Riello RLS 120/E FGR, Installation, Use And Maintenance Instructions

Page 1: ...20168262 3 01 2020 Installation use and maintenance instructions Dual fuel light oil gas burner Modulating operation CODE MODEL 20166921 RLS 120 E FGR GB ...

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

Page 3: ...n 15 4 15 Servomotor 662R5 16 4 16 Calibration of the thermal relay 16 5 Installation 17 5 1 Notes on safety for the installation 17 5 2 Handling 17 5 3 Preliminary checks 17 5 4 Operating position 18 5 5 Preparing the boiler 18 5 5 1 Boring the boiler plate 18 5 5 2 Blast tube length 18 5 6 Positioning electrode and pilot 19 5 6 1 Electrodes adjustment 19 5 6 2 Pilot operation parameters 19 5 7 S...

Page 4: ...sure switch 34 6 7 3 Minimum gas pressure switch 34 6 7 4 PVP pressure switch kit 34 6 7 5 Minimum oil pressure switch 34 6 7 6 Maximum oil pressure switch 34 6 8 Start up the flue gases recirculation system 35 6 9 Steady state operation 35 6 10 Ignition failure 35 6 11 Burner flame goes out during operation 36 6 12 Stopping of the burner 36 6 13 Final checks with burner operating 36 7 Maintenance...

Page 5: ...with the following Technical Standards EN 676 EN 267 EN 12100 and according to the European Directives MD 2006 42 EC Machine Directive LVD 2014 35 UE Low Voltage Directive EMC 2014 30 UE Electromagnetic Compatibility Quality is ensured by means of an ISO 9001 2015 certified quality and management system Legnago 21 04 2018 General Manager RIELLO S p A Burners Department Research and Development Dir...

Page 6: ...ried out correctly may cause damage to the ma chine and or injury to people DANGER DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not car ried out correctly lead to electric shocks with le thal consequences DANGER FLAMMABLE MATERIAL This symbol indicates the presence of flammable materials DANGER BURNING This symbol indicates the risks of burns due to high temperatures DAN...

Page 7: ... 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 appliance use of the burner with safety devices that are faulty incor rectly applied and or no...

Page 8: ...e Only those parts envisaged by the manufacturer can be replaced 3 2 Personnel training The user is the person body or company that has acquired the machine and intends to use it for the specific purpose He is re sponsible for the machine and for the training of the people work ing around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel undertak...

Page 9: ...f the system 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 R LS 120 E TC Emission C11 or Class 1 EN267 EN676 C22 or MZ Class 2 EN267 EN676 C33 or BLU Class 3 EN267 EN676 FS1 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION FGR 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam SV Electronic cam with variable speed with Inverter P Proportional air ...

Page 10: ...LL NL I2L I2E I2 43 46 45 3 MJ m3 0 C FR I2Er BE I2E R B LU PL I2E Model RLS 120 E FGR FS1 Power 1 Delivery 1 min max kW kg h 300 600 1200 25 50 101 Fuels Light oil max viscosity at 20 C 6 mm2 s 1 5 E 6 cSt Natural gas G20 methane gas Operation Intermittent min 1 stop in 24 hours Oil Gas modulating with kit Nozzles number 1 Standard applications Boilers water steam diathermic oil Room temperature ...

Page 11: ...lectrical supply 3 400V 50Hz 10 Auxiliary circuit electrical supply 1N 230V 50Hz Fan motor rpm V Hz W A 2890 380 415 50 2200 4 5 Pump motor rpm V Hz W A 2700 230 50 550 3 6 Ignition transformer V1 V2 I1 I2 230 V 2 x 5 kV 1 9 A 35 mA Max Absorbed electric power main electrical supply light oil gas W 2550 2550 Max Absorbed electric power auxiliary circuit electrical supply light oil gas W 500 1300 P...

Page 12: ...kW 650 Mcal h diameter 60 cm length 2 m WARNING WARNING The firing rate was obtained at an ambient tem perature of 20 C and an atmospheric pressure of 1000 mbar approx 100 m above sea level and with the combustion head adjusted as shown on page 22 WARNING WARNING For the operation inside the area B Fig 2 remove the gas nozzle as shown Removing the nozzles on page 22 A 9 1 1 3 5 7 11 mbar 12 10 8 6...

Page 13: ... type approved for boilers or ovens with combustion chambers of very different di mensions compared to those shown in the diagram of Fig 3 preliminary checks are recommended For flame inversion boilers a kit is available to reduce the CO if necessary 4 10 Burner equipment Flange for gas train No 1 Slide bar extensions TL version No 4 Gasket for flange No 1 M10x40 screws to fix the gas flange No 4 ...

Page 14: ...ilot 24 Air damper 25 Fan air inlet 26 Screws to secure fan to pipe coupling 27 Gas input pipe 28 Gas butterfly valve 29 Boiler fixing flange 30 Flame stability disc 31 Connector G1 4 32 Lifting rings 33 Flue gas recirculation butterfly valve 34 Flue gas recirculation servomotor 35 Pilot gas train 36 Flue gas temperature probe 37 K1 relay 38 K2 relay 39 K3 relay 40 Minimum oil pressure switch 41 O...

Page 15: ...ons the regulator adopts suitable measures like for example manually disarming the system These instructions describe numerous possible applications and should be used as guidelines Please always check and corroborate the fact the system is operating correctly by means of functional tests on the test bench when the system is operating Comply with the additional instructions to ensure the BT340 is ...

Page 16: ...X02 X25 X24 S9612 Any position t1 Safety circuits enabling standby time boiler and fuel t2 Gas valve opening time with valve leak detection control device active 2 4 s t3 Servomotor opening time 30 60 s t4 FGR servomotor activation time 0 t5 t5 Pre purging time adjustable t6 Pre ignition time adjustable t7 Flame ignition safety time 3s t8 Flame stabilisation time adjustable t9 2nd stage safety tim...

Page 17: ...rrelevance time P323 has an effect on the oil safety chain and on the minimum oil pressure when the air valve is opened Any position t1 Safety circuits enabling standby time boiler and fuel t2 Gas valve opening time with valve leak detection control device active 2 4 s t3 Servomotor opening time 30 60 s t4 FGR servomotor activation time 0 t5 t5 Pre purging time adjustable t6 Pre ignition time adju...

Page 18: ...on of the thermal relay press the RESET button 1 of Fig 10 The red TEST button 3 opens the NC 95 96 contact and stops the motor WARNING WARNING To avoid accidents material or environmental damage observe the following instructions Do not open modify or force the actuators WARNING WARNING Assembly notes The connection between the actuator command shaft and the control element must be rigid with out...

Page 19: ...st be free from hazardous mixes e g chloride fluoride halo gen if present it is highly recommended to carry out cleaning and maintenance more frequently WARNING WARNING The handling operations for the burner can be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check...

Page 20: ...ion device in refractory ma terial 11 must be inserted between the boiler fettling 12 and the blast tube 10 This protective fettling must not compromise the extraction of the blast tube For boilers with a water cooled frontal a refractory lining is not necessary 11 12 unless expressly requested by the boiler man ufacturer Tab K WARNING WARNING The burner is designed to operate only in positions 1 ...

Page 21: ...ng the burner to the boiler check the correct positioning of the electrodes and pilot as indicated Fig 25 WARNING WARNING Observe the dimensions shown in Fig 25 WARNING WARNING Position the electrodes according to the dimen sions shown in Fig 15 WARNING WARNING For the correct operation of the burner gas pres sure at the pilot must be between 15 and 30 mbar and the air damper must have an opening ...

Page 22: ...burner on the guides 5 by about 100 mm disconnect the electrode leads then unthread the burner completely from the guides fix the flange 9 to the boiler plate interposing the insulating gasket 8 supplied use the 4 screws supplied with a tightening torque of 35 40 Nm after protecting their thread with anti seize products Provide an adequate lifting system of the burner WARNING WARNING The seal betw...

Page 23: ...hole of the flame stability disk or loosen the screws 1 Fig 21 remove the disk 2 and replace the nozzle with the spanner 3 Fig 21 WARNING WARNING It is advisable to replace the nozzle once a year during periodical maintenance CAUTION The use of nozzles other than those specified by Riello S p A and inadequate regular maintenance may result into emission limits non conforming to the values set fort...

Page 24: ...ly on the maximum output of the burner Turn the screw 5 Fig 23 until the notch indicated by the dia gram Fig 24 corresponds with the front part of the flange 6 Example Burner maximum output 900 kW From the diagram Fig 24 it shows that for this output the ad justment of the combustion head is carried out on the notch 3 Fig 23 5 10 Electrodes adjustment 1 3 4 2 Fig 22 20122232 WARNING WARNING To fac...

Page 25: ...event the condensate flowing through the control valves and inside the fan If there is a lot of condensate it might be necessary to have a drain channel on the bottom of the casing to remove it all Establish whether reduction joints are needed to connect the flue gases recirculation control valve and the relative shut off valve The pipe should be adequately supported in order to manage its weight ...

Page 26: ...la be low IFGR CO2 R CO2 f x 100 Where CO2 R is the percentage of CO2 measured at the burner coupling CO2 f is the percentage of CO2 measured at the stack Tab L 5 12 Closing the burner Once the combustion head adjustment is completed reassemble the burner on the guides 3 at about 100 mm from the pipe coupling 4 burner in the position shown in Fig 27 insert the electrode cables and then slide the b...

Page 27: ...the burner with the by pass closed by screw 6 It is necessary to connect both flexible hoses to the pump Fig 29 The pump will break down immediately if it is run with the return line closed and the by pass screw inserted Remove the plugs from the suction and return connections of the pump Key to layout Fig 28 H Pump Foot valve height difference L Piping length Ø Inside pipe diameter 1 Burner 2 Pum...

Page 28: ...ch on pump delivery line B Oil valve group and pressure variator M Pressure gauges V Vacuometer connection OPERATION Pre purging phase valves 5 6 13 and 14 closed Ignition and operation phase valves 5 6 13 and 14 open Stop All valves closed B 11 10 P 5 M M 1 13 6 2 M 4 V M 12 3 P 15 9 8 7 14 Fig 30 20159817 WARNING WARNING The above mentioned operation is possible be cause the pump is already full...

Page 29: ... trans former to cool Do not illuminate the flame sensor or the burner will lock out the burner should lock out anyway about 10 seconds after it starts 5 13 7 Pump motor rotation Pump J7C Min delivery rate at 20 bar pressure 195 kg h Delivery pressure range 10 21 bar Max suction depression 0 45 bar Viscosity range 2 8 200 cSt Max light oil temperature 90 C Max suction and return pressure 1 5 bar P...

Page 30: ...l devices are compulsory for burners with maximum outputs over 1 200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer Explosion danger due to fuel leaks in the pres ence of a flammable source Precauti...

Page 31: ...int 1 Fig 38 13 4 mbar Pressure in combustion chamber 3 0 mbar 13 4 3 0 10 4 mbar A pressure of 10 4 mbar column 1 corresponds in to an output of 913 kW This value serves as a rough guide the effective output must be measured at the gas meter To calculate the required gas pressure at test point 1 Fig 38 set the maximum modulating output required from the burner op eration find the nearest output v...

Page 32: ... in this manual The burner has been type approved for intermittent use This means they should compulsorily be stopped at least once every 24 hours to enable the control box to per form checks of its own start up efficiency Normally burner stopping is guaranteed by the boiler s thermostat pres sure switch If this is not the case a time switch should be fitted in series to IN to provide for burner s...

Page 33: ... pressure test point 1 Fig 40 of the minimum gas pressure switch it must be lower than the maximum allowed pressure of the gas train as shown on the charac teristics label Bleed the air from the piping of the gas train connecting a plastic tube to the pressure test point 1 Fig 40 of the mini mum gas pressure switch Take the vent tube outside the building so you can notice the smell of gas Connect ...

Page 34: ...r 9 Fig 5 on page 12 on OFF and wait for the control box to carry out the switching off phase disconnect the burner from the electrical supply invert the phases on the three phase power supply 6 5 Change of fuel There are two change of fuel options 1 with the OIL EXT GAS selector 20 Fig 5 on page 12 2 with a remote selector connected to the main terminal board positioning the OIL EXT GAS selector ...

Page 35: ...ntil the CO value does not exceed 100 ppm Slowly turn the appropriate knob clockwise until the burner goes into lockout Read the value indicated by the upward arrow on the graduated scale Fig 44 Turn the knob clockwise again until the value shown on the graduated scale corresponds with the arrow point ing downwards and so recovering the hysteresis of the pressure switch shown by the white mark on ...

Page 36: ... 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 6 7 4 PVP pressure switch kit Adjust the pressure switch for the leak detection control PVP kit Fig 45 according to the instructions supplied with the kit 6 7 5 Minimum oil pressure switch The minimum oil pressure switch Fig 46 is calibrated in the...

Page 37: ...he control box FGR delay time Use a value between 5 and 15 minutes Check the FGR temperature sensor and make sure that the tem perature of the flue gases reaches the value within the time set If necessary it is possible to adjust the FGR temperature of the control box with a different value Factory setting time default 300s Factory setting FGR temperature 50 C 6 9 Steady state operation Once the s...

Page 38: ... burner operating Tab P 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 to the maximum end of scale position Turn the oil maximum pressure switch knob to the mini mum end of scale position The burner must stop in lockout Turn off the burner...

Page 39: ...n of a tester some valves are fitted with light signals or closure opening position indicators that are activated when the electrical supply arrives 7 2 3 Checking and cleaning Combustion The optimum calibration of the burner requires an analysis of the flue gases Significant differences with respect to the previous measure ments indicate the points where more care should be exercised during maint...

Page 40: ...heck the filter is clean and that air is not entering the piping Filters Check the filtering baskets on line and at nozzle present in the system Clean or replace if necessary If rust or other impurities are observed inside the pump use a separate pump to lift any water and other impurities that may have deposited on the bottom of the tank Nozzles It is advisable to replace nozzles once a year duri...

Page 41: ...echnical As sistance Centre in order to carry out the necessary adjustments Tab S 7 2 5 Checking the air and gas pressure on the combustion head To carry out this operation it is necessary to use a pressure gauge to measure the air and gas pressure at the combustion head as shown in Fig 48 GAS OPERATION EN 676 Eccesso d aria Potenza max 1 2 Potenza min 1 3 GAS CO2 max teorico 0 O2 Taratura CO2 CO ...

Page 42: ... Disassemble the two extensions from the slide bars 6 Tighten the screws 10 on the slide bars of the burner Reconnect the cables and slide in the burner until it comes to a stop Connect the socket of the maximum gas pressure switch Put back the screws 7 and connect the connector of the fuel servomotor carefully pull the electrode cables outwards until they are slightly taut Connect the pipe 4 Conn...

Page 43: ... at the end of the second safety time 9 0 0 No flame signal during the first safety time 10 0 0 No flame signal at the end of the first safety time 11 0 0 Monitoring the parasite flame does not last for the required 5 seconds 13 1 0 The flame signal appears during ignition pilot burner 103 0 0 Various data invalid 105 Unlimited 0 Data curve invalid or unavailable Curve set Fuel num ber 106 0 0 Dif...

Page 44: ...cognising this fault is described in the BT300 manual print num ber DLT1201 At least one actuator does not reach its test position 2 actuators are exchanged another problem is preventing the actuator from reaching its test position 320 1 1 Broken or open cable on the firing rate input 321 1 1 Broken or open cable on the feedback channel channel number Channel 351 1 1 Fuel change not valid when the...

Page 45: ...opens with light oil 725 0 0 The oil valves are open during the selection of the gas 727 0 0 Main gas valve 1 opens unexpectedly 728 0 0 All three gas valves remain open for too long 729 0 0 The ignition process takes too long without pilot burner 730 0 0 Maintenance mode without pilot burner 731 0 0 The ignition valve opens without pilot burner 732 0 0 Signals combination not valid on input termi...

Page 46: ...f the H889 occurs when the fault reset is sent without good reason A reset from the terminal is always possible How to reset this fault wait 15 minutes and try again to reset the fault cut off power to the BT300 for a moment reconnect the power supply and then reset the fault 921 0 0 Relay actuator self diagnostics output fault at the oil valve 922 0 0 Relay actuator self diagnostics output fault ...

Page 47: ...the condition that generated the fault is eliminated i e the drop of the safety interlock chain SIC or the power failure 996 0 0 Secure parameter writing could not be completed Device is blocked 999 contact the After Sales Service Error code TRD P301 0 P328 0 EN67 P301 2 P328 0 Description D1 D2 ...

Page 48: ...emperature or pressure Software interface kit O2 control kit CO O2 CO high efficiency control kit Gas trains in compliance with EN 676 Please refer to manual A Appendix Accessories Parameter to be checked Probe Adjustment field Type Code Temperature 100 500 C PT 100 3010110 Pressure 0 2 5 bar 0 16 bar Output probe 4 20 mA 3010213 3010214 Burner Code RLS 120 E FGR 20130843 Burner Code RLS 120 E FGR...

Page 49: ...layout 4 Functional layout BT340 5 Functional layout BT340 6 Functional layout BT340 7 Functional layout BT340 8 Functional layout LCM100 9 Functional layout LCM100 10 Electrical wiring that is the responsibility of the installer 11 Electrical wiring that is the responsibility of the installer 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Page 50: ...20168262 48 GB Appendix Electrical panel layout 0 0 0 0 1 2 3 2 1 3 4 1 5 5 5 6 5 7 5 5 5 5 5 5 5 5 5 5 6 5 ...

Page 51: ...49 20168262 GB Appendix Electrical panel layout 01 2 3 4506 7 891 01 ...

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Page 53: ...51 20168262 GB Appendix Electrical panel layout 0 0 0 1 2 1 1 0 1 1 3 0 1 0 10 1 1 1 0 1 0 1 1 1 1 1 0 1 0 1 1 40 4 4 0 1 1 1 0 1 1 2 1 1 0 1 1 56 1 ...

Page 54: ...20168262 52 GB Appendix Electrical panel layout 0 0 0 12 3456 7 12 3456 7 ...

Page 55: ...53 20168262 GB Appendix Electrical panel layout 0 0 1 2 1 3 2 2 1 2 2 1 3 1 1 4 2 2 2 2 2 5 6 75 5 75 0 2 0 20 2 2 5 2 8 8 8 9 8 5 5 8 8 8 5 8 5 5 5 5 8 8 8 8 8 5 8 5 9 5 8 2 2 2 2 2 2 ...

Page 56: ...20168262 54 GB Appendix Electrical panel layout 012 3 41 4 2 3 1 510 31 33 3 4 6 747 189 510 136 8 6 6 9 22 6 A B B B C D ...

Page 57: ...55 20168262 GB Appendix Electrical panel layout 0 0 1 2 3 4 5 667 8 667 2 9 63 8 63 63 3 5 ...

Page 58: ...20168262 56 GB Appendix Electrical panel layout 0 1 2 31 4 5 5 5 6 5 5 5 5 5 5 5 5 5 5 5 6 5 7 74 8894 3279 7 4 94 74 8894 8 2814 3 3 944 2 19 79 3 3 944 2 19 79 3 3 1 19 79 ...

Page 59: ...nimum gas pressure switch PGVP Gas pressure switch for valve leak detection con trol device POilMin Minimum oil pressure switch POilMax Maximum oil pressure switch Q1 Three phase line disconnecting switch Q2 Single phase line disconnecting switch UV Flame sensor RS Remote burner reset button S1 On off selector S5 Fuel selector S7 Fuel remote selection selector SM1 Air servomotor SM2 Gas servomotor...

Page 60: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...