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Riello RLS 280/E, Installation, Use And Maintenance Instructions, Page: 1 / 56

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Riello RLS 280/E Installation, Use And Maintenance Instructions Download Page 1

20106891 (2) - 05/2018

Installation, use and maintenance instructions

Dual fuel light oil/ gas burners

Progressive two stage or modulating operation

CODE

MODEL

20125045 - 20125046 - 20123531

RLS 280/E

20125075 - 20125082

RLS 310/E

20125083 - 20125085

RLS 410/E

20125094 - 20125095

RLS 510/E

GB

Summary of Contents for RLS 280/E

Page 1: ...d maintenance instructions Dual fuel light oil gas burners Progressive two stage or modulating operation CODE MODEL 20125045 20125046 20123531 RLS 280 E 20125075 20125082 RLS 310 E 20125083 20125085 RLS 410 E 20125094 20125095 RLS 510 E GB ...

Page 2: ...Original instructions ...

Page 3: ...lues 328 ft above sea level 68 F 14 3 9 Minimum furnace dimensions 14 3 10 Control box for the air fuel ratio LMV36 15 3 11 Actuators SQM33 5 18 4 Installation 19 4 1 Notes on safety for the installation 19 4 2 Handling 19 4 3 Preliminary checks 19 4 4 Operation position 19 4 5 Preparing the boiler 20 4 5 1 Boring the boiler plate 20 4 5 2 Blast tube length 20 4 6 Securing the burner to the boiler...

Page 4: ...Final calibration of the pressure switches 38 5 8 1 Air pressure switch 38 5 8 2 Maximum gas pressure switch 38 5 8 3 Minimum gas pressure switch 39 5 8 4 Low oil pressure switch 39 5 8 5 High oil pressure switch 39 5 9 Burner starting 40 5 9 1 Steady state operation 41 5 10 Firing failure 41 5 11 Flame signal measurement 41 5 12 Final checks with the burner working 41 6 Maintenance 42 6 1 Notes o...

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: ...e event 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...

Page 7: ...aintenance 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...

Page 8: ...113381 460 3 60 Star Delta Burner mounted 20125095 20122396 575 3 60 Model RLS 280 E RLS 310 E Output delivery 1 High kW 762 3 077 2 770 1 026 3 986 3 587 Mbtu hr 4 2 600 10 500 9 450 3 500 13 600 12 240 GPH 18 6 75 0 67 5 25 0 97 1 87 4 Low kW 308 403 Mbtu hr 4 1 050 1 375 GPH 7 5 9 8 Fuel Oil n 2 Natural gas Gas max delivery SCFH 10 396 13 465 Gas pressure at max delivery 2 WC 19 1 19 5 Operatio...

Page 9: ...Btu hr Model RLS 410 E RLS 510 E Output delivery 1 High kW 1 172 4 719 4 247 1 465 5 627 5 064 Mbtu hr 4 4 000 16 100 14 490 5 000 19 200 17 280 GPH 28 6 115 103 5 35 7 137 1 123 4 Low kW 479 586 Mbtu hr 4 1 635 2 000 GPH 11 7 14 3 Fuel Oil n 2 Natural gas Gas max delivery SCFH 15 941 19 010 Gas pressure at max delivery 2 WC 26 0 32 6 Operation Low high or modulating Nozzles 1 Standard application...

Page 10: ...mption W 6250 6350 10060 10100 Electrical control circuit consumption W max 750 Total electrical consumption W 7000 7100 10810 10850 Electrical protection NEMA 3 Model RLS 410 E RLS 510 E Control circuit power supply V Ph Hz 120 1 60 Main power supply 10 V Ph Hz 460 3 60 575 3 60 460 3 60 575 3 60 Fan motor rpm HP V A 3545 12 4 230 460 29 14 5 3545 12 4 575 11 6 3535 14 8 230 460 35 4 17 7 3535 14...

Page 11: ...re shown in the Tab E The weight of the burner complete with its packaging is shown in Tab E Tab E 3 5 Standard equipment Flange gasket No 1 Flange fixing screws M18 x 60 No 4 Gas train flange gasket No 1 Gas train flange gasket No 2 Gas train flange fixing screws M16x70 No 8 Instruction manual No 1 inch A B C lbs RLS 280 E 7121 32 41 413 4 620 RLS 310 E 941 2 6113 16 51 660 RLS 410 E 941 2 61 591...

Page 12: ...and R Tab F A I B B I A E D N C G M H O F R R L L Fig 2 20123199 inch A B C D E F G H I L M N O R RLS 280 E 49 3 4 19 9 32 6 11 16 10 5 8 20 1 2 ANSI 3 19 7 8 31 14 43 25 32 22 27 32 155 8 12 19 32 38 RLS 310 E 49 3 4 20 23 64 6 11 16 12 21 64 20 1 2 ANSI 3 20 1 4 31 14 11 16 43 25 32 25 15 5 8 12 19 32 38 RLS 410 E 49 3 4 20 23 64 6 11 16 12 21 64 20 1 2 ANSI 3 22 1 4 31 14 11 16 43 25 32 25 15 5...

Page 13: ...re switch with pressure test point 21 Flame detector 22 Indication for checking the fan motor rotation 23 Oil modulator and gas butterfly valve servomotor 24 Pump 25 Pump motor 26 Valve group see Fig 4 on page 12 27 Minimum oil pressure switch 28 Nozzle delivery pressure gauge 29 Nozzle return pressure gauge 30 Oil modulator 31 Maximum oil pressure switch 32 Reset button 33 Transparent protection ...

Page 14: ...urn safety solenoid valve 28 VROil return solenoid valve 29 UFOil delivery safety solenoid valve 30 UFOil solenoid valve 31 KO1 oil timer module and relay 32 KG1 gas timer module and relay 33 KP oil pump timer module and relay 34 KG2 auxiliary gas relay 35 KVP auxiliary fan oil pump relay 36 AH horn 37 K1 auxiliary flame alight relay 38 K3 auxiliary alarm relay 39 K5 auxiliary burner lock out rela...

Page 15: ...not be lower than the minimum limit shown in the diagram Tab G WARNING The firing rate area values have been obtained con sidering an ambient temperature of 68 F and an atmospheric pressure of 394 WC and with the combustion head adjusted as shown on page 23 Model MBtu hr RLS 280 E 2 600 RLS 310 E 3 500 RLS 410 E 4 000 RLS 510 E 5 000 0 2 4 6 8 10 12 14 16 18 20 mbar 8 7 6 5 4 3 2 0 1 w c 0 5600 52...

Page 16: ...510 E Output 19200 MBtu hr diameter 39 4 inch length 16 5 ft 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 0 948 328 100 394 1000 00 1 073 1 054 1 035 1 017 1 000 0 983 0 967 0 936 1 000 305 385 977 40 1 049 1 030 1 012 0 994 0 977 0 961 0 945 0 915 2 000 6...

Page 17: ...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 18: ...nal 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 vo...

Page 19: ...P 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 fi...

Page 20: ...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 J WARNING To avoid injury to persons damage to prop...

Page 21: ...oride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently 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 Check also that the area in which you are working is empty an...

Page 22: ...rotective fettling must not compromise the extraction of the blast tube For boilers with a water cooled front piece a refractory lining 2 5 Fig 18 on page 23 is not necessary unless expressly request ed by the boiler manufacturer Tab K 4 6 Securing the burner to the boiler Fit the heat insulation supplied onto the blast tube 4 Fig 12 Fit the entire burner onto the boiler hole prepared previously a...

Page 23: ...ight oil pipes by unscrewing the two swivel fit tings 5 F undo the screw 6 with pressure test point G release the ignition pilot retainer H release the head by lifting it from its housing 7 then take out the combustion head 4 7 Electrode and ignition pilot adjustment RLS 280 E model Place the pilot and electrodes as shown in Fig 15 WARNING To open the burner from the opposite side before removing ...

Page 24: ...ot adjustment RLS 310 410 510 E model Place the electrode and the ignition pilot observing the dimensions in Fig 15 4 9 Gas butterfly valve If necessary replace the gas butterfly valve The correct position is shown in Fig 17 on page 23 1 37 64 Fig 15 20123208 ...

Page 25: ... can be modified WARNING The burner leaves the factory with the combustion head adjusted to notch 0 Fig 18 This adjustment allows you to secure the moving parts when the burner is being transported WARNING The combustion head can be adjusted within the fol lowing fields RLS 280 E 0 12 RLS 310 E 0 11 RLS 410 E 0 8 RLS 510 E 0 11 No adjustment can be made outside these intervals 4000 6000 8000 10000...

Page 26: ...G It 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 shal...

Page 27: ...9 5 500 130 218 39 3 80 16 0 6 500 150 215 46 4 80 18 3 7 500 170 210 53 6 80 21 5 8 500 190 203 60 7 80 24 7 9 500 220 185 67 9 80 28 8 10 500 240 185 75 0 80 30 4 RLS310 3 500 Fluidics N2 N4 45 60 90 300 245 25 0 100 7 4 4 500 125 160 32 1 100 8 6 5 500 150 268 39 3 100 11 8 6 500 175 253 46 4 100 13 4 7 500 200 253 53 6 100 14 7 8 500 200 267 60 7 100 14 7 9 500 225 268 67 9 100 15 10 500 275 2...

Page 28: ...0 175 253 46 4 100 13 4 7 500 200 253 53 6 100 14 7 8 500 200 267 60 7 100 14 7 9 500 225 268 67 9 100 15 0 10 500 275 263 75 0 100 18 6 11 500 300 258 82 1 100 20 8 12 500 325 258 89 3 100 21 8 13 500 350 255 96 4 100 23 4 14 500 350 261 103 6 100 23 4 15 500 375 255 110 7 100 29 5 16 500 400 236 117 9 100 35 2 17 500 450 261 125 0 100 36 8 18 500 500 253 132 1 100 38 1 19 500 500 260 139 3 100 3...

Page 29: ...le that the suction line fails to prime or stops priming 4 12 2 The loop circuit A loop circuit consists of a loop of piping departing from and return ing 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 dist...

Page 30: ...of rotation of the fan blade The pump can be considered to be primed when the light oil starts coming out of the screw 4 Close the burner and undo the 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 opera...

Page 31: ...turn line Regulator at 90 minimum opening maximum pressure on the nozzle return line The servomotor is controlled by the electronic cam 1 Fig 6 on page 14 thanks to this device it is possible to set different curves for oil and gas on the same servomotor also for the air damper ser vomotor 4 Fig 3 on page 11 In the oil regulation the regulation is carried out on the basis of the nozzle that has be...

Page 32: ...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 7 9 8 1 4 D3776 Fig 23 WARNING See the accompanying instructions ...

Page 33: ...in combustion chamber 2 WC 11 7 2 9 7 WC An output of 10500 MBtu hr shown in Tab O corresponds to 9 7 WC pressure column 1 This value serves as a rough guide the effective delivery must be measured at the gas meter Tab O WARNING The data of thermal output and combustion head gas pressure are related to full open 90 gas butterfly valve Fig 24 20086798 MBtu hr GCV 1 p WC 2 p WC RLS280 2 600 1 2 0 01...

Page 34: ...the device is obtained only when it is correctly 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 p...

Page 35: ...le 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 WAR...

Page 36: ...ay press the button RESET Fig 26 There are two different solution to test the electronic thermal relay Device test Fig 22 Push slowly the button in the window with a little screwdriver Contact test NC 95 96 and NO 97 98 Fig 28 Insert in the window a little screwdriver and move it in the sense of the arrow Fig 26 S8109 Fig 27 S8111 S8111 Fig 28 S8110 ...

Page 37: ...tors manufactured for 208 230 460 IE3 NEMA Premium Efficiency voltage have the same connection than IE2 Epact motors but differ ent connection than IE1 motors no more star delta but star double star D3686 IE1 IE2 Epact IE3 NEMA Premium Efficiency U2 V2 W2 U3 V3 W3 U1 V1 W1 S8379 U2 V2 W2 U3 V3 W3 U1 V1 W1 S8380 460V 208 230V 460V 208 230V Fig 29 WARNING the motors manufactured for 575V IE3 NEMA Pr...

Page 38: ...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 15 on page 22 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 On...

Page 39: ...te the procedure slowly synchronizing the combustion with the two servomotors and storing the different setting points 5 7 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 combustion parameter with the air servomotor and store the maximum combustion point Complete the procedur...

Page 40: ...turning the relative knob clockwise until 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 8 2 Maximum gas pressure switch Adjust the maximum gas pressure switch after having performed all other burner adjustments with...

Page 41: ...by 0 4 WC 5 8 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 8 5 High oil pressure switch The high oil pressure switch is factory set to 43 5 PSI 3 bar If the ...

Page 42: ...ted by the regulator 10 then through piping 2 it goes back into the tank The pilot flame goes out The starting cycle ends Key Fig 38 1 Pump suction 2 Pump return line and nozzle return line 3 Pump by pass screw 4 Pump pressure regulator 5 Safety valve 6 Safety valve 7 Nozzle delivery line 8 Nozzle without interception rod 9 Nozzle return line 10 Pressure variator on nozzle return line 11 Pressure ...

Page 43: ... flame signal through the parameter 954 as indicated in Fig 39 The displayed value is expressed in percentage The value during the operation must be higher than 24 If at the burner start up the value is higher or equal of 18 the burner locks out due to the extraneous light For further and specific information please refer to the specific instruction manual The display Fig 39 shows parameter 954 fl...

Page 44: ...of the solenoid gas 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 head Open the burner and make sure that all components of the com bustion head are in good condition not deformed by the high tem peratures free of impurities from t...

Page 45: ...or if the pump runs noisily the flexible hose must be detached from the line filter and the fuel must be sucked from a tank located near the burner This measure permits the cause of the anomaly to be traced to either the suction line or the pump If the problem lies in the suction line check to make sure that the filter is clean and that air is not entering the piping Filters Check the filtering ba...

Page 46: ...lenoid 10 years or 250 000 operation cycles Pressure switches 10 years or 250 000 operation cycles Pressure adjuster 15 years Servomotor electronic cam if present 10 years or 250 000 operation cycles Oil valve solenoid if present 10 years or 250 000 operation cycles Oil regulator if present 10 years or 250 000 operation cycles Oil pipes couplings metallic if present 10 years Flexible hoses if pres...

Page 47: ...Appendix Spare parts 45 20106891 GB A Appendix Spare parts ...

Page 48: ... 11 3007079 SEAL B 12 3012455 CONNECTOR C 13 3003006 BAR C 14 3012626 U BOLT 15 3013462 SWIVEL FITTING 16 20041969 SEAL B 17 3013461 VALVE NOT RETURN B 18 3006723 CONNECTOR C 19 3020191 O RING SEAL B 20 3013328 FLANGE GASKET A 21 20075037 END CONE B 21 3013314 END CONE B 22 20073781 CYLINDER C 23 20075041 SHUTTER C 23 20074988 SHUTTER C 24 20075043 SQUARE 24 20073784 SQUARE 25 20075916 SCREW 26 20...

Page 49: ...ION WINDOW 50 3013682 SOUND DAMPING 50 20073811 SOUND DAMPING 51 3014079 SPACER 52 3003287 COIL B 53 3012384 OIL PRESSURE SWITCH A 54 3013674 OIL PRESSURE SWITCH A 55 20124466 OIL TUBE C 55 20124499 OIL TUBE C 56 20124090 VALVE B 57 20042836 PUMP MOTOR 460V C 57 20124363 PUMP MOTOR 575V C 58 3006158 PUMP C 58 3006236 PUMP C 58 3006410 PUMP C 59 20056809 AIR DAMPER 59 20126622 AIR DAMPER 60 3013683...

Page 50: ...OR SWITCH 80 20010962 SELECTOR SWITCH 81 20027020 YELLOW SIGNAL LIGHT A 82 20036017 GREEN SIGNAL LIGHT A 83 20036019 WHITE SIGNAL LIGHT A 84 20027018 RED SIGNAL LIGHT A 85 20028400 BASE 86 3014106 FUSE 87 3013940 CONNECTORS ASSEMBLY 88 20075921 VIEWING PORT 89 3013493 TUBE 90 20028329 ELECTRONIC CAM C 91 20123269 DIFFUSER 91 20124446 DIFFUSER 92 20124484 MODULATOR B 93 20124390 OIL TUBE C 93 20124...

Page 51: ...essories 49 20106891 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 52: ...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 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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