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Related Manuals for Riello RS 68/E ULX
Summary of Contents for Riello RS 68/E ULX
- Page 1 Installation, use and maintenance instructions Forced draught gas burners Modulating operation CODE MODEL TYPE 20204446 RS 68/E ULX S041T1 20204447 RS 120/E ULX S042T1 20205279 RS 160/E ULX S043T1 20204448 RS 200/E ULX S044T1 20205255 (3) - 10/2023...
- Page 2 Translation of the original instructions...
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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 5.4.1 Air adjustment for maximum output ...........................33 5.4.2 Air/fuel adjustment and output modulation system ....................33 5.4.3 Burner adjustment..............................33 5.4.4 Output upon ignition ..............................34 5.4.5 Maximum output ................................34 5.4.6 Minimum output .................................34 Final calibration of the pressure switches ........................35 5.5.1 Air pressure switch..............................35 5.5.2 Maximum gas pressure switch...........................35...
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Page 5: Information And General Warnings
Information and general warnings Information and general warnings Information about the instruction manual 1.1.1 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 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 LS 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 EV O... -
Page 9: Models Available
Technical description of the burner Models available Designation Voltage Start-up Code RS 68/E ULX TL FS1 3 ~ 400V - 50Hz Direct 20204446 RS 120/E ULX TL FS1 3 ~ 400V - 50Hz Direct 20204447 RS 160/E ULX TL FS1... -
Page 10: Maximum Dimensions
The dimensions of the open burner are indicated by position U. Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the guides. 20205146 Fig. 1 RS 68/E ULX 2" 1245 RS 120/E ULX 2"... -
Page 11: Firing Rates
The maximum output must be higher than the following values If the chosen maximum output is higher than the following va- (Tab. F): lues (Tab. G): Model Model RS 68/E ULX RS 68/E ULX RS 120/E ULX RS 120/E ULX 1175 RS 160/E ULX... - Page 12 Technical description of the burner RS 160/E ULX S10340 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 Thermal power - kW Fig. 4 RS 200/E ULX S10341 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 Thermal power - kW Fig.
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Page 13: Test Boiler
Technical description of the burner Test boiler The firing rates were obtained in special test boilers, according to Although combination is guaranteed when boiler has a CE type- EN 676 standard. In Fig. 6 you can see the diameter and length approval, preliminary tests are recommended for boilers or of the test combustion chamber. -
Page 14: Burner Description
Technical description of the burner 3.10 Burner description 20205149 19 20 6 15 Fig. 7 Lifting rings Wait for the components in contact with heat sources to cool down completely. Fan motor Air damper servomotor Combustion head gas pressure test point Combustion head Ignition electrodes Ionisation probe... -
Page 15: Electrical Panel Description
Technical description of the burner 3.11 Electrical panel description 20201623 Fig. 8 Fan motor contactor and thermal relay Ignition transformer Filter to protect against radio disturbance Switch for on/off operation Air pressure switch Cable grommets for external connections Terminal board for electric connection Display Dry contact relay 10 Control box... -
Page 16: Control Box For The Air/Fuel Ratio (Rec 27
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 17 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 flame control (can be inspected)
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Page 18: Operation Sequence Of The Burner
Technical description of the burner 3.13 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 19: 3.13.1 List Of Phases
Technical description of the burner 3.13.1 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 20: 3.14.2 Description Of The Buttons
Technical description of the burner 3.14.2 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 change mode... -
Page 21: Servomotor (Sqm33
Technical description of the burner 3.15 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 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
Fig. 16 This protective fettling must not compromise the extraction of the Ø blast tube. RS 68/E ULX M 16 For boilers with a water-cooled front piece, a refractory lining 11)- 12)(Fig. 17) is not necessary, unless expressly requested by the... -
Page 24: Securing The Burner To The Boiler
Installation Securing the burner to the boiler 20205163 Provide an adequate lifting system of the burner. Divide the combustion head from the rest of the burner, as shown in Fig. 17; you have to: loosen the 4 screws 3) and remove the cover 1); ... -
Page 25: Electrode Position
Installation Electrode position 20188099 4 ± 0.5 ± 1 Before fixing the burner to the boiler, check the correct positioning of the electrodes as in Fig. 19. WARNING ±1 Fig. 19 Central gas adjustment As you can see in Fig. 20 the gas flows through the combustion head in two different ways: 20205150 ... -
Page 26: Combustion Head Adjustment
4.10 Combustion head adjustment At this point of the installation, the combustion head is fixed to the RS 68/E ULX boiler as shown in Fig. 18 on page 22. It is therefore especially S10260 easy to adjust, and this adjustment depends only on the maxi- mum output of the burner. -
Page 27: Closing The Burner
Installation 4.11 Closing the burner Once the combustion head adjustment is completed: 20205162 reassemble the burner on the slide bars 3) at about 100 mm from the pipe coupling 4) burner in the position shown in Fig. 17 on page 22; ... -
Page 28: Gas Feeding
Installation 4.12 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 29: 4.12.4 Gas Pressure
Installation 4.12.4 Gas pressure Example RS 200/E ULX with G20 natural gas: Fixed Output operation Each diagram indicate the minimum pressure drops depending on the maximum burner output. Gas pressure at test point P1 108 mbar The values shown, refer to: Pressure in combustion chamber 8 mbar –... - Page 30 Installation RS 68/E ULX S10342 1000 1050 1100 1150 1200 Burner output – kW Fig. 26 RS 120/E ULX S10343 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 Burner output – kW Fig. 27 20205255...
- Page 31 Installation RS 160/E ULX S10353 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950 2000 Fig. 28 Burner output – kW RS 200/E ULX S10354 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950 2000 2050 2100 2150 2200 2250 2300 2350 2400 2450 2500 Burner output –...
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Page 32: Electrical Wiring
Installation 4.13 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 33: Supply Cables And External Connections Passage
Installation 4.13.1 Supply cables and external connections 20201630 passage All the cables to be connected to the burner should be routed through cable grommets. See Fig. 30. Cable grommets can be used in different manners; for example: Three-phase power supply Consent/safety Minimum gas pressure switch Gas valve leak detection control kit... -
Page 34: 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 35: 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 boiler panel. 20172251 Close thermostats/pressure switches turn switch 4)(Fig. 8 on page 13) to position “(1) - ON”. Check that the lamps or testers connected to the solenoid valves, or the pilot lights on the solenoid valves, indicate that no voltage is present. -
Page 36: Output Upon Ignition
Start-up, calibration and operation of the burner 5.4.4 Output upon ignition Ignition point - RS 68 ULX - Ignition must occur at a lower output than the max. operation out- Maximum power input (kW) 1050 put. Regulations provide that the ignition output of this burner Gas motor/butterfly setting 8°... -
Page 37: Final Calibration Of The Pressure Switches
Start-up, calibration and operation of the burner Final calibration of the pressure switches 5.5.1 Air pressure switch Adjust the air pressure switch (Fig. 34) 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 38: Minimum Gas Pressure Switch
Start-up, calibration and operation of the burner 5.5.3 Minimum gas pressure switch Adjust the minimum gas pressure switch (Fig. 36) after having adjusted the burner, the gas valves and the gas train stabiliser. With the burner operating at maximum output: –... -
Page 39: Control And Display
Control and display Control and display Visualisation and programming mode 7.1.1 Normal mode 7.1.1.4 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 c: 12) and the relative diagnostic (in the example d: 0). -
Page 40: Info Mode
Control and display 7.1.1.5 Reset procedure The burner is in lockout when the red indicator light on the oper- ator panel is lit up, and the display visualises the lockout code (in the example alongside c: 4) and the relative diagnostics (in the example d: 3) alternately. -
Page 41: 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 46. must: The factory-set parameters are not visible. -
Page 42: Parameter Modification Procedure
Control and display 7.1.4.2 Assigning parameter levels The password must only be communicated to the The parameters level is subdivided into groups as shown in qualified personnel or the Technical Assistance Tab. O. Service, and must be kept in a safe place. Parameter WARNING 100: ParA... - Page 43 Control and display 7.2.0.1 Procedure for inserting and adjusting points on 7.2.0.2 CALC function the modulation curve The diagram (Fig. 38) shows how the fuel modulation curve is Nine adjustment/calibration points (P1 ÷ P9) can be inserted in modified if the values of point “P5” are changed. By keeping the “+”...
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Page 44: Start-Up Procedure
Control and display Start-up procedure Check that the operator panel display shows the heat request and “OFF Upr”: this means it is necessary to set the modulation curve of the burner. The values shown in the figure are purely for indi- cation purposes. - Page 45 Control and display Press “+” until point “P9” is reached. At the end of the "Start-up procedure" it is nec- Once point“P9” is reached wait for the display to show the flash- essary to carry out a "Backup", which is used to ing indicator “P9”...
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Page 46: 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 47: Restore
Control and display 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 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 48: 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 is shown on the 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 49 Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Eliminate visualisation error chronology To eliminate the visualisation, set the parameter to 1, then to 2 Modification Service Mode Answer 0: process successful...
- Page 50 Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Burner operation mode (fuel supply line, modulating/ stage, servomotors, etc.) -- = not defined (eliminate curves) 1 = Gmod 2 = Gp1 mod 3 = Gp2 mod...
- Page 51 Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Gas: Valve leak detection test 0 = test deactivated 1 = valve leak detection test at start up Modification Service Mode 2 = valve leak detection test at shutdown...
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Page 52: Operation
Control and display Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment • Error chronology: 701-725.03.Error class Reading only Info mode • Error chronology: 701-725.04.Phase Reading only Info mode •... -
Page 53: Motor Lockout
Control and display Motor lockout If the motor does not start, it could be because of a thermal relay intervention due to its incorrect calibration or problems with the motor or the main power supply, to release press the button of the thermal relay, see "Calibration of the thermal relay"... -
Page 54: 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 55: Checking The Air And Gas Pressure On The Combustion Head
Maintenance 8.2.4 Checking the air and gas pressure on the Gas leaks Make sure that there are no gas leaks on the pipes between the combustion head gas meter and the burner. To carry out this operation a pressure gauge must be used to measure the air and gas pressure at the combustion head, as Gas filter shown in Fig. -
Page 56: Opening The Burner
Maintenance Opening the burner Loosen the 4 screws 1)(Fig. 41) and remove the cover 2); assemble the two extensions supplied on the slide bars 4) Disconnect the electrical supply from the burner and tighten the screws 7); by means of the main system switch. ... -
Page 57: 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 58 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27 ...system Recommended measures code Valve leak detection control Leak test V1 leaks Check if the valve on the side of the gas has any leaks. Check the wiring and make sure that the circuit is open. Leak test Check if the valve on the side of the burner has any leaks.
- Page 59 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27 ...system Recommended measures code Safety circuit /Burner flange open, POC - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light, POC - Alarm lockout at start Safety circuit open /Burner flange open, air pressure, POC - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light,...
- Page 60 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27 ...system Recommended measures code The reference of the air servomotor was not successful. It was not possible to reach the reference point. Reference error of the air servomotor 1.
- Page 61 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27 ...system Recommended measures code Check the contacts: 1. Control box connected to the power supply: the fan output must be without voltage. The safety relay contacts have joined together or the 2.
- Page 62 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27 ...system Recommended measures code Carry out a reset, repeat and check the last setting of the EEPROM writing access internal error parameters. If the error arises repeatedly, replace the flame control.
- Page 63 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27 ...system Recommended measures code The output of the TÜV test must be lower than the minor output 2 (-2) The TÜV test default output is too low limit The output of the TÜV test must be greater than the upper 3 (-3)
- Page 64 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 27 ...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 Tab.
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Page 65: A Appendix - Accessories
Appendix - Accessories Appendix - Accessories 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 66: B Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Reference indication REC 27... operational layout REC 27... operational layout REC 27... operational layout Electrical wiring that is the responsibility of the installer RWF 50... functional layout Indication of references / 1 . - Page 67 Appendix - Electrical panel layout 20205255...
- Page 68 Appendix - Electrical panel layout 20205255...
- Page 69 Appendix - Electrical panel layout 20205255...
- Page 70 Appendix - Electrical panel layout 20205255...
- Page 71 Appendix - Electrical panel layout 20205255...
- Page 72 Appendix - Electrical panel layout 20205255...
- Page 73 Appendix - Electrical panel layout Wiring layout key Flame control for the air/fuel ratio XPGVP Gas pressure switch connector for valve leak detec- tion 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...