Riello RLS 160/E Installation, Use And Maintenance Instructions Download Page 1

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20095042 (3) - 11/2016

Installation, use and maintenance instructions

Dual fuel light oil/gas burners

Progressive two-stage or modulating operation

CODE

MODEL

C9354400 - C9354410 - C9354401

RLS 160/E

C9355400 - C9355410

RLS 200/E

Summary of Contents for RLS 160/E

Page 1: ... 11 2016 Installation use and maintenance instructions Dual fuel light oil gas burners Progressive two stage or modulating operation CODE MODEL C9354400 C9354410 C9354401 RLS 160 E C9355400 C9355410 RLS 200 E GB ...

Page 2: ...Original instructions ...

Page 3: ...um furnace dimensions 11 3 9 Commercial boilers 11 3 10 Burner description 12 3 11 Control box for the air fuel ratio LMV36 14 3 12 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 Burner raising 19 4 5 Preparing the boiler 19 4 5 1 Boring the boiler plate 19 4 5 2 Blast tube length 19 4 6 Securing the burner to the bo...

Page 4: ... first firing gas 34 5 6 Burner start up 34 5 6 1 Adjusting oil air delivery 34 5 6 2 Adjusting gas air delivery 34 5 7 Final calibration of the pressure switches 35 5 7 1 Air pressure switch 35 5 7 2 Maximum gas pressure switch 35 5 7 3 Minimum gas pressure switch 36 5 7 4 Low oil pressure switch 36 5 7 5 High oil pressure switch 36 5 8 Burner starting 37 5 8 1 Steady state operation 37 5 8 2 Fir...

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: ...t 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 and or...

Page 7: ...ance 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 Under...

Page 8: ...l gas Gas pressure at maximum delivery 2 Gas Natural gas WC 5 5 10 6 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 max 140 60 C Pump delivery at 290 PSI pressure range fuel temperature GPH PSI F max 146 102 580 302 150 C Noise levels 3 dB A 83 1 85 Model RLS 160 E RBNA Code C935440...

Page 9: ... 7 5 230 17 8 3500 7 5 460 8 9 Pump motor IE2 EPACT rpm HP V A 3530 1 230 3 3530 1 460 1 5 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 7000 7000 Electrical control circuit consumption W max 750 Total electrical consumption W 7750 7750 Electrical protection NEMA 1 Model Code Code RBNA Voltage Flame safegua...

Page 10: ...t I Tab F 3 6 Standard equipment Gas train flange No 1 Flange fixing screws No 4 Adaptor G 1 4 1 4 NPT No 1 Seal for gas train flange No 1 Connector for pilot line No 1 Circular sector No 4 Washer for screws No 4 Instruction booklet No 1 Model A B C D E F G H I L M N O RLS 160 E 37 13 32 16 49 64 20 5 8 25 1 2 40 61 64 14 39 64 8 11 16 17 5 32 52 1 2 8 45 64 5 9 16 10 5 16 2 RLS 200 E 37 13 32 16 ...

Page 11: ...36 F Example RLS 160 E Rated Capacity 4111 MBtu hr Rated Air Pressure 2 33 WC Reference Altitude 328 ft Reference Temperature 20 C 68 F Real Altitude 3000 ft Real Temperature 17 C 62 6 F Temperature Difference 68 F 62 6 F 5 4 F Virtual Altitude Increment 5 4 F 3 6 F x 1000 ft 1500 ft Virtual Altitude Real Altitude Virtual Altitude Increment 3000 ft 1500 ft 4500 ft Corrected Capacity 4179 4201 2 41...

Page 12: ...3 1000 977 4 942 8 908 2 875 8 843 5 811 85 779 8 747 8 Average barometric pressure 68 F WC 399 394 385 371 358 345 332 320 307 294 CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE Altitude Rated Pressure WC 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 1 1 11 1 0 77 0 42 0 04 0 37 0 8 1 26 1 74 2 25 0 11 0 0 11 0 34 0 69 1 07 1 48 1 9...

Page 13: ...btained in terms of low NOx emissions The maximum thickness of the boiler s front door must not exceed 10 Fig 5 For flame inversion boilers a kit is available to reduce CO emis sions if required The kit includes 5 gas pipes identical to the other 5 already fit ted to the burner head In standard conditions the burner head is fitted with a second group of pipes with gas outlet in a differ ent direct...

Page 14: ...g flame and air fuel ratio 12 Operator panel with LCD display 13 Flame inspection window 14 Low air pressure switch differential operating type 15 Slide bars for opening the burner and inspecting the combus tion head 16 Safety oil solenoid valve 17 Valve assembly with pressure regulator on nozzle return 18 Gas pressure test point and head fixing screw 19 Air pressure test point 20 Air servomotor 2...

Page 15: ...gnal 52 IGNITION ON signal 53 FUEL ON signal 54 Optional holes 55 Ground terminals 56 Pump motor contactor and thermal relay with reset button 57 Delivery oil solenoid valve 58 Return oil solenoid valve 59 DIN bar for fuse holder step down transformer and OCI 412 10 60 Anchor plate for installation of step down transformer Three types of burner failure may occur Flame safeguard lock out If the fla...

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 cosϕ 0 4 Alarm output Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 A cosϕ 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 cosϕ 0 2 Fuel valves Nominal vo...

Page 18: ... 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: ...s 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 Tab I WARNING To avoid injury to persons damage to prop...

Page 20: ...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 21: ...ust be great er than the thickness of the boiler door complete with its insulation The range of lengths available L inch is as follows Tab K For boilers with front flue passes 13 or flame inversion chambers insulation material 11 must be inserted between the refractory 12 and the blast tube 10 This protective insulation must not compromise the extraction of the blast tube For boilers having a wate...

Page 22: ...electrode wires and then pull the burner com pletely off the slide bars 4 7 Combustion head calibration RLS 160 E Fig 13 At this point check whether the maximum delivery of the burner in 2nd stage operation is contained in area A or in area B of the firing rate See Firing rates on page 9 If it is in area B then no operation is required If on the other hand it is in area A pre set the combustion he...

Page 23: ...ds exclusively on the maximum delivery of the burner Turn screw 6 Fig 15 until the notch shown in diagram Fig 16 is level with the front surface of flange 5 Fig 15 Example for RLS 200 E maximum burner delivery 7250 MBtu hr If diagram Fig 16 is consulted it is clear that for this delivery the combustion head must be adjusted using notch 6 as shown in Fig 15 In case of high altitude site head settin...

Page 24: ... is advisable to replace nozzles every year during regular maintenance operations CAUTION The use of nozzles other than those specified by the Manufacturer 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 no...

Page 25: ...sure gauge 1 Fig 20 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 var iation If at the maximum capacity of the nozzle maximum pressure in the return...

Page 26: ...rner up to the sleeve so that it is positioned as shown in Fig 25 refit screws 2 Fig 25 on slide bars 3 including the safety plate 15 Fig 12 page 20 secure the burner to the sleeve by tightening screws 1 connect the oil pipes again by screwing on the two connectors 6 Fig 12 page 20 WARNING Make sure that the electrodes are positioned as shown in Fig 24 1 3 8 Fig 22 D10530 Fig 23 D10497 ELECTRODE I...

Page 27: ...ng 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 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 H Pump foot valve height difference L Piping length Ø Inside pipe dia...

Page 28: ...s 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 WARNING The pump seal will be damaged immediately if it is run with the return line closed and the by pass screw inserted Pump model TA2 Min deli...

Page 29: ... regulator 4 Low gas pressure switch 5 1st safety shut off valve 6 2nd safety shut off valve 7 Standard issue burner gasket with flange 8 Gas butterfly valve 9 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 fue...

Page 30: ...he left Example for RLS 200 EV Maximum output operation Natural gas Gas pressure at test point 1 Fig 32 9 2 WC Pressure in combustion chamber 1 2 WC 9 2 1 2 8 WC A maximum output of 8 000 MBtu hr shown in diagram corre sponds to 8 WC pressure This value serves as a rough guide the effective delivery must be measured at the gas meter Tab M The values are referred to the butterfly gas valve kW MBtu ...

Page 31: ...ectly connected to an efficient earthing system made according to current standards It is necessary to check this fundamental safety requirement In the event of doubt have the electrical system checked by qualified personnel Do not use the gas tubes as an earthing system for electrical devices The electrical system must be suitable for the maximum input power of the device as indicated on the labe...

Page 32: ...gle phase power supply and other devices with 1 2 inch cable grommet 3 Available consents safety minimum gas pressure switch gas valves and other devices with 3 8 inch cable grommet 4 Available hole for M16 5 Available for ground terminals A Fan motor B Maximum gas pressure switch C UV sensor D Air servomotor E Fuel servomotor F Air pressure switch G Oil valve H Oil pressure switch I Pump motor WA...

Page 33: ...e motor is 400V To reset in the case of an intervention of the thermal relay press the button RESET Fig 34 The button STOP Fig 34 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 35 and move it in the sense of the arrow towards right 4 16 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay press...

Page 34: ...ING the motors manufactured for 575V IE3 NEMA Premium Efficiency voltage have the same control box base of the IE1 and IE2 Epact motors Please pay attention to the indications in case of maintenance or substitution 4 19 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 IE2 Epac...

Page 35: ...completed the checks indicated in the previous heading the pilot of the burner should fire 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 Pilot adjustment has been illustrated on Fig 22 page 24 Having adjusted the pilot reconnect the main valve and ignite the main flame it might require several attempts to purge...

Page 36: ...switch to position OIL for oil op eration and GAS for gas operation 5 6 1 Adjusting oil air delivery Switch to the light oil operation During the ignition move slowly with an approximate adjust ment to the oil servomotor at maximum 90 Adjust the maximum pressure on the return nozzle through the nut and lock nut 5 Fig 20 Adjust the combustion parameter with the air servomotor and store the maximum ...

Page 37: ...ntil 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 7 2 Maximum gas pressure switch Adjust the maximum gas pressure switch after having performed all other burner adjustments with the maximum gas pressure switch set ...

Page 38: ...by 0 4 WC 5 7 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 7 5 High oil pressure switch The high oil pressure switch is factory set to 43 5 PSI 3 bar If the ...

Page 39: ...es back into the tank The spark goes out The starting cycle ends 5 8 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 pressure increa...

Page 40: ...54 0 0 5 10 Final checks with the burner working Tab N S8171 P V h min s Fig 50 Open the control limit operation Open the high limit operation 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 The burner mus...

Page 41: ...ews securing the electrical leads in the burner connections are fully tightened Clean the outside of the burner Flame inspection window Clean the flame inspection window 1 Fig 51 Nozzles It is advisable to replace nozzles once a year during periodical maintenance Do not clean the nozzle openings Hoses Check that these are in good conditions Fan Check to make sure that no dust has accumulated insid...

Page 42: ...irty Boiler Clean the boiler as indicated in its accompanying instructions in or der to maintain all the original combustion characteristics intact es pecially the flue gas temperature and combustion chamber pressure Fuel tank Approximately every 5 years suck any water on the bottom of the tank using a separate pump Combustion Adjust the burner if the combustion values found at the beginning of th...

Page 43: ...urner until it is about 4 from the sleeve re connect the leads Remove the extension bars 31 Fig 6 page 12 Slide in the burner until it comes to a stop refit screws 3 and pull the leads gently out until they are slightly stretched re couple the swivel coupling 7 to the graduated sector reconnect the light oil pipes Re screw the 2 screws and the safety plate Fig 12 page 20 DANGER Disconnect the elec...

Page 44: ...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 45: ...03 104 105 106 105 107 16 78 77 76 65 88 87 85 69 72 83 84 69 81 82 80 79 86 92 92 91 60 67 55 66 58 56 53 54 41 15 42 43 39 75 69 70 34 68 33 35 71 72 38 10 36 36 10 10 30 37 2 101 100 99 98 96 97 96 95 69 71 64 69 94 102 103 1 63 28 32 72 71 90 88 87 89 108 108 72 93 69 3 74 31 91 40 110 19 62 59 48 47 73 109 48 47 61 49 11 24 29 20 18 7 8 ...

Page 46: ...ECTOR C 16 3005482 SEAL B 17 3013926 DISPLAY 18 20028329 ELECTRONIC CAM C 19 20096592 POWER REGULATOR 20 3013940 CONNECTORS ASSEMBLY B 21 3012978 MOTOR 230 460V C 21 3014152 MOTOR 575V C 22 3014106 FUSE 6 3A A 23 20036017 GREEN SIGNAL LIGHT 24 20115421 STARTER 460V C 24 20115409 STARTER 575V C 25 20027014 WHITE SIGNAL LIGHT 26 3013681 SCREW 27 3003891 CONNECTOR C 28 3014079 SPACER 29 20043329 TIME...

Page 47: ...010962 BUTTON 52 20028411 SELECTOR SWITCH C 53 3012049 SCREW 54 3012639 CONTROL DEVICE 55 3012640 CYLINDER 56 3012641 SQUARE 57 20086579 UV PHOTOCELL A 58 3012643 END CONE 59 3020071 BASE 60 3003322 CONNECTOR C 61 3012794 INSPECTION WINDOW 62 3020068 RELAY B 63 3013938 DISC 64 3013937 HUB C 65 20028379 GRADUATE SECTOR 66 3012642 SHUTTER 67 3012647 CENTERING SUPPORT 68 3013178 SHUTTER 69 3007079 SE...

Page 48: ...9 3013674 PRESSURE SWITCH B 90 3012384 PRESSURE SWITCH B 91 3006140 PRESSURE GAUGE A 92 3013531 VALVE BODY ASSEMBLY 93 20028389 TUBE A 94 20028390 TUBE A 95 3006157 PUMP C 96 3012949 CONNECTOR C 97 3007164 SEAL B 98 3006184 BAR 99 20028392 JOINT 100 20028394 DRIVE COUPLING A 101 20031015 MOTOR 230 460V C 101 20062588 MOTOR 575V C 102 3013259 BEARING 103 3013257 BEARING 104 20028396 LEVER C 105 300...

Page 49: ...essories 47 20095042 GB Gas train according to UL Standards B Appendix Accessories WARNING The installer is responsible for the supply and instal lation of any required safety device s not indicated in this manual ...

Page 50: ...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 52: ...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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