Riello RS 160/EV BLU TC Installation, Use And Maintenance Instructions Download Page 2

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Original instructions

Summary of Contents for RS 160/EV BLU TC

Page 1: ...Installation use and maintenance instructions 20095002 3 08 2015 Forced draught gas burner Progressive two stage or modulating operation CODE MODEL TYPE 20094341 RS 160 EV BLU TC 94341X GB...

Page 2: ...Original instructions...

Page 3: ...of phases 17 4 13 Operator panel operation 17 4 13 1 Symbols description on the display 17 4 13 2 Buttons description 18 4 14 Servomotors SQM33 19 4 15 Inverter 20 4 15 1 LED status display 20 5 Insta...

Page 4: ...on 39 6 7 3 Modification of parameter acceleration deceleration ramp 39 6 8 Start up procedure 40 6 9 Backup Restore procedure 42 6 9 1 Backup 42 6 9 2 Restore 43 6 9 3 Parameter list 45 6 10 Steady s...

Page 5: ...following Technical Standards EN 676 EN 12100 and according to the European Directives MD 2006 42 EC Machine Directive LVD 2006 95 EC Low Voltage Directive EMC 2004 108 EC Electromagnetic Compatibilit...

Page 6: ...ied 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 wi...

Page 7: ...f 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 unreasonable...

Page 8: ...ce 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 specific pur...

Page 9: ...h Continuous operation 1 stop every 72h Electrical supply of the system 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Elec...

Page 10: ...LU PL II2E3B P DE II2ELL3B P FR II2Er3P AT CH CZ DK EE FI GR HU IS IT LT NO SE SI SK II2H3B P ES GB IE PT II2H3P NL II2L3B P Model RS 160 EV BLU Output 1 Max kW Mcal h 930 1860 800 1600 Min kW Mcal h...

Page 11: ...g 4 7 Firing rate The maximum output is chosen within area A of the diagram Fig 2 The minimum output must not be lower than the minimum limit of the diagram Fig 1 D1206 mm A B C D E F 1 G H I 1 L M N...

Page 12: ...it is necessary 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...

Page 13: ...boiler is EC type approved for boilers or ovens with combustion chambers of very different di mensions compared to those shown in the diagram of Fig 4 pre liminary checks are recommended 4 9 Burner e...

Page 14: ...or electrical wiring to be carried out by the installer 18 Air servomotor 19 Minimum air pressure switch differential operating type 20 Slide bars for opening the burner and inspecting the com bustion...

Page 15: ...harges must be avoided since they can damage the control box s electronic components when touched Installation notes Arrange the HV ignition cables separately as far as possible from the control box a...

Page 16: ...Ignition transformer Valve AC 230 V 50 60 Hz Max 5 A Single contact loading Fan motor contactor Rated voltage Nominal current Power factor AC 230 V 50 60 Hz 2A cos 0 4 Alarm output Rated voltage Nomi...

Page 17: ...2 5 Environmental conditions Storage Climatic conditions Mechanical conditions Temperature range Humidity DIN EN 60721 3 1 Class 1K3 Class 1M2 20 60 C 95 RH Transport Climatic conditions Mechanical c...

Page 18: ...on Ignition load Low flame Pos without load 0 S8887 Fig 7 Checking of seal Shutdown Operation Start up Timer Resolution Ratio Timer 1 parameters Timer 2 parameters Timer 3 max phase time Input signals...

Page 19: ...Ignition TA OFF Ph44 t44 interval time 1 Ph60 Operation Ph62 The burner moves to the switching off position Ph70 t13 post combustion time Ph72 The burner moves to the post purging position Ph74 t8 po...

Page 20: ...lockout Access to a lower level of the menu To navigate in Service or Info Mode and allows the selection of the parameter flashing symbol press for 1 s access to a lower level of the menu press from 1...

Page 21: ...unctional low voltage section The static torque is reduced when the electrical supply of the actuator is switched off The housing cover may only be removed for short periods of time for wiring or when...

Page 22: ...lay Key The symbols used to indicate the states of the LED have the fol lowing meaning WARNING To avoid accidents material or environmental damage observe the following instructions Avoid opening modi...

Page 23: ...e 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 burner can...

Page 24: ...nt direction compared with the others With the kit this second group of tubes is substituted so that all the tubes are the same After assembling the kit check its efficiency by measuring the flue gase...

Page 25: ...ust not compromise the extraction of the blast tube For boilers with a water cooled frontal a refractory cover is not necessary 11 12 Fig 19 unless expressly requested by the boiler manufacturer 5 6 P...

Page 26: ...es 5 by about 100 mm disconnect the electrode lead then unthread the burner completely from the guides Once this operation has been carried out fix the flange 9 to the boiler plate interposing the ins...

Page 27: ...d corresponds with the front surface 5 of the flange Central gas air R2 adjustment Loosen the 3 screws 1 Fig 21 and rotate the ring nut 2 until the notch you have found corresponds with the index 3 Bl...

Page 28: ...the burner as far as the pipe coupling burner in the position shown in Fig 22 connect the plug of the servomotor 14 Fig 19 and tighten the grommet 15 connect the socket of the maximum gas pressure sw...

Page 29: ...P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer 5 10 2 Gas train Type approved in accordance with EN...

Page 30: ...ation Gas pressure at test point 1 Fig 28 16 0 mbar Pressure in combustion chamber 3 0 mbar 16 0 3 0 13 0 mbar A maximum output of 1600 kW shown in Tab N corresponds to 13 0 mbar pressure column 1 Thi...

Page 31: ...d at least once every 24 hours to enable the control box to per form checks of its own start up efficiency Normally burner stopping is guaranteed by the boiler s thermostat pres sure switch If this is...

Page 32: ...olutions of the motor via the reading plate B fixed rigidly to the motor For its regulation proceed as follows loosen the 4 screws C with a plain screwdriver move the plate in the radial direc tion D...

Page 33: ...nect two lamps or testers to the two gas line solenoids to check the exact moment at which voltage is supplied This operation is unnecessary if each of the two solenoids is equipped with an indicator...

Page 34: ...put must be equal to or less than 150 kW with ts 3 s In order to measure the ignition output disconnect the plug socket the burner will fire and then go into lockout after the safety time has elapsed...

Page 35: ...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 ferential mode applying a second tube between the...

Page 36: ...es of the start up ignition and switch off of the burner In the example the display indicates that the burner is in Phase 30 see diagram Fig 37 and there are 12 seconds until the next phase 6 6 1 3 Di...

Page 37: ...on the modulation curve it is possible to manually check the opera tion of the burner along the entire curve Example the burner is working at the requested load percentage 20 Press the F key for 1 se...

Page 38: ...3 s or press the keys and ESC simultaneously To move on to the next parameter press the or i reset key for less than 1 s At the end of the list the display visualises End To move back to the previous...

Page 39: ...osen scroll through the list with the keys and At the end of the list the display visualises End To return to Normal visualisation mode simultaneously press the keys and ESC twice 6 6 4 2 Assigning pa...

Page 40: ...vent of difficulty it is possible to switch on the burner at a value other than the modulation mini mum P1 To access the Parameter mode group 400 referring to the Ac cess procedure with password on pa...

Page 41: ...to Access procedure with password on page 37 Using the key select the parameters group 500 Using the key select the parameters group 522 accelera tion press the info key to change parameter 522 The s...

Page 42: ...83 These phases relate to the valve seal test Phase 30 The count of the pre purging time pre set in the factory begins Phase 36 The burner goes to its switch on position point P0 defined in Tab R at p...

Page 43: ...the gas valve stabilis er Halfway through the procedure i e around point P4 or P5 you are advised to measure gas delivery and check that the output is about 50 of the maximum output If this is not the...

Page 44: ...ameter bAC_UP appears on the display screen confirm with the key i reset The display screen shows the following value Use the button The value will be set to 1 Value 1 is flashing confirm with the but...

Page 45: ...parameter bAC_UP appears on the display screen With the key select the rEStorE parameter Confirm with the key i reset The display shows the following value Use the button The value will be set to 1 V...

Page 46: ...is is to in dicate that the restore process has been completed correctly NOTE When the restore process is successfully completed the 0 value is shown on the display screen Err C information 136 D 1 re...

Page 47: ...Manual setting of output Not defined automatic operation 1 Modification zero setting 0 100 0 1 Not defined Info mode 123 Minimum output step position Index 0 BACS output Index 1 output of the external...

Page 48: ...S 201 Burner operation mode fuel supply line modulating stage servomotors etc not defined eliminate curves 1 Gmod 2 Gp1 mod 3 Gp2 mod 4 Lo mod 5 Lo 2 stage 6 Lo 3 stage 7 Gmod pneu 8 Gp1 mod pneu 9 Gp...

Page 49: ...Mode 248 Gas Post purging time t3 at deactivation of the load LR ON 1 s Modification 1s 108 min 0 2s 1s Service Mode 261 Oil Selection of flame sensor 0 QRB QRC 1 ION QRA 1 Modification 0 1 1 0 Servic...

Page 50: ...7 1 7 Service Mode 641 VSD speed standardisation control Negative value error diagnostics see error code 82 0 standardisation deactivated 1 Standardisation active 1 Modification 25 1 1 0 Service Mode...

Page 51: ...the start up phase once and makes a further ignition attempt If the flame is still absent the control box goes into lockout 947 Result of the sampling of the contact codified in bits Bit 0 0 1 Minimum...

Page 52: ...n page 35 6 14 Final checks with burner operating Tab T Open the thermostat pressure switch TL Open the thermostat pressure switch TS The burner must stop Turn the gas maximum pressure switch knob to...

Page 53: ...r Gas leaks Make sure that there are no gas leaks on the pipes between the gas meter and the burner UV cell Fig 39 Minimum value for correct operation 70 A If the value is lower it could be due to exh...

Page 54: ...ments Tab U 7 2 3 Checking the air and gas pressure on the combustion head To carry out this operation a pressure gauge must be used to mesure the air and gas pressure at the combustion head as shown...

Page 55: ...the pipe coupling Reconnect the cables and slide in the burner until it comes to a stop Connect the plug of the servomotor 7 and tighten the grom met 8 Connect the socket of the maximum gas pressure s...

Page 56: ...sure on Lockout alarm at start 20 Air pressure fuel pressure on Alarm lock at start 68 Air pressure POC on Alarm lockout at start 84 Air pressure fuel pressure POC on Alarm lockout at start 4 Extraneo...

Page 57: ...wiring Check if the closure contact of the valve opens when the valve is checked 64 POC Open Lockout alarm at the start software version V02 00 Check the wiring Check if the contact of the valve open...

Page 58: ...perform the standardisation again and check the regulation of the fuel air ratio 76 Fuel air internal checking error Carry out a reset if the error arises repeatedly replace the control box 80 VSD co...

Page 59: ...n was performed in the wrong phase The only phases allowed are 12 controller OFF restart the standardisation 21 Safety loop burner flange open The safety loop or burner flange is open repeat the stand...

Page 60: ...oints of the modulation curve Bit 2 Valence 4 7 Air servomotor Curve too steep in terms of train ratio The slope of the curve can correspond to a maximum position variation of 31 between 2 points of t...

Page 61: ...t must be without voltage 2 Disconnect the power supply Disconnect the fan The resistive connection between the fan output and the neutral wire is not allowed If one of the 2 tests fails replace the c...

Page 62: ...If the error arises repeatedly replace the control box 131 EEPROM access internal error page interrupted Carry out a reset repeat and check the last setting of the parameters If the error arises repea...

Page 63: ...mmunication between REC 37 400A2 and RDI21 has been interrupted 9 Manual lockout from PC interface Communication interrupted During an adjustment of the curve via the PC interface the communication be...

Page 64: ...ises repeatedly replace the control box 245 Internal error Carry out a reset if the error arises repeatedly replace the control box 250 Internal error Carry out a reset if the error arises repeatedly...

Page 65: ...kit for flame inversion boiler Kit for LPG operation Gas flange DN80 kit A Appendix Accessories Burner Standard head length mm Extended head length mm Code RS 160 EV BLU 373 503 3010442 Burner Thickn...

Page 66: ...erter kit variable speed drive Kit PVP Pressure Valve Proving Gas trains in compliance with EN 676 Please refer to manual Burner Code RS 160 EV BLU 3010436 Burner Model Code RS 160 EV BLU OCI412 30104...

Page 67: ...2 Indication of references 3 Layout of unifilar output 4 REC37 operational layout 5 REC37 operational layout 6 REC37 operational layout 7 REC37 operational layout 8 Electrical connection set by instal...

Page 68: ...95002 66 GB Appendix Electrical panel layout 0 0 1 0 111 2 1 340 56478 79 1 0 2 1 2 1 2 1 2 1 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 654...

Page 69: ...67 20095002 GB Appendix Electrical panel layout 0 1 2 2 2 3 2 4 2 2 2 2 2 2 2 52 5 5 2 2 3 2 67 8 9...

Page 70: ...20095002 68 GB Appendix Electrical panel layout 0 1 1 0 2 0 00 0 1 3 414 56 2 7 8 03 59 3 A...

Page 71: ...69 20095002 GB Appendix Electrical panel layout...

Page 72: ...20095002 70 GB Appendix Electrical panel layout 0 1 1 2 1 1 1 1 1 3 3 3 1 1 0 1 1 4 4 1 4 41 1 1 5 6 4 4 768 9...

Page 73: ...71 20095002 GB Appendix Electrical panel layout 0012 3 3 4 5 3 6 7 078 0 9 0 001 001 078 76 76 078 078 5 5 5 A A B B B B B B...

Page 74: ...nel layout 01 234 567 14 860 0139 0 6 71 234 6 A A A B A A A A A A A A A A A B A C C C C C C C C 0 6 6 7 92 01 0 929 13 0 6 0 23 D20 20 2 929 13 0 6 0 23 D20 20 2 929 13 6 3 26 0 06E D2 00 3 6 52 D2 0...

Page 75: ...V active voltage output remote setpoint adjust F1 VSD fuses F2 Auxiliary fuses G 2 wires Pt1000 Climatic compensation probe GF VSD G1 Load indicator G2 Modbus communication interface H Remote lockout...

Page 76: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com...

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