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Riello RLAS 1000 EV, Installation, Use And Maintenance Instructions

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Riello RLAS 1000 EV Installation, Use And Maintenance Instructions Download Page 54

Summary of Contents for RLAS 1000 EV

Page 1: ... use and maintenance instructions 20146383 1 04 2019 Dual fuel air atomizing oil gas burner Modulating operation CODE MODEL 20164347 20164348 RLAS 1000 EV FGR prepared 20164351 20164352 RLAS 1200 EV FGR prepared GB ...

Page 2: ...Original instructions ...

Page 3: ...on safety for the installation 20 4 2 Handling 20 4 3 Preliminary checks 20 4 4 Operating position 21 4 5 Removing the shutter lockout screws 21 4 6 Preparing the boiler 21 4 7 Securing the burner to the boiler 22 4 8 Access to head internal part 22 4 9 Combustion head adjustment 23 4 10 Electrode position 24 4 11 Nozzle installation 24 4 12 Light oil supply 26 4 13 Pump 28 4 14 Gas train supplied...

Page 4: ... switches 41 5 9 Final checks with the burner working 42 6 Maintenance 43 6 1 Notes on safety for the maintenance 43 6 2 Maintenance programme 43 6 3 Opening the burner 46 6 4 Closing the burner 46 7 Faults Possible causes Solutions 47 A Appendix Spare parts 48 ...

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: ... 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 and or...

Page 7: ...nance 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 unde...

Page 8: ...2 GPH 30 7 Fuel Oil 2 Natural gas Gas max delivery SCFH 39 386 42 574 Gas pessure at max delivery 3 WC 30 1 36 8 Operation Low high or modulating Nozzles 1 Standard applications Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Combustion air temperature F max 140 60 C Noise levels 4 dBA 80 90 Model RLAS 1000 EV FGR prepared RLAS 1200 EV FGR prepared Control circuit power supply ...

Page 9: ...aging The packaging of the burner Fig 1 rests on a wooden plat form that is particularly suitable for lift trucks The overall dimensions of the packaging are shown in the Tab D The weight of the burner complete with its packaging is shown in Tab D Tab D Model RIELLO Code RBNA Code Voltage Fan Motor Starting Flame safeguard RLAS 1000 EV FGR prepared 20141370 20164347 460 3 60 Inverter Burner Mounte...

Page 10: ...pen are indicated by L and R Tab E F C P T I D E L G M H R A O Fig 2 20162816 Model A C D E F G H I L M O P R T 1000 mm 1500 200 413 884 ASME 150lb 674 1375 485 1360 686 299 1640 1350 658 inch 59 1 16 7 7 8 16 17 64 34 51 64 Ø 3 26 17 32 59 9 64 19 3 32 53 35 64 27 1 64 11 49 64 64 9 16 53 5 32 25 29 32 1200 mm 1500 200 456 884 ASME 150lb 774 1375 464 1460 686 299 1640 1350 658 inch 59 1 16 7 7 8 ...

Page 11: ...ϬϬ ϮϬϬϬϬ ϮϮϱϬϬ ϮϱϬϬϬ ϮϳϱϬϬ ϯϬϬϬϬ ϯϮϱϬϬ ϯϱϬϬϬ ϯϳϱϬϬ ϰϬϬϬϬ ϰϮϱϬϬ ϰϱϬϬϬ ΎͿ ΎͿ Burner power output MBtu hr Fig 3 20162856 Combustion chamber pressure wc Firing Rate for C ETL Canadian Listing RLAS 1000 RLAS 1200 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 w c mbar 32 41 50 59 68 77 86 104 F 0 0 399 1013 00 1 087 1 068 1 049 1 031 1 013 0 996 0 980 0 9...

Page 12: ...ed in special test boilers Fig 4 indicates the diameter and length of the test combustion chamber Example Output 26510 Mbtu hr diameter 47 7 inch length 20 ft Fig 4 1000 MBtu hr760 1 5 7 5 11 3 18 9 37870 1 6 3 3 6 6 9 9 13 2 16 5 29 6 23 0 15 7 19 7 23 6 31 5 39 4 4 7 2 i nches f t ft 0 12 MBtu hr 22 7 D9084 ...

Page 13: ...Manifold 16 Thermal insulation screen for securing burner to boiler 17 Shutter 18 Ignition pilot 19 Combustion head 20 Flame stability disk 21 Nozzle 22 Atomizing lance DN40 23 Gas train flange 24 Pump motor 25 Lever for movement of combustion head 26 Max gas pressure switch with pressure test point 27 QRI flame detector 28 Hinge for opening burner 29 Air pressure switch diff operating type 30 Fan...

Page 14: ...only to avoid a break in the cable s shielding hence do not overtighten 22 Electric joint for ignition cable 23 Speed sensor terminal strip X70 24 Addictional trasformer 25 Plug socket for flame sensor 26 Plug socket for air servomotor 27 Optional hole 28 Electric joint for speed sensor 29 Pump motor contactor and thermal relay 30 Touch screen display available as kit 31 Step down transformer avai...

Page 15: ...ta Technical data Tab G WARNING To avoid accidents material or environmental dam age observe the following instructions The AZL display is a safety device Avoid opening or modifying it or forcing its operation Riello S p A cannot assume any responsibility for damage re sulting from unauthorised interventions Operating voltage AC 24 V 15 10 Power consumption 5W typical Protection level of the conta...

Page 16: ...air ratio curves are being programmed the person making the plant settings must con tinuously monitor the quality of the combustion process e g by means of a flue gas analyser Also if combustion levels are poor or in the event of danger ous situations the commissioning engineer must take appro priate action e g switching off manually To ensure the safety and reliability of the control box the foll...

Page 17: ... pump magnetic clutch nominal voltage Nominal current Power factor 1 6A cos 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cos 0 4 Terminal loading Outputs Total contact loading Mains voltage Input current of unit safety loop total load on contacts resulting from Fan motor contactor Ignition transformer Valve Oil pump magnetic clutch AC 120 V 15 10 Max 5 A Sin...

Page 18: ...V Fuel valve V1 Fuel valve V2 Fuel valve V1 Fuel valve V2 Fuel valve V3 Fuel valve SV Oil INPUTS Timer 1 Timer 2 Fuel 1 oil Fuel 2 gas Controller ON internal external Air pressure switch LP Start release oil Fuel selection Fan conductor contact GSK Interval 1 ti1 Operation 2 LK K POS SR ON Pressure test Direct start Air Aux VSD Actuator 1 4 5 CPI function with LMV52 alternative start signal Fig 9 ...

Page 19: ...n1 t78 Postpurge time 3 gas oil tn3 t80 Valve proving evacuate time t81 Leakage test time atmospheric pressure t82 Leakage test filling test t83 Leakage test time gas pressure tmn1 Min time extraneous light test 5 s after skip over of prepurge tmx1 Max damper running time tmx2 Max time startup release tmx3 Max time circulation heavy oil tn Postpurge time TSA1 Safety time 1 TSA2 Safety time 2 tv Pr...

Page 20: ... Output is active when fan is on and for another 15 s after fan is switched off 17 Parameter Start pressure switch valve PS_Re li_Inv Output pressure switch valve will be logically inverted 18 Parameter Alarm act deact deactivated The alarm output can temporarily be deactivated for cur rent error only 19 Parameter Only with LMV52 Continuous pilot gas oil Activated Pilot valve is also activated in ...

Page 21: ... low voltage section The static torque is reduced when the electrical supply of the actuator is switched off The housing cover may only be removed for short periods of time for wiring or when making the addressing In similar cases make sure that dust or dirt does not penetrate inside the actu ator The actuator comprises a PCB with ESD sensitive compo nents The top side of the board carries a cover...

Page 22: ...tention 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 25cm from the ground After positioning the burner n...

Page 23: ...ettling must not compromise the extraction of the blast tube For boilers having a water cooled front the refractory fettling 5 6 Fig 14 is not required unless it is expressly requested by the boiler manufacturer Tab J WARNING The burner is designed to operate only in posi tions 1 and 4 Fig 11 Installation 1 is preferable as it is the only one that allows the maintenance operations as described in ...

Page 24: ...r on hinge Open partially of about 5 90 inch Disconnect the cable of pilot electrode 6 Open the burner Release the ignition pilot fitting 7 Disconnect the oil pipe 8 and the air pipe 9 Unscrew the lockout screw 10 of oil air lance 10 Extract the oil air lance from the combustion head 11 Remove the combustion head 11 from the pipe coupling To close repeat the procedure in reverse order Prepare a su...

Page 25: ...NING The gas pipes leave the factory calibrated at notch 1 The adjustment shown in Fig 17 allows the gas pipes to be positioned in the best way for the application on which the burner is installed e g boilers with flame inversion chamber 20162848 1 Fig 16 1 20162850 Fig 17 20162857 ϭϰϬϬϬ ϭϵϭϱϲ ϮϰϯϭϮ Ϯϵϰϲϴ ϯϰϲϮϰ ϯϵϳϴϬ ϮϬϱϬϬ ϮϱϬϬϬ ϮϵϱϬϬ ϯϰϬϬϬ ϯϴϱϬϬ ϰϯϬϬϬ ϯϴϱϬ ϲϯϱϬ ϴϴϱϬ ϭϭϯϱϬ ϭϯϴϱϬ ϭϲϯϱϬ ϭϴϴϱϬ ϮϭϯϱϬ ...

Page 26: ...rving the dimensions specified in Fig 19 18 5 0 2 71 5 1 D9218 Electrode Diffuser Fig 19 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 ...

Page 27: ... 1200 air pressure 72 5 PSI 6 bores type 2 1 3 20150446 Fig 21 Ϭ Ϭ ϭϬϬ Ϭ ϮϬϬ Ϭ ϯϬϬ Ϭ ϰϬϬ Ϭ ϱϬϬ Ϭ ϲϬϬ Ϭ ϳϬϬ Ϭ ϴϬϬ Ϭ ϵϬϬ Ϭ ϭϬϬϬ Ϭ ϭϭϬϬ Ϭ ϭϮϬϬ Ϭ ϭϯϬϬ Ϭ ϭϰϬϬ Ϭ ϭϱϬϬ Ϭ ϭϲϬϬ Ϭ ϭϳϬϬ Ϭ ϭϴϬϬ Ϭ ϭϵϬϬ Ϭ ϮϬϬϬ Ϭ Ϭ Ϭ ϮϬ Ϭ ϰϬ Ϭ ϲϬ Ϭ ϴϬ Ϭ ϭϬϬ Ϭ ϭϮϬ Ϭ ϭϰϬ Ϭ ϭϲϬ Ϭ ϭϴϬ Ϭ ϮϬϬ Ϭ ϮϮϬ Ϭ ϮϰϬ Ϭ ϮϲϬ Ϭ ϮϴϬ Ϭ ϯϬϬ Ϭ ϯϮϬ Ϭ Ϭ ϱ ϭϬ ϭϱ ϮϬ Ϯϱ ϯϬ ϯϱ ϰϬ ϰϱ ϱϬ ϱϱ ϲϬ ϲϱ ϳϬ ϳϱ ϴϬ ϴϱ ϵϬ ϵϱ ϭϬϬ ϭϬϱ ϭϭϬ ϮϰͲzͲ ΣͲϬϬͲϲ ϮϰͲzͲ ΣͲϯͲϲ ϮϰͲzͲ ΣͲϭͲϲ...

Page 28: ...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 L Tab L Key Fig 23 H Pump Foot valve height difference L Piping length Ø Inside pipe diameter 1 Burner 2 Pump 3 Filter 4...

Page 29: ...e on nozzle line The servomotor is controlled by the electronic cam thanks to this device it is possible to set different curves for oil and gas on the same servomotor also for the air damper servomotor When adjusting the gas it is recommended to adjust the servo motor to about 90 to reduce leaks from the gas butterfly valve When adjusting the oil the adjustment is done based on the nozzle fitted ...

Page 30: ... 5 Pressure adjustment screw 6 Screw for by pass 7 Pressure gauge attachment G 1 4 Pump SUNTEC TA5 Min delivery rate at 300 psi pressure 1200 kg h Delivery pressure range 7 30 bar 101 435 psi Max suction depression 0 45 bar 6 5psi Viscosity range 2 75 cSt Max light oil temperature 150 C 302 F Max suction and return pressure 5 bar 72psi Pressure calibration in the factory 30 bar 435psi WARNING Befo...

Page 31: ...om the 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 The fuel supply line must be installed by qualified personnel in compliance with current standards and laws 10 2 3 4 5 6 11 2 12 5 4 4 7 8 1 9 Fig 27 S9785 VENT...

Page 32: ...hamber to obtain true pressure measured by a U type manometer add the counter pressure of the boiler Gas pressure Mbtu hr GCV 1 p WC 2 p WC RLAS 1000 EV 14000 3 90 2 74 19156 7 30 5 23 24312 11 70 8 22 29468 17 20 12 21 34624 22 80 16 94 39780 30 10 19 93 RLAS 1200 EV 20500 8 36 1 00 25000 12 40 1 40 29500 17 30 2 00 34000 23 00 2 70 38500 29 50 3 40 43000 36 80 3 80 WARNING The data of thermal ou...

Page 33: ...pped at least once every 24 hours to enable the control box to perform checks of its own start up efficiency Normally burner stopping is guaranteed by the boiler s thermostat pressure 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 burner is factory set for FS1 operation 1 stop every 24 h...

Page 34: ...cable grommet 2 Available single phase power supply and other devices with 3 8 inch cable grommet 3 Available consents safety minimum gas pressure switch gas valves pressure and temperature probe sensor and other devices with 1 2 inch cable grommet 4 Speed sensor cable used in the factory WARNING The control panel is in compliance with UL508A After carrying out maintenance cleaning or check ing op...

Page 35: ... terminal board of the motor Make a final visual check then close the motor casing by tight ening the 4 screws 1 Fig 31 4 15 5 Other connection WARNING For the burner to operate correctly where required it is necessary to shield the connections WARNING To make the correct shielding it is important to bear in mind the necessary length of the connections in side the motor casing WARNING 1 The connec...

Page 36: ...elding inside the clamp A2 screw in the screw until it is completely tightened on the shielding A3 In the case of clamp type B pull the indicated tabs upwards and lift until locked in the open position B1 Fig 34 insert the shielded cable with the shielding inside the clamp B2 put pressure on the indicated part until the clamp closes auto matically on the shielding B3 WARNING Do not overtighten B1 ...

Page 37: ...clamping the cable to the earth plate The screen must be earthed on both side of the cable take care for good earthing system Examples 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 35 S8203 Ground...

Page 38: ...he motor is 460V To reset in the case of an intervention of the thermal relay press the button RESET Fig 38 The button STOP Fig 38 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 39 and move it in the sense of the arrow towards right 4 17 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay pres...

Page 39: ...60V Please pay attention to the indications in case of modification of voltage maintenance or substitution WARNING the motors manufactured for 460 IE3 NEMA Pre mium Efficiency voltage have the same connec tion than IE2 Epact motors 2 4 1 3 20108739 Fig 43 ...

Page 40: ... if no remote selector is fitted the display shows the priority fuel 5 4 Adjustments before first firing gas operation In addition the following adjustments must also be made open manual valves up line from the gas train Adjust the minimum gas pressure switch Fig 50 to the start of the scale Adjust the maximum gas pressure switch Fig 49 to the end of the scale Adjust the air pressure switch Fig 48...

Page 41: ...e correct fuel If the motor starts but the flame does not appear and the flame safeguard goes into lock out reset and wait for a new firing at tempt Check the control adjustment of the pilot valve Having adjusted the pilot reconnect the main valve and ignite the main flame it might require several attempts to purge the air from the gas lines or to adjust the valve with little gas Once the burner h...

Page 42: ...utput in accordance with the load required by the system with maintenance of the pres sure or temperature of the boiler at the operating values set 3 The sequence cascade adjustment of more than one boiler through the suitable connection of the various units and the activation of the internal software of the individual systems option Further interfaces and communication functions with computers fo...

Page 43: ...witch set to the end of the scale With the burner operating at MAX output reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out Then turn the dial clockwise by 0 8 WC and repeat burner firing If the burner locks out again turn the dial again clockwise by 0 4 WC 5 8 3 Minimum gas pressure switch Adjust the minimum gas pressure switch Fig 50 af...

Page 44: ...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 The burner must not start Cover the flame sensor The burner must stop in lockout due to firing failure WARNING Make sure that the mechanical locking systems on the diff...

Page 45: ...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 Carry out an analysis of the combustion discharge gases Significant differences with respect to the previous check indicate the points where more care should be exercised during mainte ...

Page 46: ...values found at the start of the intervention do not satisfy current standards or anyway indicate a poor state of com bustion consult the table below contact the Technical Assistance Service for the necessary adjustments Gas leaks Make sure that there are no gas leaks on the pipes between the gas meter and the burner Gas filter Replace the gas filter when it is dirty Combustion If the combustion v...

Page 47: ...ctrical panel with the appropriate screws 2 arranging the cables present 6 2 6 Speed sensor adjustment To calibrate the speed sensor 1 Fig 55 proceed as follows loosen the screws 3 place the sensor on the disc blade 2 referring to the gradu ated scale 4 move backward the speed sensor 1 of one notch according to the distance from the disc blade of 5 64 inch Key Fig 55 1 Speed sensor 2 Disk 3 Screw ...

Page 48: ...all burner components as they were originally assembled DANGER Disconnect the electrical supply from the burner by means of the main system switch DANGER Close the fuel interception tap Wait for the components in contact with heat sourc es to cool down completely After carrying out maintenance cleaning or check ing operations reassemble the cover and all the safety and protection devices of the bu...

Page 49: ...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 50: ...20146383 48 GB Appendix Spare parts A Appendix Spare parts ...

Page 51: ...3 SWITCH C 18 3006211 FUSE A 19 20014365 ELECTRONIC CAM C 20 20132457 CONNECTORS ASSEMBLY B 21 20013975 PRESSURE SWITCH A 22 20112569 OVERLOAD C 23 20133520 CONVERTER 24 20112588 CONTACTOR C 29 20063409 COVER 30 3012868 O RING B 31 3013118 ELBOW 32 20117840 GAS PIPE C 33 3013105 DISTRIBUTOR 34 20029690 GAS PIPE C 35 20039358 GAS PIPE C 36 20162934 DIFFUSER DISC A 37 20125070 SUPPORT A 38 20063280 ...

Page 52: ... C 66 20052992 BAR C 67 20052999 SHUTTER C 68 20090597 CYLINDER C 68 20090461 CYLINDER C 69 3013100 FLAME FUNNEL B 69 3013391 FLAME FUNNEL B 70 3013104 FLANGE GASKET A 70 3013392 FLANGE GASKET A 71 20113414 LEVER ASSEMBLY 72 20158706 TUBE C 73 20158708 TUBE C 74 3012384 PRESSURE SWITCH A 75 3006140 PRESSURE GAUGE 76 3013430 SEAL B 77 20029137 SERVOMOTOR B 78 20129116 COUPLING A 79 20110042 MODULAT...

Page 53: ...y fittings A B C Spare parts for extended safety fittings 88 20132849 CONNECTOR C 89 20029212 SAFETY VALVE B 90 20144620 TUBE C 91 20029233 92 20158713 TUBE C 93 20158779 FILTER B 95 20045909 FAN C 95 20093001 FAN C 96 20069312 SERNSOR A N CODE RLAS 1000 EV 20164347 20164348 RLAS 1200 EV 20164351 20164352 DESCRIPTION ...

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Page 56: ...BURNERS NORTH 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 com ...

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