Riello RLS 800/M MX Installation, Use And Maintenance Instructions Download Page 43

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20148124

LED indicator and special function

8.4

LED lamps: burner operating status

OPERATING STATUSES INDICATED BY LEDS DURING NORMAL OPERATION AND CHECK MODE

Tab. R

1. LEDs form a progress bar which indicates the Flame Signal

Power in order to orientate the sensors during commissioning
(LEDs “Grow” upwards, moving away from the Status at 20%
intervals of flame power.)

2. LEDs indicate the error or lock-out code for troubleshooting.
3. LEDs change from ON to BLINKING to OFF showing the

servomotor movement control until the position-reached
feedback is received see “Problems - Causes - Remedies
signalled by LED indicators” on page 42“.

Operation

LED

●

= ON

Fan

Damper

open

Damper

closed

Modulation

Ignition

Flame

Status

Icon

Power OFF/ON

OFF

Not ready/

Diagnostics

Green

Standby

●

Green

Servomotor

movement

(Note 3)

●

OFF

Flashing

●

Flashing

OFF

Green

Waiting for closing

Green

blinking

Green

OPEN

(before ignition)

●

Green

Minimum

(before ignition)

●

Green

Ignition

●

Green

PTFI

●

Green

blinking

Green

MTFI

●

Green

Active modulation

●

Green

Minimum output

position

●

Green

With flame present

●

Green

Economy mode

●

Green

Check during

maximum opening

phase

Flashing

●

Yellow

Check during

minimum closing

phase

Flashing

●

Yellow

Check during

ignition phase with

pilot PTFI

Flashing

●

Note 1

●

Note 1

●

Note 1

●

Note 1

●

Note 1

Yellow

Check during

ignition phase with

main fuel valve

MTFI

Flashing

●

Note 1

●

Note 1

●

Note 1

●

Note 1

●

Note 1

Yellow

Fault/lock-out

●

Note 2

●

Note 2

●

Note 2

●

Note 2

●

Note 2

●

Note 2

Red

End of the cycle

●

Green

S9740

S9741

S9742

S9743

S9744

S9745

S9746

Summary of Contents for RLS 800/M MX

Page 1: ...20148124 2 11 2020 Installation use and maintenance instructions Dual fuel light oil gas burner Progressive two stage or modulating operation CODE MODEL TYPE 20147802 RLS 800 M MX 1301 T GB ...

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

Page 3: ...12 Control box RFGO A22 13 4 13 Servomotor SQM10 1 14 5 Installation 15 5 1 Notes on safety for the installation 15 5 2 Handling 15 5 3 Preliminary checks 15 5 4 Operating position 16 5 5 Removing the shutter lockout screws 16 5 6 Preparing the boiler 16 5 6 1 Boring the boiler plate 16 5 6 2 Blast tube length 16 5 7 Securing the burner to the boiler 17 5 8 Access to head internal part 17 5 9 Elec...

Page 4: ...ure switch 33 6 10 3 Minimum gas pressure switch 33 6 11 Operation sequence of the burner 34 6 11 1 Burner start up 34 6 11 2 Steady state operation 34 6 11 3 Burner flame goes out during operation 34 6 11 4 Ignition failure 34 6 12 Final checks with burner operating 35 7 Maintenance 36 7 1 Notes on safety for the maintenance 36 7 2 Maintenance programme 36 7 2 1 Maintenance frequency 36 7 2 2 Saf...

Page 5: ... 30 EU Electromagnetic Compatibility PED 2014 68 EU FS2 only Pressure Equipment Directive Such products are marked as indicated below The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BImSchV revision 2...

Page 6: ...rried out correctly may cause damage to the machine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not carried 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 CRUSH...

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 incorrectly applied an...

Page 8: ...nance 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 responsible 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 undert...

Page 9: ...800 M 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 BASIC DESIGNATION EXTENDED DESIGNATION MX 3N 400V 50Hz 3 230V 50Hz 230V 50Hz 110V 50 60Hz Heavy oil E Electronic cam EV Electronic cam and variable speed with Inverter P Proportional air gas valve BP Two stage light oil Proportional valve gas M Mechanical ...

Page 10: ...7 295 674 Fuels LIGHT OIL max viscosity at 20 C 6 mm2 s 1 5 E 6 cSt NATURAL GAS G20 methane gas G21 G22 G23 G25 LPG G31 NCV 26 kWh Nm3 Gas pressure at max output 2 Gas G20 G25 mbar 50 6 75 4 Operation Intermittent min 1 stop in 24 hours Progressive two stage or modulating by kit see accessories Pump Output at 16 5 bar Pressure range Fuel temperature kg h bar c max 560 6 30 140 Nozzles number 1 Sta...

Page 11: ... head requires the burner to be opened and the rear part turned on the hinge The maximum dimensions of the open burner are indicated by the L and R positions The l position is reference for the refractory thickness of the boiler door Tab E mm A B C D E F G H I L R S RLS 800 M MX 1333 558 173 428 626 DN80 972 988 388 1187 1061 349 I B A D E C F G H L S S R D9251 Fig 1 ...

Page 12: ...anufacturer The firing rates were obtained in special test boilers according to EN 676 standard In Fig 3 you can see the diameter and length of the test combustion chamber Example Output 7000 kW diameter 120 cm length 6 m MODULATING RATIO The modulating ratio obtained in the test boilers according to the standard EN 676 for gas EN 267 for light oil is 2 5 1 ATTENTION The firing rate value Fig 2 ha...

Page 13: ...fferential type 19 Combustion head air pressure test point 20 Maximum gas pressure switch with pressure test point 21 Flame sensor 22 Pressure test point for air pressure switch 23 Pump 24 Pump motor 25 Minimum oil pressure switch 26 Maximum oil pressure switch 27 Nozzle return pressure gauge 28 Nozzle delivery pressure gauge 29 Oil modulator 30 Pressure gauge connection 31 Pilot gas train 15 6 19...

Page 14: ... 18 Auxiliary circuits fuse 19 Plug socket servomotor 20 Plug socket valves motor 21 Fan motor thermal relay 22 Pump motor contactor and thermal relay 23 Oil Gas selection relay 24 Plug socket maximum gas pressure switch 25 Flame sensor plug sensor socket NOTE Two types of burner lockout may occur Control box lockout if the button red LED of control box 11 Fig 5 and signal button 10 Fig 5 light up...

Page 15: ...ions Do not confuse the powered conductors with the neutral ones Ensure that spliced wires cannot get into contact with neighbouring terminals Use adequate ferrules Arrange the H V ignition cables separately as far as possible from the control box and the other cables When wiring the unit make sure that AC 230 V mains voltage cables are run strictly separate from extra low voltage cables to avoid ...

Page 16: ...nt national safety standards are respected When assembling the servomotor and connecting the damper the gears can be disengaged by means of a lever allowing the drive shaft to be easily adjusted in both directions of rotation Technical data Tab G ATTENTION To avoid accidents material or environmental damage observe the following instructions Avoid opening modifying or forcing the actuators Operati...

Page 17: ...on air inside the boiler must be free from hazardous mixes e g chloride fluoride halogen if present it is highly recommended to carry out cleaning and maintenance more frequently ATTENTION Burner handling operations can be highly dangerous if not carried out with the greatest attention distance unauthorised personnel check integrity and suitability of the means available Check also that the area i...

Page 18: ... screen supplied with the burner 5 6 2 Blast tube length The length of the blast tube must be selected according to the indications provided by the manufacturer of the boiler and in any case it must be greater than the thickness of the boiler door complete with its fettling For boilers with front flue passes 1 Fig 12 or flame inversion chamber a protection in refractory material 5 must be inserted...

Page 19: ...lated to air damper and head movement undo the 4 fixing screws 1 disconnect the electrode cable 2 disconnect the light oil pipes unscrewing the two pipe fittings 3 Release the ignition pilot retainer remove the gas pressure screw test point 6 of the head disconnect the lower part of the elbow until it is released from its housing remove the internal part of the head 5 5 9 Electrode position ATTENT...

Page 20: ...00 650 700 750 Normally atomisation angles of 45 are recommended Tab J ATTENTION 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...

Page 21: ...put required In the factory the hole is adjusted for the maximum stroke hole 3 Fig 16 If for combustion reasons it is necessary to move the spacer 1 Fig 17 onto the 1st and 2nd hole of the gear while the hinge is positioned to the right the spacers 4 Fig 17 supplied as standard must be mounted Proceed as follows Fig 17 unscrew the nuts 2 and remove the tie rod 3 unscrew the spacer 1 and place it o...

Page 22: ...mote control Italy only 8 On off solenoid valve Italy only See electrical layout Connections to be carried out by the installer SV 9 Return line 10 Check valve Italy only 5 12 3 Hydraulic connections The pumps are equipped with a by pass that connects return line with suction line They are installed on the burner with the by pass closed by screw 6 Fig 22 It is therefore necessary to connect both h...

Page 23: ...pressure gauge 3 Fig 20 max pressure on return circuit must be approx 16 5 bar The relevant delivery pressure read on the pressure gauge 2 must be 20 bar see Tab I on page 18 IMPORTANT For a correct calibration the eccentric 8 must operate on the entire range of travel of the servomotor 20 130 a pressure variation must correspond to each servomotor variation Never drive the variator piston fully h...

Page 24: ...G 1 4 5 Pressure adjuster 6 By pass screw 7 Pressure gauge connection G 1 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 operation And so on After 5 or 6 starting operations allow 2 or 3 minutes for the transfo...

Page 25: ...r P3 Pressure upstream of the filter L Gas train supplied separately L1 Responsibility of the installer DANGER Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel shut off valve is closed before performing any operation on the burner ATTENTION The fuel supply line must be installed by qualified personnel i...

Page 26: ...alve P2 Fig 28 with maximum opening 90 To calculate the approximate output at which the burner operates subtract the pressure in the combustion chamber from the pressure of the gas at test point P1 Fig 28 Find in Tab L related to the burner concerned the pressure value closest to the result of the subtraction Read the corresponding output on the left DANGER Disconnect the power supply using the sy...

Page 27: ...of 6000 kW 30 2 mbar Pressure in combustion chamber 5 mbar 30 2 5 35 2 mbar pressure required at test point P1 Fig 28 Key Fig 28 P1 Head gas pressure test point P2 Butterfly valve gas pressure test point 2 Manual valve 12 Gas inlet for pilot 13 Pilot line pressure adjuster 14 Safety valve 15 Operating valve 5 13 5 Pilot gas train connection The burner is equipped with a dedicated gas train fixed t...

Page 28: ...llows to use it for applications requiring a burner operating cycle longer than 24 hours When it is used as a UV control the system is considered as non permanent requiring one burner recycle every 24 hours Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case a time switch must be applied to L N in series to stop the burner at least once every 2...

Page 29: ...it in the arrow direction to the right to carry out the thermal relay test 5 16 Motor rotation As soon as the burner starts place yourself in front of the cooling fan of the fan motor and check that it turns anticlockwise Fig 32 If this is not the case put the switch of the burner to 0 off and wait until the control box carries out the switching off phase Invert the phases on the three phase motor...

Page 30: ...of the scale Purge the air from the gas line We recommend using a plastic tube routed outside the building and to purge air until gas is smelt Fit a U type pressure gauge or a differential pressure gauge Fig 33 with socket on the gas pressure of the pipe coupling and in the combustion chamber Used to derive the approximate MAX output of the burner using the table on page 24 Connect two lamps or te...

Page 31: ...en place proceed with burner global calibration operations 6 6 Change of fuel There are two change of fuel options 1 with selector 3 Fig 34 2 with a remote selector connected to the main terminal board Placing the selector 3 Fig 34 on EXT the function for selecting the fuel remotely is active In this position if there is no remote selector the display shows the priority fuel 6 7 Combustion air adj...

Page 32: ...e servomotor The passage from one position to the next one is obtained by pressing the selector 2 Fig 36 on the symbol or For better adjustment repeatability take care to stop the rotation of the cam unit when the upper bearing that slides on the profile 4 Fig 36 is aligned with one of the adjustment screws 2 Fig 36 Screw or unscrew the pre set screw 2 Fig 36 to increase or decrease the air output...

Page 33: ... 34 At this point after the pre purging phase the servomotor stops at about 20 Adjust the outlet pressure of the pump as shown in point A oil pump outlet pressure to obtain an outlet pressure to the nozzle of 24 25 bar Adjust the minimum return pressure to approx 6 bar To do so the length of the shaft 5 Fig 37 must be varied by means of nut 6 Fig 37 Calibrate the air delivery by adjusting the vari...

Page 34: ...tor on position max approx 130 Operating with oil Cam 2 limits the servomotor limit switch at the 0 position With the burner off the air damper is completely closed Operating with oil and gas Cam 3 regulates the minimum modulating output It is factory set at 30 Operating with minimum oil Cam 4 limits the limit switch of the servomotor on position max approx 130 Operating with gas Cam 5 regulates t...

Page 35: ...ximum gas pressure switch must be regulated to a value no higher than 30 of the measurement read on the gauge when the burner is working at maximum output After making the adjustment remove the pressure gauge and close the tap 6 10 3 Minimum gas pressure switch Adjust the minimum gas pressure switch after performing all the other burner adjustments with the pressure switch set to the start of the ...

Page 36: ... the boiler point C Fig 42 The electrical control box continues to check the presence of the flame and the correct position of the air and gas maximum pressure switches If the temperature or the pressure is low so the thermostat pressure switch TR is closed the burner progressively increases the output up to the MAX value section C D Then if the temperature or pressure increases until the TR opens...

Page 37: ...inimum end of scale position Turn the air pressure switch knob to the maximum end of scale position The burner must stop in lockout Turn off the burner and cut off the power Disconnect the minimum gas pressure switch connector The burner must not start Disconnect flame detection sensor electrical connections The burner must stop in lockout due to ignition failure ATTENTION Make sure that the mecha...

Page 38: ... combustion flue gases Significant differences with respect to the previous measurements 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 head are in good condition not deformed by the high temperatures free of impurities from the surroundings and correctly positioned Burner Check that the...

Page 39: ...ed life cycles do not refer to the warranty terms indicated in the delivery or payment conditions Safety component Life cycle Flame control 10 years or 250 000 operation cycles Flame sensor 10 years or 250 000 operation cycles Gas valves solenoid 10 years or 250 000 operation cycles Pressure switches 10 years or 250 000 operation cycles Pressure adjuster 15 years Servomotor electronic cam if any 1...

Page 40: ...ake sure that the hoses are still in good condition Fuel tank Approximately every 5 years suck any water on the bottom of the tank using a separate pump Combustion If the combustion values measured before starting maintenance do not comply with applicable Standards or do not indicate efficient combustion consult the table below or contact our Technical Support Service to implement the necessary ad...

Page 41: ... to open the burner on the hinge 7 4 Closing 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 system main switch DANGER Close the fuel shut off valve Wait for the components in contact with heat sources to cool down completely 5 5 1 2 6 5 5 7 3 4 ...

Page 42: ...LED starting from the flame LED represents 20 of the signal power To exit the check mode function press the reset button the flame control will go back to the normal operating mode 8 3 Flame control lock out or emergency stop condition The RFGO control device can be locked out emergency stop at any time during the operating cycle and unlocked when already locked lock out by simply pressing the key...

Page 43: ...per open Damper closed Modulation Ignition Flame Status Icon Power OFF ON OFF Not ready Diagnostics Green Standby Green Servomotor movement Note 3 OFF Flashing Flashing OFF Green Waiting for closing Green blinking Green OPEN before ignition Green Minimum before ignition Green Ignition Green PTFI Green blinking Green MTFI Green Active modulation Green Minimum output position Green With flame presen...

Page 44: ... cause material problems severe injuries or death It is the owner or user s responsibility to make sure that the equipment described is installed used and commissioned in compliance with the requirements provided both by national and local law The lock out condition indicates the presence of a fault which occurred during the operating cycle or during stand by mode Before performing an unlock attem...

Page 45: ...elay fault Red 19 Combustion airflow switch fault in the rest position Red 20 UV no flame at the end of the 2nd safety time MTFI Red 21 Safety relay fault Red 22 Supervisor processor fault Red 23 Supervisor memory test fault Red 24 Flame loss during the operation AUTO Red 25 Supervisor processor data memory fault Red 26 Supervisor processor internal fault Red 27 Not used 28 Not used 29 Operating t...

Page 46: ...ingle phase line 50 60Hz 5 FR No flame at the end of the 2nd safety time MTFI No flame at the end of the second safety time Inspect the system check the gas pressure inspect the flame detection electrode check the wiring etc 6 FR internal circuit fault Internal fault Replace the control device 7 Internal communication fault Internal fault Replace the control device 8 Remote reset The user pressed ...

Page 47: ...rnal fault Replace the control device 41 Internal hardware fault Internal fault Replace the control device 42 Main processor fault Internal fault Replace the control device 43 Supervisor processor fault Internal fault Replace the control device 44 Supervisor processor timeout Internal fault Replace the control device 45 Off specification mains voltage Off specification mains voltage frequency Chec...

Page 48: ...8 at the wrong moment or there is no voltage when necessary Check the wiring Check the actuator 59 Internal hardware fault Internal fault Replace the control device 60 Local reset fault Local reset button pressed for more than 10 seconds or reset button locked If the problem persists replace the control device 61 Open POC fault The fuel valve is open at the wrong moment Check the wiring 62 UV stro...

Page 49: ...tentiometer Spacer kit Potentiometer kit for load position indication Soundproofing box kit Kit for the remote selection of the fuel Gas trains in compliance with EN 676 Please refer to manual A Appendix Accessories Parameter to be controlled Probe Output regulator Adjustment field Type Code Type Code Temperature 100 500 C PT 100 3010110 RWF50 2 RWF50 5 20101190 20101191 Pressure 0 2 5 bar 0 16 ba...

Page 50: ...ut star triangle starter 5 Functional layout RFGO A22 6 Functional layout RFGO A22 7 Functional layout RFGO A22 8 Functional layout RFGO A22 9 Electrical wiring kit RWF50 internal 10 Electrical wiring that is the responsibility of the installer 11 Functional layout for kit RWF50 12 Electrical wiring kit RWF50 external 1 2 Sheet no 1 A1 Coordinates Indication of references ...

Page 51: ...49 20148124 GB Appendix Electrical panel layout 0 0 1 20 0 0 20 0 1 1 3 3 1 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 ...

Page 52: ...20148124 50 GB Appendix Electrical panel layout ...

Page 53: ...51 20148124 GB Appendix Electrical panel layout 0 1 1 1 ...

Page 54: ...20148124 52 GB Appendix Electrical panel layout 0 0 1 0 1 2 0 3 0 1 0 1 1 0 0 0 0 0 40 4 4 0 0 1 2 0 1 ...

Page 55: ...53 20148124 GB Appendix Electrical panel layout 0 1 2 2 2 0 ...

Page 56: ...20148124 54 GB Appendix Electrical panel layout 0 1 1 1 2 3 45678 9 55 ...

Page 57: ...10 302 6 7 1 0 2 2 310 24 5 2 2 0 8 0219 310 24 5 1 0821 2 5 5 1 0 2 24 5 9 9 9 1 1 1 3 2 3 12 64 2 1 4 A B 2 2 B 20 27 2 2 2 2 2 0 46 1 4610 4 1 2 1 2 2 2 B0 B1 00 B1 0 B1 0 B1 00 21 1 2 21 2 3 2 1 3 2 2 2 2 09 0 2 6 0 29 1 0 29 1 0 231 2 2 0 1 B 2 2 0 1 2 1 B 2 4 2 A B 20 2 22 2 4 22 2 39 3 3 ...

Page 58: ...20148124 56 GB Appendix Electrical panel layout 0 1 2 1 3 4 56 7 8 7 8 9 1 2 3 0 1 0 0 1 0 0 9 0 9 0 0 0 1 0 2 2 2 ...

Page 59: ... 4 0 4 5 1 5 6 4 4 9 4 7 A 91 5 9 09 A 7 001B 5 4 1 C 4 7 8 4 D970 4 64 7 47 1 4 E 001 9 F4 94 1 4 1 0 7 94 G 6 1 9 4 4 A H H A A H A H 7 7 7 A 7 A A I 3 I 3 I J I K I I I I I 3I 3 I I 3 I I J I 3 3 3 L L L L A L L A L L A 47 901 9 70 4 94 47 7 4 8 4 4 9 47 7 4 8 4 4 9 7 4 4 8 944 9 09 8 944 9 09 4 8 1 5 9 09 8 1 5 9 09 ...

Page 60: ...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 61: ... contacts K6 Burner ON dry contact output relay KG Gas operation relay KO Light oil operation relay MP Pump motor MV Fan motor PA Air pressure switch PE Burner earth PGM Maximum gas pressure switch PGMin Minimum gas pressure switch PO Oil pressure switch PO1 Maximum oil pressure switch on return line RS Remote burner reset button SV General safety valve S1 Emergency stop button S2 Off automatic ma...

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Page 63: ......

Page 64: ...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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Riello RLS 800/M MX, Installation, Use And Maintenance Instructions

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