Riello RLS 300/E MX Installation, Use And Maintenance Instructions Download Page 1

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20009654 (14) - 09/2016

Installation, use and maintenance instructions

Dual fuel light oil/gas burners

Progressive two stage or modulating operation

CODE

MODEL

TYPE

3898530

RLS 300/E MX

782 T1

3898632

RLS 400/E MX

783 T1

3899632

RLS 500/E MX

1300 T1

Summary of Contents for RLS 300/E MX

Page 1: ...tallation use and maintenance instructions Dual fuel light oil gas burners Progressive two stage or modulating operation CODE MODEL TYPE 3898530 RLS 300 E MX 782 T1 3898632 RLS 400 E MX 783 T1 3899632 RLS 500 E MX 1300 T1 GB ...

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Page 3: ...ox for the air fuel ratio LMV51 14 4 13 Actuator SQM48 4 16 5 Installation 17 5 1 Notes on safety for the installation 17 5 2 Handling 17 5 3 Preliminary checks 17 5 4 Operation position 18 5 5 Removal of the locking screws from the shutter 18 5 6 Preparing the boiler 18 5 6 1 Boring the boiler plate 18 5 6 2 Blast tube length 18 5 7 Securing the burner to the boiler 19 5 8 Accessibility to the in...

Page 4: ...dulation system 33 6 8 Adjustment pressure switches 34 6 8 1 Air pressure switch CO check 34 6 8 2 Maximum gas pressure switch 34 6 8 3 Minimum gas pressure switch 34 6 8 4 Pressure switch PVP kit 34 6 9 Operation sequence of the burner 35 6 9 1 Burner starting 35 6 9 2 Undesired shutdown during operation 35 6 10 Final checks with the burner working 35 7 Maintenance 36 7 1 Notes on safety for the ...

Page 5: ...ic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BImSchV release 26 01 2010 Product Type Model Power Dual fuel light oil gas burners 782 T1 RLS 30...

Page 6: ...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 le thal 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 7: ...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 incor rectly applied and o...

Page 8: ...nce 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 re sponsible for the machine and for the training of the people work ing around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel undert...

Page 9: ... working 1 stop every 72 h Electrical supply to the system 3 400 50 3 230 50 Auxiliary voltage 230 50 60 110 50 60 R LS 500 E TC Emission Class 1 EN267 EN676 MY Class 1 EN267 Class 3 EN676 BLU Class 3 EN267 EN676 MX Class 2 EN267 Class 3 EN676 FS1 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION MX 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam EV Variable s...

Page 10: ... Fuel LIGHT OIL viscosity at 20 C 6 mm2 s 1 5 E 6 cSt NATURAL GAS G20 methane G21 G22 G23 G25 Gas pressure at maximum delivery 2 Gas G20 G25 mbar 24 33 23 33 35 4 52 6 Operation Continuous Intermittent min 1 stop in 24 hours Progressive two stage or modulating by kit see accessoires Pump delivery at 16 5 bar pressure range fuel temperature kg h bar C max 560 7 40 140 560 6 30 140 Nozzles number 1 ...

Page 11: ...g Tab D Model RLS 400 E MX RLS 500 E MX Electrical supply 3N 400V 50 Hz Fan motor IE3 rpm V kW A 2920 400 690 7 5 14 8 1 2880 400 690 12 21 8 12 6 Pump motor rpm V kW A 2870 220 240 380 415 1 5 5 9 3 4 Ignition transformer V1 V2 I1 I2 230 V 2 x 5 kV 1 9 A 35 mA Electrical power consumption Light oil Gas kW max 10 6 8 8 15 7 13 9 Protection level IP 54 A B I D E F C G H R L S S R D3505 Fig 1 mm A B...

Page 12: ...NG The firing rate area values Fig 2 have been ob tained considering a surrounding temperature of 20 C and an atmospheric pressure of 1013 mbar approx 0 m above sea level and with the com bustion head adjusted as shown on pag 21 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 0 2 4 6 8 10 12 14 16 18 m ba r 20 D9411 Fig 2 RLS 300 E MX RLS 400 E MX D8899 Pressure in combustion chamber mba...

Page 13: ...ed and or its combustion chamber dimensions are clearly smaller than those indicated in diagram Fig 3 consult the manufacturer The firing rates were set in relation to special test boilers accord ing to EN 676 regulations Fig 3 indicates the diameter and length of the test combustion chamber Example RLS 400 E MX Output 3000 kW diameter 100 cm length 4 m MODULATION RATIO The modulation ratio determ...

Page 14: ...g type 19 Air pressure test point 20 Maximum gas pressure switch with pressure test point 21 QRI cell 22 Air pressure test point pressure test point 23 Air pressure test point pressure test point 24 Oil modulator and gas butterfly valve servomotor 25 Pump 26 Pump motor 27 Minimum oil pressure switch 28 Maximum oil pressure switch 29 Pressure gauge for pressure on nozzle return 30 Nozzle delivery p...

Page 15: ... and thermal cut out 19 Main supply terminal strip 20 Air pressure switch 21 Entry for power cables external leads and kit 22 Auxiliary circuits fuse 23 Plug socket maximum gas pressure switch 24 Servomotor plug socket 25 Plug socket flame sensor 26 Oil valve Pump motor plug socket NOTE Two types of burner failure may occur Control box lock out if the control box 13 Fig 5 push button red led light...

Page 16: ...st also be observed Condensation and ingress of humidity must be avoided Should such conditions occur make sure that the unit will be completely dry before switching on again Static charges must be avoided since they can damage the unit s electronic components when touched Mechanical design The LMV5 is a microprocessor based burner management sys tem with matching system components for the control...

Page 17: ...se externally Max 16 AT Undervoltage Safety shutdown from operating position at mains voltage Restart on rise in mains voltage AC 186 V AC 188 V Oil pump magnetic clutch nominal voltage Nominal current Output factor 2A cosj 0 4 Air pressure switch test valve nominal voltage Nominal current Output factor 0 5A cosj 0 4 Terminal loading Outputs Total contact loading Mains voltage Input current of uni...

Page 18: ...onal low voltage section The holding torque is reduced when the actuator s power sup ply is switched off The housing cover may only be removed for short periods of time for wiring or when making the addressing It must be made certain that dust or dirt will not get inside the actuator while such work is carried out The actuator contains a printed circuit board with ESD sensi tive components The top...

Page 19: ...be free from hazardous mixes e g chloride fluoride halo gen if present it is highly recommended to carry out cleaning and maintenance more frequently WARNING The handling operations for the burner can be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also that ...

Page 20: ...ube length The length of the blast tube must be selected according to the in dications provided by the manufacturer of the boiler and in any case it must be greater than the thickness of the boiler door com plete with its fettling For boilers with front flue passes 1 Fig 12 or flame inversion chambers protective fettling in refractory material 5 must be in serted between the boiler fettling 2 and ...

Page 21: ...t 5 8 Accessibility to the interior of the combustion head In order to reach inside the combustion head proceed as follows Open burner at hinge Fig 13 after removing the 4 screws 1 Disconnect the wires 2 from the electrodes Disconnect the oil pipes by unscrewing the two connec tors 3 Unscrew the under part of the elbow 4 until it comes free of its slot Extract the internal part 5 of the combustion...

Page 22: ...other than those specified by Riello S p A and inadequate regular main tenance may result into emission limits non conforming to the values set forth by the reg ulations in force and in extremely serious cas es into potential hazards to people and objects The manufacturing company shall not be lia ble for any such damage arising from nonob servance of the requirements contained in this manual WARN...

Page 23: ...ving the tie rod onto holes 1 2 3 Fig 16 The choice of the hole 1 2 3 to be used is decided on the basis of diagram Fig 17 against the required maximum output Setting is pre arranged in the plant for the maximum run hole 3 Fig 16 WARNING Make sure that the electrodes are positioned as shown in Fig 15 Fig 15 mm 4 4 5 6 1 0 mm D3510 0 1 2 3 4 6 3 2 1 4 D3093 Fig 16 1200 1600 2000 2400 2800 3200 3600...

Page 24: ...tion requirements require you to move spacer 1 Fig 18 onto the 1st or 2nd hole of the gear and at the same time the hinge is on the right you need to fit the spacers 4 Fig 18 supplied with the burner Proceed as follows Fig 18 first unscrew nuts 2 remove tie rod 3 Unscrew spacer 1 and position it on the hole you want Screw the spacers 4 onto spacer 1 and screw 5 respec tively Refit the tie rod and ...

Page 25: ...ion 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 table 5 12 3 Hydraulic connections The pumps are equipped with a by pass that connects return line with suction line The pumps are installed on the burner with the by pass clo...

Page 26: ...butterfly valve In regulating with oil setting is made depending on the type of nozzle used and on the modulation required Under the conditions of minimum firing rate 20 rotation may be sufficient Key to layout Fig 21 1 Nozzle delivery pressure gauge 2 Pressure gauge for pressure on nozzle return 3 Position indicator 0 90 of pressure variator 4 Maximum oil pressure switch on return circuit 5 12 5 ...

Page 27: ...to the noise generated dur ing operation OPERATION The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet and interventions on the following points Nozzles See the information listed on pag 20 Combustion head The adjustment of the combustion head already carried out pag 21 need not be altered unless the 2nd stage delivery of the burner is changed Pump pre...

Page 28: ...rol is compulsory for burners with maximum outputs over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer WARNING Explosion danger due to fuel leaks in the pres ence of a flammable source Precauti...

Page 29: ...aximum output Combustion head adjusted as in the diagram of Fig 17 DANGER Disconnect the electrical power using the main system switch Check that there are no gas leaks Beware of train movements danger of crushing of limbs Make sure that the gas train is properly installed by checking for any fuel leaks The operator must use appropriate tools for instal lation Fig 29 D3095 P1 P4 Model kW 1 p mbar ...

Page 30: ... mbar 31 2 29 mbar A pressure of 29 mbar column 1 corresponds in the table A to an output of 4500 kW This value serves as a rough guide the effective delivery must be measured at the gas meter To calculate the required gas pressure at test point 1 Fig 30 set the maximum output required from the burner operation find the nearest output value in the table for the burner in question Read off the pres...

Page 31: ...start up efficiency Normally burner stopping is guaranteed by the boiler s thermostat pres sure 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 electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system made according to current standar...

Page 32: ...connections set by installer To reset in the case of an intervention of the thermal relay press the button RESET 1 The button STOP 3 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST TRIP 4 and move it in the sense of the arrow towards right WARNING Automatic resetting can be dangerous This action is not provided for the burner op erat...

Page 33: ...se load controls and set switch 1 Fig 34 to MAN Make sure that the lamps or testers connected to the solenoids or pilot lights on the solenoids themselves indicate that no volt age is present If voltage is present then immediately stop the burner and check electrical connections 6 4 Burner firing Having completed the checks indicated in the previous heading the burner should fire If the motor star...

Page 34: ...put with the servomotor fully open is made by using the pressure stabilizer on the gas train 6 6 1 Air adjustment for maximum output Set the servomotor to maximum opening near 90 so that the air butterfly valves are fully open Loosen screw 2 Fig 35 under the burner s intake and close grille 1 Fig 35 progressively until you achieve the required out put The only time reducing intake to a partial set...

Page 35: ...s of the load requested by the system maintaining the pressure or tem perature of the boiler at the working values set 3 a sequence cascade control of several boilers by suitably connecting different units and activation of internal software in the individual systems optional item Further interfaces and computer communication functions for re mote control or integration in central supervision syst...

Page 36: ...ressure switch is fitted in a absolute mode that is with a pipe connected to the specific pressure test point 22 Fig 4 a pag 12 6 8 2 Maximum gas pressure switch Adjust the maximum gas pressure switch after having performed all the other burner adjustments with the pressure switch set at the end of the scale Fig 37 With the burner operating at maximum output decrease adjust ment pressure by slowly...

Page 37: ...handbook supplied during the technical service training 6 10 Final checks with the burner working Open the thermostat pressure switch TL Open the thermostat pressure switch TS 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 the burner must stop in lockout Switch off the b...

Page 38: ...ow rate and provoke polluting combustion Boiler Clean the boiler as indicated in its accompanying instructions in order to maintain all the original combustion characteristics in tact especially the flue gas temperature and combustion cham ber pressure Power to photocell QRI Fig 42 Min value for a good work 3 5 Vdc AZL display flame approx 50 If the value is lower it can depend on photocell positi...

Page 39: ...make sure that the flexible hoses are still in good con dition Fuel tank Approximately every 5 years or whenever necessary suck any water or other impurities present on the bottom of the tank using a separate pump Combustion In case the combustion values found at the beginning of the inter vention do not respect the standards in force or in any case do not correspond to a proper combustion contact...

Page 40: ...sing 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 main system switch DANGER Close the fuel interception tap Wait for the components in contact with heat sources to cool down completely Fig 44 D3516 After carrying out maintenance cleaning or ch...

Page 41: ...ontrol box manual supplied When the burner starts again the red LED goes out and the con trol box is reset 8 Faults Possible causes Solutions WARNING In the event of a burner lockout more than two consecutive burner reset operations could cause damage 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 42: ...sure switch kit for leak detection control Kit software interface Continuous Purging Kit Soundproofing box kit Gas trains approved according to EN 676 Refer to the instruction manual A Appendix Accessories Parameter to control Probe Output power regulator Range Type Code Type Code Temperature 100 500 C PT 100 3010110 RWF50 RWF55 20101190 20101191 Pressure 0 2 5 bar 0 16 bar Probe with output 4 20 ...

Page 43: ...put 4 Operational layout 5 LMV51 operational layout 6 LMV51 operational layout 7 LMV51 operational layout 8 LMV51 operational layout 9 LMV51 operational layout 10 LMV51 operational layout 11 Electrical connections for internal RWF50 kit 12 Electrical connections set by installer 13 Electrical connections set by installer 14 RWF50 operational layout 15 Electrical connections for external RWF50 kit ...

Page 44: ...20009654 42 GB Appendix Electrical panel layout 0 12 2 12 2 0 0 2 3 3 4 4 2 4 2 5 4 6 4 2 4 2 2 4 4 4 4 4 74 7 7 4 4 2 5 4 2 2 2 2 2 2 2 2 ...

Page 45: ...43 20009654 GB Appendix Electrical panel layout 0 0 1 20 20 0 1 1 0 0 3 3 4 4 0 4 0 5 4 6 4 0 4 0 0 4 4 4 4 4 74 7 7 4 4 0 5 4 0 0 0 0 0 0 0 ...

Page 46: ...20009654 44 GB Appendix Electrical panel layout 0 0 1 20 0 0 20 0 1 1 3 3 4 4 0 4 0 5 4 6 4 0 4 0 0 4 4 4 4 4 74 7 7 4 4 0 5 4 0 0 0 0 0 ...

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Page 49: ...47 20009654 GB Appendix Electrical panel layout 0 0 1 2 1 2 3 1 3 4 1 5 1 3 1 3 3 1 1 1 21 2 1 61 6 6 2 1 1 3 4 1 3 ...

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Page 53: ...51 20009654 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 54: ...1 5 6 0 1 1 20 13 4 1 1 7 1089 20 13 4 0 710 91 0 1 13 4 8 8 8 0 9 9 0 9 9 0 9 9 9 9 9 9 9 2 1 2 01 53 1 0 3 A 9 B 1 1 B 1 16 1 1 1 1 9 1 35 0 350 3 0 1 0 1 1 1 B B0 B0 B0 B0 10 0 1 10 1 9 2 1 0 2 1 1 1 1 8 91 5 9189 0 9189 0 9120 9 1 1 0 B 1 1 0 1 0 B 1 3 1 A 9 B 1 19 11 1 3 11 1 9 28 2 2 ...

Page 55: ...53 20009654 GB Appendix Electrical panel layout 0012 2 001 0342 5 6 2 7 8 7 2 001 0342 5 6 7 8 7 9 7 2 001 0342 5 6 8 7 7 65 65 7 9 9 ...

Page 56: ...20009654 54 GB Appendix Electrical panel layout 0 1 0 2 2 3 3 0 3 0 4 5 5 6 5 6 7 5 5 6 5 6 6 5 5 5 5 5 15 1 1 5 5 6 7 5 6 ...

Page 57: ... 5 1 5 0 6 2 6 7 5 5 5 8 A 2 0 6 1 A 8 112B0 6 0 5 2 0 C 5 8 905 D 81 5 75 8 580 2 5 E 1120 0 0 0 F50 5 2 5 2 1 8 5 G 702 5 0 5 A H H A A H A H 8 8 8 A 8 A A I 4 I 4 I J I K I I I I I 4I 4 I I 4 I I J I 4 4 4 L L L L A L L A L L A 58 12 0 81 5 5 0 58 8 5 0 905 05 0 0 58 8 5 0 905 05 0 0 0 8 5 5 90 55 1 0 90 55 1 5 90 2 6 1 0 90 2 6 1 ...

Page 58: ...3 4 5 4 5 46 7 4 8 9 6 4 4 46 4 6 6 8 9 6 4 8 9 446 5 4 8 9 8 9 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 59: ...output relay K7 Light oil fuelled burner ON clean contacts output relay MP Pump motor MV Fan motor PA Air pressure switch PE Burner ground PGMax Maximum gas pressure switch PGMin Minimum gas pressure switch PGVP Gas pressure switch for leak detection control device PO Oil pressure switch PO1 High limit oil pressure switch on return line QRI Infrared sensor RS Remote lock out reset button S1 Emerge...

Page 60: ...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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