Riello RLS 28 Installation, Use And Maintenance Instructions Download

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Installation, use and maintenance instructions

20165123 (1) - 07/2019

Dual fuel light oil/gas burners

Two stage operation

CODE

MODEL

TYPE

20159362

RLS 28

684 T80

20159364

RLS 50

686 T80

Summary of Contents for RLS 28

Page 1: ...Installation use and maintenance instructions 20165123 1 07 2019 Dual fuel light oil gas burners Two stage operation CODE MODEL TYPE 20159362 RLS 28 684 T80 20159364 RLS 50 686 T80 GB ...

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

Page 3: ...allation 16 5 2 Handling 16 5 3 Preliminary checks 16 5 4 Operating position 17 5 5 Preparing the boiler 17 5 6 Access to head internal part 18 5 7 Electrode positions 18 5 8 Nozzle installation 19 5 9 Combustion head adjustment 20 5 10 Light oil supply 21 5 11 Pump 23 5 12 Gas supply 24 5 13 Electrical connections 27 5 14 Calibration of the thermal relay 29 5 15 Motor rotation 29 6 Start up calib...

Page 4: ... Closing the burner 40 8 LED indicator and special function 41 8 1 Description of LED lamps 41 8 2 Check mode function 41 8 3 Flame control lock out or emergency stop condition 41 8 4 LED lamps burner operating status 42 9 Problems Causes Remedies signalled by LED indicators 43 A Appendix Accessories 48 B Appendix Electrical panel layout 49 ...

Page 5: ...ance with the following Technical Standards EN 676 EN 267 EN 12100 and according to the European Directives MD 2006 42 CE Machine Directive LVD 2014 35 EU Low Voltage Directive EMC 2014 30 EU Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Legnago 21 04 2018 General Manager RIELLO S p A Burners Department Researc...

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: ...6 C22 or MZ Class 2 EN267 EN676 C33 or BLU Class 3 EN267 EN676 3 400 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 Proportional air gas valve BP Two stage light oil Proportional valve gas M Mechanical cam S L LS N Head TC Standard head TL Extended head C23 or MX ...

Page 10: ...ls Light oil max viscosity at 20 C 6 mm2 s 1 5 E 6 cSt Natural gas G20 methane G21 G22 G23 G25 LPG G30 propane G31 butane Gas pressure at max output 2 Gas G20 G25 G31 mbar 11 16 2 9 5 14 20 8 10 5 Operation Intermittent min 1 stop in 24 hours Two stage high and low flame and one stage all nothing Pump Output at 12 bar Pressure range Fuel temperature kg h bar c max 67 4 18 60 Nozzles number 2 Stand...

Page 11: ... flange No 1 Flange fixing screws M 8 x 25 No 4 Thermal flange gasket No 1 Screws to fix the burner flange to the boiler M 8 x 25 No 4 Cable grommets for electrical connection RLS 28 single phase No 5 Cable grommets for electrical wiring RLS 50 three phase No 6 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 ...

Page 12: ...n page 18 The MINIMUM OUTPUT must not be lower than the minimum limit of the diagram RLS 28 100 kW 8 5 kg h RLS 50 145 KW 12 3 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 20 Pressure in the combustion chamber mbar Fig 2 RLS 28 Pres...

Page 13: ... must be combined with a boiler that has not been EC approved and or its combustion chamber dimensions are clearly smaller than those indicated in the diagram consult the manufacturer The firing rates were set in relation to special test boilers according to EN 676 and EN 267 regulations In Fig 3 you can see the diameter and length of the test combustion chamber Example Output 350 Mcal h 407 kW di...

Page 14: ...valve 12 1st and 2nd stage valves 13 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 14 OIL GAS switch 15 Plate prearranged for 4 holes for the passage of hoses and electrical cables 16 Air inlet to fan 17 Gas input pipe 18 Boiler fixing flange 19 Flame s...

Page 15: ...otor capacitor RLS 28 4 Flame sensor 5 LED panel 6 Control box base 7 4 pole socket 8 5 pole socket 9 6 pole socket 10 7 pole socket 11 Ignition transformer Burner lockout may occur CONTROL BOX LOCKOUT if the control box 21 Fig 4 push button lights up it indicates that the burner is in lockout Press the push button to reset Fig 5 4 6 5 1 10 7 9 3 11 2 4 5 1 10 7 8 6 11 20166771 ...

Page 16: ...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 17: ... 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 18: ...n 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...

Page 19: ...ler 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 4 remove screw 14 and extract the cover 15 remove screws 2 from the two slide bars 3 remove screw 1 and pull the burner back on slide bars 3 by about 100 mm Disconnect the wires of the electrodes and then pull the burner c...

Page 20: ...e the fixing point of 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 17 to the boiler plate interposing the insulating gasket 6 Fig 11 on page 17 supplied Use the 4 screws supplied with the unit after protecting the thread with...

Page 21: ...ks together with the 1st nozzle to determine the delivery of the burner in the 2nd stage The deliveries of the 1st and 2nd stages have to be within the value range indicated 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 mainten...

Page 22: ...n 2nd stage 40 kg h The diagram Fig 19 shows that for this output the adjustment of the combustion head is carried out on the notch 4 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 23: ... 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 Manual on off valve 5 Suction line 6 Foot valve...

Page 24: ...rews 1 divide the insert piece into its two parts 2 and 3 and remove the thin diaphragm blocking the two passages 4 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 c...

Page 25: ...e pump see Fig 23 must be loosened in order to bleed off the air contained in the suction line Pump SUNTEC AN 65 B Min delivery rate at 12 bar pressure 67 kg h Delivery pressure range 4 18 bar Max suction depression 0 45 bar Viscosity range 2 12 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 ATTENTION B...

Page 26: ...ts 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 fu...

Page 27: ...h combustion chamber at 0 mbar Burner operating in 2nd stage Gas G20 methane G31 propane To calculate the approximate output at which the burner operates in the 2nd stage subtract the combustion chamber pressure from the gas pressure measured at test point 1 Fig 29 Find in Tab K related to the burner concerned the pressure value closest to the result of the subtraction Read the corresponding outpu...

Page 28: ...o 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 table Tab K 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 28 with natural gas G20 Desired output in 2nd stag...

Page 29: ...s 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 24 hours Refer to the wiring diagrams The electrical safety of the device is obtained only when it is correctly connected to an effici...

Page 30: ...ne in different manners for example as follows Fig 30 Key Fig 30 RLS 28 1 Pg 11 single phase power supply 2 Pg 11 gas valves 3 Pg 9 TL remote control 4 Pg 9 TR remote control 5 Pg 11 gas pressure switch or valve leak detection control device RLS 50 1 Pg 11 three phase power supply 2 Pg 11 single phase power supply 3 Pg 9 TL remote control 4 Pg 9 TR remote control 5 Pg 11 gas valves 6 Pg 11 gas pre...

Page 31: ...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 control box carries out the switching off phase Invert the phases on the three phase motor...

Page 32: ...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 primed when the light oil starts coming out of the screw 3 Fig 23 on page 23 Stop the burner set switch 1 Fig 33 to OFF and tighten the screw 3 The time required for this operat...

Page 33: ...ce of voltage stop the burner immediately and check the electric connections 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 time per...

Page 34: ...er 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 ts 3s ignition output must be equal to or lower than 1 3 of max ope...

Page 35: ... adjusts 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 valv...

Page 36: ...al mode 6 9 2 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 scale Fig 40 With the burner operating at maximum output increase the pressure With the burner operating in 2nd stage increase the adjustment pressure by slowly turning the relative knob clockwise until the burner stops ...

Page 37: ...g 41 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 discharge ends 66 s with ...

Page 38: ...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 flame detection sensor from the power supply The burner must stop in lockout due to ignition failure ATTENTION Make sure that the mecha...

Page 39: ...n 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 maintenance Combustion head Open the burner and make sure that all components of the combustion head are in good condition not...

Page 40: ...h operating status signalling LED will be compared to 20 of the maximum brightness press the reset button again 0 5sec to reset the standard operation of the signalling LEDs 7 2 4 Safety components The 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...

Page 41: ... 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 adjustments Tab O Gas leaks Make sure that there are no gas leaks on the pipe between the gas meter and the burner Gas filter Change the gas filter when it is dirty Combust...

Page 42: ...oved the screw 8 Fig 45 7 4 Closing the burner Remove the split pin 9 and push the burner until it is approx 100 mm from the pipe coupling Reconnect the cables and slide in the burner until it comes to a stop Replace the screws 5 and split pin 9 and carefully pull the cables outwards until they are slightly taut Reconnect the light oil pipes DANGER Disconnect the electrical supply from the burner ...

Page 43: ...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 44: ...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 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: ...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 47: ... Red 52 Piloted valve feedback fault Red 53 Actuator feedback waiting time expired Red 54 Direct ignition valve feedback fault Red 55 Internal processor fault Red 56 UV false flame during operation Red 57 FR false flame during operation Red 58 T8 inlet fault Red 59 Internal hardware fault Red 60 Local reset fault Red 61 Open POC fault Red 62 UV strong UV flame fault Red 63 Internal hardware fault ...

Page 48: ...ult Internal fault Replace the control device 16 No flame 1st safety time PTFI No flame at the end of the first safety time Inspect the system check the gas pressure check the UV scanner check the wiring etc 17 Wiring fault The system detected the presence of voltage on critical terminals T16 T17 T18 or T19 at the wrong moment or there is no voltage when necessary Inspect the wiring and make sure ...

Page 49: ...m detected the presence of voltage on T17 at the wrong moment or there is no voltage when necessary Check the wiring and make sure that the earthing is appropriate If the problem persists contact the distributor factory 52 Piloted valve feedback fault The system detected the presence of voltage on T19 at the wrong moment or there is no voltage when necessary Check the wiring and make sure that the...

Page 50: ...iance with EN 676 Please refer to manual A Appendix Accessories Burner L mm Standard head L mm Head obtainable with the kit Code RLS 28 191 326 20097840 RLS 50 216 351 20097869 Burner Type dB A Code All models C1 3 10 3010403 Burner Filter Code All models with filter 3010055 All models without filter 3010054 Burner Code All models 3010304 Burner Code All models 3010493 Burner Code All models 30103...

Page 51: ...ctional layout RFGO A22 RLS 50 4 Functional layout RFGO A22 5 Functional layout RFGO A22 RLS 28 Functional layout RFGO A22 RLS 50 6 Electrical wiring to be carried out by the installer RLS 28 Electrical wiring to be carried out by the installer RLS 50 7 Electrical wiring to be carried out by the installer RLS 50 1 2 Sheet no 1 A1 Coordinates Indication of references ...

Page 52: ...23 50 GB Appendix Electrical panel layout 0 1 2 3 1 4 5677 8 7 4 5 9 4 64 7 5 4 5 7 4 6 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 RLS 28 ...

Page 53: ...51 20165123 GB Appendix Electrical panel layout 0 1 223 1 223 4 5 0 4 6 6 7 89 542 7 8 7 45 97 8 7 84 7 5 9 A B A RLS 50 ...

Page 54: ...20165123 52 GB Appendix Electrical panel layout 0 1 1 1 ...

Page 55: ...53 20165123 GB Appendix Electrical panel layout 0 1 1 1 2 1 3 1 1 1 1 1 1 1 41 4 4 1 1 2 1 5 5 RLS 28 ...

Page 56: ...20165123 54 GB Appendix Electrical panel layout 0 1 1 1 2 1 3 1 1 1 1 1 1 1 41 4 4 1 1 2 1 5 5 RLS 50 ...

Page 57: ...165123 GB Appendix Electrical panel layout 0 0 1 2 1 3 1 1 1 4 56 56 4 7 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 8 9 9 9 9 9 9 9 8 9 9 9 RLS 28 ...

Page 58: ...20165123 56 GB Appendix Electrical panel layout 0 1 0 2 2 3 4 5 6 4 5 6 5 2 7 3 4 3 3 3 8 8 8 8 9 9 1 9 9 0 9 9 9 9 9 9 9 9 9 9 9 5 5 8 RLS 50 ...

Page 59: ...57 20165123 GB Appendix Electrical panel layout 0 0 1 2 2 2 1 2 2 2 1 2 2 3 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 2 3 2 2 2 1 2 2 2 RLS 50 ...

Page 60: ...onnecting switch Q2 Single phase line disconnecting switch SM Servomotor S1 ON OFF switch S2 1st 2nd switch S3 Oil OFF GAS switch TA Ignition transformer TL Limit thermostat TR Setting thermostat ST Safety thermostat U LED panel UV UV cell RS Reset button VS Safety valve V1 1st stage valve V2 2nd stage valve VR1 Adjustment valve VR2 Adjustment valve XV1 1st stage valve connector XV2 2nd stage valv...

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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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