Riello RS 100/E MZ Installation, Use And Maintenance Instructions Download Page 29

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5.7

Operation sequence of the burner

List of the phases

Ph00

Lockout phase

Ph01

Safety phase

Ph10

t10 = closure in pause

Ph12

Standby

Ph22

t22 = Uphill train of the fan motor (fan motor = ON,
safety valve = ON)

Ph24

The burner moves to the pre-purging position

Ph30

t1 = pre-purging time

Ph36

The burner moves to the ignition position

Ph38

t3 = pre-ignition time

Ph40

TSA1 = safety time 1 (ignition transformer ON)

Ph42

TSA1 = safety time 1 (ignition transformer OFF), t42 =
pre-ignition time OFF

Ph = Phase

Ph44

t44 = interval time 1

Ph60

Operation

Ph62

t62 = max. time to reach the low flame (the burner
moves to the switch-off position)

Ph70

t13 = post-combustion time

Ph72

The burner moves to the post-purging position

Ph74

t8 = post-purging time

Ph80

t80 = emptying time (valve leak detection)

Ph81

t81 = atmospheric test time (valve leak detection)

Ph82

t82 = filling time (valve leak detection)

Ph83

t83 = pressure test time (valve leak detection)

Ph90

Standby time due to lack of gas

Checking of

seal

Operation

Switching off

Start-up

TSA1

Number of the phase

INP

IGNA

Thermostat/pressure switch

OUT

IGNA

Thermostat/pressure switch

Ionisation probe ION

Air pressure switch PA

Minimum gas pressure switch

Maximum gas pressure switch

Gas pressure switch for leak
detection PGVP

Alternative to leak detection CPI

safety TS

Fan motor MV

Ignition transformer TA

Shutoff valve

Safety valve V1

Adjustment valve V2

Pilot valve VP

Limit lockout

indicator TL

SERVO

fue

90°

Nominal load

Pos. of post-purging

Ignition load

Low flame

Pos. without load

0°

90°

Nominal load

Pos. of post-purging

Ignition load

Low flame

Pos. without load

0°

Signal ON

Signal OFF

Any signal is allowed

Fig. 34

D7727

PGmin

PGM

Start-up, calibration and operation of the burner

Summary of Contents for RS 100/E MZ

Page 1: ... T2 RS 70 E MZ 828 T2 RS 100 E MZ 829 T2 RS 100 E MZ 829 T2 RS 130 E MZ 830 T2 RS 130 E MZ 830 T2 3787630 3787632 RS 190 E 836 T2 3789200 3789210 RS 250 E MZ 866 T1 3789201 3789211 RS 250 E MZ 866 T1 3789230 3789240 RS 250 E MZ 866 T1 3789231 3789241 RS 250 E MZ 866 T1 GB Progressive two stage or modulating operation ...

Page 2: ...cording to the European Directives GAD 90 396 EEC Gas Devices Directive MD 98 37 EEC Machine Directive LVD 73 23 EEC 2006 95 EEC Low Voltage Directive EMC 89 336 EEC 2004 108 EEC Electromagnetic Compatibility such products are marked as follows Legnago 26 06 2007 CE 0085XXXXX for RS 70 E MZ CE 0085XXXXX for RS 100 E MZ CE 0085XXXXX for RS 130 E MZ CE 0085XXXXX for RS 190 E CE 0085XXXXX for RS 250 ...

Page 3: ...f the thermal relay 19 5 Start up calibration and operation of the burner 20 5 1 Notes on safety for the first start up 20 5 2 Operations before start up 20 5 3 Burner start up 21 5 4 Final calibration of the pressure switches 21 5 5 Operator Panel with LCD display 23 5 6 Visualisation and programming modes 24 5 7 Operation sequence of the burner 29 5 8 Start up procedure 30 5 9 CALC function 32 5...

Page 4: ...or long term health risks This symbol indicates operations which if not carried out correctly may cause damage to the machine and or injury to people GENERAL DANGERS DANGER WARNING CAUTION This symbol indicates operations which if not carried out correctly lead to electric shocks with lethal consequences ENVIRONMENTAL PROTECTION This symbol gives indications for the use of the machine with respect...

Page 5: ...ring with the burner components is not al lowed apart from the parts requiring maintenance Only those parts envisaged by the manufacturer can be re placed 2 2 Personnel training The user is the person body or company that has acquired the machine and intends to use it for the specific purpose He is re sponsible for the machine and for the training of the people work ing around it The user undertak...

Page 6: ...B P ES GB IE PT II2H3P NL II2L3B P FR II2Er3P DE II2ELL3B P BE I2E R B I3P LU II2E3B P Range R Size Fuel S L LS Natural gas Light oil Light oil Natural gas Adjustment E Electronic cam EV Electronic cam and variable speed with Inverter Head TC Standard head TL Long head Flame control system FS1 FS2 Standard 1 stop every 24h Continuous operation 1 stop every 72h Electrical supply of the system 3 400...

Page 7: ...2800 230 400 4 5 15 8 9 1 126 72 2800 230 400 5 5 21 3 12 3 144 83 Ignition transformer V1 V2 I1 I2 230 V 1 x 8 kV 1 A 20 mA Absorbed electrical power kW max 1 6 2 0 2 8 5 3 6 5 Protection level IP 44 Compliance with EC Directives 98 37 90 396 89 336 2004108 73 23 2006 95 Noise level 3 dBA 75 0 77 0 78 5 83 1 83 0 Type approval class 2 EN 676 EC in progress in progress in progress in progress clas...

Page 8: ...checks are recommended Fig 3 Pressure in combus tion chamber mbar Fig 4 The maximum output is chosen within area A and B for RS 130 E MZ of the diagram Note to use area B RS 130 E MZ as well the pre calibration of the combustion head is necessary as explained in Chap 4 6 The minimum output must not be lower than the minimum limit of the diagram Warning The firing rate was obtained considering a ro...

Page 9: ...essure socket 23 Flame sensor probe 24 Air damper 25 Fan air inlet 26 Screws to secure fan to pipe coupling 27 Gas input pipe 28 Gas butterfly valve 29 Boiler fixing flange 30 Flame stability disc 31 Bracket for application of output regu lator RWF40 32 Extensions for guides 20 only for TL versions seen from A A D8038 RS 250 E MZ RS 190 E RS 70 100 130 E MZ RS 190 E RS 250 E MZ Fig 5 The burner is...

Page 10: ...al Data Fig 6 D8266 NOTE The first start up like every further operation for the internal settings of the control box requires access by means of a password and is only to be carried out by personnel of the Technical Assistance Service who have been specifically trained in the internal program ming of the tool The information for the first start up is given below WARNING Electrical supply AC 230 V...

Page 11: ...oupling They are commanded by the control box which constantly checks their position by means of a return signal from the optic sensor inside the ser vomotor For this reason it is absolutely forbidden to remove the cover of the servomotors The position in degrees of the servomotors can be seen on the display of the Operator Panel See Ch 5 18 Parameter 922 index 0 for fuel servomotor index 1 for ai...

Page 12: ...stallation 1 is preferable as it is the only one that al lows the maintenance operations as described in this manual Installations 2 3 and 4 permit operation but make maintenance and inspection of the combustion head more difficult Any other position could compromise the correct opera tion of the appliance Installation 5 is prohibited for safety reasons All the installation maintenance and disasse...

Page 13: ...ording to the indications provided by the manufacturer of the boiler and in any case it must be greater than the thickness of the boiler door complete with its refractory The available lengths L are those indicated in the table below For boilers with front flue passes 13 or flame inversion cham bers a protection in refractory material 11 must be inserted between the boiler refractory 12 and the bl...

Page 14: ...sulating gasket 8 Fig 11 sup plied Use the 4 screws supplied with a tightening torque of 35 40 Nm after protecting their thread with anti seize products The seal between burner and boiler must be airtight After the start up see Ch 5 8 check there is no leakage of flue gases into the external environment 4 6 Pre calibration of the combustion head only for the model RS 130 E MZ Fig 12 D1209 Probe El...

Page 15: ...ner output 1300 Mcal h approx 1500 kW fit the discs 1 2 Fig 16 supplied as part of the standard equipment removing the internal tube 3 Fig 16 If the mains gas pressure is low the head can be left in the standard set up limiting the modula tion minimum to 450 Mcal h approx 520 kW Example RS 70 E MZ burner output 581 kW According to diagram Fig 17 the gas and air adjustments for this output are carr...

Page 16: ...ipe coupling burner in the position shown in Fig 18 connect the plug of the servomotor 14 Fig 11 and tighten the cable grommet 15 Fig 11 connect the socket of the maximum gas pressure switch refit the screws 2 on the guides 3 fix the burner to the pipe coupling with the screws 1 When fitting the burner on the two guides it is advisable to gently draw out the high voltage cable and flame detection ...

Page 17: ...f the gas train D722 Fig 19 WARNING P2 5 6B 8 8 6A P2 P1 P1 13 12 10 12 10 1 2 3 4 7 9 1 2 3 4 7 13 11 11 L1 L L1 L P3 D3735 1 Gas input pipe 2 Manual valve 3 Vibration damping joint 4 Pressure gauge with pushbutton cock 5 Filter 6A Threaded multibloc including filter can be replaced safety valve working valve pressure adjuster 6B Flanged multibloc including safety valve working valve pressure adj...

Page 18: ...se a lockout due to firing failure The burners RS 70 100 130 190 250 E have been type approved for intermittent operation This means they should compulsorily be stopped at least once every 24 hours to enable the control box to perform checks of its own start up efficiency Normally the boiler s thermostat pressure switch ensures the stopping of the burner If this is not the case it is necessary to ...

Page 19: ... the calibration refer to the table given in electrical layout no 6 in Appendix A If the minimum value of the scale of the thermal relay is greater than the rating absorption of the motor protection is still ensured This arises when the power supply of the motor is 400 V To reset in the case of an intervention of the thermal relay press the button 1 of Fig 22 Fig 22 2 1 D8267 4 ...

Page 20: ...oint 1 Fig 27 of the minimum gas pressure switch Take the vent tube outside the building so you can notice the smell of gas Connect two lamps or testers to the two gas line so lenoids to check the exact moment at which voltage is supplied This operation is unnecessary if each of the two so lenoids is equipped with an indicator light that sig nals voltage passing through The first start up of the b...

Page 21: ...e The connection of the pressure gauge is shown in Fig 29 The standard configuration is that with the air pressure switch connected in absolute mode Note the presence of a T con nection not supplied In certain applications in strong depression situations the con nection of the pressure switch does not allow it to change over In this case it is necessary to connect the pressure switch in dif ferent...

Page 22: ...and repeat the start up of the burner If the burner locks out again turn the knob clockwise again by 1 mbar Minimum gas pressure switch Adjust the minimum gas pressure switch after having per formed all other burner adjustments with the pressure switch set to the start of the scale Fig 31 With the burner operating at maximum output increase adjust ment pressure by slowly turning the relative knob ...

Page 23: ...crolling of the parameters list Increase of value Access to a higher point of the modulation curve Scrolling of the parameters list Exit function ESC press and simultaneously Non confirmation of the value Access to a higher level of the menu Lock out lamp Flame presence Valve powered Ignition transformer powered Fan motor powered Pre heater active Request for heat Info Mode active Service Mode act...

Page 24: ...various phases of the start up ignition and switch off of the burner In the example alongside the display indicates that the burner is in phase 30 see the diagram of Fig 34 and there are 12 s until the next phase The burner is working in the requested load position in the example alongside 78 4 The display visualises alternately the error code in the example alongside c 12 and the relative diagnos...

Page 25: ...the burner does not stop immediately but the switch off phase is activated P m h m l l h D7712 P m h m l l h D7713 D7746 P m h m l l h CAUTION Manual operation procedure After the adjustment of the burner and the setting of the points on the modulation curve it is possible to manually check the opera tion of the burner along the entire curve Example To emerge from Manual mode press simultaneously ...

Page 26: ...ss the i reset key for more than 3 s Release the key immediately when the display shows SEr 954 Flame intensity 121 Manual setting of output Not defined automatic operation 922 Position of the servomotors expressed in degrees symbol 0 fuel 1 air 161 Number of errors 701 725 Log of the errors 701 725 01 Code Service Mode 3 s P m h m l l h D7719 reset D8273 Operating procedure in Info and Service Mo...

Page 27: ... Process information Visualisation of information for the remote man agement of the burner All the parameters are checked in the factory Modification tampering may compromise the good operation of the burner and cause injury to people or damage to things In any case modifications must be carried out by qualified personnel P m h m l l h D7722 DANGER Start up calibration and operation of the burner ...

Page 28: ...Note the unit of measure ment of the time is not vis ualised but is understood in seconds Press the key and increase the value to 25 seconds flashing Press the key i reset to confirm and store To return to the list of parameters press simulta neously the keys and esc P m h m l l h D7757 D7760 l h l m m h P P m h m l l h D7758 P m h m l l h D7759 Access the Parameters level group 400 referring to A...

Page 29: ...Ph80 t80 emptying time valve leak detection Ph81 t81 atmospheric test time valve leak detection Ph82 t82 filling time valve leak detection Ph83 t83 pressure test time valve leak detection Ph90 Standby time due to lack of gas Checking of seal Operation Switching off Start up t1 TSA1 Number of the phase INPUT SIGNALS Thermostat pressure switch OUTPUT SIGNALS Thermostat pressure switch Ionisation pro...

Page 30: ...e factory as it is optional Phase 30 The count of the pre purging time pre set in the factory begins Phase 36 The burner goes to the ignition position point P0 defined in the table on page 31 the display visualises the indication P0 flashing If the value proposed is suitable confirm Otherwise modify the ignition point see Procedure for inserting and adjusting points on the modulation curve Warning...

Page 31: ...vised to measure gas delivery and check that the output is about 50 of the maximum output If this is not the case work also on the gas valve stabiliser in this case however it is necessary to revise the calibrations of all the points previously set Once you have arrived at point P9 if the maximum output is not as you wish work on the gas valve stabiliser in this case however it is necessary to rev...

Page 32: ...er 10 ignitions with lockout the delivery indicated on the meter must be equal to or less than Maximum output The MAX output must be set within the firing rate of Fig 3 Gas adjustment Measure the gas delivery on the meter As a general rule this value can be found on the table on page 52 just read the gas pressure on the pressure gauge Fig 38 and follow the indications given on page 52 If it is nec...

Page 33: ...s into lockout 5 14 Stopping of the burner The burner can be stopped by intervening on the disconnecting switch of the electrical sup ply line located on the boiler panel removing the hood and working on the switch 0 1 of Fig 28 removing the transparent protection that covers the Operator Panel after loosening the relative screw and using the Panel itself according to Manual lockout procedure 5 15...

Page 34: ...dification 0 1 1 0 Parameters Mode 126 Brightness of display 1 Modification 0 100 1 75 Parameters Mode 128 Fuel meter Led pulse valence led pulses volumetric flow units 1 Modification 0 400 0 01 0 Parameters Mode 130 Eliminate visualisation error chronology To eliminate the visualisation set the parameter to 1 then to 2 Answer 0 Process successful Answer 1 Time out of 1_2 Sequence 1 Modification 5...

Page 35: ...supply to control box 1 h Reading only 0 h 999999h 1 h 0 h Info Mode 164 Total number of start ups that can be reset 1 Reset 0 999999 1 0 Info Mode 166 Total number of start ups 1 Reading only 0 999999 1 0 Info Mode 167 Volumetric delivery of fuel in the selected unit of measurement that can be reset 1 Reset 0 99999999 1 0 Info Mode 200 Checks on the burner 201 Burner operation mode fuel supply li...

Page 36: ... valve leak detection 1 s Modification 0 2 s 3 s 0 2 s 3 s Parameters Mode 245 Gas Pressure test time valve leak detection 1 s Modification 0 2 s 60 s 0 2 s 10 s Parameters Mode 261 Oil Selection of flame sensor 0 QRB QRC 1 ION QRA 1 Modification 0 1 1 0 Parameters Mode 265 Oil Pre purging time 1 s Modification 15 s 60 min 0 2 s 15 s Parameters Mode 266 Oil Pre ignition time 1 s Modification 0 2 s...

Page 37: ...01 725 03 Error class 25 Reading only 0 6 1 0 Service Mode Error chronology 701 725 04 Phase 25 Reading only 0 255 1 0 Service Mode Error chronology 701 725 05 Start up meter 25 Reading only 0 99999999 1 0 Service Mode 725 Error chronology 701 725 06 Load 25 Reading only 0 100 0 1 0 Service Mode 900 Process information 903 Current output Index 0 fuel Index 1 air 2 Reading only 0 100 0 1 0 Paramete...

Page 38: ...ernal error Carry out a reset if the error arises repeatedly replace the control box 70 Fuel air checking error Calculation position in modulation 21 Invalid load No valid load 26 Curve points not defined Adjust the curve points of all the actuators 71 Special position not defined 0 Standby position Set the standby position of all the servomotors used 1 Post purging position Set the post purging p...

Page 39: ...e 1 Circuit open Circuit open shown on the servomotor connection 1 Check the wiring Bit 3 Valence 8 Curve too steep in terms of train ratio The slope of the curve can correspond to a maximum position modification of 31 between 2 points of the modulation curve Bit 4 Valence 16 Deviation of section compared with the last reference Overloading of the servomotor or servomotor subjected to mechanical t...

Page 40: ... of fuel limiting meter input Too many disturbance impulses on the input of the fuel meter Improve the electromagnetic compatibility 121 124 EEPROM access internal error Carry out a reset repeat and check the last setting of the parameters Restore the group of parameters If the error arises repeatedly replace the control box 125 EEPROM reading access internal error Carry out a reset repeat and che...

Page 41: ...he reset and backup 255 Interruption owing to time out during the restoration Carry out a reset check the connections and repeat the backup 146 Time out of the system automation interface Refer to the Modbus User Documentation A7541 1 Modbus time out 2 Reserved 165 Internal error 166 0 Watchdog reset internal error 167 Manual lockout The control box has been manually blocked no error 1 Manual lock...

Page 42: ... the burner requires an analysis of the flue gases Significant differences with respect to the previous measurements indicate the points where more care should be exercised during maintenance Gas leaks Make sure there are no gas leaks on the conduit between the gas meter and the burner Gas filter Replace the gas filter when it is dirty Flame inspection window Clean the glass of the flame inspectio...

Page 43: ... and electrode then pull the burner back completely At this point it is possible to extract the inner part 5 after having removed the screw 6 7 4 Closing the burner Push the burner up to approximately 100 mm from the pipe coupling Reinsert the cables and slide the burner as far as the stop Connect the plug of the servomotor 7 and tighten the grom met 8 Connect the socket of the maximum gas pressur...

Page 44: ...Ionisation probe connector F1 Fan motor thermal relay G1 Load indicator G2 Communication interface for Modbus system H Remote lockout signal ION Ionisation probe IN Manual burner arrest switch K1 Clean contacts output relay burner switched on K2 Clean contacts output relay burner lockout KM Fan motor contact maker MV Fan motor PA Air pressure switch PE Burner earth PGM Maximum gas pressure switch ...

Page 45: ...45 GB Appendix Electrical panel layout A ...

Page 46: ...46 GB Appendix Electrical panel layout A ...

Page 47: ...47 GB Appendix Electrical panel layout A ...

Page 48: ...48 GB Appendix Electrical panel layout A ...

Page 49: ...49 GB Appendix Electrical panel layout A ...

Page 50: ... as standard equipment with the burner Continuous Purging Kit Code 3010094 Pipes Kit for flame inversion boilers Parameter to be checked Probe Output Regulator Adjustment field Type Code Type Code Temperature 100 500 C PT 100 3010110 RWF40 3010414 Pressure 0 2 5 bar 0 16 bar Output probe 4 20 mA 3010213 3010214 Gas train Gas train coupling on burner Gas train burner adapter Code Model Ø RS 70 E RS...

Page 51: ...C 3010166 465 2290 kW RS 250 E MZ TC 3010411 600 2700 kW RS 250 E MZ TL Burner Combustion head Kit Code RS 70 E MZ TC in progress RS 70 E MZ TL RS 100 E MZ TC in progress RS 100 E MZ TL RS 130 E MZ TC in progress RS 130 E MZ TL RS 190 E TC 3010297 RS 250 E MZ TC RS 250 E MZ TL Burner Kit Code Standard head length Head length obtained with the kit RS 70 E MZ in progress 250 mm 385 mm RS 100 E MZ in...

Page 52: ... socket pressure 1 Fig 40 Add this value to the estimated pressure in the combustion chamber Example RS 190 E Maximum output required 2000 kW Natural gas G 20 PCI 9 45 kWh Sm3 Combustion head adjusted according to the diagram of Fig 17 Gas pressure at output of 2000 kW taken from table RS 190 E column 1 11 5 mbar Pressure in combustion chamber 3 0 mbar 11 5 3 0 14 5 mbar pressure required at test ...

Page 53: ...cessary to reduce the output of the burner The reduction in output is accompanied by a reduction in the combustion chamber pressure Qr reduced output H1r reduced pressure Example 5 reduction in output Qr Q x 0 95 H1r H1 x 0 95 2 With the new values Qr and H1r repeat steps 2 5 Warning the combustion head should be adjusted in relation to the equiv alent output Qe Qe Q F kW H3 H2 x F mbar H1r H1 x Q...

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Page 56: ...RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www rielloburners com Subject to modifications ...

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