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31 

20027766

GB

Start-up, calibration and operation of the burner

6.1

Notes on safety for the first start-up

6.2

Adjustments before first firing

Adjustment of the combustion head has been illustrated on
page 20

In addition, the following adjustments must also be made:

Slowly open the manual valves situated upstream of the gas
train.

Adjust the minimum gas pressure switch to the start of the
scale.

Adjust the maximum gas pressure switch to the start of the
scale.

Adjust the air pressure switch to the zero position of the
scale.

Purge the air from the gas line.
Continue to purge the air (we recommend using a plastic tube
routed outside the building) until gas is smelt.

Fit a U-type manometer or a differential pressure gauge
(Fig. 35), with the (+) fitting on the header gas pressure tap
and (-) fitting in the combustion chamber.
The manometer readings are used to calculate MAX. burner
power using the Tab. H on page 27.

Connect two lamps or testers to the two gas line solenoid
valves to check the exact moment at which voltage is sup-
plied.
This operation is unnecessary if each of the two solenoid
valves is equipped with a pilot light that signals voltage pass-
ing through.

6.3

Burner starting

Close load controls and set switch 1)(Fig. 36) 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

Start-up, calibration and operation of the burner

WARNING

The first start-up of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.

WARNING

Check the correct working of the adjustment, com-
mand and safety devices. 

CAUTION

Before starting up the burner it is good practice to
adjust the gas train so that ignition takes place in
conditions of maximum safety, i.e. with gas deliv-
ery at the minimum.

Fig. 35

+

D3515

Fig. 36

0   AUTO   MAN

-           +

1

2

D3108

3

D3531

Summary of Contents for RLS 650/E MX

Page 1: ...20027766 10 02 2016 Installation use and maintenance instructions Dual fuel light oil gas burner Modulating operation CODE MODEL TYPE 20026857 RLS 650 E MX 1310T1 GB ...

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

Page 3: ... 13 Control box for the air fuel ratio LMV51 13 4 14 Actuator SQM48 4 15 5 Installation 16 5 1 Notes on safety for the installation 16 5 2 Handling 16 5 3 Preliminary checks 16 5 4 Operating position 17 5 5 Removal of the locking screws from the shutter 17 5 6 Preparing the boiler 17 5 6 1 Boring the boiler plate 17 5 6 2 Blast tube length 17 5 7 Securing the burner to the boiler 18 5 8 Accessibil...

Page 4: ...nt 32 6 7 Air fuel control and power modulation system 32 6 8 Adjustment pressure switches 33 6 8 1 Air pressure switch CO check 33 6 8 2 Maximum gas pressure switch 33 6 8 3 Minimum gas pressure switch 33 6 8 4 Pressure switch PVP kit 33 6 9 Operation sequence of the burner 34 6 9 1 Burner starting 34 6 9 2 Undesired shutdown during operation 34 6 10 Final checks with the burner working 34 7 Main...

Page 5: ...UE Low Voltage Directive EMC 2014 30 UE Electromagnetic 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 Mode...

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: ...e 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...

Page 8: ...aintenance 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...

Page 9: ...ply to the system 3 400 50 3 230 50 Auxiliary voltage 230 50 60 110 50 60 R LS 650 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 speed with Inverter P Air gas proportionin...

Page 10: ... 3000 6550 121 253 552 Fuel LIGHT OIL viscosity at 20 C 6 mm2 s 1 5 E 6 cSt NATURAL GAS G20 methane G21 G22 G23 G25 GPL G31 PCI 26 kWh Nm3 Gas pressure at maximum delivery 2 Gas G20 G25 mbar 58 86 5 Operation 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 6 30 140 Nozzles nu...

Page 11: ...t inspection of the combustion head requires the burner to be opened by rotating the rear part on the hinge The overall dimensions of the burner when open are indicated by L and R Position I is a reference for the thickness of the boiler door refrac tory fettling Model kg RLS 650 E MX 320 Fig 1 D10554 mm A B C D E F G H I L R S RLS 650 E MX 1325 562 164 410 630 DN80 880 950 360 1190 1055 320 Fig 2...

Page 12: ... firing rates were set in relation to special test boilers accord ing to EN 676 regulations Fig 4 indicates the diameter and length of the test combustion chamber Example Output 3000 kW diameter 100 cm length 4 m MODULATION RATIO The modulation ratio determined using test boilers according to standard EN 676 for gas EN 267 for light oil is 2 5 1 WARNING The firing rate area values Fig 3 have been ...

Page 13: ...h differential operating 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 Oil modulator and gas butterfly valve servomotor 24 Pump 25 Pump motor 26 Minimum oil pressure switch 27 Maximum oil pressure switch 28 Pressure gauge for pressure on nozzle return 29 Nozzle delivery pressure gauge 30 Oil mod...

Page 14: ...9 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 6 push button red led lights up it indicates that...

Page 15: ...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 an...

Page 16: ... 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 cos 0 4 Air pressure switch test valve nominal voltage Nominal current Output factor 0 5A cos 0 4 Terminal loading Outputs Total contact loading Mains voltage Input current of unit safety loop total load on contacts resultin...

Page 17: ...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 18: ...e 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 t...

Page 19: ...last tube 4 This protective fettling must not compromise the extraction of the blast tube For boilers having a water cooled front the refractory fettling 2 5 Fig 13 is not required unless it is expressly requested by the boiler manufacturer WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 10 Installation 1 is preferable as it is the only one that allows the maintenance o...

Page 20: ...ressure switch disconnect the leverages related to air damper and head movement unscrew the 4 x fixing screws 1 Release the cable of the electrode 2 Disconnect the oil pipes by unscrewing the two connectors 3 Release the ignition pilot retainer Remove the screw gas pressure test point 6 of the combus tion head unscrew the under part of the elbow until it comes free of its slot Extract the internal...

Page 21: ...It is advisable to replace the nozzle once a year during periodical maintenance CAUTION The use of nozzles other than those specified by Riello S p A 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 not be l...

Page 22: ... 19 against the required maximum output Setting is pre arranged in the plant for the maximum run hole 3 Fig 17 If combustion 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 unscrew nuts 2 remove tie rod 3 unscrew spacer 1 and p...

Page 23: ...indicated in Fig 20 Proceed as follows disassemble from the burner of the complete combustion head assembly unscrew the screws and remove the 8 tangential tubes 1 unscrew the 4 screws and disassemble the diffuser disc 2 unscrew and remove the 6 nozzles 3 Re assemble with reverse procedure re placing all the burner components as originally 1 2 3 D10479 Fig 20 ...

Page 24: ...lates 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 G Tab G Key to layout Fig 21 H Pump foot valve height difference L Piping length Ø Inside pipe diameter 1 Burner 2 Pump 3 Fil...

Page 25: ...hot surfaces of the boiler and where they do not hamper the opening of the burner Now connect the other end of the hoses to the suction and return lines by using the supplied nipples 5 12 4 Hydraulic system layout Key to layout Fig 22 1 Pump suction 2 Pump and nozzle return 3 By pass screw in pump 4 Pump pressure governor 5 Safety solenoid 6 Safety solenoid 7 Nozzle delivery 8 Nozzle without inter...

Page 26: ... maximum opening minimum pres sure on nozzle return Pressure governor at 90 minimum opening maximum pressure on nozzle return The servomotor is operated by the electronic cam 4 Fig 6 by means of this device it is possible to set different curves for oil and gas on the same servomotor the air gate valve servomotor 4 Fig 5 may be operated in the same way In adjusting with gas it is advisable to set ...

Page 27: ... adjustments have been made the firing of the burner must generate a noise similar 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 page 19 Combustion head The adjustment of the combustion head already carried out page 2...

Page 28: ...200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upline pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer DANGER Explosion danger due to fuel leaks in the pres ence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the f...

Page 29: ...o the result of the subtraction Read off the corresponding output on the left Example with natural gas G20 Operation at maximum modulating output Gas pressure at test point P1 Fig 31 32 8 mbar Pressure in combustion chamber 5 mbar 32 8 5 27 8 mbar A pressure of 27 8 mbar column 1 corresponds in Tab H to an output of 6000 kW This value serves as a rough guide the effective output must be measured a...

Page 30: ...onnection The burner is fitted with a dedicated gas train that is fixed to the pipe coupling It should be connected to the main train downstream the fil ter or the pressure adjuster depending on configuration Oil burners with LPG pilot can be directly connected to the LPG cylinder 5 13 6 Ignition pilot burner For proper operation adjust gas pressure measured at pressure test point 1 Fig 32 as foll...

Page 31: ...t 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 standards I...

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: ...onnect two lamps or testers to the two gas line solenoid valves to check the exact moment at which voltage is sup plied This operation is unnecessary if each of the two solenoid valves is equipped with a pilot light that signals voltage pass ing through 6 3 Burner starting Close load controls and set switch 1 Fig 36 to MAN Make sure that the lamps or testers connected to the solenoids or pilot lig...

Page 34: ...ation system installed on RLS burn er series provides a set of integrated functions ensuring top level energy and operational performance from the burner both for single and grouped burners e g boiler with a double combustion chamber or several generators in parallel The system includes the following basic functions 1 air and fuels are supplied in correct quantities by positioning the valves by di...

Page 35: ... the maximum gas pressure switch after having performed all the other burner adjustments with the maximum gas pressure switch set at the end of the scale Fig 38 With the burner operating at maximum output lower the adjust ment pressure by slowly turning the relative knob anticlockwise until the burner locks out Now turn the knob clockwise by 0 2 kPa 2 mbar and repeat the start up of the burner If ...

Page 36: ...d 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 burner and discon...

Page 37: ...ation of the burner In order to measure the current use a microammeter of 100 A c c connected to the photocell as in the scheme with a capac itor of 100 F 1V c c at the same level of the instrument Burner Check for excess wear or loose screws especially on cams Clean the outside of the burner Clean and grease the cam variable profile Fan Check to make sure that no dust has accumulated inside the f...

Page 38: ...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 39: ...urner 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 Turn off the fuel interception tap Wait for the components in contact with heat sources to cool down completely 2 1 5 5 5 5 3 4 Fig 45 D10558 After carrying out maintenance clea...

Page 40: ...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 41: ...ing unit Pressure 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 page 27 on 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...

Page 42: ...elta powered starter 5 Functional layout LMV51 6 Functional layout LMV51 7 Functional layout LMV51 8 Functional layout LMV51 9 Functional layout LMV51 10 Functional layout LMV51 11 Electrical connections for internal RWF50 kit 12 Electrical connections set by installer 13 Operational layout RWF50 14 Electrical connections for external RWF50 kit 1 2 Sheet no 1 A1 Coordinates Reference layout ...

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Page 51: ...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 52: ...20027766 50 GB Appendix Electrical panel layout 0 1 2 1 3 4 3 0 5 6 5 6 7 8 7 0 3 4 9 8 7 8 7 8 7 8 7 2 2 3 1 2 2 3 2 1 2 2 2 2 1 8 8 3 2 1 4 4 4 ...

Page 53: ... 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 54: ...4 5 4 5 46 7 4 8 09 6 4 4 46 4 6 6 8 09 6 4 8 09 446 5 4 8 09 8 09 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 55: ...contact relay MP Pump motor MV Fan motor PA Air pressure switch PE Burner ground earth connection PGM 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 Emergency stop push button S2 Dial for off automa...

Page 56: ...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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