Riello RLS Series Installation, Use And Maintenance Instructions Download | Manualshive

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Summary of Contents for RLS Series

Page 1: ...20020804 3 06 2010 Installation use and maintenance instructions Dual fuel Light oil Gas burners Code Model Type 20019910 RLS 800 E US1 19910X GB Progressive two stage or modulating operation ...

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Page 3: ...checks 12 4 4 Operation position 12 4 5 Securing the burner to the boiler 13 4 5 1 Boring the boiler plate 13 4 5 2 Blast tube length 13 4 5 3 Burner securing 13 4 5 4 Accessibility to the interior of the combustion head 13 4 6 Choice of nozzle 14 4 7 Electrode positioning 14 4 8 Combustion head setting 15 4 9 Fuel supply 16 4 9 1 Double pipe circuit 16 4 9 2 The loop circuit 16 4 10 Pressure vari...

Page 4: ...mum gas pressure switch 23 5 7 3 Minimum gas pressure switch 24 5 8 Final checks with the burner working 24 6 Maintenance 25 6 1 Notes on safety for the maintenance 25 6 2 Maintenance programme 25 6 2 1 Maintenance frequency 25 6 2 2 Checking and cleaning 25 6 3 Opening the burner 26 6 4 Closing the burner 26 7 Spare parts 27 7 1 Exploded spare parts list 27 7 2 Spare parts list 28 A Appendix Elec...

Page 5: ...ious injury death or long term health risks This symbol indicates operations which if not carried out correctly may cause damage to the machine and or injury to people 1 1 3 Danger live components This symbol indicates operations which if not carried out correctly lead to electric shocks with lethal con sequences Other symbols ENVIRONMENTAL PROTECTION This symbol gives indications for the use of t...

Page 6: ...nts most subject to wear and tear use of non original components including spare parts kits accessories and optionals force majeure furthermore declines any and every responsibility for the failure to observe the contents of this manual 1 2 1 Owner s responsibility Please pay attention to the Safety Warnings contained within this instruction manual Keep this manual for your records and provide it ...

Page 7: ...h the burner components is not allowed apart from the parts requiring maintenance 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 machine and intends to use it for the specific purpose He is re sponsible for the machine and for the training of the people working around it The user Undertakes to entru...

Page 8: ... in the table The weight of the burner complete with its packaging is shown in table Tab 1 3 Technical description of the burner MODEL RLS 800 E US1 Output 1 min max kW MBtu hr 3885 8880 13256 30300 Oil fuel max delivery 1 min max Gph Oil 2 46 210 Gas fuel max delivery pressure at max delivery 2 SCFH PSI Natural gas 28601 7 Operation Low high or modulating Standard applications Boilers water steam...

Page 9: ...he overall dimensions of the burner when open are indicated by L and R Tab 2 3 4 Burner equipment The burner is supplied complete with Flange gasket 4 flange fixing screws M 16 x 50 4 screws to secure the burner flange to the boiler M 18 x 70 2 spacers Instruction manual and spare parts list inch A B C D E F G H I L R S RLS 800 E US1 52 3 16 22 7 16 27 32 25 ANSI DN3 371 32 36 15 17 64 46 1 4 41 1...

Page 10: ... indicates the diameter and length of the test combustion chamber Example Output 26510 Mbtu hr diameter 47 7 inch length 20 ft WARNING 0 2 4 6 8 10 12 14 16 18 20 mbar 22 24 9 8 7 6 5 4 3 2 0 1 w c 0 5600 5200 4800 4400 4000 3600 3200 2800 2400 2000 1600 1200 800 400 6000 26 9200 8800 8400 8000 7600 7200 6800 6400 MBtu h kW 10 0 2000 6000 4000 8000 10000 12000 14000 16000 18000 20000 22000 24000 2...

Page 11: ... Air pressure test point 20 Maximum gas pressure switch with pressure test point 21 Fireye infrared scanner 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 Oil shutoff valve 28 Nozzle delivery pressure gauge 29 Nozzle return pressure gauge 30 Oil modulator 31 Strainer 32 Check valve 33 Securi...

Page 12: ...ds 4 Air pressure switch 5 Terminal for shielded cables Warning used only to avoid a break in the cable s shielding hence do not overtighten NOTA Two types of burner failure may occur Flame control lockout light 12 on the panel comes on to report burner lockout To reset press pushbutton 12 Motor trip release by pressing the push button on thermal 2 3 3 4 5 1 Fig 6 D10073 ...

Page 13: ...the gas butterfly valve without mechanical leverag es but via the interposition of an elastic coupling When used in connection with burner controls or electronic fuel air ratio control the associated controlling elements are con trolled depending on burner output Installation notes Always run the high voltage ignition cables separate from the unit and other cables while observing the greatest poss...

Page 14: ...d After positioning the burner near the installation point correctly dispose of all residual packaging separating the various types of material Before proceeding with the installation operations carefully clean all around the area where the burner will be installed 4 3 Preliminary checks Checking the consignment After removing all the packaging check the integrity of the contents In the event of d...

Page 15: ... first Slip the thermal protection onto the blast tube 3 Place entire burner on the boiler hole arranged previously see Fig 9 and fasten with the screws given as standard equipment The coupling of the burner boiler must be airtight 4 5 4 Accessibility to the interior of the combustion head Open burner at hinge see Fig 12 after removing the 4 screws 1 Disconnect the wires 2 from the electrodes Disc...

Page 16: ...hole in the flame stability disk Do not use any sealing products such as gaskets sealing com pound or tape Be careful to avoid damaging the nozzle sealing seat The nozzles must be screwed into place tightly but not to the maximum torque value provided by the wrench 4 7 Electrode positioning Place the electrode on the ignition pilot observing the dimensions specified in Fig 13 kg h Delivery pressur...

Page 17: ... insufficient even with the damper fully open you can use a different setting to that illustrated in diagram Fig 16 do this by moving the tie rod onto the next highest index thus in creasing the combustion head s opening and hence air delivery If combustion requirements require you to move spacer 1 Fig 15 onto the 1st or 2nd hole of the gear and at the same time the hinge is on the right you need ...

Page 18: ...line fails to prime or stops priming 4 9 2 The loop circuit A loop circuit consists 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 goes to feed the burner This circuit is extremely useful whenever the burner pump does not succeed in self priming because the tank dis tance and or height d...

Page 19: ...perated in the same way In adjusting with gas it is advisable to set the servomotor at 90 in order to reduce losses from the gas butterfly valve In regulating with oil setting is made depending on the type of nozzle used and on the modulation required Under the condi tions of minimum firing rate 20 rotation may be sufficient 4 11 Hydraulic system layout 1 Pump suction 2 Pump and nozzle return 3 By...

Page 20: ...e stepped on or come into contact with 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 4 13 Rotation of fan motor The correct motor rotation direction is indicated by the phase se quence relay 16 Fig 6 After turning the power on to the burner check the green led li...

Page 21: ...ssure switch 11 Manual valve for seal control 12 Pilot regulator 4 14 3 Gas pressure Important The pressure at the head of the burner from table refers to zero in the combustion chamber to obtain true pressure measured by a U type manometer Fig 26 add the counter pressure of the boiler Note See the accompanying instructions for the adjustment of the gas train Main gas supply 10 2 3 4 5 6 11 Vent 2...

Page 22: ...s different from those shown in the electrical lay outs Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man ual Do not invert the neutral with the phase in the electrical supply line Any inversion would cause a lockout due to firing failure The electrical safety of the device is obtained only when it is correctly connected to an effi...

Page 23: ...djust the air pressure switch Fig 25 to the start 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 Fig 26 to the gas pressure test point on the sleeve The manometer readings are used to calculate MAX burner power using the table on pag 19 Connect two lamps or testers to the...

Page 24: ...into lock out reset and wait for a new firing attempt If firing is still not achieved it may be that gas is not reaching the combustion head within the safety time period of 3 seconds In this case increase gas firing delivery The arrival of gas at the sleeve is indicated by the U type ma nometer Fig 26 Once the burner has fired now proceed with global calibration operations 5 5 Combustion air adju...

Page 25: ... programming of the instrument and for the specific application obtained with this burner The first start up and curve synchronization manual is supplied with the burner The complete manual for checking and setting all parameters will be provided on application 5 7 Final calibration of the pressure switches 5 7 1 Air pressure switch Adjust the air pressure switch after having performed all other b...

Page 26: ...t again turn the dial anti clockwise again by 0 4 WC 5 8 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 burne...

Page 27: ...g Combustion The optimum calibration of the burner requires an analysis of the flue gases Significant differences with respect to the previous measurements indicate the points where more care should be exercised during maintenance Combustion head Open the burner and make sure that all the components of the combustion head are undamaged not deformed due to high temperature free of ambient dirt or d...

Page 28: ...t the gas pressure switch test point 4 Remove screws 5 At this point it is possible to open the burner at the hinge 6 4 Closing the burner Close the burner at the hinge Apply screw 5 Connect the gas pressure switch test point 4 Connect the gas servomotor test point 3 Apply the tire rod 1 Fig 29 of the head movement lever loosening nut 2 Connect the electrical supply from the burner DANGER 5 5 1 2 ...

Page 29: ... 27 20020804 7 1 Exploded spare parts list 7 Spare parts 45 34 30 35 18 19 17 33 13 22 36 24 26 86 11 6 20 10 A A 36 88 87 75 80 72 71 21 81 44 79 31 5 56 72 81 64 53 53 70 69 28 9 99 37 68 8 8 77 43 74 6 78 76 25 ...

Page 30: ...013323 HINGE 23 3013324 INTERNAL TIE ROD C 24 20011097 LEVER ASSEMBLY 25 3013961 AIR INTAKE ASSEMBLY 26 3013327 EXTERNAL TIE ROD C 27 20011117 FLANGE GASKET A 28 3013462 CONNECTOR C 29 20011202 CONNECTOR 30 3008663 VIEWING PORT C 31 3010295 GAS PRESSURE SWITCH B 32 3007170 O RING B 33 20014024 MOTOR 28 Hp C 34 3013449 AIR PRESSURE SWITCH A 35 3012795 BEARING C 36 3005447 PRESSURE TEST POINT C 37 3...

Page 31: ...BE 69 3013554 TUBE 70 20016561 TUBE 71 20017846 TUBE 72 3006140 PRESSURE GAUGE 73 74 3006410 PUMP TA5 C 75 20016554 CHECK VALVE C 76 20017796 TUBE 77 3007079 SEAL 78 2543377 SECURITY RELIEF VALVE C 79 20016392 PUMP MOTOR 80 3012384 OIL PRESSURE SWITCH B 81 2636882 CONNECTOR C 82 83 84 85 86 3013473 8 POLE SOCKET A 87 3013558 STUD 88 3013545 JOINT 89 90 91 92 93 94 95 96 97 98 99 3013945 ELBOW N CO...

Page 32: ...l panel layout A Appendix Electrical panel layout Index of layouts 2 Indication of references 3 Burner electrical wiring 4 Burner electrical wiring 5 Burner electrical wiring1 1 2 Sheet no 1 A1 Co ordinates Indication of references ...

Page 33: ...le VP Pilot valve VR Light oil return valve VS Light oil safety valve VV Vent valve normally open VV1 Pilot vent valve normally open X1 Main supply terminal strip X4 Light oil assembly terminal block XM Light oil assembly connector XPGM Maximum gas pressure switch connection plug XSM Air and gas servomotors connector NOTE Wiring must be performed by qualified personnel in accordance with the regul...

Page 34: ...20020804 32 Appendix Electrical panel layout ...

Page 35: ...Appendix Electrical panel layout 33 20020804 ...

Page 36: ...20020804 34 Appendix Electrical panel layout ...

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Page 40: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www rielloburners com ...

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