Riello RS 250/EV MZ Installation, Use And Maintenance Instructions
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Riello RS 250/EV MZ Installation, Use And Maintenance Instructions

Riello RS 250/EV MZ 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
MODEL
TYPE
20014098 - 20014515
RS 250/EV MZ
866 T2
20068470 (5) - 03/2021

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Summary of Contents for Riello RS 250/EV MZ

  • Page 1 Installation, use and maintenance instructions Forced draught gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 20014098 - 20014515 RS 250/EV MZ 866 T2 20068470 (5) - 03/2021...
  • 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 6.4.2 Maximum output ................................32 6.4.3 Minimum output .................................32 Final calibration of the pressure switches ........................33 6.5.1 Air pressure switch..............................33 6.5.2 Maximum gas pressure switch...........................33 6.5.3 Minimum gas pressure switch............................34 6.5.4 PVP pressure switch kit .............................34 Visualisation and programming mode........................35 6.6.1 Normal mode ................................35 6.6.2...

  • Page 5: Declarations

    The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015. 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 release 26.01.2010”.

  • Page 6: Information And General Warnings

    Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction 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

    230V / 50-60Hz 110/50/60 110V / 50-60Hz 3/230/50 230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RS 250/EV MZ 3 ~ 400V - 50Hz Diretto 20014098 RS 250/EV MZ 3 ~ 400V - 50Hz Diretto 20014515 Tab. A 20068470...

  • Page 10: Burner Categories

    Technical description of the burner Burner categories Country of destination Gas category I2E(R) CY, MT I3B/P LU, PL II2E3B/P II2ELL3B/P II2Er3P AT, CH, CZ, DK, EE, FI, GR, HU, IS, IT, LT, NO, SE, SI, SK II2H3B/P ES, GB, IE, PT II2H3P II2L3B/P 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. D731 Fig. 1 RS 250/EV MZ 370-520 1322-1467 2” Tab. E...

  • Page 12: 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 13: 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 14: Burner Description

    Technical description of the burner 4.10 Burner description Seen from A 20079525 Fig. 5 Combustion head 24 Air damper Ignition electrode 25 Fan air inlet Screw for combustion head adjustment 26 Screws to secure fan to pipe coupling Maximum gas pressure switch 27 Gas input pipe Pipe coupling 28 Gas butterfly valve...

  • Page 15: 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 16 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 17 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 18: 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 19: 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 20: 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 21: 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 22: 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 23: Operating Position

    D455 Fig. 13 case it must be greater than the thickness of the boiler door com- plete with its refractory. The lengths L available are: RS 250/EV MZ 325-368 M 16 Blast tube Short (mm) Long (mm) Tab.

  • Page 24: Positioning Probe - Electrode

    Installation Positioning probe - electrode Before fixing the burner to the boiler, check from the opening of the blast tube that the probe and the electrode are correctly positioned, as in Fig. 15. WARNING If, in the previous check, the position of the probe or electrode was not correct, is necessary: ...

  • Page 25: 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 26: Combustion Head Adjustment

    Installation Combustion head adjustment At this point of the installation, the combustion head is fixed to the In the diagram (Fig. 17) find the notch at which to adjust the boiler as shown in Fig. 14. screw 2)(Fig. 18). It is therefore especially easy to adjust, and this adjustment de- pends only on the maximum output of the burner.

  • Page 27: Burner Closing

    Installation Burner closing Once the combustion head adjustment is completed:  connect the socket of the maximum gas pressure switch;  reassemble the burner on the guides 3) at about 100 mm  refit the screws 2) on the guides 3); from the pipe coupling 4) - burner in the position shown in ...

  • Page 28: Gas Feeding

    Installation 5.10 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 29: 5.10.2 Gas Train

    Installation 5.10.2 Gas train Type-approved in accordance with EN 676 and supplied sepa- rately from the burner. To select the correct model of the gas train, refer to the “burner- gas train combination” manual supplied. 5.10.3 Gas train installation Disconnect the electrical power using the main system switch.
  • Page 30 Installation Example with natural gas G 20: Maximum output operation Gas pressure at test point 1)(Fig. 26) 14.3 mbar Pressure in combustion chamber 3.0 mbar 14.3 - 3.0 11.3 mbar A maximum output of 2000 kW shown in Tab. L corresponds to 11.3 mbar pressure, column 1.

  • Page 31: Electrical Wiring

    Installation 5.11 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 32: 5.11.2 Motor Cable Shield

    Installation 5.11.2 Motor cable shield It is important to shield the motor cable 1) as indi- cated in Fig. 28. WARNING D12115 Fig. 28 Key (Fig. 28) Power supply cable (from the inverter) Single-phase power supply cable Connecting cable between inverter REC 37.400A2 electronic cam The connection from the inverter to the...

  • Page 33: 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 34: Burner Start-Up

    Start-up, calibration and operation of the burner Burner start-up Feed electricity to the burner via the disconnecting switch on the Follow the "Start-up procedure" at page 41. boiler panel. Close the thermostats/pressure switches and turn the switch of Fig. 32 to position “1”. Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present.

  • Page 35: 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. 33) 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 36: Minimum Gas Pressure Switch

    Start-up, calibration and operation of the burner 6.5.3 Minimum gas pressure switch Adjust the minimum gas pressure switch (Fig. 35) after having performed all other burner adjustments with the pressure switch set to the start of the scale. With the burner operating at maximum output, increase adjust- ment pressure by slowly turning the relative knob clockwise until the burner locks out.

  • Page 37: 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 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 38 Start-up, calibration and operation of the burner 6.6.1.5 Reset procedure 6.6.1.7 Manual operation procedure The burner is in lockout when the red indicator light on the oper- After the adjustment of the burner and the setting of the points on ator panel is lit up, and the display visualises the lockout code (in the modulation curve, it is possible to manually check the opera- the example alongside c: 4 ) and the relative diagnostics (in the...

  • Page 39: Info Mode

    Start-up, calibration and operation of the burner 6.6.2 Info mode 6.6.3 Service mode The Info mode ( InFo ) visualises general system information. To The Service mode ( SEr ) visualises the error log and certain access this level you must: technical information about the system.

  • Page 40: Parameters Mode

    Start-up, calibration and operation of the burner 6.6.4 Parameters Mode The password must only be communicated to the The Parameters Mode ( PArA ) displays and allows you to modi- qualified personnel or the Technical Assistance fy/programme the parameters list on page 45. Service, and must be kept in a safe place.

  • Page 41: Parameter Modification Procedure

    Start-up, calibration and operation of the burner Parameter modification procedure After accessing the level and group of parameters, the display To insert or adjust a point, proceed as follows. visualises the number of the parameter (flashing) on the left, and Using the keys “+”...

  • Page 42: Calc Function

    Start-up, calibration and operation of the burner 6.7.2 CALC function 6.7.3 Modification of parameter “acceleration / deceleration ramp” The diagram (Fig. 37) shows how the fuel modulation curve is modified if the values of point “ P5 ” are changed. The burner leaves the factory with the parameters 522 (acceler- By keeping the “+”...

  • 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 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.
  • Page 44 Start-up, calibration and operation of the burner Solve the problem, referring to the paragraph "Ignition failure" Halfway through the procedure (i.e. around point P4 or P5 ), you at page 50. are advised to measure gas delivery and check that the output is about 50% of the maximum output.

  • 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 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 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. that the modification carried out is correct. Refer to diagnostic code 137 to determine the cause of the WARNING error (see section "Error codes list"...

  • Page 47: Parameter List

    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 48 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. Default output for TÜV test: Not valid for TÜV test when output is activated Modification / 100% 0.1%...
  • 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. Stopping of the program 0 = deactivated 1 = pre-purging (Ph24) Modification Service Mode 2 = Ignition (Ph36) 3 = Interval 1 (Ph44)
  • 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. Oil: Maximum oil pressure switch / POC Input 0 = deactivated Modification Service Mode 1 = maximum oil pressure switch 2 = POC...

  • Page 51: 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. • Error chronology: 701-725.05.Start-up meter Reading only 99999999 Info mode Error chronology: 701-725.06.Load Reading only 100% 0.1%...

  • Page 52: Ignition Failure

    Start-up, calibration and operation of the burner 6.11 Ignition failure If the burner does not switch on, there is a lockout within 3s of the In the event of a burner lockout, more than two electrical supply reaching the gas valve. consecutive burner reset operations could cause It may be that the gas does not arrive at the combustion head damage to the installation.

  • Page 53: 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. Disconnect the electrical supply from the burner It allows you to reduce consumption and polluting emissions and by means of the main system switch.

  • Page 54: Safety Components

    Maintenance Gas filter 7.2.5 Measuring the ionisation current Replace the gas filter when it is dirty. The burner is fitted with an ionisation system to check that a flame is present. Flame inspection window The minimum current for control box operation is 4 µA. The Op- Clean the glass of the flame inspection window.

  • Page 55: Opening The Burner

    Maintenance Opening the burner  Loosen the 4 screws 1)(Fig. 41) 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 56: 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 57 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 58 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 59 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 60 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 61 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 62 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 63 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 64 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 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 65: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Long head kit Standard head length Extended head length Burner Code (mm) (mm) RS 250/EV MZ 3010412 Spacer kit Burner Thickness (mm) Code RS 250/EV MZ 3000722 Continuous purging kit Burner Code RS 250/EV MZ...
  • Page 66 Appendix - Accessories Software interface kit (ACS410 + OCI410.30) - Service Level Burner Code RS 250/EV MZ 3010436 Modbus interface kit Burner Model Code RS 250/EV MZ OCI412 3010437 Head kit for flame inversion boiler Burner Code RS 250/EV MZ...

  • Page 67: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output Operational layout REC37..Operational layout REC37..Operational layout REC37..Electrical connection set by installer RWF50... operational layout Indication of references / 1 .
  • Page 68 Appendix - Electrical panel layout 20068470...
  • Page 69 Appendix - Electrical panel layout 20068470...
  • Page 70 Appendix - Electrical panel layout 20068470...
  • Page 71 Appendix - Electrical panel layout 20068470...
  • Page 72 Appendix - Electrical panel layout 20068470...
  • Page 73 Appendix - Electrical panel layout 20068470...
  • Page 74 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio XPGVP Gas pressure switch connector for valve leak detection control device Operator panel XRWF Terminal board for output power regulator RWF Burner components Gas adjustment valve + gas safety valve Boiler components Filter to protect against radio disturbance Output 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...

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