Riello RLS 310/EV O2 MX Modulating Operation Download

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Installation, use and maintenance instructions

20182250 (2) - 09/2021

Dual fuel light oil/ gas burners

Modulating operation

CODE

MODEL

TYPE

20182022

RLS 310/EV O2 MX

1161T2

20182023

RLS 410/EV O2 MX

1162T2

20182024

RLS 510/EV O2 MX

1163T2

20182026

RLS 610/EV O2 MX

1164T2

Summary of Contents for RLS 310/EV O2 MX

Page 1: ...instructions 20182250 2 09 2021 Dual fuel light oil gas burners Modulating operation CODE MODEL TYPE 20182022 RLS 310 EV O2 MX 1161T2 20182023 RLS 410 EV O2 MX 1162T2 20182024 RLS 510 EV O2 MX 1163T2 20182026 RLS 610 EV O2 MX 1164T2 GB ...

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

Page 3: ...15 PLL52 module optional 17 4 16 Oxygen sensor QGO20 optional 18 4 17 Calibration of the thermal relay 20 5 Installation 21 5 1 Notes on safety for the installation 21 5 2 Handling 21 5 3 Preliminary checks 21 5 4 Operating position 22 5 5 Preparing the boiler 22 5 6 Securing the burner to the boiler 22 5 7 Access to head internal part 23 5 8 Position of the electrodes and central gas nozzles 23 5...

Page 4: ...oes out during operation 40 6 14 Stopping of the burner 40 6 15 Final checks 40 6 16 Pump motor lock out 40 6 17 Description of O2 trim control optional 41 7 Maintenance 42 7 1 Notes on safety for the maintenance 42 7 2 Maintenance programme 42 7 3 Opening the burner 45 7 4 Closing the burner 45 8 Faults Possible causes Solutions 46 A Appendix Accessories 47 B Appendix Electrical panel layout 48 ...

Page 5: ...e products are marked as follows RLS 310 EV O2 MX Classe 2 EN 267 Classe 3 EN 676 RLS 410 EV O2 MX Classe 2 EN 267 Classe 3 EN 676 RLS 510 EV O2 MX Classe 2 EN 267 Classe 3 EN 676 RLS 610 EV O2 MX Classe 2 EN 267 Classe 3 EN 676 The quality is guaranteed by a quality and management system certified in accordance with ISO 9001 2015 Legnago 03 05 2021 Research Development Director RIELLO S p A Burne...

Page 6: ...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 CRU...

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 incor rectly applied a...

Page 8: ...ce 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 underta...

Page 9: ...L Long head Emission C11 o C22 o MZ C33 BLU C23 MX Class 1 EN 267 EN676 Class 2 EN 267 EN676 Class 3 EN 267 EN676 Class 2 EN 267 Class 3 EN676 Adjustment E Electronic cam EV Electronic cam and variable speed with Inverter M Mechanical cam P Proportional air gas valve E O2 Electronic cam and suitable for Oxygen Control O2 EV O2 Electronic cam and variable speed with Inverter and suitable for Oxygen...

Page 10: ... 660 1800 5170 56 195 435 1000 2200 6155 110 185 516 Fuels Natural gas G20 methane gas G25 Light oil max viscosity at 20 C 6 mm2 s 1 5 E 6 cSt Gas pressure at max output 2 Gas G20 G25 mbar 31 8 47 4 47 3 70 6 47 8 71 3 68 2 101 8 Operation FS1 Intermittent min 1 stop in 24 hours FS2 Continuous min 1 stop in 72 hours The burner leaves the factory set for the intermittent operation Pump Minimum outp...

Page 11: ...re indicated by the L and R positions The l position is reference for the refractory thickness of the boiler door Tab F Model kg RLS 310 EV O2 MX 300 RLS 410 EV O2 MX 300 RLS 510 EV O2 MX 300 RLS 610 EV O2 MX 320 Fig 1 20086678 WARNING The gas adaptor is set also for DN 80 bore Fig 2 20086680 mm A B C D E F G H I L M N O R RLS 310 1270 507 176 313 520 DN65 500 790 373 1178 596 528 290 970 RLS 410 ...

Page 12: ...013 mbar approx 0 m a s l and with the combustion head adjusted as shown on page 24 WARNING Pre calibration of the combustion head only for the burner model RLS 310 M MX If the maximum burner output of the burner falls within area A of the firing rate it is necessary to replace the gas nozzles with those supplied No 8 gas nozzles Ø 5 3 Fig 17 on page 23 area B of the firing rate no modifications a...

Page 13: ... 676 regulations In Fig 4 you can see the diameter and length of the test combus tion chamber Example Output 3000 kW diameter 100 cm length 3 5 m 4 10 Burner equipment Gasket for gas train adaptor No 1 Adaptor for gas train No 1 Screws for fixing the gas train adaptor M 16 x 70 No 4 Thermal insulation screen No 1 M 18 x 60 screws to secure the burner flange to the boiler No 4 Flexible hoses No 2 H...

Page 14: ...re test point 21 Valve group 22 Hinge for opening the burner 23 Pressure test point for air pressure switch 24 Combustion head air pressure test point 25 Gas train adapter 26 Indication for checking the rotation direction of the purging motor 27 Flame inspection window 28 Flame sensor 29 Motor revolution sensor 30 Transparent protection 31 Pump 32 Pump motor 33 Minimum oil pressure switch 34 Maxim...

Page 15: ...ockout and reset button 16 OVERLOAD FAN MOTOR light signalling 17 Electronic cam transformer 18 Relay with clean contacts for signalling the burner is in oper ation 19 Thermal relay of pump motor with RESET button 20 Pump motor contactor 21 Sheath for pump motor cables 22 Change of fuel selector 23 Sheath for motor revolution sensor 24 Flame sensor 25 Fuel servomotor 26 Sheath for maximum gas pres...

Page 16: ...grammed the person making the plant settings must continu ously monitor the quality of the combustion process e g by means of a flue gas analyser Also if combustion levels are poor or in the event of danger ous situations the commissioning engineer must take appropriate action e g switching off manually To ensure the safety and reliability of the LMV5 system the fol lowing instructions must also b...

Page 17: ...l voltage Nominal current Power factor 2A cos 0 4 Air pressure switch test valve nominal voltage Nominal current Power factor 0 5A cos 0 4 Load on output terminals Total load on the contacts Mains voltage Total unit input current safety circuit load on contacts due to Fan motor contactor Ignition transformer Valve Oil pump magnetic clutch AC 230 V 15 10 Max 5 A Single contact loading Fan motor con...

Page 18: ... electrical supply of the actuator is switched off The housing cover may only be removed for short periods of time for wiring or when making the addressing In similar cas es make sure that dust or dirt does not penetrate inside the actuator The actuator comprises a PCB with ESD sensitive compo nents The top side of the board carries a cover which affords pro tection against direct contact This pro...

Page 19: ...le lengths 10 m fino a QGO20 Cross sectional areas Refer to description of QGO20 Analog inputs Air temperature detector Pt1000 LG Ni1000 Flue gas temperature Pt1000 LG Ni1000 QGO20 Refer to data sheet N7842 Interface Communication bus for LMV52 Model PLL52 Mains voltage X89 01 AC 230 V 15 10 Safety class I class with parts according to II class DIN EN 60730 1 Mains frequency 50 60 Hz 6 Power consu...

Page 20: ...aning the inlet and outlet allow the sensor to cool down for at least 1 hour Mount the sensor such that the connecting part head to flange is free so that the exchange of air is ensured Other wise measurements might get distorted possibly leading to dangerous situations Ensure that there are no chemicals such as solvent vapors near the sensor Installation notes The flue gas flow passing the measur...

Page 21: ...ue gas velocity only with AGO20 1 10 m s Fuel type Fuel oil EL or Natural gas H Measuring range 0 2 20 9 O2 Permissible cable length Max 100 m Wire diameter 10 m Power supply lines Net cable Cable diameter Cable type Min 1 mm QGO20 000D27 e g NYM 3 x 1 5 QGO20 000D17 UL AWM Style 1015 MTW or CSA AWM TEW Required operating temperature of measuring cell 700 C 50 C Environmental conditions Storage Cl...

Page 22: ...e table in the wiring diagram To reset in case of an intervention of the thermal relay press the RESET button 1 Fig 11 The red TEST button 3 opens the NC 95 96 contact and stops the motor CAUTION The automatic reset Position A button 1 can be dangerous This operation is not anticipated in the burner s operation leave it always on H There fore do not position the RESET button 1 on A Fig 11 3 1 2 RE...

Page 23: ...ler must be 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 a...

Page 24: ...efractory lining 2 5 Fig 15 is not necessary unless expressly requested by the boiler manufacturer Tab L 5 6 Securing the burner to the boiler Fit the heat insulation supplied onto the blast tube 4 Fig 15 Fit the entire burner onto the boiler hole prepared previously Fig 14 and fasten with the screws supplied WARNING The burner is designed to operate only in positions 1 2 3 and 4 Fig 13 Installati...

Page 25: ...th pressure test point F release the head by lifting it from its housing 3 then take out the combustion head 5 8 Position of the electrodes and central gas nozzles WARNING To open the burner from the opposite side before removing the pin 1 Fig 16 make sure that the 4 screws 2 are tight Then shift the pin 1 to the op posite side only then is it possible to remove the screws 2 Disconnect the socket ...

Page 26: ...e burner carry out the adjustments for the out put required and which is indicated in the diagram Fig 18 NOTE Depending on the specific application the adjustment can be modified WARNING The burner leaves the factory with the combustion head adjusted to notch 0 Fig 20 This adjustment allows you to secure the moving parts when the burner is being transported WARNING The combustion head can be adjus...

Page 27: ...every year during regular maintenance operations CAUTION The use of nozzles other than those specified by the Manufacturer 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 ob jects The manufacturing company shall not be lia ble for any such damage...

Page 28: ...onsists 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 feeds 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 table 5 12 3 Hydraulic connection...

Page 29: ... output The pressure on the return line is adjusted by varying a section by means of the rotation of the servomotor 10 Fig 5 on page 12 which also controls the gas butterfly valve at the same time Regulator at 0 maximum opening minimum pressure on the nozzle return line Regulator at 90 minimum opening maximum pressure on the nozzle return line The servomotor is controlled by the electronic cam 1 F...

Page 30: ...le return line 15 Pressure switch on pump delivery line B Oil valve group and pressure variator M Pressure gauges V Vacuometer connection OPERATION Pre purging phase valves 5 6 13 and 14 closed Ignition and operation phase valves 5 6 13 and 14 open Stop All valves closed Fig 25 20086806 WARNING The a m operation is possible because the pump is already full of fuel when it leaves the factory If the...

Page 31: ... 1200 kW 9 Gasket for flanged versions only 10 Pressure adjuster 11 Train Burner adaptor supplied separately P2 Upstream pressure of valves adjuster P3 Upstream pressure of the filter L Gas train supplied separately L1 The responsibility of the installer Explosion danger due to fuel leaks in the pres ence of a flammable source Precautions avoid knocking attrition sparks and heat Make sure the fuel...

Page 32: ...in installation DANGER Disconnect the electrical power using the main switch Check that there are no gas leaks Pay attention when handling the train danger of crushing of limbs Make sure that the gas train is properly installed by checking for any fuel leaks The operator must use the required equipment during installation Fig 30 20086798 ...

Page 33: ...pera tion find the nearest output value in the table Tab O for the burner in question Read on the right column 1 the pressure at the test point P1 Fig 30 on page 30 Add this value to the estimated pressure in the combustion chamber Example RLS 310 EV O2 MX with natural gas G20 Required burner maximum output operation 3000 kW Gas pressure at an output of 2800 kW 19 3 mbar Pressure in combustion cha...

Page 34: ...n safety and efficiency at start up Normally burner stopping is guaranteed by the boiler s thermostat pressure switch If this is not the case a time switch should be fitted in series to TL to stop the FS2 burner at least once every 72 hours Refer to the wir ing diagrams The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system made accordin...

Page 35: ...Bore for M20 4 VPS gas valve leak detection control kit Bore for M20 5 Gas train Bore for M20 6 Available Bore for M20 7 Available Bore for M16 8 Available Bore for M32 A Motor revolution sensor B Maximum gas pressure switch C Power supply servomotor D Servomotors return E Flame sensor F Oil valves G Pump motor H Minimum oil pressure switch I Maximum oil pressure switch After carrying out maintena...

Page 36: ...rt the op erating cycle of the control box At first ignition there is a momentary drop in fuel pressure due to the filling of the nozzle piping This lowering of the fuel pressure can cause the burner to lockout and can sometimes give rise to pulsations Once the following adjustments have been made the ignition of the burner must generate a noise similar to the noise generated during operation 6 3 ...

Page 37: ...indicate that no volt age is present If voltage is present stop the burner immediately and check the electrical connections When the limit thermostat TL closes the burner begins the starting cycle 6 6 Burner ignition The burner should light after having performed the above steps If the motor starts but the flame does not appear and the control box goes into lockout reset and wait for a new ignitio...

Page 38: ...t in sequence 1 Output upon ignition 2 MAX output 3 MIN output 4 Intermediate outputs between Min and Max 5 Air pressure switch 6 Maximum gas pressure switch 7 Minimum gas pressure switch 6 8 4 Output upon ignition Ignition must occur at a lower output than the max operation out put Regulations provide that the ignition output of this burner must be equal to or less than 1 3 of the MAX operation o...

Page 39: ...rrow pointing upwards on the gradu ated scale Turn the knob clockwise again until the value shown on the graduated scale corresponds with the arrow pointing downwards and so recovering the hysteresis of the pressure switch shown by the white mark on a blue background between the two arrows Now check the correct start up of the burner If the burner locks out again turn the knob anti clockwise a lit...

Page 40: ... gas pressure Adjust the minimum gas pressure switch Fig 36 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 decrease in t...

Page 41: ... pressure in the return line goes over 3 bar the burner locks out if during the flame the oil pressure in the return line goes over 3 bar the burner goes into lockout 6 11 Operation Once the start up cycle is completed the servomotor command moves on to the thermostat pressure switch that controls the pressure or the temperature in the boiler If the temperature or the pressure is low the burner pr...

Page 42: ... WARNING In the event the burner stops in order to prevent any damage to the installation do not unblock the burner more than twice in a row If the burner locks out for a third time contact the customer service DANGER In the event there are further lockouts or faults with the burner the maintenance interventions must only be carried out by qualified authorised personnel in accordance with the cont...

Page 43: ...e amount of air is reached by reducing the air rate of the air regulating actuators For that purpose the damper positions of these actuators are cal culated from some other load point on the ratio control curves Hence due to the parameterized ratio control curves the air reg ulating actuators are in a fixed relation to one another O2 trim control is supported by precontrol It calculates the air ra...

Page 44: ...ator that turn on at the same time as their power supply 7 2 3 Checking and cleaning Combustion The optimum calibration of the burner requires an analysis of the flue gases Significant differences with respect to the previous measure ments 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 h...

Page 45: ... 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 measure per mits the cause of the anomaly to be traced to either the suction piping or the pump If the problem lies in the suction line check the filter is clean and that air is not entering the piping Nozzles It is advisable to replace noz...

Page 46: ...lter Change the gas filter when it is dirty 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 the Technical As sistance Service in order to carry out the necessary adjustments 7 2 6 Checking the air and gas pressure on the combustion head To carry out this operat...

Page 47: ...ner 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 After carrying out maintenance cleaning or checking operations reassemble the cover and all the safety and protection devices of the burner ...

Page 48: ...out 8 Faults Possible causes Solutions WARNING In the event the burner stops in order to prevent any damage to the installation do not unblock the burner more than twice in a row If the burner locks out for a third time contact the customer service DANGER In the event there are further lockouts or faults with the burner the maintenance interventions must only be carried out by qualified authorised...

Page 49: ...3 RLS 510 EV O2 MX 400V 12 15 20163096 RLS 610 EV O2 MX 400V 15 15 20163096 WARNING The use of inverters other than those indicated by the manufacturer may lead to burner failure and in extreme cases a potential risk of harm to people and damage to property The manufacturing company shall not be liable for any such damage arising from non observance of the requirements contained in this manual Bur...

Page 50: ...ayout LMV 52 7 Functional layout LMV 52 8 Functional layout LMV 52 9 Functional layout LMV 52 10 Functional layout LMV 52 11 Functional layout LMV 52 12 Functional layout LMV 52 13 Electrical wiring that is the responsibility of the installer 14 Electrical wiring that is the responsibility of the installer 15 Electrical wiring that is the responsibility of the installer 1 2 Sheet no 1 A1 Co ordina...

Page 51: ...49 20182250 GB Appendix Electrical panel layout 0 1 2 0 1 2 0 0 1 2 3 0 4 556 4 7 3 3 3 3 4 4 8 0 4 556 0 4 556 4 9 0 5 A ...

Page 52: ...20182250 50 GB Appendix Electrical panel layout 0 0 0 0 0 0 0 0 ...

Page 53: ...51 20182250 GB Appendix Electrical panel layout 0 1 1 2 1 2 3 1 4 1 2 1 2 2 1 1 1 1 1 51 5 5 1 1 2 3 1 2 ...

Page 54: ...20182250 52 GB Appendix Electrical panel layout 0 0 0 1 0 0 1 2 3 2 3 4 2 4 5 2 6 2 4 2 4 4 2 2 2 32 3 2 72 7 7 3 2 2 4 5 2 4 ...

Page 55: ...53 20182250 GB Appendix Electrical panel layout 0 ...

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Page 57: ...55 20182250 GB Appendix Electrical panel layout 0 0 1 2 0 0 0 1 0 ...

Page 58: ...20182250 56 GB Appendix Electrical panel layout 0 0 0 1 0 2 0 0 0 0 0 0 0 30 3 3 0 0 1 0 ...

Page 59: ...57 20182250 GB Appendix Electrical panel layout 0 1 0 1 0 2 0 3 0 0 0 0 0 10 1 0 40 4 4 1 0 0 2 0 5 ...

Page 60: ...20182250 58 GB Appendix Electrical panel layout 01 2 2 2 2 2 3 3 3 4 3 5 3 3 3 3 3 3 3 3 3 3 4 3 01 01 0 0 0 ...

Page 61: ...59 20182250 GB Appendix Electrical panel layout 01 2 2 2 2 2 3 3 3 4 3 5 3 3 3 3 3 3 3 3 3 3 4 3 01 01 01 ...

Page 62: ...l panel layout 001 2 3 4 5 0016 7389 5 001 60 7 5 001 60 738 4 5 0016 7389 001 001 60 7 001 60 738 001 2 3 4 5 0016 7389 4 5 0016 7389 001 60 7 001 60 738 001 001 60 7 001 60 738 001 5 5 5 5 5 5 2 A B 9 C D E 0 0 E 0 0 E 0 ਅ 0 E 0 A 0 ...

Page 63: ...61 20182250 GB Appendix Electrical panel layout 0 1 0 0 2 3 0 2 4 4 3 5 5 6 5 6 7 5 5 6 5 6 6 5 5 5 5 5 15 1 1 5 5 6 7 5 6 8 ...

Page 64: ...20182250 62 GB Appendix Electrical panel layout ৼ 0 1 1 1 1 1 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 0 2 3 ...

Page 65: ... FAN MOTOR PUMP MOTOR K1 Clean contacts output relay burner switched on K2 Clean contacts output relay burner lockout K3 Clean contacts output relay inverter lockout K4 Clean contacts output relay OIL operation KMP Pump motor contactor MP Pump motor MV Fan motor PA Air pressure switch PE Earth burner PGMax Max gas pressure switch PGMin Min gas pressure switch PGVP Gas pressure switch for leak dete...

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Page 68: ...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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