39.

  • Page 35: Parameter Modification Procedure

    Start-up, calibration and operation of the burner 6.8.4.2 Assigning parameter levels The password must only be communicated to the The parameters level is subdivided into groups as shown in Tab. N. qualified personnel or the Technical Assistance Parameter Service, and must be kept in a safe place. ATTENTION 100: ParA General parameters...
  • Page 36 Start-up, calibration and operation of the burner 6.9.0.1 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.

  • Page 37: Start-Up Procedure

    Start-up, calibration and operation of the burner 6.10 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 38 Start-up, calibration and operation of the burner Press the button “+”: the display visualises the indicator “P1” way, parameter “546” will automatically be assigned the value of flashing and proposes the same settings as point “P0”. 100% and parameter “545” will have a value of 20%. Press button “+”...

  • Page 39: Backup / Restore Procedure

    Start-up, calibration and operation of the burner 6.11 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 40: 6.11.2 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.

  • Page 41: 6.11.3 List Of Parameters

    Start-up, calibration and operation of the burner The value 1 appears on the display screen: NOTE: When the restore process is successfully completed, the 0 value is shown on the display screen.  Err C information: 136 D: 1 (restore process initialised) is displayed for a brief moment.
  • Page 42 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 Default output for TÜV test: Not valid for TÜV test when output is activated Modification / 100% 0.1%...
  • Page 43 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 Stopping of the program 0 = deactivated 1 = pre-purging (Ph24) Modification Service Mode 2 = Ignition (Ph36)
  • Page 44 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 Oil: selection transformer ignition phase TA 0 = brief pre-ignition (Ph38) Modification Service Mode 1 = long pre-ignition (with fan)(Ph22)

  • Page 45: 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 46: Stopping Of The Burner

    Start-up, calibration and operation of the burner 6.16 Stopping of the burner The burner can be stopped by: There are now two possibilities:  intervening on the disconnecting switch of the electrical sup- – using the operator panel according to the manual lockout pro- ply line, located on the boiler panel;...

  • Page 47: 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. Turn off the burner's electrical supply using the It allows you to reduce consumption and polluting emissions and main system switch.

  • Page 48: Safety Components

    Maintenance Boiler 7.2.4 Safety components Clean the boiler as indicated in its accompanying instructions in The safety components should be replaced at the end of their life order to maintain all the original combustion characteristics in- cycle indicated in the following table. tact, especially: the flue gas temperature and combustion cham- The specified life cycles do not refer to the warranty terms indi- ber pressure.

  • Page 49: Uv Flame Detector

    Maintenance 7.2.7 UV Flame detector To access the flame detector (Fig. 36), proceed as follows:  unscrew the UV sensor;  clean the glass 1) from any dust that may have accumu- lated;  pay attention to the gasket 2) and thermal insulator 3). Be extremely careful while troubleshooting the detector;...

  • Page 50: Opening The Burner

    Maintenance Opening the burner  Loosen the 4 screws 1)(Fig. 38) and remove the cover 2);  disconnect the sockets 3), 4) and 7); Turn off the burner's electrical supply using the  unscrew the UV sensor 5) and the snorkel 6); main system switch.

  • Page 51: 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 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 52 Faults - Probable 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 53 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Safety circuit open /Burner flange open, fuel pressure, POC - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light, air pressure, POC - Alarm lockout at start Safety circuit open /Burner flange, air pressure, fuel pressure, POC - Alarm lockout at start...
  • Page 54 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 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 55 Faults - Probable 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 56 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 242 (-14) Backup – the backup carried out is contradictory The backup is irregular and cannot be transferred again Backup – the data comparison between the internal 243 (-13) Repeat the reset and backup microprocessors is irregular...
  • Page 57 Faults - Probable 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 58: Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Software interface kit (ACS410 + OCI410.30) - Service Level Burner Code RX 1500 S/E 3010436 Modbus interface kit Burner Model Code RX 1500 S/E OCI412 3010437 Filter kit Burner Code RX 1500 S/E Gas trains in compliance with EN 676 Please refer to manual.

  • Page 59: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output Layout of unifilar output REC 27... operational layout REC 27... operational layout REC 27... operational layout Electrical connections for output power regulator (internal) Electrical connections set by installer Electrical connections set by installer Input/output of the output power regulator...
  • Page 60 Appendix - Electrical panel layout ), 1- 20151518...
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  • Page 68 Appendix - Electrical panel layout 20151518...
  • Page 69 Appendix - Electrical panel layout Wiring layout key Electronic cam Ignition transformer connector Display and calibration unit Ignition pilot valve connector Suppressor Gas regulator valve + gas safety valve Output power regulator RWF50 internal Ignition pilot valve Fuel level measurer Output probe in current Output device in current to modify remote setpoint Pressure probe...
  • Page 72 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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