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Riello 20155654, Installation, Use And Maintenance Instructions

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Riello 20155654 Installation, Use And Maintenance Instructions Download Page 6

20155699

4 

GB

Declarations

Declaration of Conformity in accordance with ISO / IEC 17050-1

These products are in compliance with the following Technical Standards:
• EN 12100
• EN 676
According to the European Directives:
MD

2006/42/EC Machine 

Directive

LVD

2014/35/EU 

Low Voltage Directive

EMC 2014/30/EU Electromagnetic 

Compatibility

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

1

Declarations

Summary of Contents for 20155654

Page 1: ...ation use and maintenance instructions 20155699 3 08 2021 Forced draught gas burners Modulating operation CODE MODEL 20155654 RS 310 E FGR 20155657 RS 410 E FGR 20160534 RS 510 E FGR 20155659 RS 610 E...

Page 2: ...Original instructions...

Page 3: ...tio BT330 16 4 13 Burner operating sequence 17 4 14 Servomotor 662R5 18 4 15 Calibration of the thermal relay 18 5 Installation 19 5 1 Notes on safety for the installation 19 5 2 Handling 19 5 3 Preli...

Page 4: ...of check sums 38 7 4 5 Serial number 38 7 4 6 Positions of actuators 38 7 4 7 Check digital inputs outputs 39 7 4 8 Digital outputs 40 7 5 MANUAL menu path 41 7 5 1 Fault indication 41 7 6 SETTINGS me...

Page 5: ...59 9 2 5 Checking the air and gas pressure on the combustion head 59 9 2 6 Safety components 59 9 3 Opening the burner 60 9 4 Closing the burner 60 10 Faults Possible causes Solutions 61 10 1 List of...

Page 6: ...th the following Technical Standards EN 12100 EN 676 According to the European Directives MD 2006 42 EC Machine Directive LVD 2014 35 EU Low Voltage Directive EMC 2014 30 EU Electromagnetic Compatibil...

Page 7: ...ed out correctly may cause damage to the ma chine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not car ried out correctly lead to electric shocks wit...

Page 8: ...vent of damage to things or injury to people if such damage injury was due to any of the following causes incorrect installation start up use and maintenance of the burner improper incorrect or unreas...

Page 9: ...intenance Only those parts envisaged by the manufacturer can be replaced 3 2 Personnel training The user is the person body or company that has acquired the machine and intends to use it for the speci...

Page 10: ...ol system FS1 FS2 Standard 1 stop every 24 h Continuous working 1 stop every 72 h Electrical supply of the system 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 R S 310 E TC FS1 3 400 50...

Page 11: ...1 74 7 53 1 79 2 59 7 89 1 77 6 115 8 Operation FS1 Intermittent min 1 stop in 24 hours Standard applications Boilers water steam diathermic oil Ambient temperature C 0 50 Combustion air temperature...

Page 12: ...nical description of the burner 4 5 Burner weight The weight of the burner complete with its packaging is shown in Tab D Tab D Model kg RS 310 E FGR 265 RS 410 E FGR 265 RS 510 E FGR 265 RS 610 E FGR...

Page 13: ...n is reference for the refractory thickness of the boiler door Tab E Fig 2 20131490 mm A B C D E F G H I L M N O P R S RS 310 E 1178 465 178 306 520 DN65 1185 790 346 1015 615 528 290 177 890 DN100 RS...

Page 14: ...510 E FGR 680 RS 610 E FGR 1000 WARNING The firing rate value Fig 3 has been obtained considering an ambient temperature of 20 C an atmospheric pressure of 1013 mbar approx 0 m a s l and with the com...

Page 15: ...st boilers accord ing to EN 676 regulations In Fig 4 you can see the diameter and length of the test combus tion chamber Example RS 510 E Output 5000 kW diameter 100 cm length 5 m 4 9 Burner equipment...

Page 16: ...ead air pressure test point 20 Maximum gas pressure switch with pressure test point 21 ignition pilot 22 Hinge for opening the burner 23 Pressure test point for air pressure switch 24 Combustion head...

Page 17: ...tch 6 Ignition transformer 7 Free contact relay 8 Direct start up line contactor 9 Star delta start up line contactor 10 Thermal relay with reset button 11 Delta contactor star delta start up 12 Star...

Page 18: ...will take suitable action e g switch off the system manually These operating instructions describe many possible appli cations and functions and should be used as guidelines Carry out functional test...

Page 19: ...3 X01 X02 X25 X24 S9612 Any condition t1 Waiting time for safety circuits consent boiler fuel t2 Opening time of the gas valve with sealing control active 2 4 s t3 Servomotor opening time 30 60 s t4 A...

Page 20: ...SET button 1 of Fig 10 The red TEST button 3 opens the NC 95 96 contact and stops the motor WARNING To avoid accidents material or environmental damage observe the following instructions Avoid opening...

Page 21: ...must be free from hazardous mixes e g chloride fluoride halo gen if present it is highly recommended to carry out cleaning and maintenance more frequently WARNING The handling operations for the burne...

Page 22: ...lining 2 5 Fig 14 is not necessary unless expressly requested by the boiler manufacturer Tab I 5 6 Securing the burner to the boiler Fit the heat insulation supplied onto the blast tube 4 Fig 14 Fit...

Page 23: ...and release the pilot pipe 5 and the cable of electrode 11 D fully open the burner as in Fig 15 E undo the screw 4 with pressure test point F release the head by lifting it from its housing 3 then ta...

Page 24: ...gas butterfly valve The correct position is indicated in Fig 17 WARNING Check that the pilot diffuser and the electrode are placed as in Fig 16 according to the dimensions indicated 36 1 mm Fig 16 Pi...

Page 25: ...with central air gas adjust ment The factory setting is the following AIR notch 9 GAS notch 0 Only for specific cases to change the central gas setting do as follows loosen the screws 1 and rotate the...

Page 26: ...R control valve and the FGR shut off valve if used There must be sufficient condensate drip legs and catch space volume of drip legs to prevent the condensation from flowing through the control valves...

Page 27: ...3 x 4 5 13 5 m to account for bends We then obtain a maximum pipe value of 16 5 m You understand that pipe diameter is too small so we must choose a 8 diameter Maximum allowed pipe length FGR 75 3 x...

Page 28: ...1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upline pressure of valves adjuster P3 Upstream pressure of the filter L Gas train suppli...

Page 29: ...n installation DANGER Disconnect the electrical power using the main switch Check that there are no gas leaks Pay attention when handling the train danger of crushing of limbs Make sure that the gas t...

Page 30: ...ble Tab L for the burner in question Read on the right column 1 the pressure at the test point P1 Fig 26 Add this value to the estimated pressure in the combustion chamber Example for RS 410 E FGR wit...

Page 31: ...to stop the FS1 burner at least once every 24 hours Refer to the wiring diagrams The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system mad...

Page 32: ...pressure switches and set the selector 16 Fig 6 on page 15 to ON As the burner is not fitted with a device to check the sequence of the phases it may be that the rotation of the motor is incorrect As...

Page 33: ...After completing the settings of the fuel air ratio control curves without flue gas recirculation FGR the actual settings with an active actuator s channel 3 can now be made Since this might have an...

Page 34: ...utput 3 MIN output 4 Intermediate outputs between Min and Max 5 Air pressure switch 6 Maximum gas pressure switch 7 Minimum gas pressure switch 6 5 4 Output upon ignition Ignition must occur at a lowe...

Page 35: ...with a pressure gauge The connection of the pressure gauge is shown in Fig 29 The standard configuration is that with the air pressure switch con nected in absolute mode Note the presence of a T conn...

Page 36: ...e the cock of the gas pressure test point used for the measurement open completely the manual gas cock 6 6 4 PVP pressure switch kit Adjust the pressure switch for the leak detection control PVP kit F...

Page 37: ...nu in the menu window Transfer set ting values by pressing ENTER key in a parameter window Use a flushing red ENTER key to release a fault inter locker If the ENTER key is permanently lit red a fault...

Page 38: ...ls Display operating hours Use cursor keys to select menu and press ENTER to confirm The display shows the System Information menu window 1 Display operating hours selected 2 Number of burner start up...

Page 39: ...flashing Press ENTER Taste BT300 is not locked anymore Changing from fault unlock to main menu A fault is pending and the ERROR key is flashing Press BACK key ENTER key isn t flashing any more The di...

Page 40: ...more parameters which was lying in the corresponding access level changed 7 4 5 Serial number Display serial number Use cursor keys to select menu and press ENTER to confirm The display shows the Ser...

Page 41: ...pressure min present yes terminal X08 Call up 3rd page of inputs Use the cursor keys to select the next page and press EN TER to confirm The display shows the 3rd page of inputs 1 Digital inputs pict...

Page 42: ...on terminal X01 5 Oil valve 2 off terminal X02 6 Oil valve 3 off terminal X03 Call up 3rd page of outputs Use the cursor keys to select the next page and press EN TER to confirm The display shows pag...

Page 43: ...5 1 Fault indication Display burner faults Use cursor keys to select menu and press ENTER to confirm The display shows fault history selection menu 1 Burner fault pictogram selected Use keys to select...

Page 44: ...Pilot burner oil operation 3 Duration of post purge 4 Valve leakage test 5 Pilot burner gas operation Set pre purge period Use cursor keys to select menu and press ENTER to confirm The display shows...

Page 45: ...is transferred to the burner control sys tem Cancel parameter changes Select the Back key The change made to the parameter is not accepted The follow ing page appears 1 Pictogram UI300 2 Pictogram BT...

Page 46: ...2 to make settings in this function Accept or discard the entry Activate valve leakage test after flame OFF Use cursor keys to select menu and press ENTER to confirm Change the functional state ON OF...

Page 47: ...burner in oil operation 3 Press ENTER to accept settings NOTE you require access level 2 to make settings in this function Accept or discard the entry Configuration of actuating outputs Use cursor key...

Page 48: ...set positions The set point position of the first activated actuator is displayed inversely Use cursor keys to set the position of the selected ac tuator Use cursor keys to switch to a different actu...

Page 49: ...are saved You can select the next firing rate point NOTE set the other firing rate stages according to this procedure Delete firing rate curves In Settings menu path use cursor keys to select menu an...

Page 50: ...SING menu path Save dataset from BT300 Use cursor keys to select path and press ENTER to confirm The display shows the data processing menu 1 Pictogram save dataset from BT300 2 Pictogram write datase...

Page 51: ...isplays No connection between UI300 and BT300 1 UI300 User Interface pictogram 2 No connection symbol 3 BT300 burner control Display shown e g when using LSB remote software and com munication between...

Page 52: ...300 s mains potential You can set the configuration of connected flame sensors with DIP switches The burner firing rate controller function can be disabled if re quired In that case the regular firing...

Page 53: ...51 Lower limit P 52 Upper limit P 53 With activated option Control by atmospheric condition you may also implement external set point pre setting External Firing rate Input You can establish an exter...

Page 54: ...order to achieve this combine the control by atmospheric conditions with set point switch over 8 1 6 Start up sequence The firing rate controller has a start up cycle Fig 92 in order to slow down bur...

Page 55: ...1 8 Control range The control range is located around set point The content of Burner ON parameter is sub tracted from set point to form switch on value Upper control range parameter value P 0055 is...

Page 56: ...er is orientated by given controlled system Out of characteristics of the controlled system data can be deduced i e by experimental determination P share I share D share are added up and serve as adju...

Page 57: ...attenuation Stronger reaction with tendency to oscillate Faster start up with tendency to os cillate I term smaller Increase of attenuation Less reaction less tendency to os cillate Slower start up Ch...

Page 58: ...igit internal firing rate 10 V 20 mA 999 digit internal firing rate Connection external manual regular firing rate input termi nal 16 19 NOTE if 0 10 v input is used for the presetting of the firing r...

Page 59: ...ons initialisation not yet accomplished or aborted e g HW could not be initialised cannot receive any messages for at least 3 seconds CAN LED 2 Green OFF CAN Controller in Bus OFF No communication pos...

Page 60: ...ure opening position indicators that are activated when the electrical supply arrives 9 2 3 Checking and cleaning Combustion head Open the burner and make sure that all components of the combus tion h...

Page 61: ...combustion head as shown in Fig 100 9 2 6 Safety components The safety components should be replaced at the end of their life cycle indicated in the following table The specified life cycles do not r...

Page 62: ...order refit all burner components as they were originally assembled DANGER Disconnect the electrical supply from the burner by means of the main system switch DANGER Turn off the fuel interception tap...

Page 63: ...end of the second safety time 9 0 0 Flame signal does not appear during the first safety time 10 0 0 Flame signal does not appear at the end of the first safety time 11 0 0 Monitoring for parasitic l...

Page 64: ...ition 2 actuators are mixed up another problem inhibits the actuator to reach it s test position 320 1 1 Open broken wire at firing rate input 321 1 1 Open broken wire at feedback channel channel Chan...

Page 65: ...er 731 0 0 Ignition valve opens without pilot burner 732 0 0 Invalid signal combination at input terminals during operation 734 0 0 Pre ventilation period not respected 739 0 0 Leakage test main gas v...

Page 66: ...he fault again cut off the power supply from BT300 for a moment reconnect it and reset the fault subsequently 921 0 0 Relay driver self test output oil valve defect 922 0 0 Relay driver self test outp...

Page 67: ...e with EN 676 Please refer to manual A Appendix Accessories Burner Probe Adjustment field Code All models PT 100 temperature 100 500 C 3010110 All models 4 20 mA pressure 0 2 5 bar 3010213 All models...

Page 68: ...s 3 Layout of unifilar output 4 Layout of unifilar output 5 Operational layout 6 Operational layout 7 Operational layout 8 Operational layout 9 Electrical connections set by installer 10 Electrical co...

Page 69: ...67 20155699 GB Appendix Electrical panel layout 0 1 2 2 30 0 4 5 5 0 5 0 6 5 7 5 0 5 0 0 5 5 5 5 5 85 8 8 5 5 0 6 5 0 0 0 RS 310 E FGR...

Page 70: ...20155699 68 GB Appendix Electrical panel layout 0 1 2 2 30 0 4 5 5 0 5 0 6 5 7 5 0 5 0 0 5 5 5 5 5 85 8 8 5 5 0 6 5 0 0 0 RS 410 E FGR...

Page 71: ...69 20155699 GB Appendix Electrical panel layout 0 0 1 20 3 0 0 4 5 5 0 5 0 6 5 7 5 0 5 0 0 5 5 5 5 5 85 8 8 5 5 0 6 5 0 0 0 0 0 RS 510 E FGR...

Page 72: ...20155699 70 GB Appendix Electrical panel layout 0 0 1 20 3 0 0 4 5 5 0 5 0 6 5 7 5 0 5 0 0 5 5 5 5 5 85 8 8 5 5 0 6 5 0 0 0 0 0 RS 610 E FGR...

Page 73: ...71 20155699 GB Appendix Electrical panel layout RS 310 410 E FGR...

Page 74: ...20155699 72 GB Appendix Electrical panel layout RS 510 610 E FGR...

Page 75: ...73 20155699 GB Appendix Electrical panel layout 01 2 3 4506 7 891 01...

Page 76: ...20155699 74 GB Appendix Electrical panel layout...

Page 77: ...75 20155699 GB Appendix Electrical panel layout 0 0 0 1 1 1 2 1 3 1 1 1 1 1 1 1 41 4 4 1 1 2 1...

Page 78: ...20155699 76 GB Appendix Electrical panel layout 0 0 0 1 1 23 4567 23 4567...

Page 79: ...77 20155699 GB Appendix Electrical panel layout 01 2 30 3 1 2 0 40 20 22 2 3 5 636 078 40 9 025 7 5 5 8 11 5 A B B B...

Page 80: ...20155699 78 GB Appendix Electrical panel layout 0 12234 1 4 5 1 4 223 12 4 6 7 8 9 5 1 4 223 12 4 6 7 8 9 5 0 0 0 0...

Page 81: ...79 20155699 GB Appendix Electrical panel layout 0 12234 1 4 5 1 4 223 12 4 6 7 8 5 9 1 4 223 12 4 6 7 8 5 0 0 0 0...

Page 82: ...20155699 80 GB Appendix Electrical panel layout 0 1 2 0 0 3333 3333 3333 3333 4 3 5 6 75 8 3333 3333 3 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 8 8 76 8 8 8 8 6 58 7 A7 88 6 5 7 A7 88 6 5 7 A7 5B C 5...

Page 83: ...ngle starter triangle contactor KS1 Start triangle starter star contactor KST1 Star triangle starter timer K1 Clean contacts output relay burner switched on K2 Clean contacts output relay burner lock...

Page 84: ...p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com Manufacturing site Riello Heating Equipment Shanghai CO LTD No 388 Jinbai Road Jinshan Industrial Zone 201506 Shanghai...

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