Installation, use and maintenance instructions

GB Forced draught gas burner

Modulating operation

CODE MODEL TYPE

20160126 RS 810/E BLU S032T1

20160897 (5) - 06/2021

Translation of the original instructions
 Contents

1 Declarations................................................................................................................................................................................ 3

2 Information and general warnings............................................................................................................................................ 4

2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5

3 Safety and prevention................................................................................................................................................................ 6

3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6

4 Technical description of the burner ......................................................................................................................................... 7

4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Burner equipment........................................................................................................................................................ 8
4.7 Maximum dimensions.................................................................................................................................................. 9
4.8 Firing rates ................................................................................................................................................................ 10
4.9 Test boiler.................................................................................................................................................................. 10
4.10 Burner description ..................................................................................................................................................... 11
4.11 Electrical panel description........................................................................................................................................ 12
4.12 Control box for the air/fuel ratio (REC37...) ............................................................................................................... 13
4.13 Operation sequence of the burner............................................................................................................................. 15
4.13.1 List of phases ............................................................................................................................................................ 16
4.14 Operator panel operation .......................................................................................................................................... 16
4.14.1 Description of the symbols on the display ................................................................................................................. 16
4.14.2 Description of the buttons.......................................................................................................................................... 17
4.15 Servomotor (SQM33....) ............................................................................................................................................ 18
4.16 Calibration of the thermal relay ................................................................................................................................. 19

5 Installation ................................................................................................................................................................................ 20
5.1 Notes on safety for the installation ............................................................................................................................ 20
5.2 Handling .................................................................................................................................................................... 20
5.3 Preliminary checks .................................................................................................................................................... 20
5.4 Operating position ..................................................................................................................................................... 21
5.5 Removal of the locking screws from the shutter........................................................................................................ 21
5.6 Preparing the boiler ................................................................................................................................................... 21
5.6.1 Boring the boiler plate ............................................................................................................................................... 21
5.6.2 Blast tube length........................................................................................................................................................ 21
5.7 Securing the burner to the boiler ............................................................................................................................... 22
5.8 Access to head internal part...................................................................................................................................... 22
5.9 Probe-electrode position ........................................................................................................................................... 22
5.10 Combustion head adjustment.................................................................................................................................... 23
5.11 Gas feeding ............................................................................................................................................................... 24
5.11.1 Gas feeding line ........................................................................................................................................................ 24
5.11.2 Gas train.................................................................................................................................................................... 25
5.11.3 Gas train installation.................................................................................................................................................. 25
5.11.4 Gas pressure............................................................................................................................................................. 25
5.12 Electrical wiring ......................................................................................................................................................... 26
5.12.1 Supply cables and external connections passage .................................................................................................... 27

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 Contents

6 Start-up, calibration and operation of the burner ..................................................................................................................28

6.1 Notes on safety for the first start-up ...........................................................................................................................28
6.2 Adjustments prior to ignition.......................................................................................................................................28
6.3 Burner start-up ...........................................................................................................................................................28
6.4 Air / fuel adjustment ...................................................................................................................................................29
6.4.1 Air adjustment for maximum output ...........................................................................................................................29
6.4.2 Air/fuel adjustment and output modulation system ....................................................................................................29
6.4.3 Burner adjustment......................................................................................................................................................29
6.4.4 Output upon ignition ...................................................................................................................................................29
6.4.5 Maximum output ........................................................................................................................................................29
6.4.6 Minimum output .........................................................................................................................................................29
6.5 Final adjustment of the pressure switches .................................................................................................................30
6.5.1 Air pressure switch.....................................................................................................................................................30
6.5.2 Maximum gas pressure switch...................................................................................................................................30
6.5.3 Minimum gas pressure switch....................................................................................................................................31
6.5.4 PVP pressure switch kit .............................................................................................................................................31
6.6 Visualisation and programming mode........................................................................................................................32
6.6.1 Normal mode .............................................................................................................................................................32
6.6.2 Info mode ...................................................................................................................................................................33
6.6.3 Service mode .............................................................................................................................................................34
6.6.4 Parameters Mode ......................................................................................................................................................34
6.7 Parameter modification procedure .............................................................................................................................35
6.8 Start-up procedure .....................................................................................................................................................37
6.9 Backup / Restore procedure ......................................................................................................................................39
6.9.1 Backup .......................................................................................................................................................................39
6.9.2 Restore ......................................................................................................................................................................40
6.9.3 List of parameters ......................................................................................................................................................41
6.10 Operation ...................................................................................................................................................................45
6.11 Motor lockout .............................................................................................................................................................45
6.12 Ignition failure.............................................................................................................................................................45
6.13 Burner flame goes out during operation.....................................................................................................................45
6.14 Stopping of the burner ...............................................................................................................................................46
6.15 Final checks (with burner operating) ..........................................................................................................................46

7 Maintenance ..............................................................................................................................................................................47
7.1 Notes on safety for the maintenance .........................................................................................................................47
7.2 Maintenance programme ...........................................................................................................................................47
7.2.1 Maintenance frequency..............................................................................................................................................47
7.2.2 Safety test - with gas feeding closed .........................................................................................................................47
7.2.3 Checking and cleaning...............................................................................................................................................47
7.2.4 Measuring the ionisation current ................................................................................................................................48
7.2.5 Safety components ....................................................................................................................................................48
7.3 Opening the burner ....................................................................................................................................................48
7.4 Closing the burner......................................................................................................................................................48

8 Faults - Possible causes - Solutions.......................................................................................................................................49

8.1 List of error codes ......................................................................................................................................................49

A Appendix - Accessories ...........................................................................................................................................................58

B Appendix - Electrical panel layout...........................................................................................................................................59

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 Declarations

1 Declarations

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

Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burner
Model and type: RS 810/E BLU S032T1
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
MD 2006/42/EC Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
PED 2014/68/EU (only FS2) Pressure Equipment Directive
Such products are marked as follows:

0085 CE-0123CU1067 RS 810/E BLU (Class 3 EN 676)

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. BIm-
SchV revision 26.01.2010”.
Product Model Type Output
Forced draught gas burner RS 810/E BLU S032T1 1200 - 8000 kW
Legnago, 19.05.2021 Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. F. Maltempi

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 Information and general warnings

2 Information and general warnings

2.1 Information about the instruction manual

2.1.1 Introduction WARNING: MOVING PARTS

The instruction manual supplied with the burner: This symbol indicates that you must keep limbs
 is an integral and essential part of the product and must not away from moving mechanical parts; danger of
be separated from it; it must therefore be kept carefully for crushing.
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to DANGER: EXPLOSION
another system. If the manual is lost or damaged, another This symbol signals places where an explosive at-
copy must be requested from the Technical Assistance Ser- mosphere is present. An explosive atmosphere is
vice of the area; defined as a mixture of dangerous substances
 is designed for use by qualified personnel; with air, under atmospheric conditions, in the form
 offers important indications and instructions relating to the of gases, vapours, mist or dust in which, after ig-
installation safety, start-up, use and maintenance of the nition has occurred, combustion spreads to the
burner. entire unburned mixture.

Symbols used in the manual PERSONAL PROTECTION EQUIPMENT

In some parts of the manual you will see triangular DANGER These symbols indicate the equipment that must
signs. Pay great attention to these, as they indicate a situation of be worn and kept by the operator for protection
potential danger. against threats against safety and/or health while
at work.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
Maximum danger level!
This symbol indicates operations which, if not car- MOUNT CASING
ried out correctly, cause serious injury, death or This symbol indicates that it is mandatory to
DANGER long-term health risks. mount casing again after maintenance, cleaning
or checks.
This symbol indicates operations which, if not car-
ENVIRONMENTAL PROTECTION
ried out correctly, may cause serious injury, death
or long-term health risks. This symbol gives indications for the use of the
WARNING machine with respect for the environment.

This symbol indicates operations which, if not car-

IMPORTANT INFORMATION
ried out correctly, may cause damage to the ma-
chine and/or injury to people. This symbol indicates important information that
CAUTION you must bear in mind.

2.1.3 Other symbols  This symbol indicates a list.

DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
Abbreviations used
ried out correctly, lead to electric shocks with le-
DANGER
thal consequences. Ch. Chapter
Fig. Figure
DANGER: FLAMMABLE MATERIAL Page Page
This symbol indicates the presence of flammable Sec. Section
materials. Tab. Table

DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.

DANGER: CRUSHING OF LIMBS

This symbol indicates the presence of moving
parts: danger of crushing of limbs.

20160897
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 Information and general warnings

2.1.4 Delivery of the system and the instruction  The system supplier must carefully inform the user about:
manual – the use of the system;
– any further tests that may be required before activating the
When the system is delivered, it is important that:
system;
 the instruction manual is delivered to the user by the system
– maintenance, and the need to have the system checked at
manufacturer, with the recommendation to keep it in the
least once a year by a representative of the manufacturer
room where the heat generator is to be installed.
or another specialised technician.
 The instruction manual shows:
To ensure a periodic check, the manufacturer recom-
– the serial number of the burner;
mends the drawing up of a Maintenance Contract.
.........................................................................................

– the address and telephone number of the nearest Assis-

tance Centre.

.........................................................................................
.........................................................................................
.........................................................................................

2.2 Guarantee and responsibility

The manufacturer guarantees its new products from the installa-

tion date, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
WARNING tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the 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, incor-
rectly applied and/or not working;
 installation of untested supplementary components on the
burner;
 powering of the burner with unsuitable fuels;
 faults in the fuel supply system;
 use of the burner even following an error and/or an irregular-
ity;
 repairs and/or overhauls incorrectly carried out;
 modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
 insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
 the use of non-original components, including spare parts,
kits, accessories and optional;
 force majeure.

The manufacturer furthermore declines any and every re-

sponsibility for the failure to observe the contents of this
manual.

5 GB 20160897
 Safety and prevention

3 Safety and prevention

3.1 Introduction

The burners have been designed and built in compliance with the type and pressure of the fuel, the voltage and frequency of the
current regulations and directives, applying the known technical electrical power supply, the minimum and maximum deliveries for
rules of safety and envisaging all the potential danger situations. which the burner has been regulated, the pressurisation of the
It is necessary, however, to bear in mind that the imprudent and combustion chamber, the dimensions of the combustion cham-
clumsy use of the equipment may lead to situations of death risk ber and the room temperature must all be within the values indi-
for the user or third parties, as well as the damaging of the burner cated in the instruction manual.
or other items. Inattention, thoughtlessness and excessive confi-  Modification of the burner to alter its performance and desti-
dence often cause accidents; the same applies to tiredness and nations is not allowed.
sleepiness.  The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
It is a good idea to remember the following:
be quickly eliminated.
 The burner must only be used as expressly described. Any
 Opening or tampering with the burner components is not
other use should be considered improper and therefore dan-
allowed, apart from the parts requiring maintenance.
gerous.
 Only those parts envisaged by the manufacturer can be
replaced.
In particular:
The manufacturer guarantees safety and proper
it can be applied to boilers operating with water, steam, diather-
functioning only if all burner components are intact
mic oil, and to other users expressly named by the manufacturer;
and positioned correctly.
WARNING

3.2 Personnel training

The user is the person, body or company that has acquired the In addition:
machine and intends to use it for the specific purpose. He is re-
 the user must take all the measures neces-
sponsible for the machine and for the training of the people work-
sary to prevent unauthorised people gaining
ing around it.
access to the machine;
The user:  the user must inform the manufacturer if
 undertakes to entrust the machine exclusively to suitably faults or malfunctioning of the accident pre-
trained and qualified personnel; vention systems are noticed, along with any
 undertakes to inform his personnel in a suitable way about presumed danger situation.
the application and observance of the safety instructions.  Personnel must always use the personal pro-
With that aim, he undertakes to ensure that everyone knows tective equipment envisaged by legislation
the use and safety instructions for his own duties; and follow the indications given in this man-
 Personnel must observe all the danger and caution indica- ual.
tions shown on the machine.
 Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
 Personnel must inform their superiors of every problem or
dangerous situation that may arise.
 The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.

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 Technical description of the burner

4 Technical description of the burner

4.1 Burner designation

Range: R

Fuel: S Natural gas

L Light oil
LS Light oil / Methane
N Heavy oil

Size

Adjustment: BP Two stage (light oil) / Proportional valve (gas)

E Electronic cam
EV Electronic cam with variable speed (with Inverter)
P Proportional air/gas valve
M Mechanical cam

Emission: C01 or... Class 1 EN676

C02 or MZ Class 2 EN676
C03 or BLU Class 3 EN676
C03 or MX Class 3 EN676
C05 Class 5 EN676 (NOx < 56 mg/kWh)

Head: TC Standard head

TL Long head

Flame control system:

FS1 Standard (1 stop every 24h)
FS2 Continuous operation (1 stop every 72h)

Electrical supply of the system:

3/400/50 3N / 400V / 50Hz
3/230/50 3 / 230V / 50Hz

Voltage of auxiliaries:
230/50/60 230V / 50-60Hz
110/50/60 110V / 50-60Hz

R S 810 E BLU TC FS1/FS2 3/400/50 230/50/60

BASIC DESIGNATION
EXTENDED DESIGNATION

4.2 Models available

Designation Voltage Start-up Code

RS 810/E BLU 3/400/50 Star/Delta 20160126
Tab. A

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 Technical description of the burner

4.3 Burner categories - Countries of destination

Gas category Destination country

I2ELL DE
I2H AT-BG-CH-CZ-DK-EE-ES-FI-GB-GR-HU-HR-IE-IS-IT-LT-LV-NO-
PT-RO-SE-SI-SK-TR
I2Er FR
I2E LU - PL
I2E(R) BE
I2EK NL
Tab. B
4.4 Technical data

Model RS 810/E BLU

Power (1) min -
kW 1200/3500 ÷ 8000
Output (1) max
Fuels Natural gas: G20 (methane gas) - G25
Gas pressure at max. output (2) -
mbar 49.7/73
Gas: G20/G25
FS1: Intermittent (min. 1 stop in 24 hours)
Operation FS2: Continuous (min. 1 stop in 72 hours)
The burner leaves the factory set for the continuous operation.
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Burner weight Kg 300
Noise levels (3) Sound pressure 88.3
dB(A)
Sound power 103.00
Tab. C

(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at the test point 21)(Fig. 4 on page 11) with zero pressure in the combustion chamber and at maximum burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.

4.5 Electrical data

Model RS 810/E BLU

Main electrical supply 3N ~ 400V +/-10% 50 Hz
rpm 2950
V 400/690
Fan motor IE3
kW 22
A 39.4/22.7
V1 - V2 230 V - 1 x 8 kV
Ignition transformer
I1 - I2 1 A - 20 mA
Absorbed electrical power kW max 24.5
Protection level IP 54
Tab. D

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 Technical description of the burner

4.6 Maximum dimensions

The maximum dimensions of the burner are shown in Fig. 1. The maximum dimensions of the open burner are indicated by
Bear in mind that inspection of the combustion head requires the the A and R positions.
burner to be opened and the rear part turned on the hinge. The l position is reference for the refractory thickness of the boiler
door.
20162256
P T L
I G M

N
E

C F

A
R
A

Fig. 1

mm A C D E F G I L M N P R S T
RS 810/E BLU 1197 173 363 585 DN80 577 405 990 413 260 1345 1055 420 558
Tab. E
4.7 Burner equipment

Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Gasket for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
M 12 x 16 replacement screws to secure the combustion head. . No. 2
M18 x 70 screws to secure the burner to the boiler . . . . . . No. 4
 18 washer to secure the burner to the boiler . . . . . . . . . No. 4
M16 x 67 stud bolts to fix the gas elbow to the
pipe coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 8
M16 nuts to fix the gas elbow to the pipe coupling. . . . . . . No. 8
 16 washer to secure the gas flange . . . . . . . . . . . . . . . . No. 8
Pressure kit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

9 GB 20160897
 Technical description of the burner

4.8 Firing rates

The MAXIMUM OUTPUT is chosen from within the diagram area

The firing rate value (Fig. 2) has been obtained
(Fig. 2).
considering an ambient temperature of 20C, an
The MINIMUM OUTPUT must not be lower than the minimum atmospheric pressure of 1013 mbar (approx. 0 m
limit of the diagram: 1200 kW. WARNING a.s.l.), and with the combustion head adjusted as
shown on page 23.

20161991









Combustion chamber
pressure - mbar




















                  

Thermal power – kW Fig. 2

4.9 Test boiler

The burner/boiler combination does not pose any problems if the The firing rates were obtained in special test boilers, according to
boiler is EC approved and its combustion chamber dimensions EN 676 regulations.
are similar to those indicated in the diagram (Fig. 3). In Fig. 3 you can see the diameter and length of the test combus-
If the burner must be combined with a boiler that has not been EC tion chamber.
approved and/or its combustion chamber dimensions are clearly Example:
smaller than those indicated in the diagram, consult the manufac- Output 7000 kW - diameter 120 cm - length 6 m.
turer.
Combustion chamber
m

D2448
Fig. 3

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 Technical description of the burner

4.10 Burner description

2 1 1 3 4 5 6

7
17 18
16

14 13 12 11 9 8
15
19
20162260
20 21 22 23 24 25

10

27 26
Fig. 4
1 Lifting rings
The burner can be opened to the right or to the left
2 Cover for electrical panel
without links to the fuel supply side.
3 Lever for combustion head movement
4 Air pressure test point for combustion head When the burner is closed, the hinge can be refit-
CAUTION
5 Combustion head ted on the opposite side.
6 Shutter
7 Flame stability disc
8 Gas inlet flange
9 Maximum gas pressure switch
10 Gas servomotor
11 Hinge for burner opening
12 Protection
13 Air inlet for fan
14 Air damper control lever
15 Protection for viewing port
16 Reset button
17 Ignition electrode
18 Flame sensor probe
19 Fan motor
20 Gasket for boiler fixing
21 Gas pressure test point for combustion head
22 Pipe coupling
23 Air pressure test point for combustion head
24 Pressure test point for air pressure switch “+”
25 Air pressure switch
26 Fan
27 Servomotor for air dampers

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 Technical description of the burner

4.11 Electrical panel description

12
14
6

13
2
4

20162606
11
1
15
21 16

4 5
24
3
26
22 27

23 25
4
20
18 19

4 5 8
9
10

Fig. 5
1 Electrical control box
2 ON/OFF selector
3 Output regulator
4 Earth terminal
5 Supply cables and external connections passage. See sec-
tion “Electrical wiring” on page 26
6 Bracket for applying the kits
7 Main terminal supply board
8 Relay with clean contacts for signalling the burner is in lock-
out
9 Relay with clean contacts for signalling the burner is operat-
ing
10 Auxiliary circuits fuse (includes a spare fuse)
11 Air pressure switch
12 Ignition transformer
13 Ionisation probe cable
14 Operator panel with LCD display
15 Light signalling burner lockout
16 Reset button
17 Control terminal board 4-20 mA
18 Star/triangle start-up line contactor
19 Thermal relay (with RESET button)
20 Triangle contactor
21 Star contactor
22 Auxiliary contacts
23 Timer for star/triangle start up
24 Sheath for maximum gas pressure switch
25 Sheath for air servomotor
26 Sheath for gas servomotor
27 Sheath for motor cables

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 Technical description of the burner

4.12 Control box for the air/fuel ratio (REC37...)

Warnings
To avoid accidents, material and/or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
WARNING
or modifying it, or forcing its operation. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
The operators must be aware that the incorrect
setting of the visualisation and operation control
box, and of the positions of the fuel and/or air ac-
tuators, can cause dangerous conditions during
burner operation.
The control box is a system to check the burners, based on a mi-
croprocessor and equipped with components to adjust and su-
pervise medium and large capacity forced draught burners. D8266
The control box contains the following components:
Fig. 6
– burner management system with valve leak detection control
device;  The connections to the actuators do not provide a secure
– electronic device to check the fuel/air ratio with a maximum separation from the mains voltage.Before connecting or
of 2 actuators; changing the actuators the system should be off to avoid any
– Modbus interface. conditions that could cause the formation of condensation or
humidity. Otherwise, before switching on again, make sure
For the safety and reliability of the control box,
that the entire control box is perfectly dry!
comply with the following instructions:
 Static charges must be avoided since they can damage the
WARNING control box’s electronic components when touched.
 All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
 Before carrying out any checks on the wiring, fully isolate the
system from the electric mains (omnipolar separation).
Check the system is not powered and cannot be accidentally
reconnected. Failure to do this will lead to the risk of electro-
cution.
 Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
 After every intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then perform the safety
checks.
 Falls and collisions can negatively affect the safety func-
tions. In this case, the control box must not be operated,
even if it displays no evident damage.
 During the programming of the air-fuel ratio control curves,
the technician should constantly observe the quality of the
combustion process (for example using a gas analyser) and,
in the event of inadequate combustion values or dangerous
conditions, should take appropriate action, for example shut-
ting down the system manually.
 The plugs of the connection cables or other accessories can
be disconnected when the system has been switched off.

13 GB 20160897
 Technical description of the burner

Technical data
Control box Mains voltage AC 230 V -15% / +10%
Mains frequency 50 / 60 Hz ±6%
Power absorption < 30 W
Safety class I, with components in compliance with II and III, ac-
cording to DIN EN 60730-1
Load on Fuse on the control box (can be inspected) 6.3 AT
‘input’ terminals Undervoltage
– Safety switch-off from operating position to mains < AC 186V
voltage
– Restart when mains voltage picks up > AC 195V
Cable length – Main line AC 230 V Max. 100 m (100 pF / m)
– Control load (TL1-TL2) Max. 20 m (100 pF/m)
– External reset button (RS) Max 20 m (100 pF/m)
– Load exit (DC 0/2...10V) Max. 10 m (100 pF/m)
– Fuel valve Max. 3 m (100 pF/m)
– Other lines Max. 3 m (100 pF/m)
Environmental Storage DIN EN 60721-3-1
conditions – Climatic conditions Class 1K3
– Mechanical conditions Class 1M2
– Temperature range -20 ... +60 °C
– Humidity < 95% RH
Transport DIN EN 60721-3-2
– Climatic conditions Class 2K2
– Mechanical conditions Class 2M2
– Temperature range -30 ... +60 °C
– Humidity < 95% RH
Operation DIN EN 60721-3-3
– Climatic conditions Class 3K3
– Mechanical conditions Class 3M3
– Temperature range -20 ... +60 °C
– Humidity < 95% RH
Tab. F
Condensation, the formation of ice and the entry
of water are prohibited!

WARNING

20160897
14 GB
 Technical description of the burner

4.13 Operation sequence of the burner

Operation Checking of
Start-up Switching off seal

t1 TSA1

Phase number

Timer - Resolution - Ratio 5) 6) 13)

0.6s
27s 5s 30s
Timer 1 (parameters)

Timer 2 (parameters)

Timer 3 = max. phase time

RAST plug
PIN number Input signals

Thermostat/pressure switch
X3-04 Pin 1/2
safety TS
Thermostat/pressure switch
X5-03 Pin 1/4
indicator TL
X10-05 Pin 2 Pin 3/4
X10-06 Pin 1/2 Ionisation probe ION
INPUT SIGNALS

X3-02 Pin 1/2 Air pressure switch PA Pa

Min gas pressure switch

X5-01 Pin 2/3 P
PGmin
Min gas pressure switch
X5-01 Pin 2/3 P
PGMin
Max gas pressure switch
X5-02 Pin 2/3 P
PGMax
Gas pressure switch for
X9-04 Pin 2/3 P
PGVP leak detection control
Alternative to the control
X5-02 Pin 2/3
CPI seal
RAST plug
PIN number
X3-05 Pin 1 Fan motor MV

Transformer of
X4-02 Pin 2/3
TA ignition
OUTPUT SIGNALS

X6-03 Pin 2/3 Safety valve VS

X8-02 Pin 1/3 Fuel valve V1

X7-01 Pin 2/3 Fuel valve V2

X7-02 Pin 2/3 Pilot valve VP

X3-05 Pin 2 Lock-out signal

90°
Nominal load
Pos. of post-purging
Fuel

X54 Ignition load

Low flame
SERVOMOTORS

Pos. without load

0°

90°
Nominal load
Pos. of post-purging
X53 Ignition load
Air

Low flame
Pos. without load
0°

S8870
Fig. 7

Signal ON
Signal OFF

Both states are allowed

15 GB 20160897
 Technical description of the burner

4.13.1 List of phases

Phase Description Phase Description
Ph00 Lockout phase Ph44 t44 = interval time 1
Ph02 Safety phase Ph60 Operation
Ph10 Closing paused Ph62 The burner moves to the switching off position
Ph12 Standby Ph70 t13 = post-combustion time
Ph22 Fan motor (MV) = ON Ph72 The burner moves to the post-purging position
Safety valve (VS) = ON Ph74 t8 = post-purging time
Ph24 The burner moves to the pre-purging position Ph78 t3 = post-purging time
Ph30 Pre-purging time Ph80 Emptying time (valve leak detection)
Ph36 The burner moves to the ignition position Ph81 Atmospheric time test (valve leak control)
Ph38 Ignition phase (TA) = ON Ph82 Filling time (valve leak detection)
Ph39 Minimum gas pressure switch test (PGmin.) Ph83 Pressure test time (valve leak detection)
Ph40 Fuel valve (V) = ON Ph90 Standby time due to lack of gas
Ph42 Ignition (TA) = OFF

4.14 Operator panel operation

The control box REC37 ... is connected directly to the operator

panel (Fig. 8).
The buttons allow you to programme the operation and diagnos-
tics menus.
The burner management system is shown on the LCD display
(Fig. 9). To simplify the diagnostics, the display shows the oper-
ating status, type of problem, and when the problem arose.
 Observe the procedures and adjustments
shown below.
 All interventions (assembly and installation
WARNING operations, assistance, etc.) must be carried
out by qualified personnel.
 If the display and operator panel are dirty,
clean them with a dry cloth.
D9001
 Protect the panel from excessive tempera- Fig. 8
tures and liquids.

4.14.1 Description of the symbols on the display

Ignition transformer
powered Valve powered
Fan motor powered Flame presence
Pre-heater active
Lockout
only for light oil burners
Heat request Lock-out lamp

Parameter mode active

Info mode active
Service mode active
D9000
V h min s
Closure of servomotors Units of measurement
Opening of servomotors Fig. 9

The brightness of the display can be adjusted from 0 ... 100%

with the parameter 126.

20160897
16 GB
 Technical description of the burner

4.14.2 Description of the buttons

Button Button Function
To adjust the fuel servomotor
Button F
F (keep F pressed and adjust the value by pressing or )
To adjust the air servomotor
Button A
A (keep A pressed and adjust the value by pressing or )

VSD To change the mode setting parameter P

Buttons A and F
VSD function
(simultaneously press F and A plus or )
F A
• Enter in Parameters Mode
• Reset in the event of a lockout
• Access to a lower level of the menu
Button Info and • To navigate in Mode Info or Service and permits:
Enter – the selection of the parameter (flashing symbol)(press for <1 s)
/reset – 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)
Lowering the value
Button - – Access to a lower point of the modulation curve
– Scrolling the parameter list
Increasing the value
Button + – Access to a higher point of the modulation curve
– Scrolling the parameter list
ESC Quit function (ESC)

Buttons - and + (press and simultaneously)

– Does not confirm the value
– Access to a higher level of the menu
Tab. G

17 GB 20160897
 Technical description of the burner

4.15 Servomotor (SQM33....)

Warnings
To avoid accidents, material or environmental
damage, observe the following instructions!
Do not open, modify or force the actuators.
WARNING
 All interventions (assembly and installation
operations, assistance, etc.) must be carried
out by qualified personnel.
 Before modifying the wiring of the servomotor
in the connection area, fully disconnect the
burner control device from the power supply
(omnipolar separation).
 To avoid the risk of electrocution, protect the
connection terminals in a suitable manner
and correctly fix the cover.
 After every intervention (assembly and instal-
lation operations, assistance, etc.), ensure D8271
Fig. 10
the wiring is in order, then make the safety
checks. Technical data
 Falls and collisions can negatively affect the Model SQM33.5...
safety functions. In this case, the servomotor
Operating voltage AC / DC 24V ± 20%
must not be operated, even if it displays no
evident damage. Safety class 2 according to EN 60 730
Power absorption Max. 10 W
Assembly notes Protection level IP54 in compliance with EN 60 529-1
The connection between the actuator command Cable connection RAST2,5, connectors
shaft and the control element must be rigid, with-
WARNING
out any mechanical play. Rotation direction - GAS servomotor: clockwise
- Air servomotor: anticlockwise
Installation notes
The rotation direction is set in the
 The static torque is reduced when the electrical supply of the
factory using the control box param-
actuator is switched off.
eter REC ...
WARNING
During the maintenance or replacement of the Rated torque (max.) 3 Nm
actuators, be careful not to invert the connec-
tors. Static torque (max.) 3 Nm
WARNING
Running time for 90° 5 s.
Weight approx. 1.4 kg
Environmental conditions:
Operation DIN EN 60 721-3-3
Climatic conditions Class 3K5
Mechanical conditions Class 3M4
Temperature range -20...+60°C
Humidity < 95% rh
Tab. H

Condensation, the formation of ice and the entry

of water are prohibited!
WARNING

20160897
18 GB
 Technical description of the burner

4.16 Calibration of the thermal relay

The thermal relay serves to avoid damage to the motor due to an

excessive absorption increase or if a phase is missing.
For calibration 2), see the table in the wiring diagram. 1
To reset, in case of an intervention of the thermal relay, press the T
SE
“RESET” button 1) of Fig. 11. RE

The red “TEST” button 3) opens the NC (95-96) contact and 2

stops the motor. A
S T H
TE
The automatic reset (Position “A” button 1) can be
dangerous. This operation is not anticipated in the 98
burner's operation, leave it always on “H”. There- 97
CAUTION fore do not position the “RESET” button 1) on
96
“A”.
95
3
20073932
Fig. 11

19 GB 20160897
 Installation

5 Installation

5.1 Notes on safety for the installation

After carefully cleaning all around the area where the burner will
The installation of the burner must be carried out
be installed, and arranging the correct lighting of the environ-
by qualified personnel, as indicated in this manual
ment, proceed with the installation operations.
and in compliance with the standards and regula-
WARNING tions of the laws in force.
All the installation, maintenance and disassembly
operations must be carried out with the electricity Combustion air inside the boiler must be free from
supply disconnected. hazardous mixes (e.g.: chloride, fluoride, halo-
DANGER
gen); if present, it is highly recommended to carry
DANGER out cleaning and maintenance more frequently.

5.2 Handling

The packaging of the burner includes a wooden platform, so it is

possible to move the burner (still packaged) with a transpallet After positioning the burner near the installation
truck or fork lift truck. point, correctly dispose of all residual packaging,
separating the various types of material.
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 Before proceeding with the installation operations,
WARNING distance; check the integrity and suitableness of carefully clean all around the area where the burn-
the available means of handling. er will be installed.
CAUTION
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25 cm from the ground.

5.3 Preliminary checks

Checking the consignment

R.B.L. A B C
After removing all the packaging, check the integ- D E F
rity of the contents. In the event of doubt, do not GAS-KAASU X G H
use the burner; contact the supplier. GAZ-AEPIO G H
CAUTION RIELLOS.p.A.
I I-37045 Legnago (VR)

The packaging elements (wooden cage or card-

board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected and D10411
disposed of in the appropriate places. Fig. 12

A burner label, or any other component, that has

Checking the characteristics of the burner
been tampered with, removed or is missing, pre-
Check the identification label of the burner, showing: vents the definite identification of the burner and
 the model (A) (Fig. 12) and type of burner (B); WARNING makes any installation or maintenance work diffi-
 the year of manufacture, in cryptographic form (C); cult.
 the serial number (D);
 the data for electrical supply and the protection level (E);
 the absorbed electrical power (F);
 the types of gas used and the relative supply pressures (G);
 the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate).
Warning. The burner output must be within the boiler's firing
rate;
 the category of the appliance/countries of destination (I).

20160897
20 GB
 Installation

5.4 Operating position

 The burner is designed to operate only in 1 2 3 4 5

positions 1, 2, 3 and 4 (Fig. 13).
 Installation 1 is preferable, as it is the only
WARNING one that allows 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. D7739

 Any other position could compromise the cor- Fig. 13

rect operation of the appliance.
 Installation 5 is prohibited for safety reasons.
DANGER

5.5 Removal of the locking screws from the shutter

Remove the screws and the nuts 1)-2)(Fig. 14), 1

before installing the burner on the boiler. 3
2
Replace them with the screws 3) M12 X 16 sup-
WARNING
plied with the burner.

2
1 D12015 3
Fig. 14

5.6 Preparing the boiler

5.6.1 Boring the boiler plate

D1 20149117
Pierce the closing plate of the combustion chamber, as in Fig. 15.
The position of the threaded holes can be marked using the ther-
45

mal insulation screen supplied with the burner.

DF
5.6.2 Blast tube length
The length of the blast tube must be selected according to the in-
45

dications provided by the manufacturer of the boiler, and in any

case it must be greater than the thickness of the boiler door com-
Ø
plete with its refractory.
For boilers with front flue passes 1)(Fig. 16 on page 22) or flame
inversion chamber, a protection in refractory material 5) must be Fig. 15
inserted between the boiler fettling 2) and the flame funnel 4).
This protection must not compromise the extraction of the blast mm D1 DF 
tube. RS 810/M BLU 400 495 M18
For boilers with a water-cooled frontpiece, a refractory lining 2)- Tab. I
5)(Fig. 16 on page 22) is not necessary, unless expressly re-
quested by the boiler manufacturer.

21 GB 20160897
 Installation

5.7 Securing the burner to the boiler

20162275

Prepare a suitable lifting system using rings 3 3 1

3)(Fig. 16). 2
5

 Fit the heat insulation supplied onto the blast tube

4)(Fig. 16).
 Fit the entire burner onto the boiler hole prepared previously
(Fig. 15 on page 21), and fasten with the screws supplied.

The seal between burner and boiler must be

1
airtight.
WARNING
Fig. 16

5.8 Access to head internal part

 Remove the gas servomotor

 Disconnect the socket 2) of the gas pressure switch. 20162276

 Remove the 4 fixing screws 3).

 Open the burner on the hinge as in Fig. 17.
 Unhook the probe cables and electrode 4).
 Turn the underneath part of the elbow 5) anticlockwise up to
release it from its housing. 1

 Undo the screw 6) with pressure test point.

 Remove the internal part of the head 7). 6
3

Fig. 17

5.9 Probe-electrode position

Check that the probe and the electrode are placed

as in Fig. 18, according to the dimensions indicat-
ed.
WARNING

Electrode Probe 20162129

18.5 8

Fig. 18

20160897
22 GB
 Installation

5.10 Combustion head adjustment

In order to optimise performance, the burner is equipped with a

variable geometry combustion head which operates on the basis 2 1 20162133

of the delivered output.

According to the same rotation of the air servomotor, it is possible
to change the combustion head opening by moving the
lever 2)(Fig. 19) on the holes (1-2-3-4-5-6), after loosening the
0
screw 1). The choice of the hole (1-2-3-4-5-6) to use is based on
1
2
3
4

the following table, according to the required output.

5
6
These output values may not match with the actual values as the
combustion conditions change according to the plant.
The factory regulation corresponds to the minimum output (cou-
pling position: 1).
Coupling position Output (kW) Fig. 19
3 3500
4 4333
5 5166
6 6000
6 8010
Tab. J

20166577

 

 
Combustion head

 

 

 






























Output (kW)

Fig. 20

23 GB 20160897
 Installation

5.11 Gas feeding

Explosion danger due to fuel leaks in the pres- MBC “threaded”

ence of a flammable source. 7 8
Precautions: avoid knocking, attrition, sparks and
heat. 4
Make sure that the fuel interception tap is closed
before performing any operation on the burner.

The fuel supply line must be installed by qualified

personnel, in compliance with current standards
and laws. 1 2 3 P2 6A
WARNING
P3
L1 L
5.11.1 Gas feeding line D11854
Key (Fig. 21 - Fig. 22 - Fig. 23 - Fig. 24) Fig. 21
1 Gas input pipe
2 Manual valve
MBC “flanged”-VGD
3 Vibration damping joint
4 Pressure gauge with push-button cock
5 Filter
6A Includes:
– filter
– working valve
– safety valve
– pressure adjuster
6B Includes
– working valve
– safety valve
– pressure adjuster 20065706

6C Includes Fig. 22
– safety valve
– working valve
DMV “flanged or threaded”
6D Includes:
– safety valve
– working valve
7 Minimum gas pressure switch
8 Leak detection control, provided as an accessory or integrat-
ed, based on the gas train code. In compliance with the EN
676 standard, the leak detection control is compulsory for
burners with maximum outputs over 1200 kW.
9 Gasket, for “flanged” versions only
10 Pressure adjuster
P2 Up-line pressure of valves/adjuster
P3 Upstream pressure of the filter 20065609
Fig. 23
L Gas train, supplied separately
L1 The responsibility of the installer CB “flanged or threaded”

For applications according to the Pressure Equip-

ment Directive PED 2014/68/EU, the installer is
required to provide:
WARNING – suitable means for draining and venting as de-
fined in clause K.10 of DIN EN 676;
– valve proving system as defined in clause K.
14.4 of DIN EN 676.

20065707

Fig. 24

20160897
24 GB
 Installation

5.11.2 Gas train Calculate the approximate maximum output of the burner in this
Approved according to standard EN 676 and provided separately way:
from the burner. – subtract the combustion chamber pressure from the gas
pressure measured at test point P1) (Fig. 25).
– Find, in the table Tab. K related to the burner concerned, the
5.11.3 Gas train installation pressure value closest to the result of the subtraction.
– read the corresponding output on the left.
Disconnect the electrical power using the main
system switch. Example for RS 810/E BLU with G20 natural gas:
DANGER Maximum output operation
Gas pressure at test point P1)(Fig. 25) = 27.6 mbar
Pressure in combustion chamber = 2 mbar
Check that there are no gas leaks. 27.6 - 2 = 25.6 mbar
A pressure of 25.6 mbar, column 1, corresponds in the table Tab.
K to an output of 5750 kW.
Beware of train movements: danger of crushing of This value serves as a rough guide; the effective output must be
limbs. measured at the gas meter.
To calculate the required gas pressure at test point P1) (Fig. 25),
set the MAX output required from the burner operation:
Make sure that the gas train is properly installed – find the nearest output value in the table Tab. K for the burner
by checking for any fuel leaks. in question.
– read, on the right (column 1), the pressure at the test point
P1)(Fig. 25).
The operator must use appropriate tools for instal- – Add this value to the estimated pressure in the combustion
lation. chamber.

Example for RS 810/E BLU with G20 natural gas:

Required burner maximum output operation: 5740 kW
Gas pressure at an output of 5750 kW = 25.6 mbar
Pressure in combustion chamber = 2 mbar
25.6 + 2 = 27.6 mbar
Pressure required at test point P1)(Fig. 25).

The heat output and gas pressure data in the

head refer to operation with gas butterfly valve
fully open (90°).
20162279 WARNING

1 p (mbar) 2 p (mbar)
kW
G 20 G 25 G 20 G 25
3500 9.5 14.0 0.4 0.6
4250 14 20.6 0.6 1.0
5000 19.4 28.5 0.9 1.4
P1 P4
5750 25.6 37.7 1.2 1.8
Fig. 25
6500 32.7 48.1 1.5 2.3
7250 40.7 59.9 1.9 2.9
5.11.4 Gas pressure 8010 49.7 73.0 2.3 3.5
Tab. K indicates the minimum pressure drops along the gas sup- Tab. K
ply line, depending on the maximum burner output.
The values shown in Tab. K refer to:
– Natural gas G 20 NCV 9.45 kWh/Sm3 (8.2 Mcal/Sm3)
– Natural gas G 25 NCV 8.13 kWh/Sm3 (7.0 Mcal/Sm3)
Column 1
Pressure drop on combustion head.
Gas pressure measured at the test point P1) (Fig. 25), with:
• Combustion chamber at 0 mbar;
• Burner working at maximum output;
• Combustion head adjusted as in page 23.
Column 2
Pressure loss at gas butterfly valve 10)(Fig. 23) with maximum
opening: 90°.

25 GB 20160897
 Installation

5.12 Electrical wiring

Notes on safety for the electrical wiring

 The electrical wiring must be carried out with the electrical supply disconnected.
 Electrical wiring must be made in accordance with the regulations currently in force in the country of destination
and by qualified personnel. Refer to the wiring diagrams.
DANGER  The manufacturer declines all responsibility for modifications or connections different from those shown in the wir-
ing diagrams.
 Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man-
ual.
 The RS 810/E BLU burners equipped with REC 37... can operate in FS1 or FS2 mode. See the specific REC 37...
manual for continuous/intermittent operation (FS2/FS1). Refer to the following notes for the type of operation that
has been set.
 The FS1 burners have been set for intermittent operation. This means that the burner should compulsorily be
stopped at least once every 24 hours to enable the electric control box to check its own safety and efficiency at
start-up. Normally the boiler's thermostat/pressure switch ensures that the burner stops. If this is not the case, a
time switch should be fitted in series to TL to stop the FS1 burner at least once every 24 hours. Refer to the wiring
diagrams.
 The FS2 burners have been set for continuous operation. This means that the burner should compulsorily be
stopped at least once every 72 hours to enable the electric control box to check its own safety and efficiency at
start-up. Normally, burner stopping is guaranteed by the boiler's thermostat/pressure switch. If this is not the case,
a time switch should be fitted in series to TL to stop the FS2 burner at least once every 72 hours. Refer to the wir-
ing 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 system checked by qualified personnel. Do not use the gas tubes as an earthing system
for electrical devices.
 The electrical system must be suitable for the maximum power absorption of the device, as indicated on the label
and in the manual, checking in particular that the section of the cables is suitable for that level of power absorp-
tion.
 For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use a multiple pole switch with at least a 3 mm gap between the contacts (overvoltage category III), as envis-
aged by the present safety standards.
 Do not touch the device with wet or damp body parts and/or in bare feet.
 Do not pull the electric cables.
 Check the electric wiring inside the boiler complies with the national and local safety regulations.
 Live and neutral should not be mixed up (this could cause dangerous malfunctions, a loss of protection against
electric shocks, etc..).
 Make sure the cable grommets of the connected cables comply with the relevant standards (e.g.EN60730 and
EN60 335).
 When wiring the unit, make sure that AC 230V mains voltage cables are run strictly separate from extra low-volt-
age cables to avoid risks of electrical shock hazard.
Before carrying out any maintenance, cleaning or checking oper-
ations:

Disconnect the electrical supply from the burner

by means of the main system switch.
DANGER

Turn off the fuel interception tap.

DANGER

Avoid condensate, ice and water leaks from form-

ing.
DANGER

If the cover is still present, remove it and proceed with the electri-
cal wiring according to the wiring diagrams.
Use flexible cables in compliance with the EN 60 335-1 standard.

20160897
26 GB
 Installation

5.12.1 Supply cables and external connections

passage
All the cables to be connected to the burner must be threaded
through cable grommets. The use of the cable grommets can
take various forms; by way of example see Fig. 26.
Key (Fig. 26)
1 Electrical supply - Bore for M32
2 Consents and safety devices - Bore for M20
3 Minimum gas pressure switch - Bore for M20
4 VPS gas valve leak detection control kit- Bore for M20
5 Gas train - Bore for M20
6 Available - Bore for M20
7 Available - Bore for M16

A Fan motor
B Maximum gas pressure switch
C GAS servomotor
D AIR servomotor

20076574
Fig. 26

After carrying out maintenance, cleaning or

checking operations, reassemble the cover and
all the safety and protection devices of the burner.

27 GB 20160897
 Start-up, calibration and operation of the burner

6 Start-up, calibration and operation of the burner

6.1 Notes on safety for the first start-up

The first start-up of the burner must be carried out

Before igniting the burner, see the paragraph
by qualified personnel, as indicated in this manual
“Safety test - with gas feeding closed” on
and in compliance with the standards and regula-
page 47.
WARNING tions of the laws in force. WARNING

Check the correct working of the adjustment, com-

mand and safety devices.
WARNING

6.2 Adjustments prior to ignition

Combustion head adjustment is already described on page 23.

Before starting up the burner, it is good practice to
In addition, the following adjustments must also be made: adjust the gas train so that ignition takes place in
 open manual valves up-line from the gas train. conditions of maximum safety, i.e. with gas deliv-
 Adjust the minimum gas pressure switch to the start of the CAUTION ery at the minimum.
scale.
 Adjust the maximum gas pressure switch to the end of the
scale. 20162281

 Adjust the air pressure switch to the start of the scale.

 Purge the air from the gas line.
We recommend using a plastic tube routed outside the build-
ing and to purge air until gas is smelt.
 Fit a U-type pressure gauge or a differential pressure gauge
(Fig. 27), with socket (+) on the gas pressure of the pipe
coupling and (-) in the combustion chamber.
The manometer readings are used to calculate MAX burner
output using the Tab. K.
 Connect two lamps or testers to the two gas line solenoids to
check the exact moment in which voltage is supplied. This
operation is unnecessary if each of the two solenoids is
equipped with a pilot light that signals voltage passing
through.
Fig. 27

6.3 Burner start-up

Electrically power the burner using the disconnecting switch

Invert the phases on the three-phase power supply.
on the boiler panel.
This operation must be carried out with the electri-
Close the thermostats/pressure switches and set the switch of cal supply disconnected.
Fig. 28 to “1/ON”. DANGER Follow the Start-up procedure.
Make sure that the lights or testers connected to
the solenoids, or the pilot lights on the solenoids
themselves, indicate that no voltage is present.
DANGER
If voltage is present, stop the burner immediately
and check the electrical connections.
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 soon as the burner starts up, go in front of fan motor cooling
fan and check it is rotating anticlockwise or else in the direction
of the arrow shown in the diagram Fig. 4 on page 11.
If this is not the case:
– put the switch of Fig. 28 to “0/OFF” and wait until the control
box carries out the switching off phase;
20076576
– disconnect the burner form the electrical supply.
Fig. 28

20160897
28 GB
 Start-up, calibration and operation of the burner

6.4 Air / fuel adjustment

Air/fuel synchronisation is carried out with the relevant air and 6.4.4 Output upon ignition
gas servomotors by logging a calibration curve by using the elec- Ignition must occur at a lower output than the max. operation out-
tronic cam. put. Regulations provide that the ignition output of this burner
It is advisable, to reduce the loss and for a wide calibration field, must be equal to or less than 1/3 of the MAX operation output.
to adjust the servomotors to the maximum of the output used, the Example:
nearest possible to the maximum opening (90°). MAX operation output of 8010 kW.
The choking of the air, taking into account the maximum combus- The ignition output must be equal to or less than 2670 kW with ts
tion output, takes place by varying the adjustment of the combus- = 3s
tion head (See “Combustion head adjustment” on page 23.). In order to measure the ignition output:
On the gas butterfly valve, the fuel step according to the burner  disconnect the plug-socket on the ionisation probe cable
output required, with servomotor completely open, is carried out (the burner will fire and then go into lockout after the safety
by the pressure stabiliser on the gas train. time has elapsed);
 perform 10 consecutive ignitions with lockouts;
6.4.1 Air adjustment for maximum output  on the meter, read the quantity of gas burned:
 Adjust the servomotor to maximum opening (nearly 90°) so This quantity must be equal to, or lower than, the quantity
that the air butterfly valves are entirely open. given by the formula, for ts = 3s:

Qa (max. burner delivery) x n x ts

6.4.2 Air/fuel adjustment and output modulation Vg =
3600
system
Vg volume supplied in ignitions carried out (Sm3)
The air/gas regulator and output modulation system equipping
Qa ignition delivery (Sm3/h)
RS/E series burners performs a number of integrated functions to
n number of ignitions (10)
optimise burner function, in both individual installations and in
ts safety time (sec)
combination with other units (e.g. double furnace boiler or multi-
ple heat generators in parallel). Example for gas G20 (9.45 kWh/Sm3):
The basic system functions control: ignition output 8010 kW corresponding to 847.6 Sm3/h.
1 The dosage of the air and fuel through positioning using
direct servocommands of the relevant valves eliminating the 200
= 21.16 Sm3/h
possible play in the calibration systems with mechanical 9.45
cam lever mechanisms, used on traditional modulating After 10 ignitions with their lockouts, the delivery indicated on the
burners. meter must be equal to or less than: 847.6 : 360 = 2.35 Sm3.
2 The modulation of the burner output in accordance with the
load required by the system, with maintenance of the pres- Air adjustment
sure or temperature of the boiler at the operating values set.
3 The sequence (cascade adjustment) of more than one The adjustment of the air is carried out by changing the angle of
boiler through the suitable connection of the various units the air damper 17)(Fig. 4 on page 11) changing the degrees of
and the activation of the internal software of the individual the air servomotor inside the electronic cam programme.
systems (option).
Further interfaces and communication functions with computers, 6.4.5 Maximum output
for remote control or integration in central supervision systems
are available on the basis of the configuration of the system. The MAX output must be set within the firing rate (Fig. 2 on
page 10).
The first start up and every further internal setting
operation of the adjustment system or the expan- Adjustment of gas delivery
sion of the base functions require access by Measure the gas delivery on the gas meter.
WARNING means of password and are to be carried out by As an indicative guide it can be taken from Tab. O on page 38,
service personnel who are especially trained for just read the gas pressure on the pressure gauge (shown in
the internal programming of the instrument and Fig. 35 on page 48) and follow the instructions given on page 25.
the specific application created with this burner. – If it is necessary to reduce it, lower the output gas pressure
via the pressure adjuster located beneath the gas valve.
6.4.3 Burner adjustment – If delivery needs to be increased, increase the adjuster outlet
gas pressure.
The optimum adjustment of the burner requires an analysis of
flue gases at the boiler outlet.
Air adjustment
Adjust in sequence:
If necessary vary the degrees of the air servomotor.
1 - Output upon ignition
2 - MAX output
3 - MIN output 6.4.6 Minimum output
4 - Intermediate outputs between Min. and Max. The MIN output must be set within the firing rate (Fig. 2 on
5 - Air pressure switch page 10).
6 - Maximum gas pressure switch
7 - Minimum gas pressure switch

29 GB 20160897
6.5 Final adjustment of the pressure switches

6.5.1 Air pressure switch

Adjust the air pressure switch (Fig. 29) after performing all other
burner adjustments with the air pressure switch set to the start of
the scale.
With the burner operating at minimum output, insert a combus-
tion analyser in the stack, slowly close the suction inlet of the fan
(for example, with a piece of cardboard) until the CO value does
not exceed 100 ppm.
Slowly turn the appropriate knob clockwise until the burner goes
into lockout. D3951

Check the indication of the arrow pointing upwards on the gradu-

ated scale. Turn the knob clockwise again, until the value shown
on the graduated scale corresponds with the arrow pointing
downwards, and so recovering the hysteresis of the pressure Connection of the pressure gauge
with the pressure switch in absolute
switch (shown by the white mark on a blue background, between mode
the two arrows).
Now check the correct start-up of the burner. If the burner locks
out again, turn the knob anti-clockwise a little bit more. During
these operations it may be useful to measure the air pressure
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” connection,
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-
ferential 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 differ- 20163262
ential mode, as shown in Fig. 29.
On RS 810/E BLU burners the air pressure switch is fitted in an Fig. 29
“absolute” mode, that is, connected only to the pressure test point
“+” 24)(Fig. 4 on page 11).

6.5.2 Maximum gas pressure switch PA

Adjust the maximum gas pressure switch (Fig. 30) after making
all other burner adjustments with the maximum gas pressure
switch set to the end of the scale.
To calibrate the maximum gas pressure switch, open the tap and
then connect a pressure gauge to its pressure test point.
The maximum gas pressure switch must be regulated to a value
no higher than 30% of the measurement read on the gauge when
the burner is working at maximum output.
After making the adjustment, remove the pressure gauge and 20181543
close the tap.

1 kPa = 10 mbar
WARNING

PGM

D3856

Fig. 30

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6.5.3 Minimum gas pressure switch
Adjust the minimum gas pressure switch (Fig. 31) after perform-
ing all the other burner adjustments with the pressure switch set
to the start of the scale.
With the burner operating at maximum output, increase adjust-
ment pressure by slowly turning the relative knob clockwise until
the burner stops.
Now turn the knob anticlockwise by 0.2 kPa (2 mbar) and repeat
burner start-up to ensure it is uniform.
If the burner locks out again, turn the knob anticlockwise again by
0.1 kPa (1 mbar).
D3855
Fig. 31
6.5.4 PVP pressure switch kit
Adjust the pressure switch for the leak detection control (PVP kit)
(Fig. 32) according to the instructions supplied with the kit.

1 kPa = 10 mbar
WARNING

D3855 Fig. 32

31 GB 20160897
6.6 Visualisation and programming mode

6.6.1 Normal mode 6.6.1.4 Error state message, display of the errors and
The Normal mode is the standard operation mode visualised on information
the operator panel display. It is the main level of the menu. The display visualises alternately the error code (in the example
 Visualises the operation conditions and allows you to modify c: 12) and the relative diagnostic (in the example d: 0).
the operation point of the burner manually. The system goes into safety mode and the message shown in the
 It does not require any use of the keys of the Operator next figure appears.
Panel.
 It allows access to the other visualisation and programming
modes. P
From Normal mode you can access other levels:

D9005
– Info mode (InFo)
– Service mode (SEr) V h min s %
– Parameter mode (PArA)
Some examples in the standard conditions are given below. P

D9006
6.6.1.1 Burner in stand-by display
The burner is in the heat request waiting mode, or the selector “0- V h min s %
1” (Fig. 28 on page 28) is at “0”.
The burner goes into lockout.
The display visualises alternately the lockout code (in the exam-
P
ple alongside c: 4) and the relative diagnostic (in the example d:
3). The red lockout lamp is on.
D9002

V h min s %
P
6.6.1.2 Display during starting / stopping

D9007
The display visualises the various phases of the start-up, ignition
and switch-off of the burner. V h min s %
In the example, the display indicates that the burner is in
Phase 30 (see diagram Fig. 33) and there are 12 seconds until
the next phase. P

D9008
P
V h min s %

The display visualises alternately an error code and a diagnostic,

D9003

which does not take the system into safety mode.

V h min s %

6.6.1.3 Display of the work position P

D9009

The burner is working in the requested load position (in the exam-
ple alongside, 78.4%). V h min s %

P
P
D9004

D9010

V h min s %
V h min s %

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 Start-up, calibration and operation of the burner

6.6.1.5 Reset procedure Releasing the “F” key, the standard visualisation appears, with
The burner is in lockout when the red indicator light on the oper- the current load percentage flashing: this means that the burner
ator panel is lit up, and the display visualises the lockout code (in is working in Manual mode (any outside adjustment is excluded
the example alongside c: 4) and the relative diagnostics (in the and only the safety devices are active).
example d: 3) alternately.

D9016
P

V h min s

D9007
V h min s % Keep the “F” key pressed and, with the keys “+” or “–”, increase
or decrease the load percentage.

P
D9008 P

D9017
V h min s %
V h min s
To reset, press the “i/reset” key for 1 s: the display will show “rE-
SEt”. When the key is released, the lockout signal will disappear To exit manual mode, press the keys “+” and “-” (ESC) simulta-
and the red indicator light will switch off. neously for 3 seconds: the burner will work in Automatic mode
The control box is reset. and the output will depend on the thermostat/adjustment pres-
sure switch (TR).
ESC
P
D9013

/reset V h min s %
6.6.2 Info mode
6.6.1.6 Manual lockout procedure The Info mode (InFo) visualises general system information. To
If necessary, it is possible to manually block the control box and, access this level you must:
consequently, the burner, by pressing the key “i/reset” simulta-  press the “i/reset” key for 1-3 s.
neously with any other key of the operator panel.  Release the key immediately when the display shows
“InFo”.
With the selector “0-1” (Fig. 28 on page 28), the
burner does not stop immediately, but the switch-
off phase is activated. P
CAUTION

D9019
6.6.1.7 Manual operation procedure
/reset V h min s %
After the adjustment of the burner and the setting of the points on
the modulation curve, it is possible to manually check the opera- The list of parameters (in the sequence in which they are dis-
tion of the burner along the entire curve. played) is shown in Tab. L.
Example:
No. Parameter
the burner is working at the requested load percentage: 20%.
Volumetric delivery of fuel in the unit of measurement
167
selected
P 162 Operation time with flame
163 Operation time
D9014

V h min s % 164 No. of resettable ignitions

166 Total no. of ignitions
Press the “F” key for 1 second: “LoAd” is displayed and the load 113 Identification code of the burner
percentage flashes.
107 Software version
108 Software variation
P 102 Control box test date
103 Identification code of the control box
D9015

V h min s 104 Identification number of the group of parameters set

105 Version of the group of parameters
143 Reserved
End
Tab. L

33 GB 20160897
 Start-up, calibration and operation of the burner

6.6.3 Service mode 6.6.4 Parameters Mode

The Service mode (SEr) visualises the error log and certain The Parameters Mode (PArA) displays and allows you to modi-
technical information about the system. To access this level you fy/programme the parameters list on page 41.
must: The factory-set parameters are not visible.
 press the “i/reset” key for more than 3 s.
To access this level it is necessary to follow the “Access proce-
 Release the key immediately when the display shows
dure with password”.
“SEr”.
6.6.4.1 Access procedure with password
Press the “F” and “A” keys simultaneously for 1s.
P
For a moment the display will show “CodE”, and immediately af-

D9020
ter you will see 7 dashes, the first one flashing.
/reset V h min s %

The list of parameters (in the sequence in which they are dis- VSD
P
played) is shown in Tab. M.

D9025
No. Parameter F A
954 Flame intensity (%) V h min s %
960 Actual fuel which passes in units of volume / h
(m³/h, l/h, ft³/h, gal/h)
P
121 Manual setting of output

D9026
Not defined = automatic operation
922 Position of the servomotors (expressed in de- V h min s %
grees, symbol )
0 = fuel With the keys “+” and “–” select the first character of the pass-
1 = air word (letter or number), and confirm by pressing the key “i/re-
161 Number of errors set”.
701÷725 Log of the errors: 701-725.01, Code
Tab. M P

D9027
6.6.3.1 Operating mode on Info Mode and Service Mode
After access to these levels, the display visualises the number of V h min s % /reset
the parameter (flashing) on the left, and the corresponding value
on the right. Once you have confirmed, the sign “–” will appear.
Continue in the same way for the other characters.
After inserting the last character of the password, confirm by
P pressing the key “i/reset”: if the password inserted is correct you
will see “PArA” for a few seconds, then you can access the var-
D9021

ious groups of parameters.

h min s % With the keys “+” and “–” select the group you require.
If the value is not displayed, press the “i/reset” key for a period
of 1 to 3 seconds
P
To return to the Parameter List, press the “i/reset” key for more
D9022

than 3 s, or press the keys “+” and “-” (ESC) simultaneously.

To move on to the next parameter, press the key “+” or “i/reset” /reset V h min s %
for less than 1s. At the end of the list, the display visualises
“End”.
P
To move back to the previous parameter, press the key “-”.
D9023

To return to the Normal/Standard Visualisation Mode, press the

“i/reset” key for more than 3 s, or press the keys “+” and “-” V h min s %
(ESC) simultaneously.
For a moment the display will show “OPErAte”.
If the password inserted is incorrect, the message “Error” will
appear for a moment. It is then necessary to repeat the proce-
dure.

P
D9024

V h min s %

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 Start-up, calibration and operation of the burner

6.6.4.2 Assigning parameter levels

The password must only be communicated to the
The parameters level is subdivided into groups as shown in Tab.
qualified personnel or the Technical Assistance
N.
Service, and must be kept in a safe place.
WARNING
No. Parameter
Once the access procedure has been carried out, the display will 100: ParA General parameters
show “PArA” for a few seconds. Information and identification data of the system.
200: ParA Checks on the burner
Type of operation, intervention and safety times
P of the various phases.
400: Set Air/fuel modulation curve

D9022
Setting of air/fuel adjustment points
V h min s %
500: ParA Positioning of servomotors
Select the group of parameters with keys “+” and “-”, and con- Choice of positions of the air/fuel servomotors in
firm by pressing the key “i/reset”. the various phases.
Within the group you have chosen, scroll through the list with the 600: ParA Servomotors
keys “+” and “-”. At the end of the list, the display visualises Setting and addressing of the servomotors.
“End”. 700: HISt Log of the errors:
To return to Normal visualisation mode, simultaneously press the Choice of different visualisation modes for the er-
keys “+” and “-” (ESC) twice. rors log.
900: dAtA Process information
Visualisation of information for the remote man-
ESC
agement of the burner.
Tab. N
/reset All the parameters are checked in the factory.
Modification/tampering may compromise the
good operation of the burner and cause injury to
WARNING people or damage to things. In any case, modifi-
cations must be carried out by qualified person-
nel.

To modify a parameter, refer to the “Parameter modification

procedure”.

6.7 Parameter modification procedure

After accessing the level and group of parameters, the display

visualises the number of the parameter (flashing) on the left, and
the corresponding value on the right. P
D9030

P V h mi s % /reset
D9028

To return to the list of parameters, press the keys “+” and “-”
h min s % (ESC) simultaneously.

If the value is not visualised, press the key “i/reset” for 1 - 3

seconds. P ESC
Find below an example of how to modify the parameter relating
D9031

to the pre-purging time (No. 225).

Press the key “i/reset”: the value 20 (seconds) will appear. h min s %
NOTE:
The unit of measurement of the time is not visualised but is un-
derstood in seconds.

P
D9029

/reset V h min s %
Press the key “+” and increase the value to 25 seconds (flash-
ing). Press the key “i/reset” to confirm and store.

35 GB 20160897
 Start-up, calibration and operation of the burner

6.7.0.1 Procedure for inserting and adjusting points on Select another point, or exit this area by pressing the keys “+”
the modulation curve and “-” (ESC) simultaneously.
Nine adjustment/calibration points (P1 ÷ P9) can be inserted in
ESC
the control box for each servomotor, varying their position by de-
grees and, consequently, the quantity of air and fuel introduced.
The ignition point P0 is independent of the minimum modulation
value. This means that, in the event of difficulty, it is possible to
switch on the burner at a value other than the modulation mini- 6.7.0.2 CALC function
mum (P1). The diagram (Fig. 33) shows how the fuel modulation curve is
To access the Parameter mode (group 400) referring to the Ac- modified if the values of point “P5” are changed.
cess procedure with password. By keeping the “+” key pressed for more than 3 s, the points
from “P6” to “P8” are recalculated.
To insert or adjust a point, proceed as follows.
By keeping the “-” key pressed for more than 3 s, the points
Using the keys “+” and “-” insert/select the curve point you want from “P4” to “P2” are recalculated.
and wait for it to flash: this means that the servomotors are now
positioned on the values shown on the display and which corre-
D7908
spond to the point previously set. 100
It is now possible to insert/modify the position by degrees. 90
Original
80
curve
The set value does not require confirmation. el
Fu

Angle (degrees)
70
WARNING
60

50 CALC+
P
40
D9032

V h min s % 30

For the fuel servomotor, keep the key “F” pressed (the position 20 CALC-
in degrees flashes) and press the keys “+” or “-” to increase or 10
decrease the value. Recalculation
0
P0 P1 P2 P3 P4 P5 P6 P7 P8 P9
P Point of the curve
Fig. 33
D9033

F The diagram of Fig. 34 shows the fuel modulation curve when, af-
s %
ter the modification of point “P5”, the recalculation of all the other
For the air servomotor, keep the key “A” pressed (the position in points is not carried out.
degrees flashes) and press the keys “+” or “-” to increase or de- D7909
crease the value. 100

90

P 80
el
Fu
D9034

70
A
Angle (degrees)

V h min 60

To adjust the speed of the inverter (expressed in % and that is 50 50

Hz = 100 %), keep the buttons “F” and “A” simultaneously
pressed, the percentage position blinks and press buttons “+” or 40
“-” to increase or decrease the value.
30

VSD 20
P
10
D12135

F A
0
V h min %
P0 P1 P2 P3 P4 P5 P6 P7 P8 P9
Point of the curve
Fig. 34

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 Start-up, calibration and operation of the burner

6.8 Start-up procedure

Check that the operator panel display shows the heat request Otherwise, modify the ignition point (see the sectionProcedure
and “OFF Upr”: this means it is necessary to set the modulation for inserting and adjusting points on the modulation curve.
curve of the burner.

P
P

D9032
D9035
V h min s %
V h min s %

Access the Parameters Level referring to Access procedure with The values shown in the figure are purely for indi-
password. cation purposes.
The display screen displays the parameters group 400. WARNING

Phase 38:
P The ignition phase begins and the spark goes off.
D9023

Phase 40:
V h min s % The gas valves open (the count of the safety time begins). Using
the appropriate visor check there is a flame and that the combus-
Confirm with the key “i/reset”
tion parameters are correct. if necessary, vary the degrees of
opening/closing of the air and fuel servomotors.
If the control box goes into lockout, press the keys “+” and “-”
(ESC) simultaneously: the display visualises alternately the lock-
out code for flame absence c: 4) and the relative diagnostic (d:
/reset 3).
The display shows “run”

D9007
20064414

V h min s %

Confirm with the key “i/reset”. The burner starts up. P

The display shows all the phases and relative times in sequence.

D9008
The phases are listed in the section List of phases.
V h min s %
Phase 22:
Solve the problem, referring to the paragraph Ignition failure.
Start of the fan motor.
To unlock, see Reset procedure. The display visualises “OFF
Phase 24: Upr”.
The burner goes to the pre-purging position, the air servomotor Repeat the “Start-up procedure”.
opens the damper at 90°.

Phases 80, 81, 82, 83: The values previously inserted remain stored.
These phases relate to the valve seal test. WARNING

Once the ignition has occurred (point “P0”), proceed with the
Phase 30:
calibration of the modulation curve.
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. O on page 38: the display shows a flashing “P0” indication.
If the value proposed is adequate, confirm using the “+” but-
ton.

37 GB 20160897
 Start-up, calibration and operation of the burner

Press the button “+”: the display visualises the indicator “P1” If you want to make the burner work on just a part of the modula-
flashing and proposes the same settings as point “P0”. tion curve, modify the parameters “546” and “545” according to
Press button “+” again: the display shows “CALC” for a few sec- the Parameter modification procedure.
onds. Press the keys “+” and “-” (ESC) simultaneously twice, the dis-
play will show the current load position.

P
ESC P

D9041

D9014
V h min s %
V h min s %
The control box will automatically report the same values set in
points “P0” and “P1” at points “P2” to “P8”. At the end of the “Start-up procedure” it is nec-
The purpose of this is to reach point “P9” to regu- essary to carry out a “Backup”, which is used to
late/determine the maximum operation output. memorise the parameters and the data in the con-
WARNING trol box within the display RDI21…
Press “+” until point “P9” is reached.
This operation allows the parameters and the
Once point “P9” is reached wait for the display to show the flash- points of the modulation curve to be restored in
ing indicator “P9” proposing the same settings as point “P0”. the event of problems.
Now it is possible to change this value to obtain the maximum op- It is advisable to perform a backup every time that
erating power desired. a parameter is changed!
If the gas pressure is insufficient, despite opening the gas servo- For the procedure see Backup.
motor to a maximum of 90°, it is necessary to use the gas valve
stabiliser. Factory settings
Burner
P0
After adjusting point “P9” keep the “-” key on the display pressed RS 810
for about 5 seconds, “CALC” appears for a few seconds. air 15°
gas 22°

P Tab. O
D9041

V h min s %

The control box will automatically calculate the points from “P8”
to “P2”, distributing them in a straight line. These are theoretical
and must be checked.
Check that the settings of point “P8” are adequate.
If not, modify the point.
Proceed in sequence, with the “-” button, up to point “P1”.
It is possible to modify point “P1” to obtain a minimum modulation
point different to the ignition point (“P0”).
Before moving on from one point to the next, wait
for the servomotors to reach the position visual-
ised on the display.
During the adjustment of each point, work on the air and gas ser-
vomotors, without modifying the position of 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 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 completed, confirm by press-
ing the keys “+” and “-” (ESC) simultaneously: parameter “546”
will appear.
If you want to make the burner work on the entire modulation
curve, press the “+” and “-” (ESC) keys simultaneously: in this
way, parameter “546” will automatically be assigned the value of
100% and parameter “545” will have a value of 20%.

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 Start-up, calibration and operation of the burner

6.9 Backup / Restore procedure

At the end of the “Start-up procedure” it is wise to carry out a

We suggest that this operation be carried out at
backup, creating a copy of the data memorised on the REC, in
the end of any intervention that involves modifica-
the RDI 21 display panel.
tions to what has been set on the cam.
This will allow the data to be used for programming a new REC WARNING
This will allow you to carry out a restore in a simple
or to return to the memorised settings of the same REC.
manner on a new cam supplied as a replacement
part, without having to reprogramme the system.

6.9.1 Backup
To perform the backup, proceed as follows: confirm with the key “i/reset”:
 access the Parameters Level referring to Access procedure
with password.
The display screen displays the parameters group 400.

/reset
P
The display screen shows the following value:
D9023

V h min s %
P
With the key “-”:

D12143
V h min s %

Use the button “+”:

Select the parameters group 000:

P
The value will be set to 1. Value 1 is flashing:
D12140

h min s %
P
The 000 parameter blinks, confirm using the “i/reset” key:

D12144
V h min s

confirm with the button “i/reset” to activate the backup process.

/reset
The display screen shows parameter 050 blinking:

P /reset
D12141

The value 1 appears on the display screen:

h min s %
Confirm with the key “i/reset”: P
D12145

V h min s %

After approx 5 seconds (it depends on the duration of the pro-

/reset
gramme), the 0 value appears on the display screen, this is to in-
The parameter bAC_UP appears on the display screen: dicate that the backup process has been completed correctly.

P
P
D12142

D12143

V h min s %
V h min s %

39 GB 20160897
 Start-up, calibration and operation of the burner

NOTE:
If an error occurs during the backup process, the display It is advisable to perform a backup every time
screen shows a negative value. that a parameter is changed, after checking
Refer to diagnostic code 137 to determine the cause of the that the modification carried out is correct.
WARNING
error (see section List of parameters).

6.9.2 Restore
The parameter bAC_UP appears on the display screen:
Use this procedure when replacing equipment
with a parts code. In this way it is possible to have
the default parameters already memorised or
P
WARNING those memorised during the start-up.

D12142
This procedure cannot be carried out on
equipment coming from other burners. V h min s %
To perform the restore procedure, proceed as follows:
 access the Parameters Level referring to Access procedure With the key “+”
with password.
The display screen displays the parameters group 400.
select therEStorE parameter
P
D9023

D12146
V h min s %

With the key “-”: V h min s %

Confirm with the key “i/reset”:

Select the parameters group 000:

P /reset
The display shows the following value.
D12140

h min s %
P
The 000 parameter blinks, confirm using the “i/reset” key:
D12143

V h min s %

Use the button “+”:

/reset
The display screen shows parameter 050 blinking:
The value will be set to 1. Value 1 is flashing:
P
D12141

P
D12144

h min s %
Confirm with the key “i/reset”: V h min s

confirm with the button “i/reset” to activate the restore process.

/reset

/reset

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The value 1 appears on the display screen: NOTE:

When the restore process is successfully completed, the 0
value is shown on the display screen.
P Err C information: 136 D: 1 (restore process initialised) is
displayed for a brief moment.

D12145
V h min s % At the end of the restore process, it is neces-
sary to check the sequence of functions and
After approx 8 seconds (it depends on the duration of the pro- the list of parameters.
gramme), the 0 value appears on the display screen, this is to in-
dicate that the restore process has been completed correctly.

V h min s % D12143

6.9.3 List of parameters

Parameter Unit of Values interval
No. of Modifica- Degree of Predefined
measure- Access mode
No. Description elements tion Min. Max. precision setting
ment
000 INTERNAL PARAMETERS
Start backup/restore process via RDI21... / PC TOOL
(set the parameter to 1)
050 Index 0 = create backup 2 - Modification -99 2 1 0; 0 Service mode
Index 1 = perform restore
Negative values indicate errors
Burner identification number created from the backup
055 1 - Reading only 0 99999999 1 0 Service mode
on RDI21...
056 ASN number created by the backup on RDI21... 8 - Reading only 0 127 1 0 Service mode
057 Software Version created by the backup on RDI21... 1 - Reading only 0x100 0xFFF9 1 0 Service mode
100 GENERAL PARAMETERS
102 Control box identification date 1 - Reading only 0 255 1 Info mode
103 Control box identification number 1 - Reading only 0 65535 1 Info mode
104 Identification number of the group of parameters set 1 - Reading only 0 255 1 30 Info mode
105 Version of the group of parameters set 1 - Reading only 0 0xFFFF 1 V01.08 Info mode
107 Software version 1 - Reading only 0 0xFFF9 1 V03.30 Info mode
108 Software variation 1 - Reading only 0 225 1 1 Info mode
ASN number to verify the ASN number created by the
111 8 - Reading only 0 127 1 0 Service mode
backup on RDI 21…
Info Mode
113 Burner identification 1 - Modification 0 99999999 1 Not defined with password
Service Mode
Manual setting of output Modification /
121 1 % 0% 100% 0.1% Not defined Info mode
Not defined = automatic operation zero setting
Minimum output step position
Index 0: BACS output
123 Index 1: output of the external load regulator, 3 % Modification 0% 100% 0.1% 0%; 1%; 0% Service mode
analogue.
Index 2: output of the external load regulator contacts.
Beginning flame loss test (TÜV test)(define the
124 parameter at 1)(switch of flame loss fuel valves) A 1 - Modification -6 1 1 0 Service mode
negative value indicates an error (see code 150)
Frequency of main power supply
125 0 = 50 Hz 1 - Modification 0 1 1 0 Service Mode
1 = 60 Hz
126 Brightness of display 1 % Modification 0% 100% 1% 75% Service Mode
Fuel meter: Led pulse valence
128 1 - Modification 0 400 0,01 0 Service Mode
(led pulses / volumetric flow units)
Eliminate visualisation error chronology
To eliminate the visualisation, set the parameter to 1,
130 then to 2 1 - Modification -5 2 1 0 Service Mode
Answer 0: process successful
Answer -1: timeout of 1_2 - sequence

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Parameter Unit of Values interval

No. of Modifica- Degree of Predefined
measure- Access mode
No. Description elements tion Min. Max. precision setting
ment
Default output for TÜV test:
Not valid for TÜV test when output is activated Modification /
133 1 % 20% 100% 0.1% Not defined Service Mode
2,000 ..... 10,000 = low flame or first / second / third zero setting
stage
Remote management of control box
0 = off
141 1 - Modification 0 2 1 0 Service Mode
1 = Modbus
2 = reserved
Standby time before a new attempt in event of com-
munication fault
142 Set values: 1 s Modification 0s 7200s 1s 120s Service Mode
0 = not active
1 = .... 7200 s
143 Reserved 1 - Modification 1 8 1 1 Info Mode
144 Reserved 1 s Modification 10s 60s 1s 30s Service Mode
Peripheral address for Modbus
145 Set values: 1 - Modification 1 247 1 1 Service Mode
1 ... 247
Baud Rate for Modbus
Set values:
146 1 - Modification 0 1 1 1 Service Mode
0 = 9600
1 = 19200
Parity for Modbus
0 = none
147 1 - Modification 0 2 1 0 Service Mode
1 = odd
2 = even
Selection of the burner operation during the interrup-
tion of the switch-over with the system of remote man-
agement.
Set values:
With modulating operation the settings of the values
are the following: Modification /
148 1 % 0% 100% 0.1% Not defined Service Mode
0...19.9 = burner switched off zero setting
20...100 = 20...100% modulation field of the burner.
With stage operation:
0 = burner off P1, P2, P3
No setting = no function in the event of communication
interruption
161 Total number of errors 1 - Reading only 0 65535 1 0 Info mode
162 Hours of operation (that can be reset) 1 h Reset 0h 999999h 1h 0h Info mode
163 Total hours of power supply to control box 1 h Reading only 0h 999999h 1h 0h 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
Volumetric delivery of fuel in the selected unit of meas- m3, l,
167 1 Reset 0 99999999 1 0 Info mode
urement (that can be reset) ft3, gal
200 BURNER CHECKS
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
Modify/set to
201 10 = LoGp mod 1 - 1 22 1 Not defined Service Mode
zero
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 actuator
16 = Gp2 mod pneu without actuator
17 = Lo 2-stage without actuator
18 = Lo 3-stage without actuator
19 = G mod only gas actuator
20 = Gp1 mod only gas actuator
21 = Gp2 mod only gas actuator
22 = Lo mod only oil actuator

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Parameter Unit of Values interval

No. of Modifica- Degree of Predefined
measure- Access mode
No. Description elements tion Min. Max. precision setting
ment
Stopping of the program
0 = deactivated
1 = pre-purging (Ph24)
208 1 - Modification 0 4 1 0 Service Mode
2 = Ignition (Ph36)
3 = Interval 1 (Ph44)
4 = Interval 2 (Ph52)
Alarm as the pre-purging phase begins;
210 0 = Deactivated; 1 - Modification 0 1 1 0 Service Mode
1 = Activated
211 Uphill train fan motor 1 s Modification 2s 60s 0.2s 2s Service Mode
212 Maximum time to reach low flame 1 s Modification 0.2s 10 min 0.2s 45s Service Mode
Maximum repeats of safety circuit
1 = No repetition
215 1 - Modification 1 16 1 16 Service Mode
2...15 = Number of repetitions
16 = Constant repetitions
Gas: selection of flame sensor
221 0 = QRB.../ QRC 1 - Modification 0 1 1 1 Service Mode
1 = ION / QRA
Gas: Selection of the pre-purging function
222 0 = deactivated 1 - Modification 0 1 1 1 Service Mode
1 = activated
Maximum repeats of minimum gas pressure switch
intervention
223 1 = No repetition 1 - Modification 1 16 1 16 Service Mode
2...15 = Number of repetitions
16 = Constant repetitions
225 Gas: pre-purging time 1 s Modification 20s 60 min 0.2s 20s Service Mode
226 Gas: pre-ignition time 1 s Modification 0.4 s 60 min 0.2s 2s Service Mode
230 Gas: interval 1 1 s Modification 0.4 s 60s 0.2s 2s Service Mode
232 Gas: interval 2 1 s Modification 0.4 s 60s 0.2s 2s Service Mode
233 Gas: post-combustion time 1 s Modification 0.2s 60s 0.2s 8s Service Mode
234 Gas: Post-purging time (no extraneous light test) 1 s Modification 0.2s 108 min 0.2s 0.2s Service Mode
Gas: Minimum gas pressure switch input
0 = deactivated
1 = minimum gas pressure switch (upstream of the
236 1 - Modification 1 2 1 1 Service Mode
fuel valve 1 (V1))
2 = valve control via the minimum pressure switch
(between fuel vale 1 (V1) and 2 (V2))
Gas: Maximum gas pressure switch / POC Input
0 = deactivated
237 1 - Modification 1 2 1 1 Service Mode
1 = Maximum gas pressure switch
2 = POC
Gas: Valve leak detection test
0 = test deactivated
1 = valve leak detection test at start up
241 1 - Modification 0 3 1 2 Service Mode
2 = valve leak detection test at shutdown
3 = valve leak detection test at start-up and at shut-
down
Gas: Post-purging time (t3)(at deactivation of the load
248 1 s Modification 1s 108 min 0.2s 1s Service Mode
(LR)) - ON
Oil: selection of flame sensor
261 0 = QRB.../ QRC... 1 - Modification 0 1 1 0 Service Mode
1 = ION / QRA...
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 1 1 s Modification 0.4 s 60 min 0.2s 2s Service Mode
272 Oil: interval 2 1 s Modification 0.4 s 60 min 0.2s 2s Service Mode
273 Oil: post-combustion time 1 s Modification 0.2s 60s 0.2s 8s Service Mode
274 Oil: Post-purging time (no extraneous light test) 1 s Modification 0.2s 108 min 0.2s 0.2s Service Mode
Oil: Minimum input oil pressure switch
0 = deactivated
276 1 - Modification 1 2 1 1 Service Mode
1 = activated from phase 38
2 = activated from safety time (TSA)
Oil: Maximum oil pressure switch / POC Input
0 = deactivated
277 1 - Modification 1 2 1 1 Service Mode
1 = Maximum oil pressure switch
2 = POC

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Parameter Unit of Values interval

No. of Modifica- Degree of Predefined
measure- Access mode
No. Description elements tion Min. Max. precision setting
ment
Oil: selection transformer ignition phase TA
281 0 = brief pre-ignition (Ph38) 1 - Modification 0 1 1 1 Service Mode
1 = long pre-ignition (with fan)(Ph22)
Oil: Post-purging time (t3)(at deactivation of the load
284 1 s Modification 1s 108 min 0.2s 1s Service Mode
(LR)) - ON
400 AIR / FUEL MODULATION CURVES
Checking fuel servomotor 0°; 0°; 15°;
401 13 (°) Modification 0° 90° 0.1° Service Mode
(only setting of the curve) Not defined
Checking air servomotor 0°; 90°; 45°;
402 13 (°) Modification 0° 90° 0.1° Service Mode
(only setting of the curve) Not defined
500 POSITIONING OF SERVOMOTORS
Position of the fuel servomotor in absence
of flame
501 Index 0 = standby position 3 (°) Modification 0° 90° 0.1° 0°; 0°; 15° Service Mode
Index 1 = pre-purging position
Index 2 = post-purging position
Position of the air servomotor in absence of flame
Index 0 = standby position
502 3 (°) Modification 0° 90° 0.1° 0°; 90°; 45° Service Mode
Index 1 = pre-purging position
Index 2 = post-purging position
Minimum modulation limit Modification /
545 1 % 20% 100% 0.1% Not defined Service Mode
Not defined = 20% zero setting
Maximum modulation limit Modification /
546 1 % 20% 100% 0.1% Not defined Service Mode
Not defined = 100% zero setting
600 SERVOMOTORS
Tolerance limit for position check (0.1°)
Index 0 = fuel
Index 1 = air
606 2 (°) Modification 0.5° 4° 0.1° 1.7°; 1.7° Service Mode
More serious position error, where a defect has cer-
tainly been detected
- > Stop range: (P 606 - 0.6°) a P606
Analogue exit configuration
0 = DC 0...10 V
645 1 - Modification 0 2 1 2 Service Mode
1 = DC 2...10 V
2 = DC 0 / 2...10 V
700 LOG OF THE ERRORS
701 Error chronology: 701-725.01.Code 25 - Reading only 0 255 1 0 Info mode
• Error chronology: 701-725.02.Diagnostic code 25 - Reading only 0 255 1 0 Info mode
• Error chronology: 701-725.03.Error class 25 - Reading only 0 6 1 0 Info mode
• Error chronology: 701-725.04.Phase 25 - Reading 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
Actual output
903 Index 0 = fuel 2 % Reading only 0% 100% 0.1% 0% Info mode
Index 1 = air
Position of the servomotors
922 Index 0 = fuel 2 (°) Reading only -50° 150° 0.01° 0° Info mode
Index 1 = air
Heat source active
1 = output during the definition of the curves
2 = manual output
942 1 - Reading only 0 255 1 0 Service mode
3 = BACS output
4 = analogue input output
5 = output of the external load regulator contacts
Result of the sampling of the contact (codified in bits)
Bit 0.0 = 1: Minimum pressure switch
Bit 0.1 = 2: Maximum pressure switch
Bit 0.2 = 4: Pressure switch control valves
Bit 0.3 = 8: Air pressure switch
Bit 0.4 = 16: Open load check
Bit 0.5 = 32: ON load check
947 Bit 0.6 = 64: Closed load check 2 - Reading only 0 255 1 0 Info mode
Bit 0.7 = 128: Safety circuit
Bit 1.0 = 1: Safety valve
Bit 1.1 = 2: Ignition
Bit 1.2 = 4: Fuel valve 1
Bit 1.3 = 8: Fuel valve 2
Bit 1.4 = 16: Fuel valve 3/ pilot valve
Bit 1.5 = 32: Reset

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Parameter Unit of Values interval

No. of Modifica- Degree of Predefined
measure- Access mode
No. Description elements tion Min. Max. precision setting
ment
Relay request status (coded in bits)
Bit 0 = 1: Alarm
Bit 1 = 2: Safety valve
950 Bit 2 = 4: Ignition 1 - Reading only 0 255 1 0 Info mode
Bit 3 = 8: Fuel valve 1
Bit 4 = 16: Fuel valve 2
Bit 5 = 32: Fuel valve 3/ pilot valve
954 Flame intensity 1 % Reading only 0% 100% 1% 0% Info mode
m3/h, l, h,
960 Actual output 1 Reading only 0 6553,5 0,1 0 Info mode
ft3/h, gal/h
961 Status of external modules and visualisation 1 - Reading only 0 255 1 0 Info mode
981 Memory error: Code 1 - Reading only 0 255 1 0 Info mode
982 Memory error: diagnostic code 1 - Reading only 0 255 1 0 Info mode
0xFFFFFF
992 Error indicators 10 - Reset 0 1 0 Service mode
FF

Tab. P

6.10 Operation

Burner without modulating operation kit  The burner stops when the heat request is less than the heat
Once the start-up cycle is completed, the servomotor command supplied by the burner at MIN output.
moves on to the thermostat/pressure switch TR that controls the  The thermostat/pressure switch TL opens, the control box
pressure or the temperature in the boiler. carries out the switching off phase.
 If the temperature or the pressure is low (so the thermostat/  The air damper closes completely to reduce heat losses to a
pressure switch TR is closed), the burner progressively minimum.
increases the output as far as the MAX value (point “P9”). As an alternative to control through TR, the command for burner
 If the temperature or the pressure increases as far as the modulation can be made also using a 4-20 mA signal.
opening of the thermostat/pressure switch TR, the burner
progressively reduces the output as far as the MIN value Burner with modulating operation kit
(point “P1”). The sequence repeats endlessly. See manual enclosed with the adjuster kit.

6.11 Motor lockout

If the motor does not start, it could be because of a thermal relay

intervention due to its incorrect calibration or problems with the
motor or the main power supply, to release press the button of the
thermal relay, see Calibration of the thermal relay.

6.12 Ignition failure

If the burner does not switch on, there is a lockout within 3s of the
In the event the burner stops, in order to prevent
electrical supply reaching the gas valve.
any damage to the installation, do not unblock the
It may be that the gas does not arrive at the combustion head burner more than twice in a row.
within the safety time of 3s. WARNING
If the burner locks out for a third time, contact the
In this case increase gas ignition flow rate.The arrival of gas to customer service.
the pipe coupling is displayed on the pressure gauge, as shown
in (Fig. 27 on page 28). In the event there are further lockouts or faults
with the burner, the maintenance interventions
must only be carried out by qualified, authorised
DANGER personnel, in accordance with the contents of this
manual and in compliance with the standards and
regulations of current laws.

6.13 Burner flame goes out during operation

If the flame should go out during operation, the burner will lockout
within 1s.

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6.14 Stopping of the burner

The burner can be stopped by: There are now two possibilities:
 intervening on the disconnecting switch of the electrical sup- – using the operator panel according to the manual lockout pro-
ply line, located on the boiler panel; cedure on page 32;
 removing the transparent protection after unscrewing the rel- – using the switch 0-1 of Fig. 28 on page 28.
ative screw.

6.15 Final checks (with burner operating)

 Open the thermostat/pressure switch TL

 Open the thermostat/pressure switch TS  The burner must stop

 Turn the gas maximum pressure switch knob to the mini-

mum end of scale position
 Turn the air pressure switch knob to the maximum end of  The burner must stop in lockout
scale position
 Turn off the burner and cut off the power
 Disconnect the minimum gas pressure switch connector  The burner must not start

 Disconnect the connector of the ionisation probe  The burner must stop in lockout due to ignition failure

Tab. Q

Make sure that the mechanical locking systems

on the various adjustment devices are fully tight-
ened.
WARNING

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 Maintenance

7 Maintenance

7.1 Notes on safety for the maintenance

The periodic maintenance is essential for the good operation, Before carrying out any maintenance, cleaning or checking oper-
safety, yield and duration of the burner. ations:
It allows you to reduce consumption and polluting emissions and
to keep the product in a reliable state over time. Disconnect the electrical supply from the burner
The maintenance interventions and the calibration by means of the main system switch.
DANGER
of the burner must only be carried out by qualified,
authorised personnel, in accordance with the con-
DANGER tents of this manual and in compliance with the
Close the fuel interception tap.
standards and regulations of current laws.
DANGER

Wait for the components in contact with heat

sources to cool down completely.

7.2 Maintenance programme

7.2.1 Maintenance frequency IF THE ELECTRICAL SUPPLY OF THE GAS

The gas combustion system should be checked at VALVES OCCURS AT AN UNEXPECTED MO-
least once a year by a representative of the man- MENT, DO NOT OPEN THE MANUAL VALVE,
ufacturer or another specialised technician. WARNING DISCONNECT THE ELECTRICAL SUPPLY,
CHECK THE WIRING; CORRECT THE ER-
RORS AND CARRY OUT THE ENTIRE TEST
7.2.2 Safety test - with gas feeding closed AGAIN.
For its safe commissioning it is very important to make sure that 7.2.3 Checking and cleaning
the electrical wiring has been carried out correctly between the
The operator must use the required equipment
gas valves and the burner.
during maintenance.
To this end, after checking that the connections have been made
in conformity with the burner's wiring diagram, a starting cycle
should be carried out with the gas tap closed (dry test).

1 The manual gas valve should be closed with the locking/re-

leasing device (“lock-out / tag out” procedure).
2 Make sure the limit electric contacts of the burner close
3 Make sure the contact of the minimum gas pressure switch
closes Combustion
4 Proceed with a tentative start up of the burner. Carry out an analysis of the combustion discharge gases.
Significant differences with respect to the previous check indicate
The starting cycle should occur with the following phases: the points where more care should be exercised during mainte-
nance.
– Starting the fan motor for pre-purging
– Carrying out the gas valve leak detection control, if applicable Combustion head
– Completing the pre-purging Open the burner and make sure that all components of the
– Reaching the ignition point combustion head are in good condition, not deformed by the
– Power supply of the ignition transformer high temperatures, free of impurities from the surroundings
– Power supply the gas valves. and correctly positioned.
Since the gas is closed, the burner will not be able to start and its
control box will stop or go into a safety lockout. Burner
Check that there are not excess wear or loosen screws.
The effective supplying of the gas valves can be checked with the Clean the outside of the burner.
insertion of a tester; some valves are fitted with light signals (or
closure/opening position indicators) that are activated when the Fan
electrical supply arrives. Check to make sure that no dust has accumulated inside the fan
or on its blades, as this condition will cause a reduction in the air
flow rate and provoke polluting combustion.
Boiler
Clean the boiler as indicated in its accompanying instructions in
order to maintain all the original combustion characteristics in-
tact, especially the flue gas temperature and combustion cham-
ber pressure.

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 Maintenance

7.2.4 Measuring the ionisation current Air excess

The burner is fitted with an ionisation system to check that a EN 676 Max. output Min. output
flame is present.  1.2  1.3
The minimum current for control box operation is 4 µA. The oper-
CO2 theoretic CO2 % Calibration CO NOX
ator panel displays “30%” (see List of parameters, parameter no. GAS
al max. 0% O2  = 1.2 = 1.3 mg/kWh mg/kWh
954).
The burner provides a much higher current, so controls are not G 20 11.7 9.7 9.0  100  170
normally required. G 25 11.5 9.5 8.8  100  170
However, if it is necessary to measure the ionisation current, dis- G 30 14.0 11.6 10.7  100  230
connect the plug-socket on the ionisation probe cable and insert G 31 13.7 11.4 10.5  100  230
a direct current microammeter with a base scale of 100 µA, as
shown in Fig. 35. Tab. R

7.2.5 Safety components

Carefully check the polarities!
The safety components should be replaced at the end of their life
WARNING cycle indicated in the Tab. S.
The specified life cycles do not refer to the warranty terms indi-
cated in the delivery or payment conditions.
Safety component Life cycle
10 years or 250.000
Flame control
operation cycles
10 years or 250.000
+ Flame sensor
operation cycles
10 years or 250.000
Gas valves (solenoid)
- operation cycles
20163268
10 years or 250.000
Pressure switches
operation cycles
Fig. 35 Pressure adjuster 15 years
10 years or 250.000
Gas leaks Servomotor (electronic cam)
operation cycles
Make sure that there are no gas leaks on the pipes between the
10 years or 250.000
gas meter and the burner. Oil valve (solenoid)
operation cycles
Gas filter 10 years or 250.000
Replace the gas filter when it is dirty. Oil regulator
operation cycles
Combustion Pipes/ oil fittings (metallic) 10 years
If the combustion values measured before starting maintenance 5 years or 30.000
Flexible hoses (if present)
do not comply with applicable legislation or do not indicate effi- pressurised cycles
cient combustion, consult the Tab. R or contact our Technical Fan impeller 10 years or 500.000 start-ups
Support Service to implement the necessary adjustments.
It is advisable to set the burner according to the type of gas used Tab. S
and following the indications in Tab. R.

7.3 Opening the burner

Disconnect the electrical supply from the burner Wait for the components in contact with heat
by means of the main system switch. sources to cool down completely.
DANGER

See “Access to head internal part” on page 22.

Close the fuel interception tap.
DANGER

7.4 Closing the burner

Refit following the steps described but in reverse order; refit all
burner components as they were originally assembled. Carry out all maintenance work and mount the
casing again.

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 Faults - Possible causes - Solutions

8 Faults - Possible causes - Solutions

If faults arise in ignition or operations, the burner performs a

In the event the burner stops, in order to prevent
"safety stop", which is signalled by the red burner lockout LED.
any damage to the installation, do not unblock the
The display of the operator panel visualises alternately the lock- burner more than twice in a row.
out code and the relative diagnostic. WARNING
If the burner locks out for a third time, contact the
To restore start-up conditions, refer to the Reset procedure. customer service.
When the burner starts up again, the red LED goes out.
In the event there are further lockouts or faults
with the burner, the maintenance interventions
must only be carried out by qualified, authorised
DANGER personnel, in accordance with the contents of this
manual and in compliance with the standards and
regulations of current laws.

8.1 List of error codes

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

No communication between REC 37.400A2 and Check the wiring between the control box REC 37.400A2 and
No Comm
RDI21… display RDI21…
2 # No flame at the end of TSA1
1 No flame at the end of safety time 1 (TSA1)
2 No flame at the end of safety time 2 (TSA2)
No flame at the end of safety time 1 (TSA1)
4
(software version  V02.00)
3 # Air pressure error
0 Air pressure switch off
1 Air pressure switch on
4 Air pressure 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
Extraneous light during start-up, air pressure - Alarm
6
lockout at start
Extraneous light during start-up, fuel pressure - Alarm
18
lockout at start
Extraneous light during start-up, air pressure, fuel pressure
24
- Alarm lockout at start
Extraneous light during start-up, POC – Alarm lockout at
66
start
Extraneous light during start-up, air pressure, POC - Alarm
70
lockout at start
Extraneous light during start-up, fuel pressure, POC -
82
Alarm lockout at start
Extraneous light during start-up, air pressure, fuel pressure,
86
poc - Alarm lockout at start
7 # Loss of flame
0 Loss of flame
3 Flame loss (software version  V02.00)
The diagnostics covers the period between the closure of the fuel
3…255 Flame loss during TÜV test (flame loss test) valve to the point the flame loss is detected (resolution 0.2 s 

12 # Valve leak detection control
Leak test
0 V1 leaks Check if the valve on the side of the gas has any leaks.
Check the wiring and make sure that the circuit is open.

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 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

Leak test
Check if the valve on the side of the burner has any leaks.
1 V2 leaks Check if the pressure switch for the leak test (PGVP) is closed
when gas pressure is not present.
Check the wiring and check if there is a short circuit.
The valve leak detection is active, but the minimum gas
2 Valve leak detection test not possible pressure switch is selected as input for X9-04 (check
parameters 238 and 241).
The valve leak detection is active, but no input has been
3 Valve leak detection test not possible
assigned (check parameters 236 and 237).
Valve leak detection is active, but 2 inputs have already been
4 Valve leak detection not possible assigned (configure parameter 237 or maximum gas Pressure
switch or POC).
The valve leak detection is active, but 2 inputs have been
5 Valve leak detection not possible
assigned (check parameters 236 and 237).
14 # POC
0 POC Open Check if the closure contact of the valve is closed.
Check the wiring.
1 POC Closed Check if the closure contact of the valve opens when the valve
is checked.
Check the wiring.
64 POC Open - Alarm lockout at start
Check if the closure contact of the valve is closed.
Check that the pressure switch is closed when no pressure is
19 80 Fuel pressure, POC - Alarm lockout at start present from the fuel.
Check that there are no short-circuits.
20 # Pmin
0 Minimum gas/oil pressure absent Check that there are no line interruptions.
1 Scarcity of gas - Alarm lockout at start Check that there are no line interruptions.
21 # Pmax/POC
Pmax: Max. gas/oil pressure exceeded Check the wiring.
0
POC: POC open (software version  V02.00) POC: check whether the closure contact of the valve is closed.
Check the wiring.
1 POC closed (software version  V02.00) Check if the closure contact of the valve opens when the valve
is checked.
Check the wiring.
POC Open - Lockout alarm at the start (software version 
64 Check if the contact of the valve opens when the valve is
V02.00)
checked.
22
# Safety circuit/Burner flange
OFF S
0 Safety circuit open /Burner flange open
Safety circuit open /Burner flange open - Alarm lockout at
1
start
Safety circuit open /Burner flange open, extraneous light -
3
Alarm lockout at start
Safety circuit open /Burner flange open, extraneous light -
5
Alarm lockout at start
Safety circuit open /Burner flange open, extraneous light -
17
Alarm lockout at start
Safety circuit open /Burner flange open, extraneous light -
19
Alarm lockout at start
Safety circuit open /Burner flange open, extraneous light -
21
Alarm lockout at start
Safety circuit open /Burner flange open, extraneous light,
23
air pressure, fuel pressure - Alarm lockout at start
Safety circuit /Burner flange open, POC - Alarm lockout at
65
start
Safety circuit open /Burner flange open, extraneous light,
67
POC - Alarm lockout at start
Safety circuit open /Burner flange open, air pressure, POC
69
- Alarm lockout at start
Safety circuit open /Burner flange open, extraneous light,
71
air pressure, POC - Alarm lockout at start
Safety circuit open /Burner flange open, fuel pressure, POC
81
- Alarm lockout at start
Safety circuit open /Burner flange open, extraneous light,
83
air pressure, POC - Alarm lockout at start

20160897
50 GB
 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

Safety circuit open /Burner flange, air pressure, fuel

85
pressure, POC - Alarm lockout at start
Safety circuit open /Burner flange, extraneous light, air
87
pressure, fuel pressure, POC - Alarm lockout at start
Carry out a reset; if the error arises repeatedly, replace the
50 ÷ 58 # Internal error
control box.
Carry out a reset; if the error arises repeatedly, replace the
60 0 Internal error: no valid load checking device
control box.
Carry out a reset; if the error arises repeatedly, replace the
65 ÷ 67 # Internal error
control box.
Fuel/air checking error: Calculation position in
70 #
modulation
23 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 Pre-purging position Set the pre-purging position of all the servomotors used.
2 Post-purging position Set the post-purging position of all the servomotors used.
3 Ignition position Set the ignition position of all the servomotors used.
Carry out a reset; if the error arises repeatedly, replace the
72 # Fuel/air internal checking error:
control box.
Fuel/air internal checking error: multistep calculation
73 #
position
23 Position calculation, invalid stage load No valid load.
26 Position calculation, stage curve points not defined Adjust the curve points of all the servomotors.
Fuel/air ratio internal checking error: cyclical data
75 #
check
1 Check synchronisation data, different current load
2 Check synchronisation data, different target load
4 Check synchronisation data, different target positions
May be caused by different standardisation speeds (for example
following the resetting of the data set) when the VSD is active ->
16 Check synchronisation data, different positions reached
perform the standardisation again and check the regulation of
the fuel/air ratio.
Carry out a reset; if the error arises repeatedly, replace the
76 # Fuel/air internal checking error:
control box.
The standard unit could not correct the speed difference and
has reached a limit in the control range.
1. The base unit is not standardised for this motor
----> repeat the standardisation.
WARNING!
check the settings of the air/fuel ratio control!

80 # VSD control range limit 2. The VSD train times are not shorter than those of the
standard unit (parameters 522, 523).
3. The VSD characteristic is not linear. The VSD voltage input
configuration must correspond with that of the standard unit
(parameter 645).
4. The VSD does not follow the changes of the standard unit
quickly enough. Check the VSD settings (input filter, slide
compensation, different latent speeds).
1 Lower control range limit The VSD speed was too high.
2 Upper control range limit The VSD speed was too low.
Excessive electromagnetic interference on the sensor line ->
81 1 Interruption in speed limit input
improve the EMC.
82 # Error during VSD speed standardisation
Time-out at the end of the standardisation, during deceleration
Standardisation time-out (the descent time of the VSD train of VSD.
1
is too long) 1. The VSD train times are not shorter than those of the
standard unit (parameter: 523).
Error during the logging of the standardised speed ---> block the
2 Logging of the standardised speed not successful
standard unit, reset it and repeat the standardisation.

51 GB 20160897
 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

The standard unit does not receive pulses from the speed
sensor:
1. The motor does not turn.
3 Speed sensor circuit open
2. The speed sensor is not connected.
3. The speed sensor is not activated by the sensor disc (check
the distance).
The motor has not reached a stable speed after acceleration.
1. The VSD train times are not shorter than those of the
standard unit (parameters 522, 523).
2. The VSD characteristic is not linear. The VSD voltage input
configuration must correspond with that of the standard unit
Variation in speed / VSD acceleration time too long / speed
4 (parameter 645).
below the minimum limit for standardisation
3. The VSD does not follow the changes of the standard unit
quickly enough. Check the VSD settings (input filter, slide
compensation, different latent speeds).
4. The VSD speed is below the minimum for standardisation
(650 rpm).
The motor rotation direction is incorrect.
1. The motor does not rotate in the correct direction ---> modify
5 Incorrect rotation direction the parameterisation of the rotation direction, or invert 2 phases.
2. The sensor disc is incorrectly assembled ---> turn the sensor
disc.
The required pulse pattern (60°, 120°, 180°) has not been
correctly identified.
1. The speed sensor does not detect all the noses of the sensor
disc ---> check the distance.
6 Implausible speed sensor signals 2. When the motor turns, other metal parts are detected along
with the noses.
---> improve the assembly.
3. Electromagnetic interference on the sensor lines ---> check
the cable path, improve the EMC.
The standardised speed measured is not within the allowed
7 Standardised speed not valid range.
1. The motor turns too slowly or too quickly.
Microcomputer speeds 1 and 2 have an excessive deviation.
This may be caused by incorrect standardised speeds (e.g.
15 Speed deviation µC1 + µC2
after the reintegration of a set of data in a new unit)
---> repeat the standardisation and check the air/fuel ratio.
The standardisation was performed in the wrong phase.
20 Incorrect phase of the phase controller The only phases allowed are  12 ---> controller OFF, restart
the standardisation.
The safety loop or burner flange is open ---> repeat the
21 Safety loop/burner flange open
standardisation with the safety loop closed.
The air actuator has no reference, or has lost it.
1. Check whether the reference position can be approached.
22 Pneumatic actuator without reference 2. Check whether the actuators have been swapped over.
3. If the error only arises after the start of standardisation, the
actuator may be overloaded and unable to reach its destination.
The standardisation was started with the VSD deactivated --->
23 VSD deactivated
activate the VSD and repeat the standardisation.
The standardisation was started without a valid operation mode
24 No valid operation mode ---> activate a valid operation mode and repeat the
standardisation.
The standardisation was started with a pneumatic control of the
25 Pneumatic control of the air/fuel ratio air/fuel ratio ---> it is not possible to carry out the standardisation
with a pneumatic control of the air/fuel ratio.
The VSD is controlled but not standardised ---> perform the
128 Run command without prior standardisation
standardisation.
The motor turns but is not standardised ---> perform the
255 No standardised speed available
standardisation.
83 # VSD speed error The required speed has not been reached.
The speed was not reached because the control range limit was
Bit 0
Lower control range limit activated.
Valence 1
---> for the measurements, see error code 80.
Bit 1 The speed was not reached because the control range limit was
Greater control range limit
Valence 2...3 activated ---> for the measurements, see error code 80.
The speed has not been reached because there are too many
Bit 2
Stop caused by electromagnetic interference electromagnetic interferences on the sensor line. For the
Valence 4...7
measurements, see error code 81.

20160897
52 GB
 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

The speed was not reached because the curve was too steep.
1. With a train REC3... of 20 s, the speed variation between 2
points of the curve (in modulating mode) cannot exceed 10%.
With a train REC3... of 10 s, the speed variation between 2
points of the curve (in modulating mode) cannot exceed 20%.
Bit 3 With a train REC3... of 5 s, the speed variation between 2 points
Curve too steep in terms of train speed
Valence 8 of the curve (in modulating mode) cannot exceed 40%.
---> Between the ignition point (P0) and the low flame point (P1),
the speed in modulating mode may vary by a maximum of 40%,
regardless of the train REC3….
2. The VSD train must be about 20% faster than the train of the
standard unit (parameters 522, 523).
No speed detected, despite the control.
1. Check whether the motor turns.
Bit 4
Speed signal interruption 2. Check whether the speed sensor provides a signal (LED /
Valence 16
check the distance from the sensor disc).
3. Check the VSD wiring.
For about 1 s, the speed deviation was >10% outside the
Bit 5 envisaged range.
Quick switch-off due to excessive speed deviation
Valence 32 1. Check the train times of REC3.... and VSD.
2. Check the VSD wiring.
84 # Servomotors curve slope
1. With a train REC3... of 20 s, the speed variation between
points of the curve (in modulating mode) cannot exceed 10%.
.With a train REC3... of 10 s, the speed variation between points
of the curve (in modulating mode) cannot exceed 20%.
2. With a train REC3... of 5 s, the speed variation between
Bit 0
VSD: Curve too steep in terms of train speed points of the curve (in modulating mode) cannot exceed 40%.
Valence 1
---> Between the ignition point (P0) and the low flame point (P1),
the speed in modulating mode may vary by a maximum of 40%,
regardless of the train REC3….
The VSD train must be about 20% faster than the train of the
standard unit (parameters 522, 523).
Bit 1 The slope of the curve can correspond to a maximum position
Fuel servomotor: Curve too steep in terms of train ratio
Valence 2..3 variation of 31° between 2 points of the modulation curve.
Bit 2 The slope of the curve can correspond to a maximum position
Air servomotor: Curve too steep in terms of train ratio
Valence 4..7 variation of 31° between 2 points of the modulation curve.
85 # Reference error of a servomotor
The reference of the fuel servomotor was not successful.
It was not possible to reach the reference point.
0 Reference error of the fuel servomotor
1. Check if the servomotors have been inverted.
2. Check if the servomotor is blocked or overloaded.
The reference of the air servomotor was not successful.
It was not possible to reach the reference point.
1 Reference error of the air servomotor
1. Check if the servomotors have been inverted.
2. Check if the servomotor is blocked or overloaded.
The parameterisation of an actuator (e.g. the reference position)
Bit 7
Reference error owing to parameter modification has been modified. This error will be visualised to start up a new
Valence 128
reference.
86 # Fuel servomotor error
It was not possible to reach the target position within the
0 Position error required range ---> Check to see if the servomotor is blocked or
overloaded.
Open circuit detected on the connection of the servomotor
Bit 0
Circuit open ---> Check the wiring (voltage between pins 5 or 6 and 2 of the
Valence 1
X54 connector should be > 0.5 V).
Bit 3 The slope of the curve can correspond to a maximum position
Curve too steep in terms of train ratio
Valence 8 modification of 31° between 2 points of the modulation curve.
Overloading of the servomotor or servomotor subjected to
mechanical torsion.
Bit 4
Deviation of section compared with the last reference 1. Check if the servomotor is blocked in any point along its
Valence 16
range of action.
2. Check if the torque is sufficient for the application.
87 # Air servomotor error
It was not possible to reach the target position within the
0 Position error requested tolerance range.
1. Check if the servomotor is blocked or overloaded.
Open circuit detected on the connection of the servomotor
Bit 0
Circuit open ---> Check the wiring (voltage between pins 5 or 6 and 2 of the
Valence 1
X54 connector should be > 0.5 V).

53 GB 20160897
 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

Bit 3 The slope of the curve can correspond to a maximum position

Curve too steep in terms of train ratio
Valence 8 modification of 31° between 2 points of the modulation curve.
Overloading of the servomotor or servomotor subjected to
mechanical torsion.
Bit 4
Deviation of section compared with the last reference 1. Check if the servomotor is blocked in any point along its
Valence 16
range of action.
2. Check if the torque is sufficient for the application.
90 - 91 # Burner internal checking error
93 # Flame signal acquisition error
Short circuit in the QRB sensor...
3 Short circuit of the sensor 1. Check the wiring.
2. Flame detector probably faulty.
95 # Relay supervision error
3 Ignition transformers
4 Fuel valve 1
External power supply - Contact active Check the wiring.
5 Fuel valve 2
6 Fuel valve 3
96 # Relay supervision error
Check the contacts:
1. Control box connected to the power supply: the fan output
must be without voltage.
3 Ignition transformers
2. Disconnect the power supply. Disconnect the fan. The
4 Fuel valve 1
The relay contacts have joined together resistive connection between the fan output and the neutral wire
5 Fuel valve 2
is not allowed.
6 Fuel valve 3
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.
97 # Relay supervision error
Check the contacts:
1. Control box connected to the power supply: the fan output
must be without voltage.
2. Disconnect the power supply. Disconnect the fan. The
The safety relay contacts have joined together or the safety
0 resistive connection between the fan output and the neutral wire
relay has been powered by an external power supply
is 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 transformers
4 Fuel valve 1 The relay does not start up Carry out a reset; if the error arises repeatedly, replace the unit.
5 Fuel valve 2
6 Fuel valve 3
Carry out a reset; if the error arises repeatedly, replace the
99 # Relay internal checking error
control box.
Carry out a reset; if the error arises repeatedly, replace the
control box.
Software version V03.10: If error C:99 D:3 occurs during the
3 Relay internal checking error
standardisation of the VSD, temporarily deactivate the Alarm
function at the start of the pre-purging phase (parameter 210 =
0) or interrupt the signal controller-ON.
Carry out a reset; if the error arises repeatedly, replace the
100 # Relay internal checking error
control box.
105 # Contact sampling internal error
0 Min. pressure switch
1 Max. pressure switch
2 Valve operation test
pressure switch
3 Air pressure
4 Load controller open
5 Load controller on/off Can be caused by capacitive loads or presence of DC voltage
6 Load controller closed Blocked upon irregularity on the main power supply of the control box. The diagnostic
7 Safety loop / burner flange code indicates the input in which the problem arose.
8 Safety valve
9 Ignition transformers
10 Fuel valve 1
11 Fuel valve 2
12 Fuel valve 3
13 Reset
Carry out a reset; if the error arises repeatedly, replace the
106 ÷ 108 # Contact request internal error
control box.

20160897
54 GB
 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

Carry out a reset; if the error arises repeatedly, replace the

110 # Voltage monitoring test internal error
control box.
Insufficient mains voltage.
111 0 Low level of power supply Conversion of the diagnostic code ---> Voltage value (230 V AC
: 1,683).
Error code for the carrying out of a reset in the event of power
112 0 Reset power supply voltage
supply restoration (absence of error).
Carry out a reset; if the error arises repeatedly, replace the
113 # Mains voltage supervision internal error
control box.
115 # Control box meter internal error
Life cycle of the control box in the critical interval The envisaged life cycle of the control box has been exceeded.
116 0
(250,000 Start ups) Replace it.
117 0 Life cycle of the control box exceeded The switch-off threshold has been reached.
Too many disturbance impulses on the input of the fuel meter --
120 0 Interruption of fuel limiting meter input
-> Improve the electromagnetic compatibility.
Carry out a reset, repeat and check the last setting of the
121 ÷ 124 # EEPROM access internal error parameters. Restore the group of parameters: if the error arises
repeatedly, replace the control box.
Carry out a reset, repeat and check the last setting of the
125 # EEPROM reading access internal error parameters. If the error arises repeatedly, replace the control
box.
Carry out a reset, repeat and check the last setting of the
126 # EEPROM writing access internal error parameters. If the error arises repeatedly, replace the control
box.
Carry out a reset, repeat and check the last setting of the
127 # EEPROM access internal error parameters. Restore the group of parameters: if the error arises
repeatedly, replace the control box.
EEPROM access internal error - synchronisation Carry out a reset; If the error arises repeatedly, replace the
128 0
during the initialisation control box.
Carry out a reset, repeat and check the last setting of the
EEPROM access internal error – command
129 # parameters. If the error arises repeatedly, replace the control
synchronisation
box.
Carry out a reset, repeat and check the last setting of the
130 # EEPROM access internal error - time-out parameters. If the error arises repeatedly, replace the control
box.
Carry out a reset, repeat and check the last setting of the
131 # EEPROM access internal error - page interrupted parameters. If the error arises repeatedly, replace the control
box.
Carry out a reset; if the error arises repeatedly, replace the
132 # EEPROM register initialisation internal error
control box.
Carry out a reset, repeat and check the last setting of the
EEPROM access internal error – request
133 ÷ 135 # parameters. If the error arises repeatedly, replace the control
synchronisation
box.
136 1 Restoration started The restoration of a backup has been started (no error).
137 # Internal error – backup / restoration
Restoration – OK, but backup < compared with set data of Restoration successful, but the backup data installed are fewer
157 (-99)
current system than those currently present in the system.
239 (-17) Backup - logging of the backup on RDI21… failed Perform the reset and repeat backup.
240 (-16) Reset - no backup in RDI21… No backup in RDI21…
The backup has an impracticable ASN and cannot reset the
241 (-15) Reset - Interruptions relating to impracticable ASN
unit.
242 (-14) Backup – the backup carried out is contradictory The backup is irregular and cannot be transferred again.
Backup – the data comparison between the internal
243 (-13) Repeat the reset and backup.
microprocessors is irregular
The backup data are incompatible with the current version of the
244 (-12) The backup data are incompatible
software; the restoration is not possible.
245 (-11) Error in access to the parameter Restore_Complete Repeat the reset and backup.
246 (-10) Restoration – time-out during logging in EEPROM Repeat the reset and backup.
The series of backup data is not valid; restoration is not
247 (-9) The data received are contradictory
possible.
248 (-8) The restoration cannot currently be carried out Repeat the reset and backup.
Restoration – interruption caused by inadequate The backup has an inadequate identification of the burner and
249 (-7)
identification of the burner must not be transferred to the control box.
The series of backup data is not valid; restoration is not
250 (-6) Backup – the CRC of a page is not correct
possible.
251 (-5) Backup – the identification of the burner is not defined Define the identification of the burner and repeat the backup.

55 GB 20160897
 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

252 (-4) After restoration, the pages are still in INTERRUPTION Repeat the reset and backup.
253 (-3) The restoration cannot currently be carried out Repeat the reset and backup.
254 (-2) Interruption owing to transmission error Repeat the reset and backup.
255 (-1) 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
150 # TÜV test
1 (-1) Invalid phase The TÜV test can only be started in phase 60 (operation).
The output of the TÜV test must be lower than the minor output
2 (-2) The TÜV test default output is too low
limit.
The output of the TÜV test must be greater than the upper
3 (-3) The TÜV test default output is too high
output limit.
4 (-4) Manual interruption No error: Manual interruption of the TÜV test by the user.
No flame loss after the fuel valves have been closed
1. Check for any extraneous lights.
5 (-5) TÜV test timeout
2. Check that there are no short-circuits.
3. Check whether one of the valves is leaking.
165 # Internal error
166 0 Watchdog reset internal error
167 # Manual lockout The control box has been manually blocked (no error).
1 Manual lockout from remote reset command
2 Manual lockout from RDI21…
3 Manual lockout from PC interface
During a regulation of the curve via the operating panel
Manual lockout from RDI21… RDI21…the timeout for the operating menu is passed (setting
8
Timeout/interrupted communication via the 127 parameter), or else the communication between
REC 37.400A2 and RDI21... has been interrupted.
During an adjustment of the curve via the PC interface, the
Manual lockout from PC interface
9 communication between REC 37.400A2 and the operator panel
Communication interrupted
has been interrupted for more than 30 seconds.
Manual lockout after the PC tool has performed a tentative The PC tool has performed a tentative reset, even if the system
33
reset has worked correctly.
Carry out a reset; if the error arises repeatedly, replace the
168 ÷ 171 # Internal error management
control box.
200 OFF # System free of errors No error.
201 OFF
# Lockout or error at start Lockout or error due to lack of unit parameter settings.
UPr
Bit 0
No valid operation mode
Valency 1
Bit 1
No fuel train defined
Valency 2..3
Bit 2
No curve defined
Valency 4..7
Bit 3
Standardisation speed not defined
Valency 8..15
Bit 4
Backup / Reset impossible
Valency 16..31
202 # Selection of internal operation mode Redefine the operation mode (parameter 201).
Redefine the operation mode (parameter 201)
203 # Internal error Carry out a reset; if the error arises repeatedly, replace the
control box.
204 Phase number Program stop The program stop is active (no error).
Carry out a reset; if the error arises repeatedly, replace the
205 # Internal error
control box.
Combination of control box and operator panel not
206 0
allowed
207 # Compatibility of control box with operator panel
0 Obsolete version of control box
1 Obsolete version of operator panel
Carry out a reset; if the error arises repeatedly, replace the
208 - 209 # Internal error
control box.
The selected operating mode is not released for the
210 0 Select an operating mode released for the standard unit.
standard unit

20160897
56 GB
 Faults - Possible causes - Solutions

Error
Diagnostic code Meaning of the REC 37.400A2 system Recommended measures
code

Carry out a reset; if the error arises repeatedly, replace the

240 # Internal error
control box.
Carry out a reset; if the error arises repeatedly, replace the
245 # Internal error
control box.
Carry out a reset; if the error arises repeatedly, replace the
250 # Internal error
control box.

Tab. T

57 GB 20160897
 Appendix - Accessories

A Appendix - Accessories

Kit for modulating operation

Burner Output regulator Code

RWF 50.2 3-POINT OUTLET 20085417
RS 810/E BLU RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441
RWF 55.6 COMPLETE WITH RS-485/PROFIBUS INTERFACE 20074442

Burner Probe Adjustment field Code

PT 100 temperature - 100...+ 500°C 3010110
4 - 20 mA pressure 0...2.5 bar 3010213
RS 810/E BLU
4 - 20 mA pressure 0...16 bar 3010214
4-20 mA pressure 0...25 bar 3090873

UV sensor kit

Burner Code
RS 810/E BLU 20077814

Soundproofing box kit

Burner Type dB(A) Code

RS 810/E BLU C7 10 20177776

Continuous purging kit Software interface kit (ACS410 + OCI410.30) - Service

Level
Burner Code
RS 810/E BLU 20077810 Burner Code
RS 810/E BLU 3010436

Modbus interface kit

Burner Model Code

RS 810/E BLU OCI412 3010437

PVP kit (Seal control function - See gas train booklet)

Burner Ramp type Code

RS 810/E BLU MB - CB 3010344

Gas trains in compliance with EN 676

Please refer to manual.

The installer is responsible for the addition of any

safety device not foreseen in this manual.
WARNING

20160897
58 GB
 Appendix - Electrical panel layout

B Appendix - Electrical panel layout

1 Index of layouts

2 Indication of references

3 Layout of unifilar output

4 Layout of unifilar output

5 REC 37... operational layout

6 REC 37... operational layout

7 REC 37... operational layout

8 Electrical connections for power regulator (internal)

9 Electrical connections set by installer

10 Electrical connections set by installer

11 Inputs/outputs power regulator

2 Indication of references

/1.A1
Sheet no.

Co-ordinates

59 GB 20160897

     

20160897


 




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 Appendix - Electrical panel layout

Wiring layout key

A1 Electronic cam
A2 Display and calibration unit
B1 Output regulator RWF50 internal
B2 Fuel meter
BA Probe with output under current
BA1 Device with output under current, for modifying re-
mote setpoint
BMS Modulation control 4-20mA
BP Pressure probe
BP1 Pressure probe
BR Remote setpoint potentiometer
BT1 Thermocouple probe
BT2 Probe Pt100, 2 wires
BT3 Probe Pt100, 3 wires
BT4 Probe Pt100, 3 wires
BTEXT External probe for climatic compensation of the set-
point
BV Output probe in voltage
BV1 Output device in voltage to modify remote setpoint
F1 Fan motor thermal relay
FU Auxiliary circuits safety fuse
G1 Load indicator
G2 Communication interface for Modbus system
H Burner working lighting signal output
IN Burner manual stop electric switch
ION Ionisation probe
KL1 Star/triangle starter line contactor
KT1 Star/triangle 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 lockout
MV Fan motor
PA Air pressure switch
PE Burner earth
PGMax Maximum gas pressure switch
PGMin Minimum gas pressure switch
PGVP Gas pressure switch for valve leak detection control
device
RS Burner reset switch
S2 ON/OFF selector
SM1 Air servomotor
SM2 Gas servomotor
TA Ignition transformer
TL Limit thermostat/pressure switch
TR Adjustment thermostat/pressure switch
TS Safety thermostat/pressure switch
Y Gas regulator valve + gas safety valve
X1 Terminal board for main supply
X3 Terminal board for modulation control 4-20mA
XPD Plug for on board display
XPGMax Maximum gas pressure switch connector
XPGMin Minimum gas pressure switch connector
XPGVP Gas pressure switch connector for valve leak detec-
tion control device
XRWF Terminal board for output power regulator RWF50

69 GB 20160897
 RIELLO S.p.A.
I-37045 Legnago (VR)
Tel: +39.0442.630111
http:// www.riello.it
http:// www.riello.com

Subject to modifications