Riello RS 200/M BLU Installation, Use And Maintenance Instructions Download

Page: 46 / 56

20152093

Problems - Causes - Remedies signalled by LED indicators

Tab. R

UV: false flame during operation False flame detected before ignition

Check the flame sensor

FR: false flame during operation False flame detected before ignition

Check the wiring

Check the flame sensor

Make sure that earthing is appropriate

T8 inlet fault

The system detected the presence of

voltage on T8 at the wrong moment or there

is no voltage when necessary

Check the wiring

Check the actuator

Internal hardware fault

Internal fault

Replace the control device

Local reset fault

Local reset button pressed for more than 10

seconds or reset button locked

If the problem persists, replace the control

device

Open POC fault

The fuel valve is open at the wrong moment Check the wiring

UV: strong UV flame fault

The flame sensor is too close to the flame

Increase the distance between the flame

sensor and the flame OR use an orifice to

reduce the view field

Internal hardware fault

Internal fault

Replace the control device

Faults

Cause

Solution

Summary of Contents for RS 200/M BLU

Page 1: ...Installation use and maintenance instructions 20152093 2 10 2020 Forced draught gas burner Progressive two stage or modulating operation CODE MODEL TYPE 20145799 RS 200 M BLU 1106T GB ...

Page 2: ...Translation of the original instructions ...

Page 3: ...motor SQN31 16 5 Installation 17 5 1 Notes on safety for the installation 17 5 2 Handling 17 5 3 Preliminary checks 17 5 4 Operating position 18 5 5 Preparing the boiler 18 5 5 1 Introduction 18 5 5 2 Boring the boiler plate 18 5 5 3 Blast tube length 19 5 6 Positioning the probe electrode 19 5 7 Securing the burner to the boiler 20 5 8 Combustion head pre calibration 21 5 9 Combustion head adjust...

Page 4: ...afety for the maintenance 35 7 2 Maintenance programme 35 7 2 1 Maintenance frequency 35 7 2 2 Safety test with no gas supply 35 7 2 3 Checking and cleaning 35 7 2 4 Safety components 36 7 3 Opening the burner 37 7 4 Closing the burner 37 8 LED indicator and special function 38 8 1 Description of LED lamps 38 8 2 Check mode function 38 8 3 Flame control lock out or emergency stop condition 38 8 4 ...

Page 5: ...ow Voltage Directive EMC 2014 30 EU Electromagnetic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BImSchV revision 26 01 2010 Product Type Model Out...

Page 6: ...laration of Conformity and has been manufactured and distributed in compliance with the requirements defined in the Legislative Decree of January 8th 2004 and July 17th 2009 Type of product Forced draught gas burners Model RS 200 M BLU Regulation applied EN 676 and A R of January 8th 2004 July 17th 2009 Controlling organisation TÜV Industrie Service GmbH TÜV SÜD Gruppe Ridlerstrase 65 80339 Münche...

Page 7: ...the machine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not carried out correctly lead to electric shocks with lethal consequences DANGER FLAMMABLE MATERIAL This symbol indicates the presence of flammable materials DANGER BURNING This symbol indicates the risks of burns due to high temperatures DANGER CRUSHING OF LIMBS This symbol indicates the p...

Page 8: ...event 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 unreasonable use of the burner intervention of unqualified personnel carrying out of unauthorised modifications on the equipment use of the burner with safety devices that are faulty incorrectly applied an...

Page 9: ...ance 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 purpose He is responsible for the machine and for the training of the people working around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel underta...

Page 10: ...Hz Heavy oil E Electronic cam EV Electronic cam and variable speed with Inverter M Mechanical cam P Proportional air gas valve S L LS N Head TC Standard head TL Extended head Emission C01 or MZ BLU MX Class 1 EN676 Class 2 EN676 Class 3 EN676 Class 3 EN676 3 400 230 50 3N 400V 230V 50Hz Flame control system FS1 FS2 Standard 1 stop every 24 h Continuous operation use only with flame detection elect...

Page 11: ...ta Tab D Designation Power supply voltage Start up Code RS 200 M BLU TL 3 230 400V 50Hz Direct 20145799 Model RS 200 M BLU Type 1106T Output 1 Max kW Mcal h 1380 2400 1187 2064 Min kW Mcal h 550 473 Fuel Natural gas G20 methane G21 G22 G23 G25 G31 Gas pressure at max output 2 Gas G20 G25 G31 mbar 28 35 6 19 6 Operation Intermittent min 1 stop in 24 hours Progressive two stage or modulating by kit ...

Page 12: ...wer than the minimum limit of the diagram Fig 1 D1702 mm A B C D E F 1 G H I 1 L M N O RS 200 M BLU 732 427 329 573 863 373 503 221 430 1442 1587 228 141 261 Rp2 CAUTION Model firing rate Fig 2 refers to operation on G20 G25 If using G31 the minimum output goes from 550 to 630 kW ATTENTION The firing rate value Fig 2 has been obtained considering an ambient temperature of 20 C an atmospheric press...

Page 13: ...duction is also combined with a reduction of the pressure in the combustion chamber Qr reduced output H1r reduced pressure Example 5 output reduction Qr Q x 0 95 H1r H1 x 0 95 2 Using the new Qr and H1r values repeat steps 2 5 Tab F Qe Q F kW H3 H2 x F mbar ATTENTION The combustion head must be adjusted according to equivalent output Qe H1r H1 x Qr Q 2 Qe kg h mbar Qe kW mbar A H1 H2 H3 D388 Fig 3...

Page 14: ...reliminary tests are recommended for boilers or furnaces having a combustion chamber size much different than the one specified in Fig 4 4 9 Burner equipment The burner is supplied complete with Flange for gas train No 1 Seal for flange No 1 Flange fixing screws M10 x 40 No 4 Thermal flange gasket No 1 Stud bolts to fix the burner flange to the boiler M16 x 55 No 4 M16 nuts No 4 Washers No 4 Exten...

Page 15: ...s for slide bars 16 9 Motor contact maker and thermal relay with reset button 10 A switch for automatic manual off operation A button for output increase decrease 11 Terminal board 12 Cable grommets for electrical wiring to be carried out by the installer 13 Electrical control box with lockout pilot light and reset button 14 Flame inspection window 15 Minimum air pressure switch differential type ...

Page 16: ...anual off operation A button for output increase decrease 4 Terminal board for electrical connection 5 Cable grommets for electrical wiring to be carried out by the installer 6 Air pressure switch differential type 7 Sockets for electric connections 8 Ignition transformer 9 Control box base 10 Filter to protect against radio disturbance 11 Bracket to apply the RWF kit for modulating operation Fig ...

Page 17: ... ones Ensure that spliced wires cannot get into contact with neighbouring terminals Use adequate ferrules Arrange the H V ignition cables separately as far as possible from the control box and the other cables When wiring the unit make sure that AC 230 V mains voltage cables are run strictly separate from extra low voltage cables to avoid risks of electrical shock hazard Technical data Tab G Elect...

Page 18: ...ational safety standards are respected When assembling the servomotor and connecting the damper the gears can be disengaged by means of a lever allowing the drive shaft to be easily adjusted in both directions of rotation Technical data Tab H ATTENTION To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the actuators Operating v...

Page 19: ... inside the boiler must be free from hazardous mixes e g chloride fluoride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently ATTENTION Burner handling operations can be highly dangerous if not carried out with the greatest attention distance unauthorised personnel check integrity and suitability of the means available Check also that the area in whic...

Page 20: ...ed to the previous tubes Using the kit this second set of tube is replaced so that in the end all tubes are the same After installing the kit check its effectiveness by measuring flue gas and CO 5 5 2 Boring the boiler plate Pierce the closing plate of the combustion chamber as in Fig 12 The position of the threaded holes can be marked using the thermal insulation screen supplied with the burner T...

Page 21: ...boilers with a water cooled front piece a refractory lining 11 12 Fig 15 is not necessary unless expressly requested by the boiler manufacturer 5 6 Positioning the probe electrode If the probe or electrode is not correctly positioned you must remove the screw 1 Fig 13 take out the inner part 2 Fig 13 of the head and then calibrate them Blast tube Short mm Long mm RS 200 M BLU 373 503 ATTENTION Bef...

Page 22: ...nge 9 to the plate of the boiler interposing the insulating flange gasket 8 supplied with the unit Use the 4 screws supplied with a tightening torque of 35 40 Nm after protecting their thread with anti seizing products Provide an adequate lifting system of the burner ATTENTION Before fastening the burner to the boiler check whether the maximum output for the model concerned is included in area A o...

Page 23: ... adjustment depends only on the maximum output of the burner Two combustion head adjustments are available external air R1 central gas air R2 In the diagram of Fig 17 find the notch at which both air and central gas air should be adjusted ATTENTION Combustion head must be pre calibrated exclusively for the model concerned if its maximum output is included in area B of the firing rate Fig 2 on page...

Page 24: ...ion is fine and with no pulsations knocking 5 10 Closing the burner Once the combustion head adjustment is completed reassemble the burner on the slide bars 3 Fig 19 at about 100 mm from the pipe coupling 4 insert the cables of the probe and electrode then slide the burner as far as the pipe coupling the burner in the position indicated in Fig 19 for burners featuring a long blast tube remove slid...

Page 25: ...ts over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train burner adaptor supplied separately P2 Pressure upstream of valves adjuster P3 Pressure upstream of the filter L Gas train supplied separately L1 Responsibility of the installer Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fu...

Page 26: ... 1 Combustion head pressure drop Gas pressure measured at test point 1 Fig 25 with combustion chamber at 0 mbar burner working at maximum output Column 2 Pressure loss at gas butterfly valve 2 Fig 25 with maximum opening 90 DANGER Disconnect the electrical power supply using the system main switch Check that there are no gas leaks Pay attention when handling the train danger of crushing of limbs M...

Page 27: ...mbar column 1 corresponds in Tab L to an output of 1800 kW This value serves as a rough guide the effective output must be measured at the gas meter To calculate the required gas pressure at test point 1 Fig 25 set the maximum modulating output required from the burner operation find the nearest output value in Tab L for the burner in question Read on the right column 1 the pressure at the test po...

Page 28: ...onger than 24 hours When it is used as a UV control the system is considered as non permanent requiring one burner recycle every 24 hours Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case you must apply a time switch to L N in series to stop the burner at least once every 24 hours Refer to the wiring diagrams The electrical safety of the devi...

Page 29: ...y 2 M20 7 pole socket input 3 M20 4 pole socket input 4 M20 6 pole socket input 5 Available 6 Drill if you wish to add a union 7 6 pole socket for gas valves gas pressure switch or the valve leak detection device 8 Terminal board 9 4 pole socket for TR thermostat pressure switch 10 Single phase power supply 7 pole socket for TR thermostat pressure switch After carrying out maintenance cleaning or ...

Page 30: ...e window TEST TRIP 4 and move it in the arrow direction to the right to carry out the thermal relay test 5 14 Motor rotation As soon as the burner starts place yourself in front of the cooling fan of the fan motor and check that it turns anticlockwise If this is not the case put the switch of the burner to 0 off and wait until the control box carries out the switching off phase Invert the phases o...

Page 31: ...gas Fit a U type pressure gauge Fig 29 to the gas pressure test point on the pipe coupling It is used to calculate approximate MAX burner output using the Tab L on page 24 Connect two lamps or testers to the two gas line solenoid valves to check the exact moment in which voltage is supplied This operation is not required if each of the two solenoid valves is equipped with a pilot light that signal...

Page 32: ...ithin the safety time period of 3 seconds In this case increase gas ignition delivery The arrival of gas to the sleeve is indicated by the U type pressure gauge Fig 29 on page 29 Once ignition has taken place proceed with burner global calibration operations ATTENTION Do not alter the factory setting for the 5 cams just check that they are as specified below Cam I 130 Limits rotation toward maximu...

Page 33: ...n page 32 and keep it pressed until the servomotor has opened the air damper and the gas butterfly valve Adjustment of gas delivery Measure the gas delivery on the meter A rough indication can be obtained from table Tab F on page 11 just read the gas pressure on the pressure gauge see Fig 35 on page 33 and follow the indications given on page 11 If it needs to be reduced decrease outlet gas pressu...

Page 34: ...about 15 Adjust the screws until optimal combustion is obtained Proceed in the same way with the other screws Take care that the cam profile variation is progressive Switch the burner off with switch 1 Fig 32 OFF position Release cam 4 from the servomotor by pressing and shifting button 3 to the right and check several times that by rotating cam 4 forwards and backwards by hand the movement is sof...

Page 35: ...ications in strong depression situations the connection of the pressure switch does not allow it to change over In this case it is necessary to connect the pressure switch in differential mode applying a second tube between the air pressure switch and the fan suction line mouth In this case also the pressure gauge must be connected in differential mode as shown in Fig 35 6 7 2 Maximum gas pressure...

Page 36: ...o the TR remote control is closed the burner progressively increases the output up to the MAX value section C D If the temperature or pressure then increases until the TR opens the burner progressively decreases its output to the MIN value section E F And so on The burner locks out when the heat request is less than the heat supplied by the burner at MIN output section G H The TL remote control op...

Page 37: ...ate as soon as they are powered 7 2 3 Checking and cleaning Combustion head Open the burner and make sure that all components of the combustion head are in good condition not deformed by the high temperatures free of impurities from the surroundings free of material corrosion and correctly positioned Make sure the gas outlet holes for the ignition phase in the distributor of the combustion head ar...

Page 38: ...nts indicate the points where most care should be exercised during maintenance If the combustion values measured before starting maintenance do not comply with applicable Standards or do not indicate efficient combustion consult the table below or contact our Technical Support Service to implement the necessary adjustments Tab M 7 2 4 Safety components The safety components must be replaced at the...

Page 39: ...m from the pipe coupling Reconnect the cables and slide in the burner until it comes to a stop Replace the screws 3 Fig 42 and carefully pull the probe and electrode cables outwards until they are slightly taut Reconnect the articulated coupling 7 to the graduated sector 8 Remove the two extensions from the slide bars 4 Connect the power plug the signal and adjustment plug and the gas train plug t...

Page 40: ... power To exit the check mode function press the reset button the flame control will go back to the normal operating mode 8 3 Flame control lock out or emergency stop condition The RFGO control device can be locked out emergency stop at any time during the operating cycle and unlocked when already locked lock out by simply pressing the key on the front panel or by means of the terminal T21 on the ...

Page 41: ...n Damper open Damper closed Modulation Ignition Flame Status Icon Power OFF ON OFF Not ready Diagnostics Green Standby Green Servomotor movement Note 3 OFF Flashing Flashing OFF Green Waiting for closing Green blinking Green OPEN before ignition Green Minimum before ignition Green Ignition Green PTFI Green blinking Green MTFI Green Active modulation Green Minimum output position Green With flame p...

Page 42: ... cause material problems severe injuries or death It is the owner or user s responsibility to make sure that the equipment described is installed used and commissioned in compliance with the requirements provided both by national and local law The lock out condition indicates the presence of a fault which occurred during the operating cycle or during stand by mode Before performing an unlock attem...

Page 43: ...ombustion airflow switch fault in the rest position Red 20 UV no flame at the end of the 2nd safety time MTFI Red 21 Safety relay fault Red 22 Supervisor processor fault Red 23 Supervisor memory test fault Red 24 Flame loss during the operation AUTO Red 25 Supervisor processor data memory fault Red 26 Supervisor processor internal fault Red 27 Not used 28 Not used 29 Operating temperature out of r...

Page 44: ...0Hz 5 FR No flame at the end of the 2nd safety time MTFI No flame at the end of the second safety time Inspect the system check the gas pressure inspect the flame detection electrode check the wiring etc 6 FR internal circuit fault Internal fault Replace the control device 7 Internal communication fault Internal fault Replace the control device 8 Remote reset The user pressed the remote reset butt...

Page 45: ...l device 41 Internal hardware fault Internal fault Replace the control device 42 Main processor fault Internal fault Replace the control device 43 Supervisor processor fault Internal fault Replace the control device 44 Supervisor processor timeout Internal fault Replace the control device 45 Off specification mains voltage Off specification mains voltage frequency Check the mains voltage level or ...

Page 46: ...o voltage when necessary Check the wiring Check the actuator 59 Internal hardware fault Internal fault Replace the control device 60 Local reset fault Local reset button pressed for more than 10 seconds or reset button locked If the problem persists replace the control device 61 Open POC fault The fuel valve is open at the wrong moment Check the wiring 62 UV strong UV flame fault The flame sensor ...

Page 47: ...s purging kit Soundproofing box kit Signal converter kit Potentiometer kit A Appendix Accessories Burner Standard head length mm Extended head length mm Code RS 200 M BLU 373 503 3010442 Burner Code RS 200 M BLU 20008971 Parameter to be controlled Probe Output regulator Adjustment field Type Code Type Code Temperature 100 500 C PT 100 3010110 RWF50 RWF55 20099869 20099905 Pressure 0 2 5 bar 4 20 m...

Page 48: ...Gas flange kit DN80 Gas trains in compliance with EN 676 Please refer to manual Burner Code RS 200 M BLU 20144943 Burner Code RS 200 M BLU 3010329 Burner Code RS 200 M BLU 3010439 ATTENTION The installer is responsible for the addition of any safety device not foreseen in this manual ...

Page 49: ...lectrical panel layout Index of layouts 2 Indication of references 3 Functional layout RFGO A22 4 Functional diagram 5 Electrical wiring that is the responsibility of the installer 6 Functional layout RWF50 1 2 Sheet no 1 A1 Coordinates Indication of references ...

Page 50: ... 5 6 7899 32 9 6 7 6 235 86 9 7 6 729 6 3 8 2 2 1 1 2 1 A A 1 6 7899 32 9 6 7 6 235 86 9 7 6 729 6 3 8 5 B 4 5 4 5 4 5 4 5 4 5 4 5 4 5 C 4 4 4 C 4 4 4 C 4 4 D 4 C 4 4 4 E C 4 4 4 C 4 4 4 C 4 4 4 C 4 4 4 C 4 4 4 C 4 4 4 C 4 4 4 C 4 4 4 C 4 4 4 C 4 4 4 4 D 4 4 4 C 4 4 4 ...

Page 51: ...49 20152093 GB Appendix Electrical panel layout 0 ...

Page 52: ...20152093 50 GB Appendix Electrical panel layout 0 1 0 1 2 3 0 0 4 4 4 5 4 4 4 4 4 4 4 4 4 4 4 5 4 6 6 7 6 3 3 6 7 7 8 6 6 6 6 9 ...

Page 53: ...8 9 0451 05 5 9 8 9 9 9 7 9 8 8 8 9 8 9 9 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 9 7 9 7 9 80605 1 5 3 4 8 5 3 3 6 808 A 6 65 3 3 6 808 A 6 65 3 3 6 0 08 0B A 65 05 5 6 A 65 05 5 0B A 01 05 5 6 A 01 05 5 ...

Page 54: ...ine fuses F1 Thermal relay H Lockout signalling light h1 Hour counter IN Burner manual stop switch ION Ionisation probe KM Motor contactor MV Fan motor PA Air pressure switch PGM Maximum gas pressure switch PGmin Minimum gas pressure switch Q1 Three phase disconnecting switch Q2 Single phase disconnecting switch RS Remote reset S1 Operating mode switch MAN manual AUT automatic OFF off S2 Button fo...

Page 55: ......

Page 56: ...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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