Riello RLS 130/EV, Installation, Use And Maintenance Instructions

Page 1: ...20096088 4 11 2022 Installation use and maintenance instructions Dual fuel light oil gas burner Progressive two stage or modulating operation CODE MODEL 20110941 RLS 130 EV GB ...

Page 2: ...Original instructions ...

Page 3: ... F 8 3 7 Minimum furnace dimensions 9 3 8 Standard equipment 9 3 9 Burner description 10 3 10 Control box for the air fuel ratio LMV36 12 3 11 Actuators SQM33 5 15 4 Installation 16 4 1 Notes on safety for the installation 16 4 2 Handling 16 4 3 Preliminary checks 16 4 4 Burner raising 17 4 5 Preparing the boiler 17 4 5 1 Boring the boiler plate 17 4 5 2 Blast tube length 17 4 6 Securing the burne...

Page 4: ...djusting oil air delivery 32 5 8 Final calibration of the pressure switches 33 5 8 1 Air pressure switch 33 5 8 2 Maximum gas pressure switch 33 5 8 3 Minimum gas pressure switch 34 5 8 4 Low oil pressure switch 34 5 8 5 High oil pressure switch 34 5 9 Burner starting 35 5 10 Steady state operation 36 5 11 Firing failure 36 5 12 Flame signal measurement 36 5 13 Final checks with the burner working...

Page 5: ... car ried out correctly may cause damage to the ma chine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not car ried out correctly lead to electric shocks with lethal consequences DANGER FLAMMABLE MATERIAL This symbol indicates the presence of flammable materials DANGER BURNING This symbol indicates the risks of burns due to high temperatures DANGER...

Page 6: ...e event of damage to things or injury to peo ple if such damage injury was due to any of the following causes incorrect installation start up use and maintenance of the burner improper incorrect or unreasonable use of the burner intervention of unqualified personnel carrying out of unauthorised modifications on the equipment use of the burner with safety devices that are faulty incorrectly applied...

Page 7: ...aintenance Only those parts envisaged by the manufacturer can be replaced 2 2 Personnel training The user is the person body or company that has acquired the ma chine and intends to use it for the specific purpose He is responsi ble for the machine and for the training of the people working around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel...

Page 8: ... Fuel 2 Fuel oil Natural gas Gas pressure at maximum delivery 2 Gas Natural gas WC 4 29 Operation Modulating oil gas Nozzle number 1 Standard applications Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Combustion air temperature F max 140 60 C Pump delivery at 290 PSI pressure range fuel temperature GPH PSI F max 85 145 304 5 194 90 C Noise levels 3 Sound pressure Sound power ...

Page 9: ...burners are given in Fig 2 Inspection of the combustion head requires the burner to be opened and the rear part withdrawn on the slide bars The maximum dimension of the burner when open without casing is give in measurement I Tab E Model Code RBNA code Voltage Flame safeguard RLS 130 EV 20110268 tbd 460 3 60 Burner mounted 575 3 60 inch A B C lbs RLS 130 EV 58 17 64 33 39 3 8 242 Fig 1 D36 Model A...

Page 10: ...ual to Qburner Qfoc F 4 500 0 908 4 956 Mbtu h Model MBtu hr GPH RLS 130 EV 1750 12 5 WARNING The firing rate area values have been obtained con sidering an ambient temperature of 68 F and an atmospheric pressure of 394 WC and with the combustion head adjusted Fig 3 D10920 Combustion chamber pressure WC AIR TEMPERATURE Altitude Altitude bar press bar press 0 5 10 15 20 25 30 40 C ft a s l m a s l ...

Page 11: ...and length of the test combustion chamber Example Output 4000 MBtu hr diameter 24 inch length 8 2 ft 3 8 Standard equipment Gas train flange No 1 Flange gasket No 1 Flange fixing screws No 4 Adaptor G 1 8 1 8 NPT No 1 Connector for pilot line No 1 Seal for adaptor No 1 Washer for screw No 4 Instruction booklet No 1 Fig 4 Diameter inches length ft Furnace dimensions D10921 ...

Page 12: ...n of the burner 3 9 Burner description 1 28 13 33 15 22 27 26 25 20 17 4 35 62 19 29 30 14 5 55 60 31 56 10 36 37 38 9 12 59 43 44 11 7 34 16 57 58 24 18 3 2 8 21 32 23 55 40 41 42 39 61 45 46 47 48 49 50 51 52 53 54 54 6 Fig 5 20097288 ...

Page 13: ...switch 30 Ignition transformers T2 for gas operation 31 Lifting rings and extension bars 32 Oil gas actuator 33 High oil pressure switch 34 Ignition transformer T1 for oil operation 35 Terminal board for oil valve X2 36 Timer module and relay KO1 37 Timer module and relay KG1 38 K3 relay 39 K2 relay 40 K1 relay 41 KG2 relay 42 K5 relay 43 Horn 44 Auxiliary fuse 45 Switch OFF ON 46 Switch LOCAL REM...

Page 14: ...rcuits via which it is possible to easily identify any causes of malfunctioning Mechanical design The following system components are integrated in the LMV36 basic unit Burner control with gas valve proving system Electronic air fuel ratio control Control frequency converter air fan Modbus interface Installation notes Always run high voltage ignition cables separately while ob serving the greatest...

Page 15: ...nal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 cos 0 4 Alarm output Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 A cos 0 4 Ignition transformer Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 or 250 VA ignition load declaration to UL372 cos 0 2 Fuel valves Nominal vo...

Page 16: ... T P 10 Shutdown Operation Startup Valve proving OUTPUTS INPUTS Phase number Fuel Actuator 2 Air Actuator 1 Actuators Safety limit thermostat STB Control thermostat or pressurestat R Flame signal FS Air pressure switch LP Pressure switch min Pmin Pressure switch max Pmax Valve proving leakage test P LT POC alternative to Pmax No load position Ignition load Postpurge position Nominal load Low fire ...

Page 17: ...s can be seen on the dis play of the Operator Panel Index 0 for fuel actuator index 1 for air actuator Installation notes Always run the high voltage ignition cables separate from the unit and other cables while observing the greatest possible dis tance The holding torque is reduced when the actuator is disconnect ed from power Technical data Tab I WARNING To avoid injury to persons damage to prop...

Page 18: ...ention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling 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 quickly move if the burner should fall When handling keep the load at not more than 20 25 cm from the ground After positioning the burner n...

Page 19: ...it must be great er than the thickness of the boiler door complete with its insulation The range of lengths available L inch is as follows Tab J For boilers with front flue passes 13 or flame inversion chambers insulation material 11 must be inserted between the refractory 12 and the blast tube 10 This protective insulation must not compromise the extraction of the blast tube For boilers having a ...

Page 20: ...de bars 5 by about 4 install the extension bars 31 Fig 5 page 10 and re screw the screws 2 including the safety plate 15 disconnect the electrode wires and then pull the burner com pletely off the slide bars 4 7 Electrode position 4 8 Ignition pilot adjustment Place the pilot and electrode as shown in Fig 13 The pilot works correctly at pressures ranging from 3 4 WC Tab L 4 13 L 11 12 6 14 4 5 15 ...

Page 21: ... Fig 16 WARNING It is advisable to replace the nozzle once a year dur ing periodical maintenance CAUTION The use of nozzles other than those specified by Ri ello S p A and inadequate regular maintenance may result into emission limits non conforming to the values set forth by the regulations in force and in extremely serious cases into potential hazards to people and objects The manufacturing comp...

Page 22: ...pressure gauge 1 Fig 18 The output and the pressure of the nozzle are at maximum when the servomotor is positioned on maximum The proper setting of the eccentric 6 is possible when its operation field follows the servomotor operation field 0 90 so that every variation of the servomotor position corresponds to a pressure var iation If at the maximum capacity of the nozzle maximum pressure in the re...

Page 23: ...om the sleeve 4 burner positioned as shown in Fig 11 page 18 insert the ignition electrode cables Remove the extension bars 31 Fig 5 page 10 Slide the burner up to the sleeve so that it is positioned as shown in Fig 21 refit screws 2 Fig 21 on slide bars 3 including the safety plate 15 Fig 11 page 18 secure the burner to the sleeve by tightening screws 1 connect the oil pipes again by screwing on ...

Page 24: ...f piping exiting and returning to the tank with an auxiliary pump that circulates the fuel under pressure A branch connection from the loop goes to feed the burner This circuit is extremely useful whenever the burner pump does not succeed in self priming because the tank distance and or height difference are higher than the values listed in the Tab M Tab M H Pump foot valve height difference L Pip...

Page 25: ... screw 4 12 3 Pump priming If the pump fails to prime at the first starting of the burner and the burner locks out wait approx 15 seconds reset the burner and then repeat the starting operation as often as required After 5 or 6 starting operations allow 2 or 3 minutes for the trans former to cool Whenever the length of the suction piping exceeds 66 98 ft the supply line must be filled using a sepa...

Page 26: ...ressure regulator 4 Low gas pressure switch 5 1st safety shut off valve 6 2nd safety shut off valve 7 Standard issue burner gasket with flange 8 Gas butterfly valve 9 Burner Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel interception tap is closed before performing any operation on the burner WARNING ...

Page 27: ...gas pres sure measured at test point 1 Fig 28 Find the nearest pressure value to your result in Fig 28 Read off the corresponding output on the left Example Maximum output operation Natural gas Gas pressure at test point 1 Fig 28 5 04 WC Pressure in combustion chamber 0 79 WC 5 0 0 79 4 21 WC A maximum output of 4900 MBtu hr shown in Fig 27 corresponds to 4 21 WC pressure natural gas This value se...

Page 28: ... 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 input powe...

Page 29: ...ble speed sensor B Maximum gas pressure switch C UV sensor D Air servomotor E Fuel servomotor F Air pressure switch G Oil valve H Oil pressure switch I Pump motor 4 14 2 Cable shielding Key Fig 30 1 Motor supply cable 2 Single phase supply cable 3 Clamp for connection of controls cable shielding from Inverter WARNING It is very important to shield the motor cable 1 as shown in Fig 30 It is very im...

Page 30: ... clamping the cable to the earth plate The screen must be earthed on both side of the cable take care for good earthing system Example Number 1 2 3 show not proper ways to earth a cable screen WARNING Following it is reported an example how to con nect the Inverter For further information please refer to the relevant Inverter instruction manual L1 L2 N PE 3 M U PE L1 L2 VWPE PE Fig 31 S8203 Ground...

Page 31: ...he motor is 400V To reset in the case of an intervention of the thermal relay press the button RESET Fig 34 The button STOP Fig 34 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 35 and move it in the sense of the arrow towards right 4 15 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay pres...

Page 32: ...tors manufactured for 208 230 460 IE3 NEMA Premium Efficiency voltage have the same connection than IE2 Epact motors but differ ent connection than IE1 motors no more star delta but star double star D3686 IE1 IE2 Epact IE3 NEMA Premium Efficiency U2 V2 W2 U3 V3 W3 U1 V1 W1 S8379 U2 V2 W2 U3 V3 W3 U1 V1 W1 S8380 460V 208 230V 460V 208 230V Fig 39 WARNING the motors manufactured for 575V IE3 NEMA Pr...

Page 33: ...e it might require several attempts to purge the air from the gas lines or to adjust the valve with little gas Once the burner has fired now proceed with calibration operations 5 4 Adjustments before first firing gas operation Ensure that the gas supply company has carried out the sup ply line vent operations eliminating air or inert gases from the piping Slowly open the manual valves situated ups...

Page 34: ...ly with an approximate adjust ment to the oil servomotor at maximum 90 Adjust the maximum pressure on the return nozzle throught the nut and lock nut 5 Fig 18 Adjust the combustion parameter with the air servomotor and store the maximum combustion point Complete the procedure slowly synchronizing the combustion with the two servomotors Store the different setting points DANGER Make sure that the l...

Page 35: ...he knob counter clockwise about 20 of the set point and start up the burner again to ensure the set point is correct If the burner locks out again turn the knob counter clockwise a little bit more 5 8 2 Maximum gas pressure switch Adjust the maximum gas pressure switch Fig 46 after making all other burner adjustments with the maximum gas pressure switch set to the end of the scale To calibrate the...

Page 36: ... gas pressure switch until it inter venes causing the burner shutdown remove the pressure gauge and close the cock of the gas pres sure test point used for the measurement open completely the manual gas cock 5 8 4 Low oil pressure switch The low oil pressure switch is factory set to 261 PSI 18 bar If the oil pressure goes down this value in the delivery piping the pressure switch stops the burner ...

Page 37: ...solenoid valves 8 9 2 close the passage to the nozzle Air damper and pressure regulator are positioned on MIN out put Ignition electrode strikes a spark Solenoid valves 8 9 2 open the fuel passes through the piping 10 and filter 11 and enters the nozzle A part of the fuel is then sprayed out through the nozzle ignit ing when it comes into contact with the spark flame at a low output level the rest...

Page 38: ...urement Check the flame signal through the parameter 954 as indicated in Fig 50 The displayed value is expressed in percentage The value during the operation must be higher than 24 If at the burner start up the value is higher or equal of 18 the burner locks out due to the extraneous light For further and specific information please refer to the specific in struction manual The display Fig 50 show...

Page 39: ...fety lockout condition The actual electrical supply of the solenoid gas valves can be ver ified by inserting a tester Some valves are equipped with light sig nals or close open position indicator that turn on at the same time as their power supply 6 2 3 Checking and cleaning Combustion The optimum calibration of the burner requires an analysis of the flue gases Significant differences with respect...

Page 40: ...lue gas temperature and combustion chamber pressure 6 2 4 Safety components The safety components must be replaced at the end of their life cycle indicated in Tab Q The specified life cycles do not refer to the warranty terms indicated in the delivery or payment conditions Tab Q 1 Fig 51 D10500 2 Fig 52 20113100 Safety component Life cycle Flame control 10 years or 250 000 operation cycles Flame s...

Page 41: ... Fuel tank Approximately every 5 years or whenever necessary suck any water or other impurities present on the bottom of the tank using a separate pump Combustion In case the combustion values found at the beginning of the inter vention do not respect the standards in force or in any case do not correspond to a proper combustion contact the Technical Assis tant and have him carry out the necessary...

Page 42: ...llows push the burner until it is about 4 from the sleeve re connect the leads Remove the extension bars 31 Fig 5 page 10 Slide in the burner until it comes to a stop refit screws 3 Fig 54 page 40 and pull the leads gently out until they are slightly stretched re couple the swivel coupling 7 to the graduated sector reconnect the light oil pipes Re screw the 2 screws and the safety plate Fig 11 pag...

Page 43: ...ntrol box manual supplied When the burner starts again the red LED goes out and the control box is reset 7 Faults Possible causes Solutions WARNING In the event of a burner lockout more than two con secutive burner reset operations could cause dam age to the installation On the third lockout contact the Aftersales Service DANGER If further lockouts or burner faults occur interven tions must only b...

Page 44: ... 66 67 66 61 88 87 85 69 72 83 84 69 81 82 80 79 86 92 92 91 2 76 70 68 50 96 97 96 95 69 71 64 69 94 77 78 1 63 28 32 72 71 90 88 87 89 72 93 69 3 91 40 29 46 44 49 17 19 18 20 22 11 9 5 8 7 48 59 24 75 74 69 71 72 35 33 34 38 39 45 45 30 10 36 36 31 37 65 41 15 42 43 54 53 56 55 58 60 4 6 47 62 59 48 98 59 48 73 16 ...

Page 45: ...W 27 3003891 CONNECTOR C 28 3014079 SPACER 29 20031413 HORN 30 20030010 HIGH VOLTAGE LEAD 31 20031657 ELECTRODE A 32 20008601 SERVOMOTOR B 33 20031872 TUBE 34 20040666 DIFFUSER DISC 35 20032440 DISTRIBUTOR 36 20032443 ELECTRODE A 37 20032445 IGNITION PILOT TUBE C 38 20032465 EXTERNAL TUBE A 39 3012042 ELBOW 40 20027422 SELECTOR SWITCH 41 3007891 SEAL B 42 3013055 TUBE A 43 3012969 GAS PRESSURE SWI...

Page 46: ...74 20032490 TUBE 75 20032496 TUBE 76 20031015 MOTOR C 77 3013259 BEARING C 78 3012357 BEARING C 79 3003204 SEAL B 80 3007150 O RING B 81 3003287 COIL B 82 3012474 MODULATOR B 83 3003005 CONNECTOR C 84 20035934 CONNECTOR C 85 3012126 CONNECTOR C 86 3003200 NUT 87 3014179 CONNECTOR C 88 3013462 CONNECTOR C 89 20028396 LEVER C 90 3012384 PRESSURE SWITCH A 91 3006140 PRESSURE GAUGE 92 3013531 NEEDLE V...

Page 47: ...essories 45 20096088 GB Gas train according to UL Standards B Appendix Accessories WARNING The installer is responsible for the supply and instal lation of any required safety device s not indicated in this manual ...

Page 48: ...ncy Low Fire High Fire Low Fire Flame Signal Overfire Draft High Fire Flame Signal OIL OPERATION Oil supply pressure CO2 Low Fire High Fire Oil suction pressure O2 Low Fire High Fire Control Power Supply CO Low Fire High Fire Burner Firing Rate NOX Low Fire High Fire Low Fire Flame Signal Net Stack Temp Low Fire High Fire High Fire Flame Signal Comb Efficiency Low Fire High Fire Low Fire Nozzle Si...

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Page 52: ...RTH AMERICA 35 Pond Park Road http www riello ca 2165 Meadowpine Blvd Hingham Massachusetts Mississauga Ontario U S A 02043 1 800 4 RIELLO Canada L5N 6H6 RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...