Riello RLS 250/M, Installation, Use And Maintenance Instructions

Page 1: ...5 09 2013 Installation use and maintenance instructions Dual fuel gas oil gas burner Two stage progressive or modulating operation gas side two stage gas oil side CODE MODEL TYPE 20034278 RLS 250 M MZ 1302 T GB ...

Page 2: ...Original instructions ...

Page 3: ... data 10 4 6 Packaging Weight 10 4 7 Overall dimensions 11 4 8 Firing rate 11 4 9 Test boiler 12 4 9 1 Commercial boilers 12 4 9 2 Modulation ratio 12 4 10 Burner description 13 4 11 Standard equipment 13 5 Installation 14 5 1 Notes on safety for the installation 14 5 2 Handling 14 5 3 Preliminary checks 14 5 4 Installer Servicer notes for the use of Gas oil with Bio blends up to 10 15 5 5 Operati...

Page 4: ... operation 29 6 6 Burner firing gas operation 29 6 7 Burner calibration gas operation 29 6 7 1 Firing output 29 6 7 2 MAX burner output 29 6 7 3 MIN burner output 30 6 7 4 Intermediate outputs 30 6 8 Pressure switch adjustment 31 6 8 1 Air pressure switch 31 6 8 2 Maximum gas pressure switch 31 6 8 3 Minimum gas pressure switch 31 6 9 Combustion checks 32 6 10 Burner operation 32 6 10 1 Burner sta...

Page 5: ...006 95 EC Low Voltage Directive EMC 2004 108 EC Electromagnetic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BImSchV release 26 01 2010 Product T...

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

Page 7: ...ance 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 Riello warranty is subject to correct burner appliance and appli cation matching and set up ...

Page 8: ...er at the tank and then a sec ondary filter of 100 Microns protecting the burner from con tamination If an existing oil storage tank is to be used then in addition to the materials checks as detailed above it will be essen tial that the tank is first inspected for condition and checked for water or other contamination Riello strongly recom mends that the tank is cleaned and oil filters replaced pr...

Page 9: ...nd maintenance errors or to improper use 3 3 Basic safety rules Children or inexpert persons must not use the appliance Under no circumstances must the intake grids dissipation grids and ventilation vents in the installation room be cov ered up with cloths paper or any other material Unauthorised persons must not attempt to repair the appli ance It is dangerous to pull or twist the electric leads ...

Page 10: ... 1 230 50 3 230 50 Auxiliary voltage 230 50 60 R LS 250 TC Emission C11 or Class 1 EN267 EN676 C22 or MZ Class 2 EN267 Class 2 EN676 C33 or BLU Class 3 EN267 EN676 C23 or MX Class 2 EN267 Class 3 EN676 FS1 3 230 400 50 230 50 BASIC DESIGNATION EXTENDED DESIGNATION 1 230V 50Hz 3 230V 50Hz 230V 50 60Hz Heavy oil Two stage M Modulating 1 Single stage S L LS N Head TC Standard head TL Extended head 11...

Page 11: ... B I3P LU II2E3B P NO CY MT I3B P RO I2H Model RLS 250 M MZ Type 1302 T Output 1 Delivery 1 2nd stage kW kg h 1230 2460 104 207 min 1st stage kW kg h 550 47 5 Fuel Gas oil viscosity at 20 C 6 mm2 s max 1 5 E 6 cSt Gas oil and Blends of gas oil and bio fuel FAME in accordance with EN 14214 up to 10 Natural gas G20 methane G21 G22 G23 G25 Gas pressure at maximum delivery 2 Gas G20 G25 mbar 42 9 55 7...

Page 12: ...00 230 400 5500 21 6 12 5 144 83 Pump motor Pump motor capacitor V W A µF 220 240 550 3 6 25 Ignition transformer V1 V2 I1 I2 230 V 2 x 5 kV 1 9 A 30 mA Electrical power consumption gas oil gas W max 7500 6000 Electrical protection IP 44 Model RLS 250 M MZ Electrical supply V Ph Hz 400 3 50 Auxiliary power supply V Ph Hz 230 1N 50 Fan motor Running current Start up current rpm V W A A 2920 230 400...

Page 13: ...g operation burner output varies between a MAXIMUM OUTPUT selected within area A and a MINIMUM OUTPUT which must not be lower than the minimum limit in the diagram Fig 2 D3169 mm A B C D E F 1 G H I 1 L M N O RLS 250 M MZ 904 427 477 555 863 412 542 222 435 1442 1587 237 141 186 Rp2 Model kW kg h RLS 250 M MZ 550 46 WARNING The firing rate value Fig 3 has been obtained considering an ambient tempe...

Page 14: ...mum thickness of the boiler s front door must not ex ceed 250 mm See Fig 5 The burner boiler match is assured where the boiler is EC type approved for boilers and furnaces with combustion chambers featuring dimensions differing considerably from those given in the diagram Fig 4 it is advisable to perform preliminary tests 4 9 2 Modulation ratio The modulation ratio determined using test boilers ac...

Page 15: ...atic manual off operations Button for increase reduction power 22 Motor contactor and thermal cut out with reset button 23 Bracket for mounting the power regulator RWF40 24 Terminal strip 25 Fairleads for electrical connections by installer 26 Flame inspection window 27 Minimum air pressure switch differential operating type 28 Pump motor 29 Pump 30 Safety solenoid valve 31 1st and 2nd stage valve...

Page 16: ... the standards and regula tions of the laws in force WARNING The handling operations for the burner can be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also that the area in which you are working is empty and that there is an adequate escape area i e a free s...

Page 17: ...uitable for bio fuel use check with Riello if in doubt Riello have carefully chosen the specification of the bio compatible components including the flexible oil lines to protect the pump safety value and nozzle The Riello war ranty is dependent upon the use of Riello genuine compo nents including the oil lines being used The burner must be commissioned and combustion parameters set to appli ance ...

Page 18: ...ws 4 and pull the burner back on slide bars 5 by about 100 mm Disconnect the electrode wires and then pull the burner completely off the slide bars Secure the sleeve with flange 11 to the boiler plate inter posing the thermal insulating screen 9 supplied with the burner Use the 4 screws also supplied with the unit after first pro tecting the thread with an anti locking product 5 8 Nozzles The burn...

Page 19: ...ove screw 1 Fig 11 and extract the internal part 2 Fit two nozzles with the box spanner 16 mm 1 Fig 12 after having removed the plastic plugs 2 Fitting the spanner through the central hole in the flame sta bility disk or loosen screws 1 Fig 13 Remove disk 2 Fig 13 and replace the nozzles using the wrench 3 The nozzle for the 1st stage of operation is the one lying beneath the firing electrodes Fig...

Page 20: ...alve The servomotor rotates through 130 degrees in 33 seconds Do not alter the factory setting for the 5 cams simply check that they are set as indicated below Cam I 130 Limits rotation toward maximum position When the burner is at max output the gas butterfly valve must be fully open 90 Cam II 0 Limits rotation toward the minimum position When the burner is shut down the air gate valve and the ga...

Page 21: ...fference 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 Rapid closing manual valve remote controlled only Italy 8 On off solenoid valve only Italy 9 Return line 10 Check valve only Italy 11 Tank filter Tab K WARNING Where gas oil containing bio diesel is in use it is recommended to avoid over oxygenation of the blended fuels Wher...

Page 22: ...flows out Key Fig 18 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 Rapid closing manual valve remote controlled only Italy 8 On off solenoid valve only Italy 11 Tank filter Tab L 5 13 Hydraulic system layout Key Fig 19 1 Pump suction 2 Filter 3 Pump 4 Pressure governor 5 Return pipe 6 By pass ...

Page 23: ...ontact with hot surfaces of the boiler and where they do not hamper the opening of the burner Now connect the other end of the hoses to the suction and return lines by using the supplied nipples 5 15 Pump Technical data Tab M Key Fig 21 1 Suction G 1 2 2 Return G 1 2 3 Pressure gauge attachment G 1 8 4 Vacuum meter attachment G 1 2 5 Pressure adjustment screw 6 By pass screw Fig 20 D3176 WARNING I...

Page 24: ... 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 Do not illuminate the UV cell or the burner will lock out the burner should lock out anyway about 10 seconds after it starts WARNING Before starting the burner make sure that the tank return line is not clo...

Page 25: ...on control is compulsory for burners with maximum outputs over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer Explosion danger due to fuel leaks in the pres ence of a flammable source Precautio...

Page 26: ... G 20 PCI 9 45 kWh Sm3 Gas pressure at test point 1 Fig 25 24 0 mbar Pressure in combustion chamber 3 0 mbar 24 0 3 0 21 0 mbar A maximum output of 2050 kW shown in Tab N corresponds to 21 0 mbar pressure column 1 This value serves as a rough guide the effective delivery must be measured at the gas meter To calculate the required gas pressure at test point 1 Fig 25 set the maximim output required ...

Page 27: ...r corresponds to that shown on the identification label and in this manual The burners have been set for intermittent operation This means they should compulsorily be stopped at least once every 24 hours to enable the control box to perform checks of its own start up efficiency Normally the boiler s thermostat pressure switch ensures the stopping of the burner If this is not the case it is necessa...

Page 28: ...ards right Before carrying out any maintenance cleaning or checking oper ations 5 19 Current to the UV photocell Min value for a good work 70 µA If the value is lower it can depend on exhausted photocell low current lower than 187V bad regulation of the burner In order to measure the current use a microammeter of 100 µA c c connected to the photocell as in the scheme with a capac itor of 100 µF 1V...

Page 29: ... Burner calibration gas oil operation 6 3 1 Firing Set switch 1 Fig 31 to MAN During the first firing during the passage from the 1st to the 2nd stage there is a momentary lowering of the fuel pressure caused by the filling of the 2nd stage nozzle tubing This lowering of the fuel pressure can cause the burner to lock out and can sometimes give rise to pulsations Once the following adjustments have...

Page 30: ...ring gas operation Adjustment of the combustion head has been illustrated on pag 27 In addition the following adjustments must also be made open manual valves up line from the gas train Adjust the minimum gas pressure switch to the start of the scale Fig 32 Adjust the maximum gas pressure switch to the start of the scale Fig 33 Adjust the air pressure switch to the zero position of the scale Fig 3...

Page 31: ...ulations prescribe that the value be defined according to the control box safety time ts for ts 2s firing output must be equal to or lower than 1 2 of max operation output for ts 3s firing output must be equal to or lower than 1 3 of max operation output Example MAX operation output of 600 kW Firing output must be equal to or lower than 300 kW con ts 2s 200 kW con ts 3s In order to measure the fir...

Page 32: ...w since this is used to set the air gate valve to its fully closed position 6 7 4 Intermediate outputs Adjustment of gas delivery No adjustment of gas delivery is required Adjustment of air delivery Press the key 2 Fig 36 at page 29 output increase a little so that the servomotor turns by about 15 Adjust the screws until optimal combustion is obtained Proceed in the same way with the other screws ...

Page 33: ...hing may be obtained by fitting a second pipe between the air pressure switch and the suction in let of the fan In such a manner the air pressure switch operates as differential pressure switch 6 8 2 Maximum gas pressure switch Adjust the maximum gas pressure switch after having performed all the other burner adjustments with the maximum gas pressure switch set at the end of the scale Fig 40 With ...

Page 34: ... boiler temperature or pressure point C Fig 42 The control box will continue however to monitor flame pres ence and the correct position of the air and gas max pressure switches If the temperature or pressure is low and the TR load con trol is consequently closed the burner progressively increases its output to the MAX value section C D Fig 42 If subsequently the temperature or pressure increases ...

Page 35: ...ed inside the fan or on its blades as this condition will cause a reduction in the air flow rate and provoke polluting combustion Burner Check for excess wear or loose screws in the mechanisms con trolling the air gate valve and the gas butterfly valve Also make sure that the screws securing the electrical leads in the burner terminal strip are fully tightened Clean the outside of the burner takin...

Page 36: ...ded to inspect even more frequently the hoses and replace them where contamination has occurred Check to make sure that the hoses are still in good condi tion Nozzles Do not clean the nozzle openings do not even open them The nozzle filters however may be cleaned or replaced as re quired It is advisable to replace nozzles every year during regular main tenance operations Combustion must be checked...

Page 37: ...h the burner until it is about 100 mm from the sleeve Re connect the leads and slide in the burner until it comes to a stop Refit screws 3 and pull the probe and electrode leads gen tly out until they are slightly stretched Re couple the articulated coupling 8 to the graduated sector 9 Reconnect the light oil pipes 7 Remove the two extensions from the slide bars 4 and return them to their original...

Page 38: ...ssure switch intervenes Adjust pressure switch or eliminate overpressure No electrical power supply Close all switches Check connec tions No gas oil Check the gas oil supply circuit Control box fuse blown Replace Pump is jammed Replace Defective motor command control device Replace Defective control box Replace Defective electrical motor Replace The pilot burner does not work Check Defective safet...

Page 39: ...eplace photocell or control box Dirty photocell Clean Smoke in flame dark Bachar ach Not enough air Adjust head and fan gate Erroneous pump pressure Adjust Nozzle filter clogged Clean or replace Boiler room air vents insufficient Increase Nozzle worn or dirty Replace Flame disk dirty loose or deformed Clean tighten in place or replace Smoke in flame yellow Bacharach Too much air Adjust head and ai...

Page 40: ...ght as suction pipe Air enters suction piping Tighten connectors Pump leaks gas oil Leakage from sealing organ Replace pump Dirty combustion head Nozzle or filter dirty Replace Unsuitable nozzle delivery or angle See recommended nozzles Loose nozzle Tighten Impurities on flame stability disk Clean Erroneous head adjustment or not enough air Adjust open air damper Blast tube length unsuited to boil...

Page 41: ...switch pressure point pipe blocked Clean Poorly adjusted head Adjust Dirty fan Clean High negative draft in chamber Ask our technical office The burner starts and then goes into lock out Fault in flame detection circuit Replace control box The burner remains in pre purging phase Contact servomotor does not operate Minimum cam Adjust cam minimum or replace servomotor After pre purge and the safety ...

Page 42: ...uses temporary opening of the pressure switch itself the valve immediately clos es and the burner comes to a halt Pressure increases again the pressure switch closes again and the firing cycle is repeated And so on Reduce operating pressure of minimum gas pressure switch Replace gas filter Lock out without symbol indi cation Flame simulation Replace control box During operation the burner stops in...

Page 43: ... a special kit is available as given in the following table EXTENDED HEAD KIT Standard head burners can be transformed into extended head versions by using the special kit The kits available for the various burners giving the original and the extended lengths are listed below SOUND PROOFING BOX If noise emission needs reducing even further sound proofing boxes is available SPACER KIT If burner hea...

Page 44: ...x Electrical panel layout Index of layouts 2 References layout 3 LFL 1 Operational layout 4 LFL 1 Operational layout 5 LFL 1 Operational layout 6 Electrical connections set by installer 7 RWF40 Operational layout 1 2 Sheet no 1 A1 Coordinates Reference layout ...

Page 45: ...43 20034293 GB Appendix Electrical panel layout ...

Page 46: ...20034293 44 GB Appendix Electrical panel layout ...

Page 47: ...45 20034293 GB Appendix Electrical panel layout ...

Page 48: ...20034293 46 GB Appendix Electrical panel layout ...

Page 49: ...47 20034293 GB Appendix Electrical panel layout ...

Page 50: ...O Relay KO1 Relay MP Pump motor MV Fan motor PA Air pressure switch PE Burner ground PGMin Minimum gas pressure switch PGM Maximum gas pressure switch Q1 Three phase disconnect switch Q2 Single phase disconnect switch RS Remote lock out reset button S1 Switch for following operations off automatic manual S2 Button for power increase reduction S3 Oil gas selector SM Servomotor SV External oil valve...

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Page 52: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www rielloburners com ...