Riello RLS 160/M MX, Installation, Use And Maintenance Instructions

Page 1: ... instructions Dual fuel light oil gas burners Progressive two stage or modulating operation gas side two stage light oil side CODE MODEL TYPE 20147789 RLS 160 M MX 781T 20147790 RLS 160 M MX 781T 20147887 RLS 160 M MX 781T 20147888 RLS 160 M MX 781T GB ...

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

Page 3: ...rner description 11 4 12 Burner equipment 11 4 13 Electrical panel description 12 4 14 Control box RFGO A22 13 4 15 Servomotor SQN31 14 4 16 Calibration of the thermal relay 15 4 17 Motor rotation 15 5 Installation 16 5 1 Notes on safety for the installation 16 5 2 Handling 16 5 3 Preliminary checks 16 5 4 Operating position 17 5 5 Preparing the boiler 17 5 5 1 Boring the boiler plate 17 5 5 2 Bla...

Page 4: ...itch adjustment 34 6 10 1 Air pressure switch 34 6 10 2 Maximum gas pressure switch 34 6 10 3 Minimum gas pressure switch 34 6 11 Operation sequence of the burner gas 35 6 11 1 Burner start up 35 6 11 2 Steady state operation 35 6 11 3 Ignition failure 35 6 12 Final checks with burner operating 36 7 Maintenance 37 7 1 Notes on safety for the maintenance 37 7 2 Maintenance programme 37 7 2 1 Mainte...

Page 5: ... EU Low Voltage Directive EMC 2014 30 EU Electromagnetic Compatibility Such products are marked as indicated below The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 CE 0085 BN 0625 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BImSchV revision 26 0...

Page 6: ...rried out correctly may cause damage to the machine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not carried out correctly lead to electric shocks with lethal consequences DANGER FLAMMABLE MATERIAL This symbol indicates the presence of flammable materials DANGER BURNING This symbol indicates the risks of burns due to high temperatures DANGER CRUSH...

Page 7: ...event of damage to things or injury to people if such damage injury was due to any of the following causes incorrect installation start up use and maintenance of the burner improper incorrect or unreasonable use of the burner intervention of unqualified personnel carrying out of unauthorised modifications on the equipment use of the burner with safety devices that are faulty incorrectly applied an...

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

Page 9: ...ndard 1 stop every 24 h Continuous operation only with flame detection electrode ionisation Electrical supply of the system 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 R LS 160 M TC Emission Class 1 EN267 EN676 MY Class 1 EN267 Class 3 EN676 BLU Class 3 EN267 EN676 MX Class 2 EN267 Class 3 EN676 FS1 3 400 50 230 50 BASIC DESIGNATION EXTENDED DESIGNATION MX 3N 400V 50Hz 3 230V 50Hz...

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 160 M MX Flame stability disc with round sectors 3 Fig 17 Flame stability disc without round sectors 3 Fig 17 Output 1 Delivery 1 Light oil 2nd stage min max kW kg h 965 1846 81 155 1132 2013 95 169 1st stage min kW kg h 488 41 560 47 Natural gas 2nd stage min max kW 940 1730 940 1840 1st stage min kW 300 300 Fuels Light ...

Page 11: ...itions The l position is reference for the refractory thickness of the boiler door Tab F Blast tube short long Model Code RLS 160 M MX 20147789 20147790 RLS 160 M MX 20147887 20147888 Main electrical supply 3 400V 10 3 230V 10 Auxiliary circuit electrical supply 1N 230V 10 50Hz Fan motor rpm V W A 2895 400 4500 8 7 2895 230 4500 15 Pump motor V W A µF 230 550 3 6 25 Ignition transformer V1 V2 I1 I...

Page 12: ...run off from the bottom three flue passes on which the best results for low NOx emissions are obtained The boiler front door maximum thickness must not exceed 250 mm Fig 5 Although combination is guaranteed when boiler has a CE type approval preliminary tests are recommended for boilers or furnaces having a combustion chamber size much different than the one specified in the diagram Fig 4 For flam...

Page 13: ...s pressure switch 17 Safety valve 18 Servomotor controlling the gas butterfly valve and the air damper by means of a variable profile cam mechanism When the burner is not operating the air damper is fully closed in order to reduce heat dispersion from the boiler due to the flue draught which draws air from the fan suction inlet 19 Fan motor 20 Extensions for slide bars 8 21 1st and 2nd stage valve...

Page 14: ...Cable grommets for external connections to be carried out by the installer 8 Air pressure switch differential type 9 Control box base 10 Oil gas switch 11 Flame sensor 12 Power relay 13 Relay 14 Dry contact relay 15 Plug to connect the RWF kit of modulating operation NOTE Two types of burner lockout may occur Control box lockout if the control box 9 Fig 6 push button lights up it indicates that th...

Page 15: ...ions Do not confuse the powered conductors with the neutral ones Ensure that spliced wires cannot get into contact with neighbouring terminals Use adequate ferrules Arrange the H V ignition cables separately as far as possible from the control box and the other cables When wiring the unit make sure that AC 230 V mains voltage cables are run strictly separate from extra low voltage cables to avoid ...

Page 16: ...fety standards are respected When assembling the servomotor and connecting the damper the gears can be disengaged by means of a lever allowing the drive shaft to be easily adjusted in both directions of rotation Technical data Tab H ATTENTION To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the actuators Operating voltage AC ...

Page 17: ... 4 and move it in the arrow direction to the right to carry out the thermal relay test 4 17 Motor rotation As soon as the burner starts place yourself in front of the cooling fan of the fan motor and check that it turns anticlockwise Fig 11 If this is not the case put the switch of the burner to 0 off and wait until the control box carries out the switching off phase Invert the phases on the three...

Page 18: ...n air inside the boiler must be free from hazardous mixes e g chloride fluoride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently ATTENTION Burner handling operations can be highly dangerous if not carried out with the greatest attention distance unauthorised personnel check integrity and suitability of the means available Check also that the area in...

Page 19: ... inserted between the boiler fettling 14 and the blast tube 12 This protection must not compromise the extraction of the blast tube For boilers with a water cooled front piece a refractory lining 13 14 Fig 15 is not necessary unless expressly requested by the boiler manufacturer ATTENTION The burner is designed to operate only in positions 1 2 3 and 4 Fig 13 Installation 1 is preferable as it is t...

Page 20: ...the two screws 4 and pull the burner back on slide bars 5 by about 100 mm disconnect the electrode cables then completely unthread the burner from the slide bars Fix the pipe coupling with the flange 11 Fig 15 to the boiler plate interposing the insulating gasket 9 Fig 15 supplied with the equipment Use the 4 screws also supplied after protecting their thread with an anti locking product 5 7 Elect...

Page 21: ...1630 0 9 1812 kW 1812 2 906 kW per nozzle so two equal nozzles of 60 12 bar are required 1 18 GPH 2 18 GPH or the following two different nozzles 1 16 GPH 2 20 GPH Tab I GPH kg h kW 12 bar 10 bar 12 bar 14 bar 10 0 10 5 11 0 12 0 12 3 13 0 13 8 14 0 15 0 15 3 16 0 17 0 17 5 18 0 19 0 19 5 20 0 21 5 22 0 22 5 23 0 23 5 24 0 24 5 25 0 25 5 26 0 26 5 27 0 27 5 28 0 38 4 40 4 42 3 46 1 47 3 50 0 53 1 ...

Page 22: ...tion shown in Fig 15 Insert the electrode cables and then slide the burner up to the pipe coupling the burner in the position indicated in Fig 20 Refit screws 2 on slide bars 3 Fig 20 Fix the burner to the pipe coupling with screws 1 Fig 20 Reconnect the light oil pipes by screwing the two fittings 6 Fig 15 Reconnect the articulated coupling 7 to the graduated sector 5 Fig 20 ATTENTION It is advis...

Page 23: ...dicated in diagram Fig 22 corresponds with the front part of the flange 6 Fig 21 Example Burner RLS 160 M MX Burner maximum output 1500 kW The diagram Fig 22 shows that for this output the adjustment of the combustion head is carried out on notch 7 ATTENTION To facilitate the adjustment loosen the screw 1 Fig 17 adjust then block Fig 21 D1149 Fig 22 No of holes Max burner output kW D2996 ...

Page 24: ...branch from the loop supplies 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 Tab J Tab J Key Fig 23 H Pump Foot valve height difference L Piping length Ø Inside pipe diameter 1 Burner 2 Pump 3 Filter 4 Manual on off valve 5 Suction line 6 Foot valve 7 Quick...

Page 25: ...ith the supplied seals into the connections and screw them down During the installation hoses must not be stressed with twisting Position hoses so that they cannot be stepped on or get into contact with hot parts of the boiler and so that they allow burner opening Connect finally the other end of the flexible hoses to the suction and return lines using nipples supplied with the equipment 5 11 4 Hy...

Page 26: ...F and tighten the screw 3 Fig 26 The time required for this operation depends upon the diameter and length of the suction tubing 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 And so on After 5 or 6 starting operations allow 2 or 3 minutes for the transformer...

Page 27: ...over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train burner adaptor supplied separately P2 Pressure upstream of valves adjuster P3 Pressure upstream of the filter L Gas train supplied separately L1 Responsibility of the installer DANGER Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure th...

Page 28: ...the approximate maximum output of the burner in this way Subtract the combustion chamber pressure from the gas pressure measured at test point 1 Fig 33 Find in Tab L the pressure value closest to the result of the subtraction Read the corresponding output on the left Example with natural gas G20 Operation at maximum modulating output 1550 kW A pressure of 15 0 mbar corresponds in Tab L to an outpu...

Page 29: ...9 GB Installation Example with natural gas G20 Operation at maximum modulating output 1550 kW Gas pressure at test point 1 Fig 33 15 0 mbar Pressure in combustion chamber 3 0 mbar 15 0 3 0 18 0 mbar Fig 33 S9865 ...

Page 30: ...it for applications requiring a burner operating cycle longer than 24 hours When it is used as a UV control the system is considered as non permanent requiring one burner recycle every 24 hours Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case a time switch must be applied to L N in series to stop the burner at least once every 24 hours Refer...

Page 31: ...ge light oil valve opens 6 3 Adjustments prior to ignition light oil The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet and interventions on the following points 1st and 2nd stage nozzles See information on page 19 Combustion head The adjustment of the combustion head already carried out needs not to be altered unless the 2nd stage output of the burne...

Page 32: ...ering of the fuel pressure can cause the burner to lockout and can sometimes give rise to pulsations When first ignited the burner should make a noise to show it is operating 6 6 2 Operation The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet and interventions on the following points 1st and 2nd stage nozzles See information on page 19 Combustion head ...

Page 33: ...calculate MAX burner output using the Tab L Connect two lamps or testers to the two gas line solenoid valves to check the exact moment in which voltage is supplied This operation is not required if each of the two solenoid valves is equipped with a pilot light that signals voltage passing through 6 8 Burner start up gas Turn off the remote controls and set the switch 1 Fig 36 on page 30 to MAN As ...

Page 34: ...kWh Sm3 Max operation output 600 kW corresponding to 63 5 Sm3 h After 10 ignitions with a lockout the delivery indicated on the meter must be equal to or lower than 63 5 360 0 176 Sm3 Air adjustment The air is adjusted by changing the angle of cam III Fig 35 on page 29 and by using the selector 2 Fig 36 on page 30 To adjust the cam of the servomotor see Fig 35 on page 29 6 9 2 Maximum output The M...

Page 35: ...um output of the burner carry out air adjustment on higher intermediate positions of the servomotor The passage from one position to the next one is obtained by pressing the button 2 on the symbol or Fig 36 on page 30 Press button 2 Fig 36 on page 30 Output increase briefly so that the servomotor rotates by about 20 see servomotor graduated index Fig 39 and air damper graduated index 5 Fig 38 on p...

Page 36: ...re 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 close the tap 6 10 3 Minimum gas pressure switch Adjust the minimum gas pressure switch after performing all the other burner adjustments with the pressure switch set ...

Page 37: ...e pressure or temperature in the boiler point C The electric control box carries on checking the presence of the flame and the correct position of the air and gas maximum pressure switches If the temperature or pressure is low so the TR remote control is closed the burner progressively increases the output up to the MAX value section C D If the temperature or pressure then increases until the TR o...

Page 38: ...nect the minimum gas pressure switch connector The burner must not start Disconnect flame detection sensor electrical connections The burner must stop in lockout due to ignition failure Obscure the flame sensor The burner must stop in lockout due to ignition failure Turn off the burner and cut off the power Disconnect the maximum gas pressure switch connector The burner must not start Turn off the...

Page 39: ... that activate as soon as they are powered 7 2 3 Checking and cleaning Combustion Carry out an analysis of the combustion flue gases Significant differences with respect to the previous measurements indicate the points where most care should be exercised during maintenance Combustion head Open the burner and make sure that all components of the combustion head are in good condition not deformed by...

Page 40: ...on page 41 Check Mode With burner flame on hold the reset button on the flame control pressed for at least 3 sec the button colour will change from green to yellow each operating status signalling LED will be compared to 20 of the maximum brightness press the reset button again 0 5sec to reset the standard operation of the signalling LEDs 7 2 5 Safety components The safety components must be repla...

Page 41: ...to make sure that the hoses are still in good condition Fuel tank Approximately every 5 years suck any water on the bottom of the tank using a separate pump Combustion If the combustion values measured before starting maintenance do not comply with applicable Standards or do not indicate efficient combustion consult the table below or contact our Technical Support Service to implement the necessar...

Page 42: ...lectrode cables then completely retract the burner At this point it is possible to extract the inner part 5 after having removed the screw 6 Fig 47 7 4 Closing the burner Refit following the steps described but in reverse order refit all burner components as they were originally assembled DANGER Disconnect the electrical supply from the burner by means of the system main switch DANGER Close the fu...

Page 43: ...t LED starting from the flame LED represents 20 of the signal power To exit the check mode function press the reset button the flame control will go back to the normal operating mode 8 3 Flame control lock out or emergency stop condition The RFGO control device can be locked out emergency stop at any time during the operating cycle and unlocked when already locked lock out by simply pressing the k...

Page 44: ...per open Damper closed Modulation Ignition Flame Status Icon Power OFF ON OFF Not ready Diagnostics Green Standby Green Servomotor movement Note 3 OFF Flashing Flashing OFF Green Waiting for closing Green blinking Green OPEN before ignition Green Minimum before ignition Green Ignition Green PTFI Green blinking Green MTFI Green Active modulation Green Minimum output position Green With flame presen...

Page 45: ... cause material problems severe injuries or death It is the owner or user s responsibility to make sure that the equipment described is installed used and commissioned in compliance with the requirements provided both by national and local law The lock out condition indicates the presence of a fault which occurred during the operating cycle or during stand by mode Before performing an unlock attem...

Page 46: ...elay fault Red 19 Combustion airflow switch fault in the rest position Red 20 UV no flame at the end of the 2nd safety time MTFI Red 21 Safety relay fault Red 22 Supervisor processor fault Red 23 Supervisor memory test fault Red 24 Flame loss during the operation AUTO Red 25 Supervisor processor data memory fault Red 26 Supervisor processor internal fault Red 27 Not used 28 Not used 29 Operating t...

Page 47: ... Red 52 Piloted valve feedback fault Red 53 Actuator feedback waiting time expired Red 54 Direct ignition valve feedback fault Red 55 Internal processor fault Red 56 UV false flame during operation Red 57 FR false flame during operation Red 58 T8 inlet fault Red 59 Internal hardware fault Red 60 Local reset fault Red 61 Open POC fault Red 62 UV strong UV flame fault Red 63 Internal hardware fault ...

Page 48: ...lt Internal fault Replace the control device 16 No flame 1st safety time PTFI No flame at the end of the first safety time Inspect the system check the gas pressure check the flame sensor check the wiring etc 17 Wiring fault The system detected the presence of voltage on critical terminals T16 T17 T18 or T19 at the wrong moment or there is no voltage when necessary Inspect the wiring and make sure...

Page 49: ...tected the presence of voltage on T17 at the wrong moment or there is no voltage when necessary Check the wiring and make sure that the earthing is appropriate If the problem persists contact the distributor factory 52 Piloted valve feedback fault The system detected the presence of voltage on T19 at the wrong moment or there is no voltage when necessary Check the wiring and make sure that the ear...

Page 50: ...al circuit breaker kit Potentiometer kit Gas trains in compliance with EN 676 Please refer to manual A Appendix Accessories Parameter to be controlled Probe Output regulator Adjustment field Type Code Type Code Temperature 100 500 C PT 100 3010110 RWF50 2 RWF55 5 20099869 20099905 Pressure 0 2 5 bar 0 16 bar Output probe 4 20 mA 3010213 3010214 Burner Standard head length mm Extended head length m...

Page 51: ...out Index of layouts 2 Indication of references 3 Functional layout RFGO A22 4 Functional layout RFGO A22 5 Functional layout RFGO A22 6 Electrical wiring that is the responsibility of the installer 7 Functional diagram RWF50 1 2 Sheet no 1 A1 Coordinates Indication of references ...

Page 52: ...20148049 50 GB Appendix Electrical panel layout 00 0 1 02 3 02 3 45 45 67 67 8 9 0 0 1 0 0 0 0 0 02 0 RLS 160 M MX 20147789 20147790 ...

Page 53: ... Electrical panel layout 0 1 1 1 2 34 34 56 56 7 8 0 9 1 9 1 9 1 9 1 9 1 9 1 9 1 9 1 9 1 9 1 9 1 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 RLS 160 M MX 20147887 20147888 ...

Page 54: ...20148049 52 GB Appendix Electrical panel layout 0 1 0 1 2 2 2 3 2 4 2 2 2 2 2 2 2 52 5 5 2 2 3 2 ALL MODELS ...

Page 55: ...53 20148049 GB Appendix Electrical panel layout 01 2 3 4 1 5 5 3 4 1 6 2 4 1 0144 0 14 5 1 7 858 9 6 2 1 470 9 7 A A A B A C A A A A A A A A A A B A ALL MODELS ...

Page 56: ...20148049 54 GB Appendix Electrical panel layout 0 1 1 2 2 0 3 3 4 5 6 0 2 7 8 9 5 6 4 0 4 4 1 2 1 RLS 160 M MX 20147789 20147790 ...

Page 57: ...55 20148049 GB Appendix Electrical panel layout 0 1 1 2 2 0 3 3 4 5 6 0 2 7 8 4 6 0 9 4 9 4 1 2 1 RLS 160 M MX 20147887 20147888 ...

Page 58: ...62 16 6 9 8 9 9 9 9 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 A A A A A 8 A A 8 A 91716 2 6 4 5 9 6 4 4 7 919 B 7 76 4 4 7 919 B 7 76 4 4 7 1 19 1C B 76 16 6 0 7 B 76 16 6 1C B 012 16 6 0 7 B 012 16 6 ALL MODELS ...

Page 59: ...KM Motor contactor KMP Relay K0 Relay K01 Relay MP Pump motor MV Fan motor PA Air pressure switch PGMin Minimum gas pressure switch PGM Maximum gas pressure switch Q1 Three phase disconnecting switch Q2 Single phase disconnecting switch RS Remote reset button S1 Off automatic manual selector S2 Output increase decrease selector S3 Oil gas selector switch SM Servomotor SV External light oil valve T...

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 ...