Riello RLS 650/M MX, Installation, Use And Maintenance Instructions

Page 1: ...20027761 10 01 2017 Installation use and maintenance instructions Dual fuel light oil gas burner Progressive two stage or modulating operation CODE MODEL TYPE 20026139 RLS 650 M MX 1310T GB ...

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

Page 3: ...ment 12 4 13 Control box LFL1 333 13 4 14 Servomotor SQM10 1 14 5 Installation 15 5 1 Notes on safety for the installation 15 5 2 Handling 15 5 3 Preliminary checks 15 5 4 Operating position 16 5 5 Removal of the locking screws from the shutter 16 5 6 Preparing the boiler 16 5 6 1 Boring the boiler plate 16 5 6 2 Blast tube length 16 5 7 Securing the burner to the boiler 17 5 8 Accessibility to th...

Page 4: ...l adjustment 32 6 7 1 Procedures for setting the burner 33 6 8 Servomotor 33 6 9 Adjustment pressure switches 34 6 9 1 Air pressure switch CO check 34 6 9 2 Maximum gas pressure switch 34 6 9 3 Minimum gas pressure switch 34 6 10 Operation sequence of the burner 35 6 10 1 Burner starting 35 6 10 2 Steady state operation 35 6 10 3 Undesired shutdown during operation 35 6 10 4 Firing failure 35 6 11...

Page 5: ...5 UE Low Voltage Directive EMC 2014 30 UE Electromagnetic Compatibility Such products are marked as follows 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 BImSchV release 26 01 2010 Product Type Mode...

Page 6: ...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 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...

Page 7: ...e 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...

Page 8: ...aintenance 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...

Page 9: ...ystem 3 400 50 3 230 50 Auxiliary voltage 230 50 60 110 50 60 R LS 650 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 60 BASIC DESIGNATION EXTENDED DESIGNATION MX 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam EV Variable speed with Inverter P Air gas proportioning valve BP T...

Page 10: ...t maximum delivery 2 Gas G20 G25 mbar 58 86 5 Operation Intermittent min 1 stop in 24 hours Progressive two stage or modulating by kit see accessoires Pump delivery at 16 5 bar pressure range fuel temperature kg h bar C max 560 6 30 140 Nozzles number 1 Standard applications Boilers water steam diathermic oil Room temperature C 0 50 Combustion air temperature C max 60 Noise level 3 Sound pressure ...

Page 11: ...at inspection of the combustion head requires the burner to be opened by rotating the rear part on the hinge The overall dimensions of the burner when open are indicated by L and R Position I is a reference for the thickness of the boiler door refrac tory fettling Tab E Model kg RLS 650 M MX 320 Fig 1 D10541 mm A B C D E F G H I L R S RLS 650 M MX 1325 562 164 410 630 DN80 880 950 360 1190 1055 32...

Page 12: ... firing rates were set in relation to special test boilers accord ing to EN 676 regulations Fig 4 indicates the diameter and length of the test combustion chamber Example Output 3000 kW diameter 100 cm length 4 m MODULATION RATIO The modulation ratio determined using test boilers according to standard EN 676 for gas EN 267 for light oil is 2 5 1 WARNING The firing rate area values Fig 3 have been ...

Page 13: ...erential operating type 19 Air pressure test point 20 Maximum gas pressure switch with pressure test point 21 QRI cell 22 Air pressure test point pressure test point 23 Pump 24 Pump motor 25 Minimum oil pressure switch 26 Maximum oil pressure switch 27 Pressure gauge for pressure on nozzle return 28 Nozzle delivery pressure gauge 29 Oil modulator 30 Pressure gauge attachment 31 Pilot gas train Fig...

Page 14: ...its fuse 19 Servomotor plug socket 20 Plug socket valve pump motor 21 Fan motor thermal cut out 22 Pump motor contactor and thermal cut out 23 Oil gas selection relay 24 Plug socket maximum gas pressure switch 25 Plug socket flame sensor NOTE Two types of burner failure may occur Control box lock out if the control box 11 Fig 6 push button red led and the reset button 10 Fig 6 light up it indicate...

Page 15: ...eutral ones Ensure that spliced wires cannot get into contact with neigh bouring terminals Use adequate ferrules Arrange the H V ignition cables separately as far as possi ble 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 risks of electrical shock hazard Electrical wiring ...

Page 16: ...national safety standards are respected When assembling the servomotor and connecting the damp er the gears can be disengaged by means of a lever allow ing the drive shaft to be easily adjusted in both directions of rotation Technical data Tab G WARNING To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the actua tors Operating...

Page 17: ...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 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 ...

Page 18: ...last tube 4 This protective fettling must not compromise the extraction of the blast tube For boilers having a water cooled front the refractory fettling 2 5 Fig 13 is not required unless it is expressly requested by the boiler manufacturer WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 10 Installation 1 is preferable as it is the only one that allows the maintenance o...

Page 19: ... pressure switch disconnect the leverages related to air damper and head movement unscrew the 4 x fixing screws 1 Release the cable of the electrode 2 Disconnect the oil pipes by unscrewing the two connectors 3 Release the ignition pilot retainer Remove the screw gas pressure test point 6 of the combus tion head unscrew the under part of the elbow until it comes free of its slot Extract the intern...

Page 20: ...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 forth by the regulations in force and in extremely serious cases into potential hazards to people and objects The manufacturing company shall not be l...

Page 21: ...against the required maximum output Setting is pre arranged in the plant for the maximum run hole 3 Fig 17 If combustion requirements require you to move spacer 1 Fig 18 onto the 1st or 2nd hole of the gear and at the same time the hinge is on the right you need to fit the spacers 4 Fig 18 supplied with the burner Proceed as follows Fig 18 unscrew nuts 2 remove tie rod 3 unscrew spacer 1 and posit...

Page 22: ...indicated in Fig 20 Proceed as follows disassemble from the burner of the complete combustion head assembly unscrew the screws and remove the 8 tangential tubes 1 unscrew the 4 screws and disassemble the diffuser disc 2 unscrew and remove the 6 nozzles 3 Re assemble with reverse procedure re placing all the burner components as originally 1 2 3 D10479 Fig 20 ...

Page 23: ...lates 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 J Tab J Key to layout Fig 21 H Pump foot valve height difference L Piping length Ø Inside pipe diameter 1 Burner 2 Pump 3 Fil...

Page 24: ...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 12 4 Hydraulic system layout Key to layout Fig 22 1 Pump suction 2 Pump and nozzle return 3 By pass screw in pump 4 Pump pressure governor 5 Safety solenoid 6 Safety solenoid 7 Nozzle delivery 8 Nozzle without inter...

Page 25: ...ariable eccentric Calibration pressure on return line With a servomotor position of 20 the nut and the corresponding lock nut 6 Fig 24 are fixed in contact with the eccentric 8 During the rotation towards 130 of the servomotor the eccentric will push the modulator shaft taking the pressure read on the pressure gauge 3 Fig 24 to the desired value To calibrate the eccentric proceed as follow loosen ...

Page 26: ... nozzle maximum pressure in the return line pressure fluctuations are detected on the manometer 3 slightly decrease the pressure till their com plete elimination NOTE the burner is calibrated from factory with maximum pressure on the return line of approximately 16 5 bar and delivery pressure of approximately 20 bar 5 12 7 Burner calibration Note It is advisable to first set the burner for operati...

Page 27: ...200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upline pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer DANGER Explosion danger due to fuel leaks in the pres ence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the f...

Page 28: ... the result of the subtraction Read off the corresponding output on the left Example with natural gas G20 Operation at maximum modulating output Gas pressure at test point P1 Fig 31 32 8 mbar Pressure in combustion chamber 5 mbar 32 8 5 27 8 mbar A pressure of 27 8 mbar column 1 corresponds in Tab K to an output of 6000 kW This value serves as a rough guide the effective output must be measured at...

Page 29: ...onnection The burner is fitted with a dedicated gas train that is fixed to the pipe coupling It should be connected to the main train downstream the fil ter or the pressure adjuster depending on configuration Oil burners with LPG pilot can be directly connected to the LPG cylinder 5 13 6 Ignition pilot burner For proper operation adjust gas pressure measured at pressure test point 1 Fig 32 as foll...

Page 30: ...t 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 TL to stop the burner at least once every 24 hours Refer to the wiring 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 I...

Page 31: ...connections set by installer To reset in the case of an intervention of the thermal relay press the button RESET 1 The button STOP 3 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST TRIP 4 and move it in the sense of the arrow towards right WARNING Automatic resetting can be dangerous This action is not provided for the burner op erat...

Page 32: ...nnect two lamps or testers to the two gas line solenoid valves to check the exact moment at which voltage is sup plied This operation is unnecessary if each of the two solenoid valves is equipped with a pilot light that signals voltage pass ing through 6 3 Burner starting Close load controls and set switch 1 Fig 36 to MAN Make sure that the lamps or testers connected to the solenoids or pilot ligh...

Page 33: ...ombustion head To reduce pressure loss and to have a wider adjustment range it is best to set the servomotor to the maximum output used as near to maximum opening 130 as possible On the gas butterfly valve the fuel s partial setting adjustment based on required output with the servomotor fully open is made by using the pressure stabilizer on the train The value reported in the table can be a refer...

Page 34: ...so as to prevent possible shifting of air gas setting positions Key to layout Fig 38 1 Cam 2 Adjustment screws 3 Fixing screws 4 Variable profile 6 7 Air fuel adjustment When setting the air fuel ratio for oil burners the following adjust ments must be made A Delivery pressure of the oil pump turn the screw 5 Fig 23 on the pump B Air cam turn the threaded regulators 2 Fig 38 after loosening the sc...

Page 35: ...e and to reach maximum output as soon as pos sible maximum run for the servomotor 130 set the return pressure on the eccentric screw 4 Fig 39 to obtain the output required by the nozzle and then continue with setting the intermediate levels Check the levels of the combustion parameters at the vari ous modulation outputs and adjust if necessary Move selector 3 Fig 36 to GAS and check the correct op...

Page 36: ...ssure by slowly turning the relative knob anticlockwise until the burner locks out Now turn the knob clockwise by 0 2 kPa 2 mbar and repeat the start up of the burner If the burner locks out again turn the knob clockwise again by 0 1 kPa 1 mbar 6 9 3 Minimum gas pressure switch Adjust the minimum gas pressure switch after performing all the other burner adjustments with the pressure switch set to ...

Page 37: ...ever to check that the flame is present and that the air and gas max pressure switches are in the correct position If the temperature or pressure is low and the thermostat pressure switch TR is consequently closed the burner pro gressively increases its output to the MAX value section C D If subsequently the temperature or pressure increases until thermostat pressure switch TR opens the burner pro...

Page 38: ...the mini mum end of scale position Rotate the air pressure switch knob to the maximum end of scale position the burner must stop in lockout Switch off the burner and disconnect the voltage Disconnect the minimum gas pressure switch connector the burner must not start Disconnect the UV probe wire the burner must stop in lockout due to firing failure Make sure that the mechanical locking systems on ...

Page 39: ...ation of the burner In order to measure the current use a microammeter of 100 A c c connected to the photocell as in the scheme with a capac itor of 100 F 1V c c at the same level of the instrument Burner Check for excess wear or loose screws especially on cams Clean the outside of the burner Clean and grease the cam variable profile Fan Check to make sure that no dust has accumulated inside the f...

Page 40: ...sure that the flexible hoses are still in good con dition 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 ...

Page 41: ...he hinge 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 main system switch DANGER Turn off the fuel interception tap Wait for the components in contact with heat sources to cool down completely 5 5 1 2 6 5 5 7 3 4 Fig 48 D10553 After...

Page 42: ... set of fail ures that may occur and result in irregular burner operation or no functioning at all If a burner malfunction is detected first of all check that the electrical wiring is adequately connected check whether fuel is delivered check that every adjustment parameter is adequately set 8 Faults Probable causes Solutions Fig 49 S8889 Lockout indicator a b Start up sequence b b Idle stages wit...

Page 43: ...hes on but then stops in lockout Failure to the flame detection circuit Replace control box The burner remains in pre purging phase Contact III of the servomotor terminals 10 8 control box does not intervene Adjust cam III or replace servomotor Once the pre purging and the safety time has elapsed the burner goes into lockout without the flame appearing The VP1 solenoid lets too little gas through ...

Page 44: ...tioned near the burner itself Internally rusted pump Water in the tank Remove the water with a pump Noisy pump unstable pressure Air in the suction line Block the couplings Depression value too high higher than 35 cm Hg Excessive difference of level between burner and tank Power the burner from a loop circuit Piping diameter too small Increase Dirty suction line filters Clean Suction line valves c...

Page 45: ...e burner does not switch on and the lock out appears Flame simulation Replace the control box Faulty motor remote control switch Replace Defective electrical motor Replace Motor lockout Release the thermal relay The burner starts up but stops at the damper maximum opening The servomotor contact does not intervene maximum cam opening Cam adjustment maximum opening or replace the servomotor The burn...

Page 46: ...ch intervention Adjust or replace Defective control box Replace The burner continues to repeat the start up cycle without lockout The gas pressure in the gas mains lies very close to the value to which the minimum gas pressure switch has been set The sudden drop in pressure after valve open ing causes temporary opening of the pressure switch itself the valve immediately closes and the burner comes...

Page 47: ...Analogic signal converter the Potentiometer Potentiometer kit for the indication of load position Soundproofing box kit Kit for the remote fuel selection Gas trains approved according to EN 676 Refer to the instruction manual A Appendix Accessories Parameter to control Probe Output power regulator Range Type Code Type Code Temperature 100 500 C PT 100 3010110 RWF50 2 RWF50 5 20101190 20101191 Pres...

Page 48: ...ut star powered starter delta powered starter 5 Operational layout LFL 1 6 Operational layout LFL 1 7 Operational layout LFL 1 8 Operational layout LFL 1 9 Operational layout RWF50 10 Electrical connections set by installer 11 Electrical connections for internal RWF50 kit 12 Electrical connections for external RWF50 kit 1 2 Sheet no 1 A1 Coordinates Reference layout ...

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Page 55: ...66 8 8 0 0 0 2 9 2 9 2 9 2 31 9 2 9 103 9 4 3 8 0 221 9 8 2214 9 9 2 3 9 3 9 37 9 3A 3 31 1 9 3 9 31 9 317 4 0 1 9 4 07 9 2 9 4 0 1 3 01 9 13 9 13 9 13 7 012 771 9 012 7 9 012 7 9 012 77 8 30 01 9 3 8 9 30 9 3 31 9 0 9 31 9 31 131 9 12 9 13 9 12 7 7 3 9 7 3 10 9 7 3 10 9 7 3 0 2 3 3 71 9 02 3 9 3 7 9 02 3 8 0 2219 3 9 8 22149 3 9 9 37 9 2 9 3 331 9 314 9 331 9 3 2 ...

Page 56: ...20027761 54 GB Appendix Electrical panel layout 0 1 2 1 3 4 56 7 8 7 8 9 3 1 2 9 3 9 3 0 1 0 0 1 0 0 9 0 9 0 0 0 1 0 2 2 2 ...

Page 57: ... 7 806 6 1 6 9 A B 01 4 2 7 0 3 A B 9 334C2 7 2 6 4 2 D 6 90 26 E 93 6 8609 692 4 0 61 1F 3342 20 1 2 2 G62 6 4 6 4 30 1 9 6 H 824 1 06 2 6 A B I I A B A B I A B I 9 9 A B 9 A B A B J J K J L J J J J J J J J J J J L J M M M M A B M M A B M M A B 690 0 34 21 93 6 6 2 6909 6 2 26 26 2 2 6909 6 2 26 26 2 2 0 209 6 60 2 66 0 3 2 2 66 0 3 60 2 04 7 0 3 2 2 04 7 0 3 ...

Page 58: ...4 5 4 5 46 7 4 8 09 6 4 4 46 4 6 6 8 09 6 4 8 09 446 5 4 8 09 8 09 1 3 2 6 4 6 4 8 A 7 6 68 B 7 7 C 5 7 C 7 5 6 6 5 6 7 6 8 46 8 4 8 67 4 6 6 7 6 7 6 7 C C 6 6 C 6 C 6 C 6 7 7 7 6 7 7 7 6 6 6 75 6 6 76 5 6 76 5 4 6 6 7 6 C 7 7 7 6 C 5 68 7 B C 7 7 6 68 6 7D 7 5 57 D ...

Page 59: ...tput relay KG Gas operation relay KO Light oil operation relay MP Pump motor MV Fan motor PA Air pressure switch PE Burner ground earth connection PGM Maximum gas pressure switch PGMin Minimum gas pressure switch PO Oil pressure switch PO1 High limit oil pressure switch on return line RS Remote lock out reset button S1 Emergency stop push button S2 Dial for off automatic manual S4 Power dial for i...

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 ...