Riello RLS 310/E O2 MX Installation, Use And Maintenance Instructions Download

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20182649

Appendix - Electrical panel layout

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Summary of Contents for RLS 310/E O2 MX

Page 1: ...ce instructions 20182649 2 11 2021 Dual fuel gas oil gas burners Modulating operation CODE MODEL TYPE 20182632 RLS 310 E O2 MX 1161T1 20182634 RLS 410 E O2 MX 1162T1 20182635 RLS 510 E O2 MX 1163T1 20182636 RLS 610 E O2 MX 1164T1 GB ...

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

Page 3: ... 15 PLL52 module optional 18 4 16 Oxygen sensor QGO20 optional 19 4 17 Calibration of the thermal relay 21 5 Installation 22 5 1 Notes on safety for the installation 22 5 2 Handling 22 5 3 Preliminary checks 22 5 4 Operating position 23 5 5 Preparing the boiler 23 5 6 Securing the burner to the boiler 23 5 7 Access to head internal part 24 5 8 Position of the electrodes and central gas nozzles 24 ...

Page 4: ...oes out during operation 40 6 14 Stopping of the burner 40 6 15 Final checks 41 6 16 Pump motor lock out 41 6 17 Description of O2 trim control optional 42 7 Maintenance 43 7 1 Notes on safety for the maintenance 43 7 2 Maintenance programme 43 7 3 Opening the burner 45 7 4 Closing the burner 45 8 Faults Possible causes Solutions 46 A Appendix Accessories 47 B Appendix Electrical panel layout 48 ...

Page 5: ...tibility The products are marked as follows RLS 310 E O2 MX Class 2 EN 267 Class 3 EN676 RLS 410 E O2 MX Class 2 EN 267 Class 3 EN676 RLS 510 E O2 MX Class 2 EN 267 Class 3 EN676 RLS 610 E O2 MX Class 2 EN 267 Class 3 EN676 The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Legnago 03 05 2021 Research Development Director RIELLO S p A Burner Dep...

Page 6: ...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 CRU...

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 incor rectly applied a...

Page 8: ...ce 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 underta...

Page 9: ...N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil S L LS N Head TC Standard head TL Long head Emission C11 o C22 o MZ C33 BLU C23 MX Class 1 EN 267 EN676 Class 2 EN 267 EN676 Class 3 EN 267 EN676 Class 2 EN 267 Class 3 EN676 Adjustment E Electronic cam EV Electronic cam and variable speed with Inverter M Mechanical cam P Proportional air gas valve E O2 Electronic cam and suitable for Oxy...

Page 10: ...iangle 20182636 Gas category Destination country I2H AT BG CH CZ DK EE ES FI GB GR HU IE IS IT LT LV NO PT RO SE SI SK TR I2ELL DE I2EK NL I2Er FR I2E R BE I2E LU PL Model RLS 310 E O2 MX RLS 410 E O2 MX RLS 510 E O2 MX RLS 610 E O2 MX Type 1161T1 1162T1 1163T1 1164T1 Power 1 Delivery 1 min max kW Kg h 600 1200 3600 50 100 305 640 1500 4200 55 126 352 660 1800 5170 56 195 435 1000 2200 6155 110 18...

Page 11: ...30 230 400 9 2 28 6 16 5 Absorbed electrical power Gas Light oil kW max 9 1 11 10 9 13 STAR TRIANGLE START UP Model RLS 510 E O2 MX RLS 610 E O2 MX Main electrical supply Fan motor IE3 rpm V kW A 2920 400 690 12 21 12 2 2915 400 690 15 26 8 15 5 Absorbed electrical power Gas Light oil kW max 13 8 16 17 1 19 Pump motor rpm V kW A 2890 220 380 1 5 5 9 3 4 Ignition transformer V1 V2 I1 I2 230 V 2 x 5...

Page 12: ...y the L and R positions The l position is reference for the refractory thickness of the boiler door Tab G Model kg RLS 310 E O2 MX 300 RLS 410 E O2 MX 300 RLS 510 E O2 MX 300 RLS 610 E O2 MX 320 Fig 1 20086678 WARNING The gas adaptor is set also for DN 80 bore Fig 2 20086680 mm A B C D E F G H I L M N O R RLS 310 E O2 MX 1270 507 178 313 520 DN65 490 790 373 1178 596 528 290 970 RLS 410 E O2 MX 12...

Page 13: ...heric pressure of 1013 mbar approx 0 m a s l and with the combustion head adjusted as shown on page 25 WARNING Pre calibration of the combustion head only for the burner model RLS 310 E O2 MX If the maximum burner output of the burner falls within area A of the firing rate it is necessary to replace the gas nozzles with those supplied No 8 gas nozzles Ø 5 3 Fig 17 area B of the firing rate no modi...

Page 14: ...N 676 regulations In Fig 4 you can see the diameter and length of the test combus tion chamber Example Output 5000 kW diameter 100 cm length 5 m 4 10 Burner equipment Gasket for gas train adaptor No 1 Adaptor for gas train No 1 Screws for fixing the gas train adaptor M 16 x 70 No 4 Thermal insulation screen No 1 M 18 x 60 screws to secure the burner flange to the boiler No 4 Flexible hoses No 2 Hy...

Page 15: ...tch with pressure test point 21 Valve group 22 Hinge for opening the burner 23 Pressure test point for air pressure switch 24 Combustion head air pressure test point 25 Gas train adapter 26 Indication for checking the rotation direction of the purging motor 27 Flame inspection window 28 Flame sensor 29 Nozzle delivery pressure gauge 30 Transparent protection 31 Pump 32 Pump motor 33 Minimum oil pr...

Page 16: ... 16 OVERLOAD FAN MOTOR light signalling 17 Electronic cam transformer 18 Relay with clean contacts for signalling the burner is in OIL operation 19 Thermal relay of pump motor with RESET button 20 Triangle contactor of pump motor 21 Star contactor Star triangle start up 22 Auxiliary contacts 23 Timer for star triangle start up 24 Triangle contactor Star triangle start up 27 Change of fuel selector...

Page 17: ...grammed the person making the plant settings must continu ously monitor the quality of the combustion process e g by means of a flue gas analyser Also if combustion levels are poor or in the event of danger ous situations the commissioning engineer must take appropriate action e g switching off manually To ensure the safety and reliability of the LMV5 system the fol lowing instructions must also b...

Page 18: ...l voltage Nominal current Power factor 2A cos 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cos 0 4 Load on output terminals Total load on the contacts Mains voltage Total unit input current safety circuit load on contacts due to Fan motor contactor Ignition transformer Valve Oil pump magnetic clutch AC 230 V 15 10 Max 5 A Single contact loading Fan motor con...

Page 19: ... electrical supply of the actuator is switched off The housing cover may only be removed for short periods of time for wiring or when making the addressing In similar cas es make sure that dust or dirt does not penetrate inside the actuator The actuator comprises a PCB with ESD sensitive compo nents The top side of the board carries a cover which affords pro tection against direct contact This pro...

Page 20: ...le lengths 10 m fino a QGO20 Cross sectional areas Refer to description of QGO20 Analog inputs Air temperature detector Pt1000 LG Ni1000 Flue gas temperature Pt1000 LG Ni1000 QGO20 Refer to data sheet N7842 Interface Communication bus for LMV52 Model PLL52 Mains voltage X89 01 AC 230 V 15 10 Safety class I class with parts according to II class DIN EN 60730 1 Mains frequency 50 60 Hz 6 Power consu...

Page 21: ...aning the inlet and outlet allow the sensor to cool down for at least 1 hour Mount the sensor such that the connecting part head to flange is free so that the exchange of air is ensured Other wise measurements might get distorted possibly leading to dangerous situations Ensure that there are no chemicals such as solvent vapors near the sensor Installation notes The flue gas flow passing the measur...

Page 22: ...ue gas velocity only with AGO20 1 10 m s Fuel type Fuel oil EL or Natural gas H Measuring range 0 2 20 9 O2 Permissible cable length Max 100 m Wire diameter 10 m Power supply lines Net cable Cable diameter Cable type Min 1 mm QGO20 000D27 e g NYM 3 x 1 5 QGO20 000D17 UL AWM Style 1015 MTW or CSA AWM TEW Required operating temperature of measuring cell 700 C 50 C Environmental conditions Storage Cl...

Page 23: ...e the table in the wiring diagram To reset in case of an intervention of the thermal relay press the RESET button 1 Fig 11 The red TEST button 3 opens the NC 95 96 contact and stops the motor CAUTION The automatic reset Position A button 1 can be dangerous This operation is not anticipated in the burner s operation leave it always on H There fore do not position the RESET button 1 on A Fig 11 3 1 ...

Page 24: ...ler must 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 a...

Page 25: ...2 5 Fig 15 is not necessary unless expressly requested by the boiler manufacturer Tab N 5 6 Securing the burner to the boiler Fit the heat insulation supplied onto the blast tube 4 Fig 15 Fit the entire burner onto the boiler hole prepared previously Fig 14 and fasten with the screws supplied WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 13 Installation 1 is preferabl...

Page 26: ...th pressure test point F Release the head by lifting it from its housing 3 then take out the combustion head 5 8 Position of the electrodes and central gas nozzles WARNING To open the burner from the opposite side before removing the pin 1 Fig 16 make sure that the 4 screws 2 are tight Then shift the pin 1 to the op posite side only then is it possible to remove the screws 2 Disconnect the socket ...

Page 27: ...ents for the out put required and which is indicated in the diagram Fig 18 NOTE Depending on the specific application the adjustment can be modified WARNING The burner leaves the factory with the combustion head adjusted to notch 0 Fig 20 This adjustment allows you to secure the moving parts when the burner is being transported WARNING The combustion head can be adjusted within the following field...

Page 28: ...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 ob jects The manufacturing company shall not be lia ble for any such damage arising fr...

Page 29: ...onsists of a loop of piping departing from and re turning to the tank with an auxiliary pump that circulates the fuel under pressure A branch connection from the loop feeds 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 connection...

Page 30: ... output The pressure on the return line is adjusted by varying a section by means of the rotation of the servomotor 10 Fig 5 on page 13 which also controls the gas butterfly valve at the same time Regulator at 0 maximum opening minimum pressure on the nozzle return line Regulator at 90 minimum opening maximum pressure on the nozzle return line The servomotor is controlled by the electronic cam 1 F...

Page 31: ...le return line 15 Pressure switch on pump delivery line B Oil valve group and pressure variator M Pressure gauges V Vacuometer connection OPERATION Pre purging phase valves 5 6 13 and 14 closed Ignition and operation phase valves 5 6 13 and 14 open Stop All valves closed Fig 25 20086806 WARNING The a m operation is possible because the pump is already full of fuel when it leaves the factory If the...

Page 32: ... 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 Explosion danger due to fuel leaks in the pres ence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel...

Page 33: ...in installation DANGER Disconnect the electrical power using the 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 30 20086798 ...

Page 34: ...output value in the table Tab Q for the burner in question Read on the right column 1 the pressure at the test point P1 Fig 30 on page 31 Add this value to the estimated pressure in the combustion chamber Example RLS 410 E O2 MX with natural gas G20 Required burner maximum output operation 3000 kW Gas pressure at an output of 3000 kW 24 4 mbar Pressure in combustion chamber 5 mbar 24 4 5 29 4 mbar...

Page 35: ...n safety and efficiency at start up Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case a time switch should be fitted in series to TL to stop the FS2 burner at least once every 72 hours Refer to the wir ing diagrams The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system made accordin...

Page 36: ...nimum gas pressure switch Bore for M20 4 VPS gas valve leak detection control kit Bore for M20 5 Gas train Bore for M20 6 Available Bore for M20 7 Available Bore for M16 A Fan motor B Maximum gas pressure switch C FUEL servomotor D AIR servomotor E Flame sensor F Oil valve G Pump motor H Minimum oil pressure switch I Maximum oil pressure switch After carrying out maintenance cleaning or checking o...

Page 37: ...rt the op erating cycle of the control box 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 Once the following adjustments have been made the ignition of the burner must generate a noise similar to the noise generated during operation 6 3 ...

Page 38: ... If voltage is present stop the burner immediately and check the electrical connections When the limit thermostat TL closes the burner begins the starting cycle 6 6 Burner ignition The burner should light after having performed the above steps 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 is still not a...

Page 39: ...tlet Adjust in sequence 1 Output upon ignition 2 MAX output 3 MIN output 4 Intermediate outputs between Min and Max 5 Air pressure switch 6 Maximum gas pressure switch 7 Minimum gas pressure switch 6 8 4 Output upon ignition Ignition must occur at a lower output than the max operation out put Regulations provide that the ignition output of this burner must be equal to or less than 1 3 of the MAX o...

Page 40: ...rrow pointing upwards on the gradu ated scale Turn the knob clockwise again until the value shown on the graduated scale corresponds with the arrow pointing downwards and so recovering the hysteresis of the pressure switch shown by the white mark on a blue background between the two arrows Now check the correct start up of the burner If the burner locks out again turn the knob anti clockwise a lit...

Page 41: ... gas pressure Adjust the minimum gas pressure switch Fig 36 after having adjusted the burner the gas valves and the gas train stabiliser With the burner operating at maximum output install a pressure gauge downstream of the gas train stabilis er for example at the gas pressure test point on the burner combustion head choke slowly the manual gas cock until the pressure gauge detects a decrease in t...

Page 42: ...he burner stops when the heat request is less than the heat supplied by the burner at MIN output The thermostat pressure switch TL opens the control box carries out the switching off phase The air damper closes completely to reduce heat losses to a minimum 6 12 Ignition failure If the burner does not switch on there is a lockout within 3s of the electrical supply reaching the fuel valve It may be ...

Page 43: ...the thermostat pressure switch TL Open the thermostat pressure switch TS the burner must stop Turn the gas maximum pressure switch knob to the mini mum end of scale position Turn the air pressure switch knob to the maximum end of scale position the burner must stop in lockout Disconnect the minimum gas pressure switch connector the burner must stop in lockout Disconnect the maximum oil pressure sw...

Page 44: ...e amount of air is reached by reducing the air rate of the air regulating actuators For that purpose the damper positions of these actuators are cal culated from some other load point on the ratio control curves Hence due to the parameterized ratio control curves the air reg ulating actuators are in a fixed relation to one another O2 trim control is supported by precontrol It calculates the air ra...

Page 45: ...ator that turn on at the same time as their power supply 7 2 3 Checking and cleaning Combustion The optimum calibration of the burner requires an analysis of the flue gases Significant differences with respect to the previous measure ments 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 h...

Page 46: ...rities are observed inside the pump use a separate pump to lift any water and other impurities that may have deposited on the bottom of the tank 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 Fuel tank Approximately every 5 years suck any water on the bottom of the tank using a sepa...

Page 47: ...combustion head as shown in Fig 34 7 3 Opening the burner See section Access to head internal part on page 24 7 4 Closing the burner Refit following the steps described but in reverse order refit all burner components as they were originally assembled GAS OPERATION EN 676 Air excess Max output 1 2 Min output 1 3 GAS Theoretical max CO2 0 O2 Calibration CO2 CO mg kWh 1 2 1 3 G 20 11 7 9 7 9 0 100 G...

Page 48: ...out 8 Faults Possible causes Solutions WARNING In the event the burner stops in order to prevent any damage to the installation do not unblock the burner more than twice in a row If the burner locks out for a third time contact the customer service DANGER In the event there are further lockouts or faults with the burner the maintenance interventions must only be carried out by qualified authorised...

Page 49: ...t field Code All models PT 100 temperature 100 500 C 3010110 All models 4 20 mA pressure 0 2 5 bar 3010213 All models 4 20 mA pressure 0 16 bar 3010214 Burner Type dB A Code RLS 310 410 E O2 MX C7 10 3010376 RLS 510 610 E O2 MX C7 PLUS 10 20085111 Burner Code All models 20077810 Burner Code All models 20008903 Burner Code All models 20045187 Burner Code All models 3010377 Burner Code All models 30...

Page 50: ...unctional layout star triangle starter RLS 510 610 E MX 400 V Star Triangle Start Up 5 Functional layout LMV 52 6 Functional layout LMV 52 7 Functional layout LMV 52 8 Functional layout LMV 52 9 Functional layout LMV 52 10 Functional layout LMV 52 11 Functional layout LMV 52 12 Functional layout LMV 52 12B Functional layout LMV 52 13 Electrical wirings that are the responsibility of the installer ...

Page 51: ...49 20182649 GB Appendix Electrical panel layout 0 1 2 2 30 0 2 0 1 2 2 30 2 2 2 4 0 5 5 0 5 0 6 5 7 5 0 5 0 0 5 5 5 5 5 85 8 8 5 5 0 6 5 0 0 0 0 0 RLS 310 E O2 MX 400V Direct Start up ...

Page 52: ...20182649 50 GB Appendix Electrical panel layout 0 1 1 2 1 3 0 1 1 2 1 1 1 4 5 5 5 6 5 7 5 5 5 5 5 5 5 85 8 8 5 5 6 5 RLS 410 E O2 MX 400V Direct Start up ...

Page 53: ...51 20182649 GB Appendix Electrical panel layout 0 0 1 20 0 0 3 0 1 3 3 20 3 3 3 4 0 5 5 0 5 0 6 5 7 5 0 5 0 0 5 5 5 5 5 85 8 8 5 5 0 6 5 0 0 0 0 0 0 0 RLS 510 E O2 MX 400V Star Triangle Start up ...

Page 54: ...20182649 52 GB Appendix Electrical panel layout 0 1 2 2 3 0 2 2 1 2 2 2 4 5 5 5 6 5 7 5 5 5 5 5 5 5 85 8 8 5 5 6 5 RLS 610 E O2 MX 400V Star Triangle Start up ...

Page 55: ...53 20182649 GB Appendix Electrical panel layout 0 0 0 0 0 0 0 0 RLS 310 410 E O2 MX 400V Star Triangle Start up ...

Page 56: ...20182649 54 GB Appendix Electrical panel layout 0 0 0 0 0 0 0 0 RLS 510 610 E O2 MX 400V Star Triangle Start up ...

Page 57: ...55 20182649 GB Appendix Electrical panel layout 0 1 1 2 1 2 3 1 4 1 2 1 2 2 1 1 1 1 1 51 5 5 1 1 2 3 1 2 All models ...

Page 58: ...20182649 56 GB Appendix Electrical panel layout 0 0 0 1 0 0 1 2 3 2 3 4 2 4 5 2 6 2 4 2 4 4 2 2 2 32 3 2 72 7 7 3 2 2 4 5 2 4 All models ...

Page 59: ...57 20182649 GB Appendix Electrical panel layout 0 All models ...

Page 60: ...20182649 58 GB Appendix Electrical panel layout All models ...

Page 61: ...59 20182649 GB Appendix Electrical panel layout 0 0 1 2 0 0 0 1 0 All models ...

Page 62: ...20182649 60 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 All models ...

Page 63: ...61 20182649 GB Appendix Electrical panel layout 0 1 0 1 0 2 0 3 0 0 0 0 0 10 1 0 40 4 4 1 0 0 2 0 5 All models ...

Page 64: ...20182649 62 GB Appendix Electrical panel layout 01 2 2 2 2 2 3 3 3 4 3 5 3 3 3 3 3 3 3 3 3 3 4 3 01 01 0 0 0 All models ...

Page 65: ...63 20182649 GB Appendix Electrical panel layout 01 2 2 2 2 2 3 3 3 4 3 5 3 3 3 3 3 3 3 3 3 3 4 3 01 01 01 All models ...

Page 66: ...20182649 64 GB Appendix Electrical panel layout 0 1 0 2 3 2 4 5 67 5 7 5 7 6 5 7 8 4 9 9 9 4 2 3 1 2 0 1 1 2 1 0 1 0 1 0 3 3 3 9 9 RLS 310 E MX 400V Direct Start up ...

Page 67: ...65 20182649 GB Appendix Electrical panel layout 0 1 0 2 3 2 4 5 67 5 7 5 7 6 5 7 8 4 9 4 2 3 1 2 0 1 1 2 1 0 1 0 1 A 0 3 3 3 A RLS 410 E MX 400V Direct Start up ...

Page 68: ...20182649 66 GB Appendix Electrical panel layout 0 1 0 2 3 2 4 5 67 5 7 5 7 6 5 7 8 4 9 9 4 2 3 1 2 0 1 1 2 1 0 1 0 1 A 0 3 3 3 A RLS 510 E MX 400V Star Triangle Start up ...

Page 69: ...67 20182649 GB Appendix Electrical panel layout 0 1 0 2 3 2 4 5 67 5 7 5 7 6 5 7 8 4 9 9 4 2 3 1 2 0 1 1 2 1 0 1 0 1 0 3 3 3 RLS 610 E MX 400V Star Triangle Start up ...

Page 70: ...20182649 68 GB Appendix Electrical panel layout ৼ 0 1 1 1 1 1 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 0 2 3 All models ...

Page 71: ... lockout K3 Clean contacts output relay OIL operation KL1 Star triangle starter line contactor KM Direct start up contactor KMP Pump motor contactor KS1 Start triangle starter star contactor KST1 Star triangle starter timer KT1 Star triangle starter triangle contactor MP Pump motor MV Fan motor PA Air pressure switch PE Earth burner PGMax Max gas pressure switch PGMin Min gas pressure switch PGVP ...

Page 72: ...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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