Riello RS 810/EV BLU Installation, Use And Maintenance Instructions
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Riello RS 810/EV BLU Installation, Use And Maintenance Instructions

Riello RS 810/EV BLU Installation, Use And Maintenance Instructions

Forced draught gas burner
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Installation, use and maintenance instructions
Forced draught gas burner
GB
Modulating operation
CODE
MODEL
TYPE
20160292
RS 810/EV BLU
S032T2
20163082 (3) - 06/2021

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Summary of Contents for Riello RS 810/EV BLU

  • Page 1 Installation, use and maintenance instructions Forced draught gas burner Modulating operation CODE MODEL TYPE 20160292 RS 810/EV BLU S032T2 20163082 (3) - 06/2021...
  • 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 Notes on safety for the first start-up ...........................27 Adjustments prior to ignition............................27 Burner start-up ................................27 Air / fuel adjustment ..............................28 6.4.1 Air adjustment for maximum output ...........................28 6.4.2 Air/fuel adjustment and output modulation system ....................28 6.4.3 Burner adjustment..............................28 6.4.4 Output upon ignition ..............................28 6.4.5 Maximum output ................................28...

  • 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 revision 26.01.2010”. Product Model Type...

  • 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

    BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RS 810/EV BLU 3/400/50 Inverter 20160292 Tab. A *The burner leaves the factory set up for FS1 op- eration. If FS2 operation is required, see section “Modify the parameter for continuous/intermittent operation (FS2/FS1)”...

  • Page 10: Burner Categories - Countries Of Destination

    Gas category Destination country 2ELL AT-BG-CH-CZ-DK-EE-ES-FI-GB-GR-HU-HR-IE-IS-IT-LT-LV-NO- PT-RO-SE-SI-SK-TR LU - PL 2E(R) Tab. B Technical data Model RS 810/EV BLU Power 1200/3500 ÷ 8000 Output Fuels Natural gas: G20 (methane gas) - G25 Gas pressure at max. output mbar 49.7/73 Gas: G20/G25 FS1: Intermittent (min.

  • Page 11: Burner Equipment

    Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part turned on the hinge. The l position is reference for the refractory thickness of the boiler door. 20162256 Fig. 1 RS 810/EV BLU 1197 DN80 1345 1055 Tab. E...

  • Page 12: Firing Rates

    If the burner must be combined with a boiler that has not been EC tion chamber. approved and/or its combustion chamber dimensions are clearly Example: RS 810/EV BLU smaller than those indicated in the diagram, consult the manufac- Output 7000 kW - diameter 120 cm - length 6 m.

  • Page 13: Burner Description

    Technical description of the burner 4.10 Burner description 20163248 Fig. 4 Lifting rings The burner can be opened to the right or to the left Cover for electrical panel without links to the fuel supply side. Lever for combustion head movement When the burner is closed, the hinge can be refit- Air pressure test point for combustion head CAUTION...

  • Page 14: Electrical Panel Description

    Technical description of the burner 4.11 Electrical panel description 20081976 Fig. 5 Electrical control box ON/OFF selector Output regulator Earth terminal Supply cables and external connections passage. See “Electrical wiring” on page 25. 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- 10 Auxiliary circuits fuse (includes a spare fuse)

  • Page 15: Control Box For The Air/Fuel Ratio (Rec37

    To avoid accidents, material and/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 16 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 17: Operation Sequence Of The Burner

    Technical description of the burner 4.13 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 18: 4.13.1 List Of Phases

    Technical description of the burner 4.13.1 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 19: 4.14.2 Description Of The Buttons

    Technical description of the burner 4.14.2 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 Buttons A and F VSD function...

  • Page 20: Servomotor (Sqm33

    Technical description of the burner 4.15 Servomotor (SQM33..) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Do not open, modify or force the actuators. WARNING  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel.

  • Page 21: 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 22: Operating Position

    For boilers with front flue passes 1) (Fig. 15) or flame inversion  chamber, a protection in refractory material 5) must be inserted RS 810/EV BLU between the boiler fettling 2) and the flame funnel 4). Tab. I This protection must not compromise the extraction of the blast tube.

  • Page 23: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler 20162275 Prepare a suitable lifting system using rings 3)(Fig. 15).  Fit the heat insulation supplied onto the blast tube 4)(Fig. 15).  Fit the entire burner onto the boiler hole prepared previously (Fig.

  • Page 24: Combustion Head Adjustment

    Installation 5.10 Combustion head adjustment In order to optimise performance, the burner is equipped with a variable geometry combustion head which operates on the basis 20162133 of the delivered output. According to the same rotation of the air servomotor, it is possible to change the combustion head opening by moving the lever 2)(Fig.

  • Page 25: Gas Feeding

    Installation 5.11 Gas feeding 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 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 26: 5.11.2 Gas Train

    – read the corresponding output on the left. Disconnect the electrical power using the main Example for RS 810/EV BLU with G20 natural gas: system switch. Maximum output operation DANGER Gas pressure at test point P1)(Fig. 24) 27.6 mbar...

  • Page 27: Electrical Wiring

     Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man- ual.  The RS 810/EV BLU burners equipped with REC 37... can operate in FS1 or FS2 mode. See section “Modify the parameter for continuous/intermittent operation (FS2/FS1)” on page 36. Refer to the following notes for the type of operation that has been set.

  • Page 28: 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. 25. Key (Fig.

  • Page 29: 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 30: 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 31: Final Adjustment Of The Pressure Switches

    In this case also, the pressure gauge must be connected in differ- 20163262 ential mode, as shown in Fig. 28. On RS 810/EV BLU burners the air pressure switch is fitted in an “absolute” mode, that is, connected only to the pressure test point “+” 24)(Fig. 4 on page 11).

  • Page 32: Pressure Switch Adjustment

    Pressure switch adjustment 6.6.1 Maximum gas pressure switch Adjust the maximum gas pressure switch (Fig. 29) after making all other burner adjustments with the maximum gas pressure switch set to the end of the scale. To calibrate the maximum gas pressure switch, open the tap and then connect a pressure gauge to its pressure test point.

  • Page 33: Visualisation And Programming Mode

    Visualisation and programming mode 6.7.1 Normal mode 6.7.1.4 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 34: Info Mode

    6.7.1.5 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 35: Service Mode

    Start-up, calibration and operation of the burner 6.7.3 Service mode 6.7.4 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 41.

  • Page 36: Parameter Modification Procedure

    Start-up, calibration and operation of the burner 6.7.4.2 Assigning parameter levels 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 37 Start-up, calibration and operation of the burner 6.8.0.1 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 38: Modify "Acceleration- Deceleration Train" Parameter

    Start-up, calibration and operation of the burner 6.8.1 Modify "acceleration- deceleration train" 6.8.2 Modify the parameter for continuous/ parameter intermittent operation (FS2/FS1) The burner leaves the factory with the parameters 522 (acceler- The burner leaves the factory with parameter 239 set at "1". This ation) and 523 (deceleration) already set.

  • Page 39: 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 sectionProcedure and “OFF Upr”: this means it is necessary to set the modulation for inserting and adjusting points on the modulation curve. curve of the burner.
  • Page 40 Start-up, calibration and operation of the burner Press the button “+”: the display visualises the indicator “P1” If you want to make the burner work on just a part of the modula- flashing and proposes the same settings as point “P0”. tion curve, modify the parameters “546”...

  • Page 41: Backup / Restore Procedure

    Start-up, calibration and operation of the burner 6.10 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 42: 6.10.2 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. Refer to diagnostic code 137 to determine the cause of the WARNING error (see section List of parameters).

  • Page 43: 6.10.3 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 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 Default output for TÜV test: Not valid for TÜV test when output is activated Modification / 100% 0.1%...
  • Page 45 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 46 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 47: 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 48: Stopping Of The Burner

    Start-up, calibration and operation of the burner 6.15 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 49: 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 50: Measuring The Ionisation Current

    Maintenance 7.2.4 Measuring the ionisation current Air excess The burner is fitted with an ionisation system to check that a EN 676 Max. output Min. output flame is present.  1.2  1.3 The minimum current for control box operation is 4 µA. The oper- % Calibration theoretic ator panel displays “30%”...

  • Page 51: Opening The Burner

    Maintenance Opening the burner Disconnect the electrical supply from the burner Wait for the components in contact with heat by means of the main system switch. sources to cool down completely. DANGER See “Access to head internal part” on page 21. Close the fuel interception tap.

  • Page 52: 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 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 53 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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).
  • Page 54 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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.
  • Page 55 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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 56 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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 57 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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 58 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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 59 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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.
  • Page 60 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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.

  • Page 61: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Kit for modulating operation Burner Output regulator Code RWF 50.2 3-POINT OUTLET 20085417 RS 810/EV BLU RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441 RWF 55.6 COMPLETE WITH RS-485/PROFIBUS INTERFACE 20074442 Burner Probe Adjustment field...
  • Page 62 Appendix - Accessories PVP kit (Seal control function - See gas train booklet) Burner Ramp type Code RS 810/EV BLU MB - CB 3010344 Spacer kit Burner Code RS 810/EV BLU 20008903 Gas trains in compliance with EN 676 Please refer to manual.

  • Page 63: 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 37... operational layout REC 37... operational layout REC 37... operational layout Electrical connections for power regulator (internal) Electrical connections set by installer Electrical connections set by installer Inputs/outputs power regulator...
  • Page 64 Appendix - Electrical panel layout 20163082...
  • Page 65 Appendix - Electrical panel layout 20163082...
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  • Page 70 Appendix - Electrical panel layout 20163082...
  • Page 71 Appendix - Electrical panel layout 20163082...
  • Page 72 Appendix - Electrical panel layout 20163082...
  • Page 73 Appendix - Electrical panel layout Wiring layout key Electronic cam XPGVP Gas pressure switch connector for valve leak detec- tion control device Display and calibration unit XRWF Terminal board for output power regulator Output regulator RWF internal XSM1 Air servomotor connector Output regulator RWF external XSM2 Gas servomotor connector...
  • 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...

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