Riello RLS 120/E Installation, Use And Maintenance Instructions Download Page 10

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20036952

Technical description of the burner

3.3.2

Three phase burner

Tab. E

Tab. F

Fan motor and pump motor IE2/EPACT

Model

RLS 68/E

RBNA Code

C9352400

C9352410

C9352401

Control circuit power supply

V/Ph/Hz

120/1/60

Main electrical supply (+/- 10%)

V/Ph/Hz

208-220/3/60

460/3/60

575/3/60

Fan motor

rpm

V
A

3500

208 - 230

7.8

3500

460

3.9

3500

575

3.1

Pump motor

rpm

V
A

3520

208 - 230

3.2

3520

460

1.6

3520

575

1.3

Ignition transformer

Oil

V1 - V2

I1 - I2

120 V - 2 x 5 kV

2.7 A - 30 mA

Gas

V1 - V2

I1 - I2

120 V - 1 x 8 kV

1.6 A - 20 mA

Electrical power consumption

W max

3550

Electrical control circuit consumption

750

Total electrical consumption

4300

Electrical protection

NEMA 1

Fan motor and pump motor IE2/EPACT

Model

RLS 120/E

RBNA Code

C9353400

C9353410

C9353401

Control circuit power supply

V/Ph/Hz

120/1/60

Main electrical supply (+/- 10%)

V/Ph/Hz

208-220/3/60

460/3/60

575/3/60

Fan motor

rpm

V
A

3500

208 - 230

7.8

3500

460

3.9

3500

575

3.1

Pump motor

rpm

V
A

3520

208 - 230

3.2

3520

460

1.6

3520

575

1.3

Ignition transformer

Oil

V1 - V2

I1 - I2

120 V - 2 x 5 kV

2.7 A - 30 mA

Gas

V1 - V2

I1 - I2

120 V - 1 x 8 kV

1.6 A - 20 mA

Electrical power consumption

W max

3550

Electrical control circuit consumption

750

Total electrical consumption

4300

Electrical protection

NEMA 1

Summary of Contents for RLS 120/E

Page 1: ...se and maintenance instructions Dual fuel light oil gas burners Progressive two stage or modulating operation CODE MODEL C9352400 RLS 68 E C9352410 RLS 68 E C9352401 RLS 68 E C9353400 RLS 120 E C9353410 RLS 120 E C9353401 RLS 120 E GB ...

Page 2: ......

Page 3: ...iring rate 11 3 8 1 Procedure to refer burner operating condition in high altitude plants 11 3 9 Minimum furnace dimensions 13 3 10 Control box for the air fuel ratio LMV36 14 3 11 Actuators SQM33 5 17 4 Installation 18 4 1 Notes on safety for the installation 18 4 2 Handling 18 4 3 Preliminary checks 18 4 4 Boiler plate 18 4 5 Burner raising 19 4 6 Blast tube length 19 4 7 Securing the burner to ...

Page 4: ... start up 32 5 4 1 Adjusting gas air delivery 32 5 4 2 Adjusting oil air delivery 32 5 5 Final calibration of the pressure switches 33 5 5 1 Air pressure switch 33 5 5 2 Maximum gas pressure switch 33 5 5 3 Minimum gas pressure switch 34 5 5 4 Low oil pressure switch 34 5 5 5 High oil pressure switch 34 5 6 Burner starting fuel oil adjustment 35 5 6 1 Steady state operation 35 5 6 2 Firing failure...

Page 5: ... generator is to be installed The instruction manual shows the serial number of the burner the address and telephone number of the nearest Assis tance Centre The system supplier carefully informs the user about the use of the system any further tests that may be necessary before the system is started up maintenance and the need to have the system checked at least once a year by the manufacturer or...

Page 6: ...is manual 1 2 1 Owner s responsibility Please pay attention to the Safety Warnings contained within this instruction manual Keep this manual for your records and provide it to your quali fi ed service agency for use in profession ally setting up and maintaining your burner Your burner will provide years of ef fi cient operation if it is pro fessionally installed and maintained by a qualifi ed serv...

Page 7: ...th the burner components is not allowed apart from the parts requiring maintenance 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 machine and intends to use it for the specific purpose He is re sponsible for the machine and for the training of the people working around it The user Undertakes to entr...

Page 8: ...LS 120 E Output 1 Delivery 1 High MBtu hr 4 kW GPH 1194 2934 350 860 8 5 21 2047 4094 600 1200 14 5 29 Low MBtu hr 4 kW GPH 682 200 5 1023 300 7 3 Fuel 2 Fuel oil Natural gas Gas pressure at maximum delivery 2 Gas Natural gas WC 5 7 7 Operation Modulating oil gas Nozzle number 1 Standard applications Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Combustion air temperature F m...

Page 9: ...wer consumption W max 3400 3800 3350 Electrical control circuit consumption W 750 Total electrical consumption W 4150 4550 4100 Electrical protection NEMA 1 Fan motor and pump motor IE1 Model RLS 120 E RBNA Code C9353400 C9353410 C9353401 Control circuit power supply V Ph Hz 120 1 60 Main electrical supply 10 V Ph Hz 208 220 3 60 460 3 60 575 3 60 Fan motor rpm HP V A 3400 3 208 230 8 5 3400 3 460...

Page 10: ...ical power consumption W max 3550 Electrical control circuit consumption W 750 Total electrical consumption W 4300 Electrical protection NEMA 1 Fan motor and pump motor IE2 EPACT Model RLS 120 E RBNA Code C9353400 C9353410 C9353401 Control circuit power supply V Ph Hz 120 1 60 Main electrical supply 10 V Ph Hz 208 220 3 60 460 3 60 575 3 60 Fan motor rpm HP V A 3500 3 208 230 7 8 3500 3 460 3 9 35...

Page 11: ...nd extention bars 32 Oil gas actuator 33 High oil pressure switch 34 Ignition transformer T1 for oil operation 35 Terminal strip for oil valve X2 36 Timer module and relay KO1 37 Timer module and relay KG1 38 K3 relay 39 K1 relay 40 KG2 relay 41 K5 relay 42 K2 relay 43 Horn 44 Auxiliary fuse 45 OFF ON switch 46 LOCAL REMOTE switch 47 ALARM SILENCE button 48 OIL OFF GAS switch 49 POWER ON signal 50...

Page 12: ...s The maximum dimension of the burner when open without casing is give in measurement I Tab H 3 7 Standard equipment Gas train flange No 1 Flange gasket No 1 Flange fixing screws No 4 Adaptor G 1 8 1 8 NPT No 1 Connector for pilot line No 1 Seal for adaptor No 1 Instruction booklet No 1 inch A B C lbs RLS 68 E 55 33 64 30 29 32 39 3 8 220 RLS 120 E 55 33 64 30 29 32 39 3 8 233 Fig 2 D36 Model A B ...

Page 13: ...arts are based only on altitude variation reference temper ature 68 F 20 C To get the combined correction in case of different air temper ature a compensation of 1000 ft each 20 F 305 m each 11 C is applicable 100 ft 2 F Example Rated capacity 3000 MBtu hr Rated air pressure 1 WC Real altitude 3000 ft Real temperature 88 F 88 F 68 F reference temp 20 F equiva lent 1000 ft variation Proceeding as d...

Page 14: ... 8 908 2 875 8 843 5 811 85 779 8 747 8 Average barometric pressure 68 F w c 399 394 385 371 358 345 332 320 307 294 CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE Altitude Rated Pressure m a s l 0 100 305 610 915 1220 1525 1830 2135 2440 ft a s l 0 328 1000 2000 3000 4000 5000 6000 7000 8000 0 50 0 49 0 50 0 51 0 53 0 55 0 57 0 59 0 62 0 64 0 67 1 00 0 99 1 00 1 02 1 06 1 10 1 14 1 19 1 23 1...

Page 15: ...rnace dimensions The firing rate was set in relation to certified test boilers Fig 5 indicates the diameter and length of the test combustion chamber Example Output 4000 MBtu hr diameter 24 inch length 8 2 ft Fig 5 Diameter inches Length ft Furnace dimensions D10921 ...

Page 16: ...rcuits via which it is possible to easily identify any causes of malfunctioning Mechanical design The following system components are integrated in the LMV36 basic unit Burner control with gas valve proving system Electronic air fuel ratio control Control frequency converter air fan Modbus interface Installation notes Always run high voltage ignition cables separately while ob serving the greatest...

Page 17: ... voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 cos 0 4 Alarm output Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 A cos 0 4 Ignition transformer Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 or 250 VA ignition load declaration to UL372 cos 0 2 Fuel valves Nominal volta...

Page 18: ...P T P 10 Shutdown Operation Startup Valve proving OUTPUTS INPUTS Phase number Fuel Actuator 2 Air Actuator 1 Actuators Safety limit thermostat STB Control thermostat or pressurestat R Flame signal FS Air pressure switch LP Pressure switch min Pmin Pressure switch max Pmax Valve proving leakage test P LT POC alternative to Pmax No load position Ignition load Postpurge position Nominal load Low fire...

Page 19: ...tors can be seen on the dis play of the Operator Panel Index 0 for fuel actuator index 1 for air actuator Installation notes Always run the high voltage ignition cables separate from the unit and other cables while observing the greatest possible dis tance The holding torque is reduced when the actuator is disconnect ed from power Technical data WARNING To avoid injury to persons damage to propert...

Page 20: ...st be carried out by qualified personnel as indicated in this manual and in compliance with the standards and regulations of the laws in force WARNING The handling operations for the burner can be high ly dangerous if not carried out with the greatest at tention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling CAUTION After position...

Page 21: ...n of the blast tube For boilers having a water cooled front the insula tion 11 12 Fig 11 is not required unless it is required by the boil er manufacturer 4 7 Securing the burner to the boiler Detach the combustion head from the burner Fig 11 disconnect the oil pipes by unscrewing the two connectors 6 loosen the 4 screws 3 and remove the cover 1 disengage the swivel coupling 14 from the graduated ...

Page 22: ...NING It is advisable to replace nozzles every year dur ing regular maintenance operations CAUTION The use of nozzles other than those specified by the Manufacturer and inadequate regular main tenance may result into emission limits non conforming to the values set forth by the regu lations in force and in extremely serious cases into potential hazards to people and objects The manufacturing compan...

Page 23: ...re gauge 1 Fig 15 The output and the pressure of the nozzle are at maximum when the servomotor is positioned on maximum The proper setting of the eccentric 6 is possible when its operation field follows the servomotor operation field 0 90 so that every variation of the servomotor position corresponds to a pressure vari ation If at the maximum capacity of the nozzle maximum pressure in the return l...

Page 24: ... 18 refit screws 2 Fig 18 on slide bars 3 including the safety plate 15 Fig 11 page 19 secure the burner to the sleeve by tightening screws 1 connect the oil pipes again by screwing on the two connectors 6 Fig 11 page 19 connect the swivel coupling 7 from the graduate sector WARNING Make sure that the electrodes are positioned as shown in Fig 17 5 32 to 3 16 3 32 Fig 17 D10108 WARNING When fitting...

Page 25: ...the burner from the same height in this way it will be less probable that the suction line fails to prime or stops priming The loop circuit A loop circuit consists of a loop of piping exiting and returning to the tank with an auxiliary pump that 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 doe...

Page 26: ...crew 4 11 4 Pump priming 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 After 5 or 6 starting operations allow 2 or 3 minutes for the trans former to cool Whenever the length of the suction piping exceeds 66 98 ft the supply line must be filled using a separa...

Page 27: ... time range The pilot gas train must be connected to the gas attachment 5 Fig 22 and can enter the burner from the right or left side 4 13 Gas train It must be type approved according to UL Standards and is sup plied separately from the burner Legend 1 Gas input pipe 2 Manual valve 3 Pressure regulator 4 Low gas pressure switch 5 1st safety shut off valve 6 2nd safety shut off valve 7 Standard iss...

Page 28: ...t pressure value to your result in Fig 24 Read off the corresponding output on the left Example Maximum output operation Natural gas Gas pressure at test point 1 Fig 25 4 41 WC Pressure in combustion chamber 0 79 WC 4 41 0 79 3 62 WC A maximum output of 3616 MBtu hr shown in Tab I corresponds to 3 62 WC pressure column 1 natural gas This value serves as a rough guide the effective delivery must be...

Page 29: ... the electri cal layouts Check that the electrical supply of the burner corresponds to that shown on the identification label and in this manual Do not invert the neutral with the phase in the electrical supply line Any inversion would cause a lockout due to firing failure The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system made accor...

Page 30: ...e motor is 400V To reset in the case of an intervention of the thermal relay press the button RESET Fig 27 The button STOP Fig 27 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 28 and move it in the sense of the arrow towards right 4 15 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay press...

Page 31: ... 575V WARNING the motors manufactured for 575V IE2 Epact voltage have the same control box base of the IE1 motors Please pay attention to the indications in case of maintenance or substitution 4 18 Reversible direction WARNING If it is necessary to reverse the direction then reverse the two main supply phases For example L1 with L2 there is not difference between IE1 and IE2 Epact D3686 IE1 IE2 Ep...

Page 32: ...ich is set to 360 PSI by the manufacturer This pressure must be checked and adjusted if required after the burner has been ignited The only operation required in this phase is the application of a pressure gauge on the appropriate pump attachment 5 2 3 Air damper adjustment The first time the burner is fired leave the factory setting unchanged for both low and high fire operation 5 2 4 Ignition pi...

Page 33: ...f the scale Adjust the maximum gas pressure switch Fig 39 to the end of the scale Adjust the air pressure switch Fig 40 to the start of the scale Purge the air from the gas line Fit a U type manometer Fig 41 to the gas pressure test point on the sleeve The manometer readings are used to calculate the MAX burner power using the diagram on page 26 Before starting up the burner it is good practice to...

Page 34: ...omotor at maximum 90 Adjust the maximum pressure on the return nozzle throught the nut and lock nut 5 Fig 15 Adjust the combustion parameter with the air servomotor and store the maximum combustion point Complete the procedure slowly synchronizing the combustion with the two servomotors Store the different setting points DANGER Make sure that the lamps or testers connected to the solenoids or indi...

Page 35: ...til the burner locks out Then turn the knob counter clockwise about 20 of the set point and start up the burner again to ensure the set point is correct If the burner locks out again turn the knob counter clockwise a little bit more 5 5 2 Maximum gas pressure switch Adjust the maximum gas pressure switch Fig 45 after having per formed all other burner adjustments with the maximum gas pres sure swi...

Page 36: ... by 0 4 WC 5 5 4 Low oil pressure switch The low oil pressure switch is factory set to 261 PSI 18 bar If the oil pressure goes down this value in the delivery piping the pressure switch stops the burner Burner starts again automatically if the pressure goes above 261 PSI 18 bar after burner start up 5 5 5 High oil pressure switch The high oil pressure switch is factory set to 43 5 PSI 3 bar If the...

Page 37: ...ng 7 it goes back into the tank The spark goes out The starting cycle ends 5 6 1 Steady state operation At the end of the starting cycle the servo motor control then pass es to load control for boiler pressure or temperature If the temperature or pressure is low and the load control is consequently closed the burner progressively increases out put up to MAX If subsequently the temperature or press...

Page 38: ...4 0 0 5 8 Final checks with the burner working S8171 P V h min s Fig 49 Open the control limit operation Open the high limit operation Æ The burner must stop Rotate the maximum gas pressure switch knob to the mini mum end of scale position Rotate the air pressure switch knob to the maximum end of scale position Rotate the maximum oil pressure switch at the minimum of the scale Æ The burner must st...

Page 39: ...zle filters however may be cleaned or replaced as required Replace the nozzles every 2 3 years or whenever necessary Combustion must be checked after the nozzles have been changed Flexible hoses fuel oil Check to make sure that the flexible hoses are still in good condi tion and that they are not crushed or otherwise deformed UV scanner In order to reach the UV scanner proceed as follows Extract t...

Page 40: ... screw the 2 screws and the safety plate Fig 11 page 19 Pull the burner fully back Now extract the internal part 5 after having removed the screw 6 6 2 2 To close the burner To close the burner proceed sa follows push the burner until it is about 4 from the sleeve re connect the leads Remove the extension bars 31 Fig 1 page 9 Slide in the burner until it comes to a stop refit screws 3 and pull the...

Page 41: ... 40 45 55 45 55 48 47 73 67 44 32 6 21 26 4 101 99 27 3 90 88 87 85 77 69 70 87 88 90 94 93 97 98 96 96 91 2 81 82 42 43 80 79 86 76 69 15 41 57 63 32 105 105 106 83 72 71 59 62 107 69 95 102 10 41 61 60 66 58 53 54 56 65 22 20 64 64 69 69 69 69 110 108 33 39 38 109 31 37 109 108 34 36 35 30 28 74 75 68 104 92 92 100 1 68 89 103 111 111 89 ...

Page 42: ... 20028329 ELECTRONIC CAM C 19 20031411 RWF 40 20 20010971 CONNECTORS ASSEMBLY C 21 20028308 MOTOR C 22 3006211 FUSE A 23 20027013 GREEN SIGNAL LIGHT C 24 20028310 CONTACTOR C 25 20027014 WHITE SIGNAL LIGHT C 26 3013681 SCREW 27 3003891 CONNECTOR 28 3003973 HIGH VOLTAGE LEAD A 29 20028312 THERMAL RELAY C 30 20030010 HIGH VOLTAGE LEAD A 31 20038216 ELECTRODE A 32 20008601 SERVOMOTOR 33 3013377 TUBE ...

Page 43: ...EAL A 63 3013938 DISC 64 3013937 HUB C 65 20035928 GRADUATE SECTOR 66 20030203 SHUTTER C 66 20030202 SHUTTER C 67 20028400 BASE 68 3012357 BEARING 69 3007079 SEAL A 70 3006896 CONNECTOR 71 3012455 CONNECTOR 72 2003006 BAR 73 20030708 RELAY B 74 20038226 TUBE C 75 20038227 TUBE C 76 3006721 CONNECTOR 77 20035934 CONNECTOR 79 3003204 SEAL A 80 3007150 O RING A 81 3003287 COIL B 82 3012474 MODULATOR ...

Page 44: ... 20032501 TUBE A 95 3006369 PUMP C 96 3012949 CONNECTOR 97 3007164 SEAL A 98 3006184 BAR 99 3013050 JOINT C 100 20028394 DRIVING COUPLING A 101 20031015 MOTOR C 102 3012971 ELBOW 103 3007077 SEAL A 104 3000805 SEAL A 105 3006098 PIN JOINT 106 3013897 TIE ROD 107 20032430 SHAFT 108 3013380 SUPPORT 109 20038228 SUPPORT 110 20031413 HORN C 111 3003592 BAR C 113 3013259 BEARING N RLS 68 E RLS 120 E CO...

Page 45: ...cessories 43 20036952 GB Gas train according to UL Standards B Appendix Accessories WARNING The installer is responsible for the supply and installation of any required safety device s not indicated in this manual ...

Page 46: ...ncy Low Fire High Fire Low Fire Flame Signal Overfire Draft High Fire Flame Signal OIL OPERATION Oil supply pressure CO2 Low Fire High Fire Oil suction pressure O2 Low Fire High Fire Control Power Supply CO Low Fire High Fire Burner Firing Rate NOX Low Fire High Fire Low Fire Flame Signal Net Stack Temp Low Fire High Fire High Fire Flame Signal Comb Efficiency Low Fire High Fire Low Fire Nozzle Si...

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Page 48: ...Pond Park Road 1 800 4 RIELLO 2165 Meadowpine Blvd Hingham Massachusetts 1 800 474 3556 Mississauga Ontario U S A 02043 Canada L5N 6H6 http www riello burners com RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www rielloburners com ...

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Riello RLS 120/E, Installation, Use And Maintenance Instructions

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