Riello RS 34/E MZ Installation, Use And Maintenance Instructions Download

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20068131

Appendix - Electrical panel layout

RS 44/E MZ

Summary of Contents for RS 34/E MZ

Page 1: ...ght gas burners Progressive two stage or modulating operation CODE MODEL TYPE 3789400 3789410 RS 34 E MZ 888 T 3789401 3789411 RS 34 E MZ 888 T 3789500 3789510 RS 44 E MZ 889 T 3789501 3789511 RS 44 E MZ 889 T 3789530 3789540 RS 44 E MZ 889 T 3789531 3789541 RS 44 E MZ 889 T GB ...

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

Page 3: ...f phases 18 4 13 Operator panel operation 18 4 13 1 Symbols description on the display 18 4 13 2 Buttons description 19 4 14 Servomotors SQN13 20 5 Installation 21 5 1 Notes on safety for the installation 21 5 2 Handling 21 5 3 Preliminary checks 21 5 4 Operating position 22 5 5 Preparing the boiler 22 5 5 1 Introduction 22 5 5 2 Boring the boiler plate 22 5 5 3 Blast tube length 22 5 6 Positionin...

Page 4: ...6 9 1 Backup 41 6 9 2 Restore 42 6 9 3 Parameter list 44 6 10 Steady state operation 48 6 11 Ignition failure 48 6 12 Burner flame goes out during operation 48 6 13 Stopping of the burner 48 6 14 Final checks with burner operating 49 7 Maintenance 50 7 1 Notes on safety for the maintenance 50 7 2 Maintenance programme 50 7 2 1 Maintenance frequency 50 7 2 2 Checking and cleaning 50 7 2 3 Measuring...

Page 5: ...aly Tel 39 0442630111 www riello com Distributed by RIELLO NV Ninovesteenweg 198 9320 Erembodegem Tel 053 769 030 Fax 053 789 440 e mail info riello be URL www riello be It is hereby certified that the apparatuses specified below conform with the model of the type described n the CE conformity decla ration and they are produced and placed in circulation in conformity with the provisions defined in...

Page 6: ...NOx emission limits specified by German standard 1 BIm SchV release 26 01 2010 Product Type Model Power Forced draught gas burners 889T RS 44 E MZ 80 550 kW Legnago 01 12 2015 Executive General Manager RIELLO S p A Burner Department Research Development Director RIELLO S p A Burner Department Mr U Ferretti Mr F Comencini ...

Page 7: ...ried 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 with le thal 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 CRU...

Page 8: ...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 incor rectly applied and or ...

Page 9: ...nce 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 re sponsible for the machine and for the training of the people work ing around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel undert...

Page 10: ...60 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz 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 Long head Emission MZ BLU MX Class 1 EN676 Class 2 EN676 Class 3 EN676 Class 3 EN676 3 400 230 50 3N 400V 230V 50Hz Designation Voltage Start up Code RS 34 E MZ TC 230V 50 60Hz Direct 3789...

Page 11: ... RS 44 E MZ Output 1 Max kW Mcal h 125 390 108 336 203 550 175 473 203 550 175 473 Min kW Mcal h 45 39 80 69 80 69 Fuel Natural gas G20 methane gas G21 G22 G23 G25 Gas pressure at max output 2 Gas G20 G25 mbar 13 1 19 5 16 7 24 9 16 7 24 9 Operation Intermittent min 1 stop in 24 hours Two progressive or modulating stages with kit see ACCESSORIES Standard applications Boilers water steam diathermic...

Page 12: ...A The minimum output must not be lower than the minimum limit of the diagram RS 34 E MZ 45 kW RS 44 E MZ 80 kW Fig 1 D3831 mm A D E F 1 H I L O N V M RS 34 E MZ 442 422 508 216 351 140 305 138 780 84 177 1 1 2 RS 44 E MZ 442 422 508 216 351 152 305 138 780 84 177 1 1 2 WARNING The firing rate Fig 2 was obtained considering a room temperature of 20 C and an atmospheric pressure of 1013 mbar approx ...

Page 13: ...1 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 in output Qr Q x 0 95 H1r H1 x 0 95 2 With the new values Qr and H1r repeat steps 2 5 Tab F Qe Q F kW H3 H2 x F mbar WARNING The combustion head should be adjusted in rela tion to the equivalent outp...

Page 14: ...th 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 equipment The burner is supplied complete with Gas train flange No 1 Gasket for gas train flange No 1 Screws M8 x 25 to fix the flange No 4 Screws M8 x 25 to fix the burner flange to the boiler No 4 Thermal insulation screen No 1 Plugs for electrical w...

Page 15: ...for TL versions 13 Filter to protect against radio disturbance 14 Flame inspection window 15 Ignition transformer 16 Sockets for electrical wiring 17 Air servomotor 18 Air pressure switch differential type 19 Guides for opening the burner and inspecting the combus tion head 20 Gas pressure test point and head fixing screw 21 Air pressure socket 22 Flame sensor probe 23 Air damper 24 Fan air inlet ...

Page 16: ...charges 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 and the other cables Check the electric wiring inside the boiler complies with the national and local safety regulations Phase and neutral should not be exchanged cause of dan gerous malfunctions loss...

Page 17: ...h components in compliance with II and III ac cording to DIN EN 60730 1 Load on input terminals F1 unit fuse internal 6 3 AT Main fuse of perm network external Max 16 AT Undervoltage Safety switch off from operating position to mains voltage Restart when mains voltage picks up AC 186 V AC 195 V Input currents and input voltages UeMax UeMin Iemax IeMin UN 10 UN 15 1 5 mA peak 0 7 mA peak Voltage de...

Page 18: ...ply lines They should be sized for rated currents as per the pri mary external fuse and the fuse of the internal unit Min cross section Fuses used inside the control box F1 max 6 3 AT 0 75 mm 6 3 AT DIN EN 60127 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 M...

Page 19: ...RVOMOTORS Air Fuel 90 Nominal load Post purging pos Ignition load Low flame Pos without load 0 S8870 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 PGmin PGMin Max gas pressure switch PGMax CPI seal TA ignition 90 Nominal load Post purging pos Ignition load Low flame Pos without load 0 RAST plug X...

Page 20: ...2 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 post purging time Ph78 t3 post purging time Ph80 Emptying time valve leak detection Ph81 Atmospheric test time valve leak detection Ph82 Filling time valve leak detection Ph83 Pressure test time valve ...

Page 21: ... 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 3 s access to a higher level of the menu press from 3 8 s access to another Mode press for 8 s Button Reduction of the value Access to a lower point of the modulation curve Scrolling of the paramete...

Page 22: ...for the fixing screws should be 1 5 Nm It is recommended that this value is not exceeded to prevent damaging the servomotor To avoid an excessive load on the bearings due to rigid hubs the use of compensation clutches without any mechanical play is recommended e g metal bellows type clutches It is advisable to oversize the drive shaft in relation to the rated torque of the actuator The static torq...

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 be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also that t...

Page 24: ...be greater than the thickness of the boiler door com plete with its refractory The lengths L available are For boilers with front flue passes 13 Fig 17 a protection in re fractory material 11 must be inserted between the boiler refrac tory 12 and the blast tube 10 This protection must not compromise the extraction of the blast tube For boilers with a water cooled frontal a refractory cover is not ...

Page 25: ...head and adjust them WARNING Before fixing the burner to the boiler check from the opening of the blast tube that the probe and the electrode are correctly positioned as in Fig 16 WARNING Do not rotate the probe leave it as in Fig 16 If it is located too close to the ignition electrode the control box amplifier may be damaged WARNING Observe the dimensions shown in Fig 16 2 1 Fig 15 D8008 Fig 16 P...

Page 26: ... 8 Use the 4 screws supplied with a tightening torque of 35 40 Nm after protecting their thread with anti seize products 5 8 Combustion head adjustment At this point of the installation the combustion head is fixed to the boiler as shown in Fig 15 It is therefore especially easy to adjust and this adjustment de pends only on the maximum output of the burner In the diagram Fig 18 find the notch at ...

Page 27: ...p 5 9 Burner closing Once the combustion head adjustment is completed reassemble the burner on the guides 3 at about 100 mm from the pipe coupling 4 burner in the position shown in Fig 17 insert the probe and electrode cables then slide the burner as far as the pipe coupling burner in the position shown in Fig 21 connect the plug of the servomotor 14 Fig 17 and tighten the grommet 15 refit the scr...

Page 28: ...ak detection control is compulsory for burners with maximum outputs over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer Explosion danger due to fuel leaks in the pres ence of a flammable source...

Page 29: ...Pressure loss at gas butterfly valve 2 Fig 27 with maximum opening 90 To know the approximate output at which the burner is operating at its maximum Subtract the combustion chamber pressure from the gas pressure measured at test point 1 Fig 27 Find in the Tab K relating to the burner concerned column 1 the pressure value closest to the result you want Read the corresponding output on the left DANG...

Page 30: ... at the gas meter To know the required gas pressure at test point 1 Fig 27 set the maximum output required from the burner operation then find the nearest output value in the Tab K for the burner in question Read on the right column 1 the socket pressure 1 Fig 27 Add this value to the estimated pressure in the combustion chamber Example with natural gas G 20 for RS 44 E MZ Maximum output required ...

Page 31: ...his is not the case a time switch should be fitted in series to TL to stop the 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 made according to current standards It is necessary to check this fundamental safety requirement In the event of doubt have the electrical s...

Page 32: ...ith removable cover 4 5 pole socket for three phase power supply 5 2 pole socket for maximum gas pressure switch accessory 6 6A Prepared for pipe unions drill if 6A pipe unions are re quired 5 12 Calibration of the thermal relay only for RS 44 E MZ three phase The thermal relay is used to avoid damage to the motor owing to a strong increase in absorption or the lack of a phase For the calibration ...

Page 33: ...lding so you can notice the smell of gas Connect 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 light that signals voltage passing through 6 3 Burner start up Feed electricity to the burner via the disconnecting switch on the boiler panel Close the the...

Page 34: ...be equal to or less than 150 kW with ts 3 s In order to measure the ignition output disconnect the plug socket 6 Fig 5 at page 13 on the ioni sation probe cable the burner will fire and then go into lock out after the safety time has elapsed perform 10 ignitions with consecutive lockouts on the meter read the quantity of gas burned this quantity must be equal to or lower than the quantity given by...

Page 35: ...re switch connected in absolute mode Note the presence of a T connec tion 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 differ ential mode applying a second tube between the air pressure switch and the fan suction line mouth In this case also...

Page 36: ...us phases 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 36 and there are 12s to the succes sive stage 6 6 1 3 Display of the work position The burner is working in the requested load position in the exam ple alongside 78 4 6 6 1 4 Condition error message display of the errors and information The display vis...

Page 37: ... is working in Manual mode any outside adjustment is excluded and only the safety devices are active Keep the F key pressed and with the keys or increase or decrease the load percentage To exit manual mode press the keys and ESC simultane ously for 3 seconds the burner will work in Automatic mode and the output will depend on the thermostat adjustment pressure switch TR 6 6 2 Info mode The Info mo...

Page 38: ...mmed the list of parameters indicated on page 44 The factory set parameters are not visible To access this level you must follow Access procedure with password 6 6 4 1 Access procedure with password Press the F and A keys simultaneously for 1s For a moment the display will show CodE and immediately af ter you will see 7 dashes the first one flashing With the keys and select the first character of ...

Page 39: ...un derstood in seconds Press the key and increase the value to 25 seconds flash ing Press the key i reset to confirm and store To return to the list of parameters press the keys and ESC simultaneously WARNING The password must only be communicated to the qualified personnel or the Technical Assistance Service and must be kept in a safe place D9022 P s h min V reset ESC No Parameter 100 ParA Genera...

Page 40: ...he value For the air servomotor keep the key A pressed the position in degrees flashes and press the keys or to increase or de crease the value To adjust the speed of the inverter expressed in and that is 50 Hz 100 keep the buttons F and A simultaneously pressed the percentage position blinks and press buttons or to increase or decrease the value Select another point or exit this area by pressing ...

Page 41: ...e the section Procedure for inserting and adjusting points on the modulation curve at page 38 Phase 38 The ignition phase begins and the spark goes off Phase 40 The gas valves open the count of the safety time begins Check the presence of the flame from the special inspection window and that the combustion parameters are correct if necessary vary the degrees of opening closing of the air and fuel ...

Page 42: ...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 the calibration of point P1 is finished confirm by simulta neously pressing keys and ESC the parameter 546 ap pears If you want to make the burner work on the entire modulation curve press the and ESC keys simultaneously in this way parame...

Page 43: ...i reset The parameter 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 button i reset to activate the backup process The value 1 appears on the display screen After approx 5 seconds it depends on the duration of the pro gramme the 0 value appears on the displ...

Page 44: ...The parameter bAC_UP appears on the display screen With the key Select therEStorE parameter 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 button i reset to activate the restore process WARNING It is advisable to perform a backup every time that a parameter is changed after checking the modifi...

Page 45: ...his 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 restore process initialised is displayed for a brief moment IMPORTANT At the end of the restore process it is neces sary to check the sequence of functions and the list of parameters D12145 h min s P V...

Page 46: ...1 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 load regulator analogue Index 2 output of the external load regulator contacts 3 Modification 0 100 0 1 0 1 0 Service mode 124 Beginning flame loss test TÜV test define the parameter at 1 switch of...

Page 47: ...l Reset 0 99999999 1 0 Info mode 200 CHECKS ON THE BURNER 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 Gp2 mod pneu 10 LoGp mod 11 LoGp 2 stage 12 Lo mod 2 fuel valves 13 LoGp mod 2 fuel valves 14 G mod pneu without actuator 15 Gp1 mod pneu without ...

Page 48: ...fication 0 3 1 2 Service 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 Service mode 265 Oil pre purging time 1 s Modification 15s 60 min 0 2s 15s Service mode 266 Oil pre ignition time 1 s Modification 0 6s 60 min 0 2s 2s Service mode 270 Oil interval ...

Page 49: ...eading only 0 255 1 0 Info mode Error chronology 701 725 05 Start up meter 25 Reading only 0 99999999 1 0 Info mode 725 Error chronology 701 725 06 Load 25 Reading only 0 100 0 1 0 Info mode 900 PROCESS INFORMATION 903 Actual output Index 0 fuel Index 1 air 2 Reading only 0 100 0 1 0 Info mode 922 Position of the servomotors Index 0 fuel Index 1 air 2 Reading only 50 150 0 01 0 Info mode 942 Heat ...

Page 50: ...f Fig 39 at page 51 6 12 Burner flame goes out during operation If the flame accidentally goes out during operation the control box carries out a recycle i e it repeats the start up phase once and makes a further ignition attempt If the flame is still absent the control box goes into lockout 6 13 Stopping of the burner The burner can be stopped by intervening on the disconnecting switch of the ele...

Page 51: ...e mini mum end of scale position Turn the air pressure switch to the maximum end of scale position The burner must stop in lockout Switch off the burner and disconnect the voltage Disconnect the minimum gas pressure switch connector The burner must not start Disconnect the ionisation probe wire The burner must stop in lockout due to firing failure WARNING Make sure that the mechanical locking syst...

Page 52: ...urner Gas filter Replace the gas filter when it is dirty Boiler Clean the boiler as indicated in its accompanying instructions in order to maintain all the original combustion characteristics intact especially the flue gas temperature and combustion chamber pressure Combustion If the combustion values found at the start of the intervention do not satisfy current standards or anyway indicate a poor...

Page 53: ...ls are not normally required However if it is necessary to measure the ionisation current dis connect the plug socket on the ionisation probe cable and insert a direct current microammeter with a base scale of 100 µA see Fig 38 7 2 4 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 combustio...

Page 54: ...ximately 100 mm from the pipe coupling Reinsert the cables and slide the burner as far as the stop Connect the plug of the servomotor 14 Fig 17 at page 24 and tighten the grommet 15 Tighten the screws 5 Fig 40 and carefully pull the probe and electrode cables outwards until they are slightly taut Remove the two extensions from the guides 3 fix them in their original positions and replace the nuts ...

Page 55: ...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 Extraneous light 0 Extraneous light during start up 1 Extraneous light during switch off 2 Extraneous light during start up Lockout alarm at start 6 Extraneous light during start up air pressure Alarm lockout...

Page 56: ...wiring Check if the closure contact of the valve opens when the valve is checked 64 POC Open Alarm lockout at the start software version V02 00 Check the wiring Check if the contact of the valve opens when the valve is checked 22 OFF S Safety circuit Burner flange 0 Safety circuit open Burner flange open 1 Safety circuit open Burner flange open Alarm lockout at start 3 Safety circuit open Burner f...

Page 57: ...nce point 1 Check if the servomotors have been inverted 2 Check if the servomotor is blocked or overloaded 1 Reference error of the air servomotor The reference of the air servomotor was not successful It was not possible to reach the reference point 1 Check if the servomotors have been inverted 2 Check if the servomotor is blocked or overloaded Bit 7 Valence 128 Reference error owing to parameter...

Page 58: ...s not allowed If one of the 2 tests fails replace the control box because the contacts are definitively joined together and it is no longer possible to guarantee safety 98 Relay supervision error 2 Safety valve 3 Ignition transformer 4 Fuel valve 1 5 Fuel valve 2 6 Fuel valve 3 The relay does not start up Carry out a reset if the error arises repeatedly replace the unit 99 Relay internal checking ...

Page 59: ...e last setting of the parameters If the error arises repeatedly replace the control box 132 EEPROM register initialisation internal error Perform a reset if the error arises repeatedly replace the control box 133 135 EEPROM access internal error request synchronisation Carry out a reset repeat and check the last setting of the parameters If the error arises repeatedly replace the control box 136 1...

Page 60: ...ing an adjustment of the curve via the PC interface the communication between REC 27 100A2 and the operating panel has been interrupted for more than 30 s 33 Manual lockout after the PC tool has performed a tentative reset The PC tool has performed a tentative reset even if the system has worked correctly 168 171 Internal error management Carry out a reset if the error arises repeatedly replace th...

Page 61: ...nternal 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 replace the control box Error code Diagnostic code Meaning of the REC 27 100A2 system Recommended measures ...

Page 62: ...own gas kit A Appendix Accessories Burner Standard head length mm Extended head length mm Code RS 34 E MZ 216 351 3010428 RS 44 E MZ 216 351 3010429 Burner Thickness mm Code RS 34 34 E MZ 100 3010095 Burner Code RS 34 34 E MZ 3010449 Burner Type dB A Code RS 34 34 E MZ C1 3 10 3010403 Parameter to be checked Probe Output regulator Adjustment field Type Code Type Code Temperature 100 500 C PT 100 3...

Page 63: ... Level Modbus interface kit PVP kit Pressure Valve Proving Gas trains in compliance with EN 676 Please refer to manual Burner Code RS 34 34 E MZ 3010448 Burner Code RS 34 34 E MZ 3010418 Burner Code RS 34 34 E MZ 3010419 Burner Code RS 34 34 E MZ 3010436 Burner Model Code RS 34 34 E MZ OCI412 3010437 Burner Gas train type Code RS 34 34 E MZ MB CB 3010344 ...

Page 64: ... layouts 2 Indication of references 3 REC27 operational layout 4 REC27 operational layout 5 REC27 operational layout 6 Electrical connections set by installer 7 Electrical connections for kit 8 Electrical connections for external RWF kit 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

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Page 74: ...burner arrest switch KM Fan motor contact maker MV Fan motor PA Air pressure switch PE Burner earth PGM Maximum gas pressure switch PGMin Minimum gas pressure switch PGVP Gas pressure switch for valve leak detection control device Q1 Three phase disconnecting switch Q2 Single phase disconnecting switch RS Remote burner reset button S1 On off selector SM1 Air servomotor SM2 Gas servomotor TA Igniti...

Page 75: ......

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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Riello RS 34/E MZ, Installation, Use And Maintenance Instructions

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