Riello 20010541 Installation, Use And Maintenance Instructions
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Riello 20010541 Installation, Use And Maintenance Instructions

Riello 20010541 Installation, Use And Maintenance Instructions

Forced draught gas burner
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Installation, use and maintenance instructions
Forced draught gas burner
GB
Progressive two-stage or modulating operation
CODE
MODEL
TYPE
20010541
RS 250/E MZ
866 T80
20010575 (7) - 04/2021

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Summary of Contents for Riello 20010541

  • Page 1 Installation, use and maintenance instructions Forced draught gas burner Progressive two-stage or modulating operation CODE MODEL TYPE 20010541 RS 250/E MZ 866 T80 20010575 (7) - 04/2021...
  • 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

    3 / 230V / 50Hz 3/400-230/50 3N / 400V-230V / 50Hz Voltage of auxiliaries : 220/60 220V / 60Hz 3/380/60 220/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RS 250/E MZ 3 ~ 380V - 60Hz Direct 20010541 Tab. A 20010575...

  • 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

    Technical description of the burner Maximum dimensions The dimensions of the burner are shown in Fig. 1. 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.

  • 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 D9261 Fig. 5 Combustion head 21 Gas pressure test point and head fixing screw Ignition electrode 22 Air pressure socket Screw for combustion head adjustment 23 Flame sensor probe Maximum gas pressure switch 24 Air damper Pipe coupling 25 Fan air inlet...

  • Page 15: Control Box For The Air/Fuel Ratio (Rec 27.100A2)

    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 of Start up Shutdown 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 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

    Installation Operating position  The burner is designed to operate only in  Any other position could compromise the cor- positions 1 , 2 , 3 and 4 (Fig. 12). rect operation of the appliance.  Installation 1 is preferable, as it is the only ...

  • 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 Once this operation has been carried out:  fix the flange 9) to the boiler plate, interposing the supplied Provide an adequate lifting system of the burner. insulating gasket 8).  Use the 4 screws supplied, with a tightening torque of 35 ÷ 40 Nm, after protecting their thread with anti-seize products.

  • Page 26: Combustion Head Adjustment

    Installation Combustion head adjustment At this point of the installation, the combustion head is fixed to the Two adjustments of the head are foreseen: boiler as shown in Fig. 14. – – 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: When fitting the burner on the two guides, it is  reassemble the burner on the guides 3) at about 100 mm advisable to gently draw out the high voltage from the pipe coupling 4) - burner in the position shown in cable and flame detection probe cable until they Fig.

  • 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 Column 1 Load loss at combustion head. Gas pressure measured at the test point 1)(Fig. 26), with: • combustion chamber at 0 mbar; • burner working at maximum output; Column 2 Pressure loss at gas butterfly valve 2)(Fig. 26) with maximum opening: 90°.

  • 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: Calibration Of The Thermal Relay

    Installation 5.12 Calibration of the thermal relay The thermal relay is used to avoid damage to the motor owing to a strong increase in absorption or the lack of a phase. For the calibration, refer to the electrical wiring. If the minimum value of the scale of the thermal relay is greater than the rating absorption of the motor, protection is still ensured.

  • Page 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 40. boiler panel. Close the thermostats/pressure switches and turn the switch of Fig. 30 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 6.5.2 Maximum gas pressure switch Adjust the air pressure switch (Fig. 31) after having performed all Adjust the maximum gas pressure switch (Fig. 32) after making other burner adjustments with the air pressure switch set to the all other burner adjustments with the maximum gas pressure start of the scale.

  • 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. 33) 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 Condition error message, display of the errors and information The Normal mode is the standard operation mode visualised on the operator panel display. It is the main level of the menu. The display visualises alternately the error code (in the example ...

  • Page 38: Info Mode

    Start-up, calibration and operation of the burner 6.6.1.5 Reset procedure Releasing the key “ F ” the standard visualisation appears, with the current load percentage flashing: this means that the burner is The burner is in lockout when the red indicator light on the oper- working in Manual mode (any outside adjustment is excluded and ator panel is lit up, and the display visualises the lockout code (in only the safety devices are active).

  • Page 39: Service Mode

    Start-up, calibration and operation of the burner 6.6.3 Service mode 6.6.4 Parameter mode The Service mode ( SEr ) visualises the error log and certain The Parameters Mode ( PArA ) displays, and allows to be mod- technical information about the system. To access this level you ified/programmed, the list of parameters indicated on pag.

  • Page 40: Parameter Modification Procedure

    Start-up, calibration and operation of the burner 6.6.4.2 Allocating the levels of the parameters The password must only be communicated to the The parameters' level is subdivided into groups as shown in Tab. qualified personnel or the Technical Assistance Service, and must be kept in a safe place. WARNING Parameter 100: ParA...
  • Page 41 Start-up, calibration and operation of the burner 6.7.0.1 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 42: Start-Up Procedure

    Start-up, calibration and operation of the burner Start-up procedure Check that the operator panel display shows the heat request Otherwise, modify the ignition point, see the section "Procedure and “OFF Upr” : this means it is necessary to set the modulation for inserting and adjusting points on the modulation curve"...
  • Page 43 Start-up, calibration and operation of the burner The control box will automatically report the same values set at the points “ P0 ” and “ P1 ” to points “ P2 ” to “ P8 ”. The purpose is to reach the point “ P9 ” to adjust/fix the maximum operating power.

  • Page 44: Backup / Restore Procedure

    Start-up, calibration and operation of the burner Backup / Restore procedure At the end of the "Start-up procedure" it is opportune to make a We suggest carrying out this operation at the end backup, creating a copy of the data memorised on the REC, in of each intervention that modifies what has been the display panel RDI 21.

  • Page 45: Restore

    Start-up, calibration and operation of the burner NOTE: It is advisable to perform a backup every time If an error occurs during the backup process, the display that a parameter is changed, after checking screen shows a negative value. the modification carried out is correct. To determine the cause of the error refer to diagnostic code WARNING 137 (see section "Error codes list"...
  • Page 46 Start-up, calibration and operation of the burner The value 1 appears on the display screen: h min s After approx 8 seconds (it depends on the duration of the pro- gramme), the 0 value appears on the display screen, this is to in- dicate that the restore process has been completed correctly.

  • Page 47: Parameter List

    Start-up, calibration and operation of the burner 6.9.3 Parameter list Parameter Value range No. ele- Unit of Modifica- Degree of Default Acces mode ments measure tion accuracy setting Description Min. Max. INTERNAL PARAMETERS Start backup/restore process via RDI21... / PC TOOL (set the parameter to 1) Index 0 = create backup Modification...
  • Page 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. Baud Rate for Modbus Values set: Modification Service mode 0 = 9600 1 = 19200 Parity for Modbus 0 = none...
  • 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. Gas: selection of flame sensor 0 = QRB.../ QRC Modification Service mode 1 = ION / QRA Gas: Selection of the pre-purging function 0 = deactivated...
  • 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. Position of the fuel servomotor in absence of flame Index 0 = standby position (°) Modification 0°...

  • 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. /h, l, h, Actual output Reading only 6553.5 Info mode /h, gal/h Status of external modules and visualisation Reading only Info mode...

  • Page 52: Final Checks (With Burner Operating)

    Start-up, calibration and operation of the burner 6.14 Final checks (with burner operating)   Open the thermostat/pressure switch TL The burner must stop  Open the thermostat/pressure switch TS  Turn the gas maximum pressure switch knob to the mini- ...

  • Page 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 leaks 7.2.5 Measuring the ionisation current Make sure that there are no gas leaks on the pipes between the The burner is fitted with an ionisation system to check that a gas meter and the burner. flame is present. The minimum current for control box operation is 4 µA.

  • Page 55: Opening The Burner

    Maintenance Opening the burner  Loosen the 4 screws 1)(Fig. 39) 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 Overloading of the servomotor or servomotor subjected to mechanical torsion. Bit 4 Deviation of section compared with the last reference 1. Check if the servomotor is blocked in any point along its Valence ...
  • Page 60 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code Insufficient mains voltage. Low level of power supply Conversion of the diagnostic code Voltage value (230 V AC : 1,683) Error code for the carrying out of a reset in the event of power Reset power supply voltage supply restoration (absence of error) Carry out a reset;...
  • Page 61 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the REC 27.100A2 system Recommended measures code 254 (-2) Interruption owing to transmission error Repeat the reset and backup 255 (-1) Interruption owing to time-out during the restoration Carry out a reset, check the connections and repeat the backup Time-out of the system automation interface Refer to the Modbus User Documentation (A7541) Modbus time-out...
  • 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 Internal error control box Carry out a reset; if the error arises repeatedly, replace the Internal error control box Tab.

  • Page 63: A Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Long head kit Burner Standard head length (mm) Extended head length (mm) Code RS 250/E MZ 3010412 Soundproofing chamber kit Burner Type dB(A) Code RS 250/E MZ C4/5 3010404 Output power regulator kit for modulating operation With the modulating operation, the burner continually adapts the Two components should be ordered: power to the heat request, ensuring a high level of stability for the...

  • Page 64: Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Operational layout REC27... Operational layout REC27... Operational layout REC27... Electrical connection set by installer Electrical connection set by installer Operational layout RWF50 Indication of references / 1 .
  • Page 65 Appendix - Electrical panel layout 20010575...
  • Page 66 Appendix - Electrical panel layout 20010575...
  • Page 67 Appendix - Electrical panel layout 20010575...
  • Page 68 Appendix - Electrical panel layout 20010575...
  • Page 69 Appendix - Electrical panel layout 20010575...
  • Page 70 Appendix - Electrical panel layout 20010575...
  • Page 71 Appendix - Electrical panel layout Wiring layout key Control box for the air/fuel ratio XPGMin Minimum gas pressure switch connector Operator Panel XPGVP Gas pressure switch connector for valve leak detec- tion control device Burner components XRWF Terminal board for output power regulator RWF Boiler components XSM1 Air servomotor connector...
  • 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...

This manual is also suitable for:

Rs 250/e mz866 t80

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