Riello RLS 1000/M MX Installation, Use And Maintenance Instructions Download Page 1

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Installation, use and maintenance instructions

20148180 (2) - 11/2020

Dual fuel light oil/gas burners

Progressive two-stage or modulating operation

CODE

MODEL

TYPE

20147815

RLS 1000/M MX

1311 T

20147814

RLS 1200/M MX

1312 T

Summary of Contents for RLS 1000/M MX

Page 1: ...on use and maintenance instructions 20148180 2 11 2020 Dual fuel light oil gas burners Progressive two stage or modulating operation CODE MODEL TYPE 20147815 RLS 1000 M MX 1311 T 20147814 RLS 1200 M MX 1312 T GB ...

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

Page 3: ...5 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 Removing the shutter lockout screws 16 5 6 Preparing the boiler 16 5 7 Securing the burner to the boiler 17 5 8 Access to head internal part 17 5 9 Electrode position 17 5 10 Nozzle installation 18 5 11 Combustion head adjustment 19 5 12 Light oil supply 20 5 13 Pump 22 5 14 Gas su...

Page 4: ...erating 36 7 Maintenance 37 7 1 Notes on safety for the maintenance 37 7 2 Maintenance programme 37 7 3 Opening the burner 40 7 4 Closing the burner 40 8 LED indicator and special function 41 8 1 Description of LED lamps 41 8 2 Check mode function 41 8 3 Flame control lock out or emergency stop condition 41 8 4 LED lamps burner operating status 42 9 Problems Causes Remedies signalled by LED indica...

Page 5: ...68 EU FS2 only Pressure Equipment Directive Such products are marked as indicated below 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 revision 26 01 2010 Product Type Model Output Dual fuel ...

Page 6: ...ried 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 CRUSHI...

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 a...

Page 8: ...intenance 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 un...

Page 9: ... Class 1 EN267 EN676 C22 or MZ Class 2 EN267 EN676 C33 or BLU Class 3 EN267 EN676 FS1 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION MX 3N 400V 50Hz 3 230V 50Hz 230V 50Hz 110V 50 60Hz Heavy oil E Electronic cam EV Electronic cam and variable speed with Inverter P Proportional air gas valve BP Two stage light oil Proportional valve gas M Mechanical cam S L LS N Head TC Standard head TL E...

Page 10: ...0 171 462 942 Fuels Light oil max viscosity at 20 C 6 mm2 s 1 5 E 6 cSt Natural gas G20 methane G25 Gas pressure at max output 2 Gas G20 G25 mbar 67 8 101 1 97 2 145 Operation Intermittent min 1 stop in 24 hours Progressive two stage or modulating by kit see accessories Pump Output at 30 bar Pressure range Fuel temperature kg h bar c max 1400 9 40 140 1826 9 40 140 Nozzles number 1 Standard applic...

Page 11: ...burner to be opened and the rear part turned on the hinge The maximum dimensions of the open burner are indicated by the L and R positions The l position is reference for the refractory thickness of the boiler door Tab E Fig 1 20062787 mm A B C D E F G H I L R RLS 1000 M MX 1637 674 200 413 885 DN80 1206 1338 484 1425 1350 RLS 1200 M MX 1637 658 200 456 885 DN80 1250 1338 465 1425 1350 ...

Page 12: ...e manufacturer The firing rates were obtained in special test boilers according to EN 676 standard In Fig 3 you can see the diameter and length of the test combustion chamber Example Output 7000 kW diameter 120 cm length 6 m MODULATING RATIO The modulating ratio obtained in test boilers according to standard EN 676 for gas EN 267 for light oil is of 4 1 for light oil and 7 1 for gas WARNING The fi...

Page 13: ...bustion head air pressure test point 20 Maximum gas pressure switch with pressure test point 21 UV cell 22 Pressure test point for air pressure switch 23 Pump 24 Pump motor 25 Maximum oil pressure switch 26 Minimum oil pressure switch 27 Nozzle return pressure gauge 28 Screws to lock the shutter during transportation replace them with the M12x25 screws supplied as standard 29 Oil modulator 30 Pres...

Page 14: ... Oil Gas selection relay 20 Flame sensor plug sensor socket 21 Light signalling of mains live state 22 Heat request lighting signal 23 Light signalling of main fuel valve open 24 Terminal board for RWF50 kit NOTE Two types of burner lockout may occur Control box lockout if the button red LED of control box 9 Fig 5 and signal button 8 light up the burner is locked out Release by pressing button 8 M...

Page 15: ...tions 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: ...nt national safety 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 G WARNING To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the actuators Operating...

Page 17: ...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 WARNING 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 whi...

Page 18: ...nt flue passes 1 Fig 12 or flame inversion chamber a protection in refractory material 5 must be inserted between the boiler fettling 2 and the blast tube 4 This protection must not compromise the extraction of the blast tube For boilers with a water cooled front piece a refractory lining 2 5 Fig 12 is not necessary unless expressly requested by the boiler manufacturer WARNING The burner is design...

Page 19: ... burner on the hinge disconnect the cable 14 from the electrode 2 disconnect the light oil pipes unscrewing the two pipe fittings 3 Release the ignition pilot fitting 13 remove the gas pressure screw test point 6 of the head unscrew the locking screw of the oil lance 9 and extract the oil lance from the combustion head 10 pull out the inner part of the head 5 5 9 Electrode position Prepare a suita...

Page 20: ...al 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 liable for any such damage arising from non observance of the requ...

Page 21: ...16 The selection of the hole to be used is determined based on the maximum output requested as illustrated in Tab J In the factory the hole is adjusted for the maximum stroke hole 10 Fig 16 Tab J Fig 16 20062792 Leverage hole Output kW From To RLS 1000 M 5 1200 3750 5 3750 6700 8 6700 8600 8 8600 10600 RLS 1200 M 5 1500 5500 5 5500 7500 6 7500 9600 10 9600 11500 WARNING The gas pipes leave the fac...

Page 22: ...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 K Tab K Key Fig 18 H Pump Foot valve height difference Ø Inside pipe diameter 1 Burner 2 Pump 3 Filter 4 Manual on off valve 5 Suction line 6 Foot valve 7 Quick closing manual valve with remote control Italy only 8 On...

Page 23: ...creasing the difference between the maximum and minimum capacity of the nozzle Calibration pressure on delivery line To adjust the delivery pressure operate on the pump as described on pag 22 Example if you use a 750 kg h nozzle and you want to obtain an output of 6650 kW the pressure read on the pressure gauge 3 Fig 20 max pressure on return circuit must be approx 19 bar Relevant delivery pressur...

Page 24: ...screws 4 The time required for this operation depends upon the diameter and length of the suction tubing If the pump fails to prime at first start up and the burner locks out wait approx 15 seconds reset the burner and then repeat the start up operation And so on After 5 or 6 starting operations allow 2 or 3 minutes for the transformer to cool Do not light the UV cell in order to prevent the burne...

Page 25: ...juster P3 Pressure upstream of the filter L Gas train supplied separately L1 Responsibility of the installer Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel shut off valve is closed before performing any operation on the burner WARNING The fuel supply line must be installed by qualified personnel in co...

Page 26: ...pply using the system main switch Check that there are no gas leaks Pay attention when handling the train danger of crushing of limbs Make sure that the gas train is properly installed by checking for any fuel leaks The operator must use the required equipment during installation Fig 26 20062795 kW 1 p mbar 2 p mbar G 20 G 25 G 20 G 25 RLS 1000 M MX 3750 9 2 13 7 1 0 1 4 4000 10 8 16 0 1 1 1 6 450...

Page 27: ...umn 1 the pressure at the test point 1 Fig 27 Add this value to the estimated pressure in combustion chamber Example RLS 1000 M MX with natural gas G20 Operation at maximum modulating output Gas pressure at an output of 8000 kW 39 2 mbar Pressure in combustion chamber 5 mbar 39 2 5 44 2 mbar pressure required at test point 1 Fig 27 5 14 5 Pilot gas train connection The burner is equipped with a de...

Page 28: ... lance for light oil Fig 29 shows the 3 way valve used for the mechanical activation of the burner lance and the point at which the compressed air input A must be connected It must operate at 6 7 bar A Fig 29 D12066 S8484 VU VALVE OIL LANCE Return line PUMP Delivery line Oil regulator Compressed air ...

Page 29: ...ws to use 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 h...

Page 30: ... TEST TRIP 4 and move it in the arrow direction to the right to carry out the thermal relay test 5 18 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 32 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...

Page 31: ... signal must be switched on At first ignition there is a momentary drop in fuel pressure due to the filling of the nozzle piping This lowering of the fuel pressure can cause the burner to lockout and can sometimes give rise to pulsations If the burner locks out again refer to chapter Problems Causes Remedies signalled by LED indicators a pag 43 Once the following adjustments have been made the ign...

Page 32: ...closed the heat request indication CALL FOR HEAT 3 Fig 33 must be displayed and the burner starts the starting cycle 6 6 Burner ignition If the motor starts but the flame does not appear and the control box goes into lockout reset and wait for a new ignition attempt If ignition does not occur it is possible that gas is not reaching the combustion head within the safety time period of 3 seconds The...

Page 33: ...release 6 9 Combustion air adjustment The fuel combustion synchronization is made by means of a servomotor connected to two variable profile cams which act on the outlet air damper 1 Fig 36 and gas damper 2 and on the combustion head by appropriate levers It is advisable to reduce the loss and for a wide calibration field to adjust the servomotor to the maximum of the output used the nearest possi...

Page 34: ...ase the air output so as to adjust it to the corresponding gas output Key Fig 37 1 Cam 2 Adjustment screws 3 Locking screws 4 Adjustable profile 6 11 Air fuel adjustment The following adjustments must be performed during the calibration of the air fuel ratio A Oil pump outlet pressure turn screw 5 Fig 21 a pag 22 on the pump B Air cam turn the adjustment screws 2 Fig 37 after having loosened screw...

Page 35: ...rst adjustment increase the output supplied via the automatic return selector on the control panel Pause after a 15 rotation of the servomotor and perform another adjustment by means of the variable profile cam of the air It is recommended to perform a calibration that will prevent the formation of a smoky flame and arrive as soon as possible to the maximum output maximum stroke of the servomotor ...

Page 36: ...e 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 12 3 Minimum gas pressure switch Adjust the minimum gas pressure switch after performing all the other burner adjustments with the pressure switch set to the start of ...

Page 37: ...ler point C Fig 42 The electrical control box continues to check the presence of the flame and the correct position of the air and gas maximum pressure switches If the temperature or the pressure is low so the thermostat pressure switch TR is closed the burner progressively increases the output up to the MAX value section C D Then if the temperature or pressure increases until the TR opens the bur...

Page 38: ...minimum end of scale position Turn the air pressure switch knob to the maximum end of scale position The burner must stop in lockout Turn off the burner and cut off the power Disconnect 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 WARNING Make sure that the mechan...

Page 39: ...e 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 the high temperatures free of impurities from the surroundings and correctly positioned Burner Check that th...

Page 40: ...d life cycles do not refer to the warranty terms indicated in the delivery or payment conditions Safety component Life cycle Flame control 10 years or 250 000 operation cycles Flame sensor 10 years or 250 000 operation cycles Gas valves solenoid 10 years or 250 000 operation cycles Pressure switches 10 years or 250 000 operation cycles Pressure adjuster 15 years Servomotor electronic cam if any 10...

Page 41: ...ke 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 necessary adj...

Page 42: ...e 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 system main switch DANGER Close the fuel shut off valve Wait for the components in contact with heat sources to cool down completely Fig 45 20062800 After carrying out maintenanc...

Page 43: ...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 key...

Page 44: ...er 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 present...

Page 45: ...n 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 atte...

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: ...sor fault 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 UV scanner 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...

Page 49: ...ystem detected 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...

Page 50: ... to be ordered are two the analogue signal converter the potentiometer Continuous purging kit Soundproofing box 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 RWF55 20101190 20101191 Pressure 0 2 5 bar 0 16 bar Output probe 4 20 m...

Page 51: ...5 Functional layout RFGO A22 6 Functional layout RFGO A22 7 Functional layout RFGO A22 8 Functional layout RFGO A22 9 Electrical wiring kit RWF50 internal 10 Electrical wiring to be carried out by the installer RLS 1000 M MX RLS 1200 M MX 11 Electrical wiring that is the responsibility of the installer 12 Functional layout RWF50 13 Electrical wiring kit RWF50 external 1 2 Sheet no 1 A1 Coordinates...

Page 52: ...20148180 50 GB Appendix Electrical panel layout 0 0 0 0 12342 5 56 7 8 0 0 0 0 7 7 9 7 RLS 1000 M MX ...

Page 53: ...51 20148180 GB Appendix Electrical panel layout 0 0 0 0 12342 5 56 7 8 0 0 0 0 7 7 9 7 RLS 1200 M MX ...

Page 54: ...20148180 52 GB Appendix Electrical panel layout 0 0 0 0 0 0 0 0 ...

Page 55: ...53 20148180 GB Appendix Electrical panel layout 0 0 0 1 0 2 0 0 0 0 0 0 0 30 3 3 0 0 1 0 ...

Page 56: ...20148180 54 GB Appendix Electrical panel layout 0 0 1 0 1 2 0 3 0 1 0 1 1 0 0 0 0 0 40 4 4 0 0 1 2 0 1 ...

Page 57: ...55 20148180 GB Appendix Electrical panel layout 0 1 2 2 2 0 ...

Page 58: ...20148180 56 GB Appendix Electrical panel layout 0 1 1 1 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 4 5 6789 77 ...

Page 59: ...10 302 6 7 1 0 2 2 310 24 5 2 2 0 8 0219 310 24 5 1 0821 2 5 5 1 0 2 24 5 9 9 9 1 1 1 3 2 3 12 64 2 1 4 A B 2 2 B 20 27 2 2 2 2 2 0 46 1 4610 4 1 2 1 2 2 2 B0 B1 00 B1 0 B1 0 B1 00 21 1 2 21 2 3 2 1 3 2 2 2 2 09 0 2 6 0 29 1 0 29 1 0 231 2 2 0 1 B 2 2 0 1 2 1 B 2 4 2 A B 20 2 22 2 4 22 2 39 3 3 ...

Page 60: ...20148180 58 GB Appendix Electrical panel layout 0 1 2 3 4 32 5 6 5 0 2 2 2 2 1 0 5 2 6 2 1 2 2 2 1 72 8 29 2 1 2 1 8 8 2 4 1 1 3 2 2 1 1 6 2 6 6 1 1 RLS 1000 M MX ...

Page 61: ...59 20148180 GB Appendix Electrical panel layout 0 1 2 3 21 4 5 4 1 1 1 1 0 4 1 5 1 0 1 1 1 0 61 7 18 1 0 1 0 7 7 9 9 1 3 0 9 0 9 2 9 1 9 1 9 9 09 0 9 9 59 1 5 5 9 0 9 0 9 RLS 1200 M MX ...

Page 62: ...20148180 60 GB Appendix Electrical panel layout 0 12 3 4 5 4 5 6 7 6 8 9 8 9 7 7 0 0 0 ...

Page 63: ... 4 0 4 5 1 5 6 4 4 9 4 7 A 91 5 9 09 A 7 001B 5 4 1 C 4 7 8 4 D970 4 64 7 47 1 4 E 001 9 F4 94 1 4 1 0 7 94 G 6 1 9 4 4 A H H A A H A H 7 7 7 A 7 A A I 3 I 3 I J I K I I I I I 3I 3 I I 3 I I J I 3 3 3 L L L L A L L A L L A 47 901 9 70 4 94 47 7 4 8 4 4 9 47 7 4 8 4 4 9 7 4 4 8 944 9 09 8 944 9 09 4 8 1 5 9 09 8 1 5 9 09 ...

Page 64: ...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 65: ... operation clean contacts KG Gas operation relay KO Light oil operation relay MP Pump motor MV Fan motor PA Air pressure switch PE Burner earth PGM Maximum gas pressure switch PGMin Minimum gas pressure switch PO Oil pressure switch PO1 Maximum oil pressure switch on return line RS Remote burner reset button S1 Emergency stop button S2 Off automatic manual selector S4 Output increase decrease sele...

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Page 68: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...

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