Riello RLS 100 Installation, Use And Maintenance Instructions Download | Manualshive

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Installation, use and maintenance instructions

20148653 (2) - 12/2021

Dual fuel light oil/ gas burners

Two stage operation

CODE

MODEL

TYPE

20147798

RLS 70

687 T1

20149563

RLS 70

687 T1

20147799

RLS 100

688 T1

20149565

RLS 100

688 T1

20147800

RLS 130

689 T1

20148028

RLS 130

689 T1

GB

1
2
3
...
»

Summary of Contents for RLS 100

Page 1: ...uctions 20148653 2 12 2021 Dual fuel light oil gas burners Two stage operation CODE MODEL TYPE 20147798 RLS 70 687 T1 20149563 RLS 70 687 T1 20147799 RLS 100 688 T1 20149565 RLS 100 688 T1 20147800 RLS 130 689 T1 20148028 RLS 130 689 T1 GB ...

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

Page 3: ...scription 14 4 12 Control box RFGO A22 15 4 13 Servomotor LKS 210 16 5 Installation 17 5 1 Notes on safety for the installation 17 5 2 Handling 17 5 3 Preliminary checks 17 5 4 Operating position 18 5 5 Preparing the boiler 18 5 5 1 Boring the boiler plate 18 5 5 2 Blast tube length 18 5 5 3 Securing the burner to the boiler 18 5 6 Access to head internal part 19 5 6 1 Combustion head pre calibrat...

Page 4: ...2 6 9 Servomotor adjustment 33 6 10 Pressure switch adjustment 34 6 10 1 Air pressure switch check CO 34 6 10 2 Gas minimum pressure switch 34 6 11 Operation sequence of the burner 35 6 11 1 Burner start up 35 6 11 2 Ignition failure 35 6 11 3 Burner flame goes out during operation 35 6 11 4 LED PANEL 35 6 12 Final checks with burner operating 36 7 Maintenance 37 7 1 Notes on safety for the mainte...

Page 5: ... with the following Technical Standards EN 676 EN 267 EN 12100 and according to the European Directives GAR 2016 426 EU Gas Appliances Regulation MD 2006 42 EC Machine Directive LVD 2014 35 EU Low Voltage Directive EMC 2014 30 EU Electromagnetic Compatibility Such products are marked as follows The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 ...

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: ...ance 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 underta...

Page 9: ...Electrical supply of the system 3 400 50 3 230 50 Voltage of auxiliaries 230 50 60 110 50 60 R LS 70 TC Emission C11 or Class 1 EN267 EN676 C22 or MZ Class 2 EN267 EN676 C33 or BLU Class 3 EN267 EN676 3 230 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION 3N 400V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil E Electronic cam EV Electronic cam and variable speed with Inverter P Proportion...

Page 10: ...FI AT GR DK ES GB IT IE PT IS CH NO I2H DE I2ELL NL I2L I2E I2 43 46 45 3 MJ m3 0 C FR I2Er BE I2E R B LU PL I2E Model RLS 70 RLS 100 RLS 130 Type 687 T1 688 T1 689 T1 Power 1 Delivery 1 min max kW kg h 232 465 814 19 39 69 349 698 1163 29 5 59 98 465 930 1395 39 78 118 Fuels Light oil max viscosity at 20 C 6 mm2 s 1 5 E 6 cSt Natural gas G20 methane G25 LPG G31 butane Gas pressure at max output 2...

Page 11: ...t electrical supply 1N 230V 50Hz Fan motor IE3 rpm V W A 2880 220 240 1100 4 3 2 5 2890 220 240 1500 5 9 3 4 2890 380 415 2200 8 4 6 Pump motor rpm V W A 2700 230 550 3 6 Pump motor capacitor µF 25 Ignition transformer V1 V2 I1 I2 230 V 2 x 5 kV 1 9 A 30 mA Maximum absorbed electric power Light oil Gas W Max W Max 2 3 1 7 2 7 2 1 3 5 2 9 Protection level IP 44 ...

Page 12: ...nge for gas train No 1 Seal for flange No 1 Flange fixing screws M 10 x 35 No 4 Thermal flange gasket No 1 Screws to fix the burner flange to the boiler M 12 x 35 No 4 Flexible hoses No 2 Nipples for flexible hoses with gaskets No 2 Kit for LPG operation No 1 Label for LPG operation No 1 Instruction No 1 Spare parts list No 1 Fig 1 D1176 mm A B C D E F 1 G H I L M N O RLS 70 691 296 395 555 840 25...

Page 13: ...UT must not be lower than the minimum limit of the diagram RLS 70 232 kW 19 0 kg h RLS 100 349 kW 29 5 kg h RLS 130 465 KW 39 0 kg h ATTENTION The firing rate value Fig 2 has been obtained considering an ambient temperature of 20 C an atmospheric pressure of 1013 mbar approx 0 m a s l and with the combustion head adjusted as shown on page 21 Pressure in the chamber pressure mbar Thermal power kW F...

Page 14: ...ts combustion chamber dimensions are clearly smaller than those indicated in the diagram consult the manufacturer The firing rates were obtained in special test boilers according to EN 676 regulations In Fig 3 you can see the diameter and length of the test combustion chamber Example Output 650 Mcal h 407 kW diameter 60 cm length 2 m MODULATING RATIO The modulating ratio obtained in test boilers a...

Page 15: ...he combustion head 16 Safety valve 17 1st and 2nd stage valves 18 Gas pressure test point and head fixing screw 19 Air pressure test point 20 Servomotor When the burner is not operating the air damper is fully closed in order to reduce heat dispersion from the boiler due to the flue draught which draws air from the fan suction inlet 21 Pump motor Two types of burner lockout may occur CONTROL BOX L...

Page 16: ...for 1st and 2nd stage 3 Motor contactor and thermal relay with reset button 4 Led panel 5 Terminal board for electrical connection 6 Cable grommets for external connections to be carried out by the installer 7 Air pressure switch differential type 8 Control box base 9 Oil gas switch 10 Flame sensor 11 Relay 1 3 4 5 2 6 8 7 11 9 10 Fig 5 20164425 ...

Page 17: ...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 18: ... the servomotor must not be operated even if it displays no evident damage Assembly notes Check the relevant 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 E ATTENTION To avoid accidents material or enviro...

Page 19: ...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 in w...

Page 20: ... manufacturer 5 5 3 Securing the burner to the boiler Separate the combustion head from the rest of the burner Fig 11 disconnect the light oil pipes unscrewing the two unions 6 loosen the 4 screws 3 and remove the cover 1 remove screws 2 from the two slide bars 5 remove the two screws 4 and pull the burner back on slide bars 5 by about 100 mm disconnect the electrode cables then completely unthrea...

Page 21: ...g 13 and disassemble the blast tube 2 Move the rod 3 Fig 13 from position A to position B thereby drawing back the shutter 4 Reassemble the blast tube 2 Fig 13 and the screws 1 Once this operation if necessary has been carried out fix the flange 9 Fig 11 on page 18 to the boiler plate interposing the insulating gasket 7 Fig 11 on page 18 supplied Use the 4 screws also supplied with the unit after ...

Page 22: ...ed Tab A on page 8 Use nozzles with a 60 spray angle at the recommended pressure of 12 bar In general both nozzles have the same delivery Tab H 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 ...

Page 23: ...n 2nd stage 72 kg h The diagram Fig 19 shows that for this output the adjustment of the combustion head is carried out on the notch 3 as in Fig 18 Pump adjustment No adjustment of gas delivery is required The pump leaves the factory set at 12 bar a pressure to be checked and eventually modified after the burner has been started In this phase therefore limit to apply a pressure gauge on the specifi...

Page 24: ... an auxiliary pump makes the pressurised fuel flow A branch from the loop supplies 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 Tab I Tab I Key Fig 20 H Pump Foot valve height difference L Piping length Ø Inside pipe diameter 1 Burner 2 Pump 3 Filter 4 Ma...

Page 25: ...rew them down Place the pipes so that they are not crushed or are in contact with hot parts of the boiler and so it is possible to open the burner Connect finally the other end of the flexible hoses to the suction line and return line ducts by nipples supplied with the equipment 5 10 3 Hydraulic circuit diagram Key Fig 21 1 Pump suction line 2 Filter 3 Pump 4 Pressure adjuster 5 Return pipe 6 Bypa...

Page 26: ...order to bleed off the air contained in the suction line Pump SUNTEC AJ 6 CC Min delivery rate at 12 bar pressure 220 kg h Delivery pressure range 10 20 bar Max suction depression 0 45 bar Viscosity range 2 8 75 cSt Max light oil temperature 60 C Max suction and return pressure 2 bar Pressure calibration in the factory 12 bar Filter mesh width 0 150 mm Fig 23 D1177 ATTENTION Before starting the bu...

Page 27: ... over 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train burner adaptor supplied separately P2 Pressure upstream of valves adjuster P3 Pressure upstream of the filter L Gas train supplied separately L1 Responsibility of the installer Explosion danger due to fuel leaks in the presence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel...

Page 28: ...he 2nd stage subtract the combustion chamber pressure from the gas pressure measured at test point 1 Fig 29 on page 27 Find in Tab K 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 electrical power using the main switch Check that there are no gas leaks Pay attention when handling the train ...

Page 29: ... calculate the required gas pressure at test point 1 Fig 29 with the output fixed at that required for the burner in the 2nd stage find the nearest output value in the Tab K on page 26 for the burner in question Read on the right column 1 the pressure at the test point 1 Fig 29 Add this value to the estimated pressure in combustion chamber Example RLS 100 with natural gas G20 Desired output in 2nd...

Page 30: ...FR amplifier circuit is subject to constant auto control which allows 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 you must apply a time s...

Page 31: ... move it in the arrow direction to the right to carry out the thermal relay test 5 15 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 con trol box carries out the switching off phase Invert the phases on the three phas...

Page 32: ...rvomotor adjustment on page 33 6 3 Burner ignition light oil Start the burner by closing the remote controls with the switch 1 Fig 33 in the ON position and with the fuel selector switch set to OIL Fig 34 The pump can be considered to be primed when the light oil starts coming out of the screw 3 Fig 23 on page 24 Stop the burner set switch 1 Fig 33 to OFF and tighten the screw 3 The time required ...

Page 33: ...If voltage is present stop the burner immediately and check the electrical wiring 6 6 Burner ignition Once the above steps are completed the burner should ignite 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 does not occur it is possible that gas is not reaching the combustion head within the safety tim...

Page 34: ...W Burners with MAX output above 120 kW Ignition must occur at a lower output than the max operation output If ignition output does not exceed 120 kW no calculations are required If ignition output exceeds 120 kW the regulatory standard sets that the value be defined according to the control box safety time ts for ts 2s ignition output must be equal to or lower than 1 2 of max operation output for ...

Page 35: ...usts the position of the air damper with the burner operating in 1st stage RED LEVER It adjusts the position of the air damper with the burner operating in 2nd stage BLACK LEVER Determines when the 2nd stage gas or light oil valve opens It must always intervene slightly before the red lever and after the orange lever It must not intervene with the red lever to prevent the gas or light oil valve fr...

Page 36: ...to too low gas pressure Adjust the minimum gas pressure switch Fig 40 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 dec...

Page 37: ... of the LEDs See Fig 43 Key 0 s TL closes fan motor starts in case of oil operation pump motor starts 6 s servomotor starts maximum opening 11 s air damper is at its maximum opening 42 s servomotor closing phase starts at the minimum output 45 s air damper is in the ignition point position minimum output 48 s ignition transformer strikes a spark 54 s 1st stage fuel valve opens 57 s ignition discha...

Page 38: ...he minimum 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 electrically the flame sensor The burner must stop in lockout due to ignition failure ATTENTION Make sure that the mechanical lockin...

Page 39: ...ply of gas valves can be checked by inserting a tester some valves are equipped with lights or closing opening position indicators that activate as soon as they are powered 7 2 3 Checking and cleaning Combustion Carry out an analysis of the combustion flue gases Significant differences with respect to the previous measurements indicate the points where most care should be exercised during maintena...

Page 40: ...he flue gas temperature and combustion chamber pressure Pump The delivery pressure must comply with the table on page 24 The depression must be less than 0 45 bar Unusual noise must not be evident during pump operation If the pressure is unstable or the pump runs noisily the flexible hose must be detached from the line filter and the fuel must be sucked from a tank located near the burner This mea...

Page 41: ...safety components should be replaced at the end of their life cycle indicated in the following table The specified life cycles do not refer to the warranty terms indicated in the delivery or payment conditions Tab O GAS OPERATION EN 676 Air excess CO Max output 1 2 Max output 1 3 GAS Theoretical max CO2 0 O2 CO2 Calibration mg kWh 1 2 1 3 G 20 11 7 9 7 9 100 G 25 11 5 9 5 8 8 100 G 30 14 0 11 6 10...

Page 42: ...he burner to approximately 100 mm from the pipe coupling Reconnect the cables and slide in the burner until it comes to a stop Replace the screws 3 and carefully pull the cables outwards until they are slightly taut Reconnect the light oil pipes DANGER Disconnect the electrical supply from the burner by means of the main system switch DANGER Close the fuel shut off valve Wait for the components in...

Page 43: ... 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 on the front panel or by means of the terminal T21 on the ...

Page 44: ...n 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 p...

Page 45: ... 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 46: ...ombustion 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 temperature out of r...

Page 47: ...Hz 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 the remote reset butto...

Page 48: ...ol 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 Check the mains voltage level or...

Page 49: ...o 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 strong UV flame fault The flame sensor ...

Page 50: ...d L mm Head obtainable with the kit Code RLS 70 250 385 3010345 RLS 100 250 385 3010346 RLS 130 250 385 3010347 Burner Type dB A Code All models C4 5 10 3010404 Burner Filter Code All models with filter 3010055 All models without filter 3010054 Burner Code All models 3010305 Burner Code All models 3010493 Burner Code All models 20098337 Burner Code 50 Hz 60 Hz All models 3010123 20050030 3010125 2...

Page 51: ...l panel layout Index of layouts 2 Indication of references 3 Operational layout 4 RFGO A22 operational layout 5 RFGO A22 operational layout 6 RFGO A22 operational layout 7 Electrical connection set by the installer 1 2 Sheet no 1 A1 Coordinates Indication of references ...

Page 52: ...20148653 50 GB Appendix Electrical panel layout 0 0 0 0 1 2 34 5 5 5 4 6 4 4 5 4 4 7 5 4 5 45 4 4 4 5 4 5 4 4 4 4 4 5 4 5 4 4 5 5 4 4 4 5 4 4 6 4 4 5 4 4 4 RLS 70 ...

Page 53: ...51 20148653 GB Appendix Electrical panel layout 0 0 1 1 1 1 2 3 45 6 6 6 5 7 5 5 6 5 5 8 6 5 6 56 5 5 5 6 5 6 5 5 5 5 5 6 5 6 5 5 6 6 5 5 5 6 5 5 7 5 5 6 5 5 5 RLS 100 ...

Page 54: ...20148653 52 GB Appendix Electrical panel layout 0 0 0 0 1 2 34 5 5 5 4 6 4 4 5 4 4 7 5 4 5 45 4 4 4 5 4 5 4 4 4 4 4 5 4 5 4 4 5 5 4 4 4 5 4 4 6 4 4 5 4 4 4 RLS 130 ...

Page 55: ...53 20148653 GB Appendix Electrical panel layout 0 1 2 1 2 3 3 3 4 3 5 3 3 3 3 3 3 3 63 6 6 3 3 4 3 ...

Page 56: ...20148653 54 GB Appendix Electrical panel layout 0 1 1 1 ...

Page 57: ...55 20148653 GB Appendix Electrical panel layout 0 1 1 1 2 2 ...

Page 58: ...20148653 56 GB Appendix Electrical panel layout 0 1 2 1 3 3 0 4 0 3 5 6 7 6 7 8 99 8 99 6 7 4 2 1 8 6 6 RLS 70 ...

Page 59: ...57 20148653 GB Appendix Electrical panel layout 0 1 2 1 3 3 0 4 0 3 5 6 7 6 7 8 99 8 99 6 7 4 2 1 8 6 8 6 RLS 100 ...

Page 60: ...20148653 58 GB Appendix Electrical panel layout 0 1 2 1 3 3 0 4 0 3 5 6 7 6 7 8 99 8 99 6 7 4 2 1 6 6 RLS 130 ...

Page 61: ... Q1 Three phase disconnecting switch Q2 Single phase disconnecting switch SM Servomotor S1 ON OFF switch S2 1st 2nd stage switch S3 Oil OFF Gas selector TA Ignition transformer TL Limit thermostat TR Adjustment thermostat TS Safety thermostat U Led panel UV UV sensor VS Safety valve V1 2nd stage valve V2 Valvola 2 stadio VR1 Adjustment valve VR2 Adjustment valve XV1 1st stage valve connector XV2 2...

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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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