Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Riello RS 68/EV ULX
Summary of Contents for Riello RS 68/EV ULX
- Page 1 Installation, use and maintenance instructions Forced draught gas burners Modulating operation CODE MODEL TYPE 20205444 RS 68/EV ULX S041T2 20205447 RS 120/EV ULX S042T2 20205450 RS 160/EV ULX S043T2 20205451 RS 200/EV ULX S044T2 20205886 (3) - 10/2023...
- 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 Air / fuel adjustment ..............................35 5.4.1 Air adjustment for maximum output ...........................35 5.4.2 Air/fuel adjustment and output modulation system ....................35 5.4.3 Burner adjustment..............................35 5.4.4 Output upon ignition ..............................35 5.4.5 Maximum output ................................35 5.4.6 Minimum output .................................36 Final calibration of the pressure switches ........................36 5.5.1 Air pressure switch..............................36 5.5.2...
-
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/EV ULX TL FS2 3 ~ 400V - 50Hz Inverter 20205444 RS 120/EV ULX TL FS2 3 ~ 400V - 50Hz Inverter 20205447 RS 160/EV ULX TL FS2... -
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/EV ULX 2" 330.35 607 1245 RS 120/EV 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/EV ULX RS 68/EV ULX RS 120/EV ULX RS 120/EV ULX 1175 RS 160/EV ULX... - Page 12 Technical description of the burner RS 160/EV ULX S10340 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 Thermal power - kW Fig. 4 RS 200/EV ULX S10341 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 Thermal power - kW Fig.
-
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 19 20 6 15 20208910 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 20208967 Fig. 8 Flame control 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 20205886... -
Page 16: 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 17 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 18: Operation Sequence Of The Burner
Technical description of the burner 3.13 Operation sequence of the burner Funzionamento Controllo di Avviamento Spegnimento tenuta TSA1 Numero fase Timer - Risoluzione - Rapporto 0.6s Timer 1 (parametri) Timer 2 (parametri) Timer 3 = tempo max. di fase Spina RAST Segnali di ingresso Numero PIN Termostato/pressostato... -
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/EV 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
3) behind the flame disc. 4.9.1 Central gas setting The factory setting for the central gas is with the following passa- ge holes of the disc 1) in Fig. 21. RS 68/EV ULX 7 mm RS 120/EV ULX 10.5 mm RS 160/EV ULX... -
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/EV 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/EV 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/EV ULX S10342 1000 1050 1100 1150 1200 Burner output – kW Fig. 26 RS 120/EV ULX S10343 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 Burner output – kW Fig. 27 20205886...
- Page 31 Installation RS 160/EV 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/EV 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 –...
-
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 20209583 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: Single-phase power supply Consent/safety Minimum gas pressure switch Gas valve leak detection control kit... -
Page 34: Adjustment Fan Motor Covering With External Rpm
Installation 4.15 Adjustment fan motor covering with external rpm To calibrate the rpm sensor 6)(Fig. 32), 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 35: 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 36: 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. D8970 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 37: 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 38: Minimum Output
Start-up, calibration and operation of the burner Indication for the burner ignition To determine the calibrations to use at the first start, proceed as follows: In Tab. L the calibrations of the air and gas servomotors at the Determine the maximum power required by the burner. ignition point for each model are summarized according to the Open the combustion head as indicated in Fig. -
Page 39: 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. 36) 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 40: 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 41: 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 42: 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 48. must: The factory-set parameters are not visible. -
Page 43: 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 44 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. 39) 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 “+”...
-
Page 45: Modification Of Parameter "Acceleration / Deceleration Ramp
Control and display 7.2.1 Modification of parameter “acceleration / deceleration ramp” The burner leaves the factory with the parameters 522 (acceler- ation) and 523 (deceleration) already set. If the operator needs to modify them, proceed as follows: Access the Parameters Level referring to “Access procedure with password”... -
Page 46: 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 47 Control and display Press button “+” again: the display shows “CALC” for a few If you want to make the burner work on the entire modulation seconds. curve, press the “+” and “-” (ESC) keys simultaneously: in this way, parameter “546” will automatically be assigned the value of 100% and parameter “545”...
-
Page 48: 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 49: 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 50: 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 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 Default output for TÜV test: Modification / Not valid for TÜV test when output is activated 100% 0.1% Not defined...
- Page 52 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 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 53 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 Oil: Maximum oil pressure switch / POC Input 0 = deactivated Modification Service Mode 1 = Maximum oil pressure switch 2 = POC Oil: selection transformer ignition phase TA 0 = brief pre-ignition (Ph38)
-
Page 54: 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 Result of the sampling of the contact (codified in bits) Bit 0.0 = 1: Minimum pressure switch Bit 0.1 = 2: Maximum pressure switch Bit 0.2 = 4: Pressure switch control valves Bit 0.3 = 8: Air pressure switch... -
Page 55: Stopping Of The Burner
Control and display Stopping of the burner The burner can be stopped by: There are now two possibilities: intervening on the disconnecting switch of the electrical sup- – using the operator panel according to the manual lockout pro- ply line, located on the boiler panel; cedure on page 38;... -
Page 56: 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 57: 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 58: Opening The Burner
Maintenance Opening the burner Loosen the 4 screws 1)(Fig. 42) 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 59: 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 60 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37 ...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 61 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37 ...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 62 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37 ...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 63 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37 ...system Recommended measures code Check the contacts: 1. Flame control connected to the power supply: the fan output must be without voltage. The safety relay contacts have joined together or the 2.
- Page 64 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37 ...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 65 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37 ...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 66 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the REC 37 ...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.
-
Page 67: A Appendix - Accessories
Burner Code RS 68-200/EV ULX 3010344 Inverter kit (variable speed drive) Burner Max. output (kW) Code RS 68/EV ULX 20163060 RS 120/EV ULX 20163064 RS 160-200/EV ULX 20163071 Gas trains in compliance with EN 676 Please refer to manual. The installer is responsible for the addition of any safety device not foreseen in this manual. -
Page 68: B Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Reference indication Layout of unifilar output REC 37... operational layout REC 37... operational layout Electrical wiring that is the responsibility of the installer RWF 50... functional layout Indication of references / 1 . - Page 69 Appendix - Electrical panel layout 20205886...
- Page 70 Appendix - Electrical panel layout 20205886...
- Page 71 Appendix - Electrical panel layout 20205886...
- Page 72 Appendix - Electrical panel layout 20205886...
- Page 73 Appendix - Electrical panel layout 20205886...
- Page 74 Appendix - Electrical panel layout 20205886...
- Page 75 Appendix - Electrical panel layout Wiring layout key flame control for the air/fuel ratio Connector for output power regulator kit RWF Operator panel Operator panel connector Burner components XPGM Maximum gas pressure switch connector Boiler components XPGMin Minimum gas pressure switch connector Filter to protect against radio disturbance XPGVP Gas pressure switch connector for valve leak detec- tion control device...
- 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...