Riello RS 310/EV ULX Installation, Use And Maintenance Instructions
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Riello RS 310/EV ULX Installation, Use And Maintenance Instructions

Riello RS 310/EV ULX Installation, Use And Maintenance Instructions

Forced draught gas burners
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Installation, use and maintenance instructions
Forced draught gas burners
GB
Modulating operation
CODE
20205452
20205455
MODEL
RS 310/EV ULX
RS 510/EV ULX
TYPE
S045T2
S046T2
20205882 (3) - 09/2023

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Summary of Contents for Riello RS 310/EV ULX

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Modulating operation CODE MODEL TYPE 20205452 RS 310/EV ULX S045T2 20205455 RS 510/EV ULX S046T2 20205882 (3) - 09/2023...
  • Page 2 Translation of the original instructions...

  • Page 3: Table Of Contents

    Contents Information and general warnings............................3 Information about the instruction manual ........................3 1.1.1 Introduction.................................. 3 1.1.2 General dangers................................3 1.1.3 Other symbols ................................3 1.1.4 Delivery of the system and the instruction manual ...................... 4 Guarantee and responsibility............................4 Safety and prevention................................
  • Page 4 Contents Burner start-up ................................30 Air / fuel adjustment ..............................31 5.4.1 Air adjustment for maximum output ...........................31 5.4.2 Air/fuel adjustment and output modulation system ....................31 5.4.3 Burner adjustment..............................31 5.4.4 Output upon ignition ..............................31 5.4.5 Maximum output ................................31 5.4.6 Minimum output .................................32 Final adjustment of the pressure switches .........................32 5.5.1 Air pressure switch..............................32...

  • Page 5: Information And General Warnings

    Information and general warnings Information and general warnings Information about the instruction manual 1.1.1 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 6: Delivery Of The System And The Instruction Manual

    Information and general warnings 1.1.4 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 7: 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 8: Technical Description Of The Burner

    Technical description of the burner Technical description of the burner Burner designation Range: R Fuel: Natural gas Light Oil Light Oil/Natural gas Heavy Oil Size: Adjustment: Two stage (light oil / proportional valve (gas) Mechanical cam Electronic Cam Electronic cam and variable speed (with Inverter) Electronic cam with integrated Inverter Electronic cam and suitable for Oxygen Control (O Electronic cam and variable speed (with Inverter) and suitable for Oxygen Control O...

  • Page 9: Models Available

    Technical description of the burner Models available Designation Voltage Start-up Code RS 310/EV ULX 3N/400/50 Inverter 20205452 RS 510/EV ULX 3N/400/50 Inverter 20205455 Tab. A Technical data Model RS 310/EV ULX RS 510/EV ULX Type S045T2 S046T2 Power Min. - Max.

  • Page 10: Burner Equipment

    Bear in mind that inspection of the combustion head requires the fractory thickness of the boiler door. burner to be opened and the rear part turned on the hinge. 20209585 Fig. 1 RS 310/EV ULX 1015 518 DN65 511 290 1104 886 RS 510/EV ULX 1015 518 DN65 557 290 1104 886 Tab.

  • Page 11: Firing Rates

    The maximum output must be higher than the following values If the chosen maximum output is lower than the following val- (Tab. E): ues (Tab. F): Model Model RS 310/EV ULX 1250 RS 310/EV ULX 1860 RS 510/EV ULX 1900...

  • Page 12: 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 13: Burner Description

    Technical description of the burner Burner description 20209603 Fig. 4 Lifting rings Wait for the components in contact with heat Fan motor sources to cool down completely. Air damper servomotor Combustion head gas pressure test point Combustion head The burner can be opened to the right or to the left Ignition electrodes without links to the fuel supply side.

  • Page 14: Electrical Panel Description

    Technical description of the burner 3.10 Electrical panel description 20081976 Fig. 5 Flame control ON/OFF selector Output regulator Earth terminal Supply cables and external connections passage. See sec- tion “Electrical wiring” on page 27 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: Flame Control For The Air/Fuel Ratio (Rec 37

    To avoid accidents, material and/or environmental D8266 damage, observe the following instructions! The flame control is a safety device! Avoid open- ing or modifying it, or forcing its operation. Riello WARNING S.p.A. cannot assume any responsibility for dam- age resulting from unauthorised interventions!
  • Page 16 Technical description of the burner Technical data Flame control 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 flame control (can be inspected)

  • Page 17: Operation Sequence Of The Burner

    Technical description of the burner 3.12 Operation sequence of the burner Operation Checking of Start-up Switching off seal Phase number 10 12 81 82 Timer - Resolution - Ratio 0,6 s 27 s 30 s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max.

  • Page 18: 3.12.1 List Of Phases

    Technical description of the burner 3.12.1 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 19: 3.13.2 Description Of The Buttons

    Technical description of the burner 3.13.2 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 20: Servomotor (Sqm33

    Technical description of the burner 3.14 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 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

    4).  The refractory can have a conical shape (minimum 60°). This protective fettling must not compromise the extraction of the RS 310/EV ULX blast tube. RS 510/EV ULX For boilers with a water-cooled front piece, a refractory lining 2)- Tab.

  • Page 23: Access To Head Internal Part

    Installation Access to head internal part The burner leaves the factory set for opening to the right, there- fore maintaining the pin 1)(Fig. 15) in the housing. To open the burner towards the right, proceed as follows: disconnect the plug/socket 6)(Fig. 15) of the maximum gas pressure switch;...

  • Page 24: Combustion Head Adjustment

    3200 3400 3600 3800 following ranges: Max burner output (kW) RS 310/EV ULX: 0 - 10 WARNING RS 510/EV ULX: 0 - 10 RS 510/EV ULX The adjustment cannot be carried out outside these ranges. No. Notches (air = gas)

  • Page 25: Central Gas Adjustment

    The factory setting for the central gas is with the following pas- sage holes (Fig. 20). RS 310/EV ULX Central hole + 2 open holes RS 510/EV ULX Central hole + 2 open holes If necessary, modify as indicated in “Firing rates” on page 9: ...

  • Page 26: Gas Feeding

    Installation 4.11 Gas feeding 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 and laws. Precautions: avoid knocking, attrition, sparks and WARNING heat.

  • Page 27: 4.11.4 Gas Pressure

    Natural gas G 20 NCV 9.45 kWh/Sm (8.2 Mcal/Sm RS 310/EV ULX S10334 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 Burner output –...
  • Page 28 Installation To calculate the required gas pressure at test point P1)(Fig. 23), 20198299 set the MAX output required from the burner operation: – find the nearest output value. – Read the pressure at the test point P1)(Fig. 22). – Add this value to the estimated pressure in the combustion chamber.

  • Page 29: Electrical Wiring

    Installation 4.12 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 30: Supply Cables And External Connections Passage

    Installation 4.12.1 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. 24. Key (Fig.

  • Page 31: 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 32: Burner Start-Up

    Start-up, calibration and operation of the burner Burner start-up Electrically power the burner using the disconnecting switch on the boiler panel. Close the thermostats/pressure switches and set the switch of Fig. 27 to “1/ON”. Make sure that the lights or testers connected to the solenoids, or the pilot lights on the solenoids themselves, indicate that no voltage is present.

  • Page 33: Air / Fuel Adjustment

    Start-up, calibration and operation of the burner Air / fuel adjustment 5.4.4 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 34: Minimum Output

    Start-up, calibration and operation of the burner Indication for the burner ignition Calculate the pressure required downstream of the gas train: this value is given by the sum of the boiler back pres- In Tab. K the calibrations of the air and gas servomotors at the sure at the maximum burnt power and the pressure drop ignition point for each model are summarized according to the read on the diagrams of Fig.

  • Page 35: Maximum Gas Pressure Switch

    Start-up, calibration and operation of the burner 5.5.2 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 36: Control And Display

    Control and display Control and display Visualisation and programming mode 7.1.1 Normal mode The Normal mode is the standard operation mode visualised on the operator panel display. It is the main level of the menu.  Visualises the operation conditions and allows you to modify the operation point of the burner manually.

  • Page 37: Info Mode

    Control and display To exit manual mode, press the keys “+” and “-” (ESC) simulta- neously for 3 seconds: the burner will work in Automatic mode and the output will depend on the thermostat/adjustment pres- sure switch (TR). min s To reset, press the “i/reset”...

  • Page 38: Service Mode

    Control and display 7.1.3 Service mode 7.1.4 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 44. must: The factory-set parameters are not visible.

  • Page 39: Parameter Modification Procedure

    Control and display Parameter The password must only be communicated to the 100: ParA General parameters qualified personnel or the Technical Assistance Information and identification data of the system. Service, and must be kept in a safe place. WARNING 200: ParA Checks on the burner Type of operation, intervention and safety times Once the access procedure has been carried out, the display will...
  • Page 40 Control and display positioned on the values shown on the display and which corre- spond to the point previously set. D7908 It is now possible to insert/modify the position by degrees. The set value does not require confirmation. original curve WARNING CALC+ For the fuel servomotor, keep the key “F”...

  • Page 41: Modify "Acceleration- Deceleration Train" Parameter

    Control and display 7.2.1 Modify "acceleration- deceleration train" 7.2.2 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 42: Start-Up Procedure

    Control and display Start-up procedure Check that the operator panel display shows the heat request Phase 24: and "OFF Upr": this means it is necessary to set the modulation The burner goes to the pre-purging position, the air servomotor curve of the burner. opens the damper at 90°.
  • Page 43 Control and display Solve the problem, referring to the paragraph “Ignition failure” on Halfway through the procedure (i.e. around point P4 or P5), you page 49.. are advised to measure gas delivery and check that the output is about 50% of the maximum output. To unlock, see “Reset procedure”...

  • Page 44: Backup / Restore Procedure

    Control and display 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 45: Restore

    Control and display It is advisable to perform a backup every time NOTE: that a parameter is changed, after checking If an error occurs during the backup process, the display that the modification carried out is correct. screen shows negative value.

  • Page 46: List Of Parameters

    Control and display The value 1 appears on the display screen: NOTE: When the restore process is successfully completed, the 0 value shown display screen. Err C information: 136 D: 1 (restore process initialised) is displayed for a brief moment. At the end of the restore process, it is neces- h min s sary to check the sequence of functions and...
  • Page 47 Control and display Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Default output for TÜV test: Not valid for TÜV test when output is activated Modification / 100% 0.1% Not defined...
  • Page 48 Control and display Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Stopping of the program 0 = deactivated 1 = pre-purging (Ph24) Modification Service Mode 2 = Ignition (Ph36) 3 = Interval 1 (Ph44) 4 = Interval 2 (Ph52) Alarm as the pre-purging phase begins;...
  • Page 49 Control and display Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Oil: Maximum oil pressure switch / POC Input 0 = deactivated Modification Service Mode 1 = Maximum oil pressure switch 2 = POC Oil: Intermittent operation 0 = deactivated...

  • Page 50: Operation

    Control and display Parameter Unit of Values interval No. of Degree of Predefined measure- Modification Access mode elements precision setting Description Min. Max. ment Actual output Index 0 = fuel Reading only 100% 0.1% Info mode Index 1 = air Position of the servomotors Index 0 = fuel (°)

  • Page 51: Ignition Failure

    Control and display Ignition failure If the burner does not switch on, there is a lockout within 3s of the In the event the burner stops, in order to prevent electrical supply reaching the gas valve. any damage to the installation, do not unblock the It may be that the gas does not arrive at the combustion head burner more than twice in a row.

  • Page 52: 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 53: Safety Components

    Maintenance 8.2.5 Measuring the ionisation current Boiler Clean the boiler as indicated in its accompanying instructions in The burner is fitted with an ionisation system to check that a order to maintain all the original combustion characteristics in- flame is present. tact, especially the flue gas temperature and combustion cham- The minimum current for flame control operation is 4 μA.

  • Page 54: Adjustment Fan Motor Covering With External Rpm

    Maintenance Adjustment fan motor covering with external rpm To calibrate the rpm sensor 6)(Fig. 36), proceed as follows:  remove the cover 1) unscrewing the screws 2);  unscrew or screw the nuts 3) - 5) and the rpm detection disc 4) so that its distance from the rpm sensor 6) is about 2 mm;...

  • Page 55: 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 56 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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 57 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 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 58 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37.400A2 system Recommended measures code The standard unit does not receive pulses from the speed sensor: 1. The motor does not turn. Speed sensor circuit open 2. The speed sensor is not connected. 3.
  • Page 59 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 60 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 61 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 flame control. Insufficient mains voltage. Low level of power supply Conversion of the diagnostic code --->...
  • Page 62 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 63 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 flame control. Carry out a reset; if the error arises repeatedly, replace the Internal error flame control.

  • Page 64: A Appendix - Accessories

    Line Inverter Output Burner Motor Output (kW) Code voltage (kW) RS 310/EV ULX 400V 20163074 RS 510/EV ULX 400V 20163096 The use of inverters other than those indicated by the manufacturer may lead to burner failure and, in extreme cases, a potential risk of harm to people and damage to property.

  • Page 65: 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 Operational layout Operational layout Operational layout Kit for power regulator RWF Electrical connections set by installer Electrical connections set by installer Inputs/outputs power regulator Indication of references...
  • Page 66 Appendix - Electrical panel layout 20205882...
  • Page 67 Appendix - Electrical panel layout 20205882...
  • Page 68 Appendix - Electrical panel layout 20205882...
  • Page 69 Appendix - Electrical panel layout 20205882...
  • Page 70 Appendix - Electrical panel layout 20205882...
  • Page 71 Appendix - Electrical panel layout 20205882...
  • Page 72 Appendix - Electrical panel layout 20205882...
  • Page 73 Appendix - Electrical panel layout 20205882...
  • Page 74 Appendix - Electrical panel layout 20205882...
  • Page 75 Appendix - Electrical panel layout Wiring layout key Flame control Display and calibration unit Output regulator RWF50 internal Fuel meter Probe with output under current Device with output under current, for modifying re- mote setpoint Modulation control 4-20mA Pressure probe Pressure probe Remote setpoint potentiometer Thermocouple probe...
  • 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 510/ev ulxS045t2S046t2

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