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20109674 (3) - 02/2022

Installation, use and maintenance instructions

Light oil burner

Modulating operation

CODE

MODEL

20074606

RL 190/E

Содержание RL 130/E

Страница 1: ...20109674 3 02 2022 Installation use and maintenance instructions Light oil burner Modulating operation CODE MODEL 20074606 RL 190 E GB ...

Страница 2: ...Original instructions ...

Страница 3: ...3 5 14 4 Installation 15 4 1 Notes on safety for the installation 15 4 2 Handling 15 4 3 Preliminary checks 15 4 4 Operation position 15 4 5 Burner raising 16 4 6 Preparing the boiler 16 4 6 1 Commercial boilers 16 4 6 2 Boring the boiler plate 16 4 6 3 Length of the blast tube 17 4 7 Securing the burner to the boiler 17 4 8 Electrode adjustment 17 4 9 Nozzle 18 4 9 1 Recommended nozzles 18 4 9 2 ...

Страница 4: ...Final calibration of the pressure switch 29 5 4 1 Air pressure switch 29 5 4 2 Maximum oil pressure switch 29 5 5 Flame signal measurement 30 5 6 Final checks with the burner working 30 6 Maintenance 31 6 1 Notes on safety for the maintenance 31 6 2 Maintenance programme 31 6 2 1 Maintenance frequency 31 6 2 2 Checking and cleaning 31 6 2 3 Fuel pump and or couplings replacement 32 6 2 4 Safety co...

Страница 5: ...car 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 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 ...

Страница 6: ... of damage to things or injury to peo ple 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 and or...

Страница 7: ...ance 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 ma chine and intends to use it for the specific purpose He is responsi ble 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 under...

Страница 8: ...utput 1 Delivery 1 High MBtu hr 2 GPH 5376 9184 38 4 65 6 Low MBtu hr 2 GPH 1792 5376 12 8 38 4 Fuel 2 Fuel oil Operation Low high or modulating Nozzle number 1 return flow nozzle Standard applications Boilers water steam thermal oil Ambient temperature F 32 104 0 40 C Combustion air temperature F max 140 60 C Pump TA2 delivery at 290 PSI pressure range fuel temperature GPH PSI F max 146 101 5 580...

Страница 9: ... the combustion head requires the burner to be opened and the rear part withdrawn on the slide bars The maximum dimension of the burner when open without casing is given in measurement I Tab E 1 Blast tube short long obtainable with kit 3 6 Standard equipment The burner is supplied complete with Seals No 1 Adaptor G 1 4 1 4 NPT No 1 Instruction booklet and spare parts list No 1 inch A B C lbs RL 1...

Страница 10: ...d 3 8 Minimum furnace dimensions The firing rates were set in relation to certified test boilers Fig 4 indicates the diameter and length of the test combustion chamber Example Output 2579 MBtu hr diameter 24 inch length 6 6 ft WARNING The firing rate area values have been obtained con sidering an ambient temperature of 68 F and an atmospheric pressure of 394 WC and with the combustion head adjuste...

Страница 11: ...an pressure test point 10 Boiler mounting flange 11 Flame stability disk 12 Servomotor provides adjustment of fuel delivery regulator 13 Slide bars for opening the burner and inspecting the combus tion head 14 HT lead 15 High oil pressure switch 16 Fan air inlet 17 Servomotor controlling the air damper 18 Valve assembly with pressure regulator on nozzle return 19 Pressure gauge for pressure on noz...

Страница 12: ...es for cables grommets for electrical wirings accessories and power supply to be carried out by the installer 20 LOCAL REMOTE switch 21 POWER ON signal 22 CALL FOR HEAT signal 23 ALARM signal 24 IGNITION ON signal 25 FUEL ON signal 26 Auxiliary fuse 27 Din bar available for accessories 28 Din bar for fuse holder step down transformer and OCI 412 10 available Two types of burner failure may occur F...

Страница 13: ...f the air and fuel circuits via which it is possible to easily identify any causes of malfunctioning Mechanical design The following system components are integrated in the LMV37 4 basic unit Electronic air fuel ratio control Control frequency converter air fan Modbus interface Installation notes Always run high voltage ignition cables separately while ob serving the greatest possible distance to ...

Страница 14: ...inal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 cos 0 4 Alarm output Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 A cos 0 4 Ignition transformer Nominal voltage Nominal current Power factor AC 120 V 50 60 Hz 1 6 A pilot duty load declaration to UL372 or 250 VA ignition load declaration to UL372 cos 0 2 Fuel valves Nominal v...

Страница 15: ...Z ON BV ON Z OFF Interval 1 t44 Operation 1 stationary Operation 2 LK K POS Combine Postburn time t13 Safety phase Standby stationary M ON SV IN LK BV POS Postpurge time t8 LK N POS Lockout phase Homerun Prepurge OUTPUTS INPUTS Phase number Fuel Actuator 2 Air Actuator 1 Actuators Parameter number Parameter number Safety limit thermostat STB Control thermostat or pressurestat R Flame signal FS Air...

Страница 16: ... be seen on the display of the Operator Panel Index 0 for fuel actuator index 1 for air actuator Installation notes Always run the high voltage ignition cables separate from the unit and other cables while observing the greatest possible dis tance The holding torque is reduced when the actuator is disconnect ed from power Technical data Tab G WARNING To avoid injury to persons damage to proper ty ...

Страница 17: ...n force WARNING The handling operations for the burner can be highly dangerous if not carried out with the greatest atten tion keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also that the area in which you are working is empty and that there is an adequate escape area i e a free safe area to which you can quickly move if the...

Страница 18: ...e boiler door complete with its refractory This protection must not compromise the extraction of the blast tube For boilers having a water cooled front the refractory fettling is not required unless it is expressly requested by the boiler manufactur er The maximum thickness of the boiler s front door must not ex ceed 16 Fig 12 4 6 2 Boring the boiler plate Drill the combustion chamber mounting pla...

Страница 19: ... front the insulation 10 11 Fig 14 is not required unless it is required by the boiler man ufacturer 4 7 Securing the burner to the boiler Disassemble the blast tube 9 from the burner 6 by proceeding as follows Fig 14 loosen the four screws 3 and remove the cover 1 Remove the screws 2 from the two slide bars 5 Remove the two screws 4 fixing the burner 6 to the flange 7 Withdraw the blast tube 9 co...

Страница 20: ...ed to the boiler proceed as outlined below pull back the burner on its slide bars as shown in Fig 14 at page 17 Remove the nuts 1 Fig 17 and the disk 2 Use wrench 3 Fig 17 to change the nozzles 4 9 3 Choice of nozzle In case an intermediate delivery between the two values indicated in the diagrams Fig 19 at page 19 is required a nozzle with high er delivery must be chosen Delivery reduction will b...

Страница 21: ...ecrease the eccentricity and consequently the difference between the min and max ca pacity of the nozzle The proper setting of the eccentric 7 is possible when its operation field follows the servomotor operation field 20 130 so that every variation of the servomotor position corre sponds to a pressure variation When the setting is carried out verify manually that no slow down occurs between 0 and...

Страница 22: ...ram Fig 22 indicates that for a delivery of 48 GPH the RL 190 E Model requires the combustion head to be set to approx three notches 4 11 Burner refitting Finally remount the burner 3 Fig 23 on the slide bars 2 and slide it up to the flange 5 keeping it slightly raised to prevent the flame stability disk from pressing against the blast tube Tighten the screws 1 on the slide bars 2 and screws 4 fix...

Страница 23: ...onsists of a loop of piping exiting and returning 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 distance and or height difference are higher than the values listed in the Tab J Tab J Key H Pump foot valve ...

Страница 24: ... are not stretched or twisted during installation Install the hoses where they cannot be stepped on or come into contact with hot surfaces of the boiler Now connect the other end of the hoses to the suction and return lines 4 12 2 Hydraulic system layout Key Fig 26 1 Pump suction 2 Solenoid valve 3 Pump 4 Pressure regulator 5 Return pipe 6 By pas screw 7 Pump return 8 Solenoid valve 9 Solenoid val...

Страница 25: ...TA2 Min delivery rate at 290 PSI pressure GPH 150 Delivery pressure range PSI 102 580 Max suction pressure Hg 13 Viscosity range cSt 4 800 Max light oil temperature F 284 140 C Max suction and return pressure PSI 72 5 Pressure calibration in the factory PSI 360 Fig 27 D1979 WARNING Before starting the burner make sure that the tank return line is not clogged Obstructions in the line could cause th...

Страница 26: ... device is obtained only when it is correctly connected to an efficient earthing system made according to current standards It is necessary to check this fundamental safety requirement In the event of doubt have the electrical system checked by qualified personnel Do not use the gas tubes as an earthing system for electrical devices The electrical system must be suitable for the maximum input powe...

Страница 27: ...d other devices with 1 2 inch cable grommet 3 Available consents safety minimum gas pressure switch gas valves and other devices with 3 8 inch cable grommet 4 Available hole for M16 5 Available for ground terminals A Fan motor B UV sensor C Air servomotor D Fuel servomotor E Air pressure switch F Oil valve G Oil pressure switch WARNING The control panel is in compliance with UL508A After carrying ...

Страница 28: ...is a nominal value To reset in the case of an intervention of the thermal relay press the button RESET Fig 29 The button STOP Fig 29 opens the NC 95 96 contact and stops the motor To test the thermal relay insert a screwdriver in the window TEST Fig 33 and move it in the sense of the arrow towards right 4 15 2 Electronic thermal relay To reset in the case of an intervention of the thermal relay pr...

Страница 29: ...tors manufactured for 208 230 460 IE3 NEMA Premium Efficiency voltage have the same connection than IE2 Epact motors but differ ent connection than IE1 motors no more star delta but star double star D3686 IE1 IE2 Epact IE3 NEMA Premium Efficiency U2 V2 W2 U3 V3 W3 U1 V1 W1 S8379 U2 V2 W2 U3 V3 W3 U1 V1 W1 S8380 460V 208 230V 460V 208 230V Fig 34 WARNING the motors manufactured for 575V IE3 NEMA Pr...

Страница 30: ...ote op eration 5 Start up calibration and operation of the burner WARNING The first start up of the burner must be carried out by qualified personnel as indicated in this manual and in compliance with the standards and regula tions of the laws in force WARNING Check the correct working of the adjustment com mand and safety devices DANGER Make sure that the lamps or testers connected to the solenoi...

Страница 31: ...tive knob clockwise until the burner locks out Then turn the knob counter clockwise about 20 of the set point and start up the burner again to ensure the set point is correct If the burner locks out again turn the knob counter clockwise a little bit more 5 4 2 Maximum oil pressure switch The high oil pressure switch is factory set to 43 5 PSI 3 bar If the oil pressure goes above this value in the ...

Страница 32: ... 954 flashing on the left On the right the flame s intensity is displayed as a percentage Example 954 0 0 5 6 Final checks with the burner working Tab L S8171 P V h min s Fig 41 Open the control limit operation Open the high limit operation The burner must stop Rotate the air pressure switch knob to the maximum end of scale position Rotate the maximum oil pressure switch at the minimum of the scal...

Страница 33: ...ause a reduction in the air flow rate and provoke polluting combustion Flame inspection window Clean the flame inspection window Fig 42 Burner Make sure that the screws securing the electrical leads in the burn er connections are fully tightened Clean the outside of the burner taking special care with the linkag es joints and cam Nozzle Do not clean the nozzle orifices Replace the nozzles every 2 ...

Страница 34: ...he following filters on line 1 in pump 2 at nozzle 3 and clean or replace as required Fig 43 If rust or other impurities are observed inside the pump use a sep arate pump to suck out any water and other impurities that may have deposited on the bottom of the tank Flexible hoses Check to make sure that the flexible hoses are still in good condi tion UV flame sensor In order to reach the UV flame se...

Страница 35: ... 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 present 10 years or 250 000 operation cycles Oil valve solenoid if present 10 years or 250 000 operation cycles Oil regulator if present 10 years or 250 000 operation cycles Oil pipes cou...

Страница 36: ... 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 main system switch DANGER Close the fuel interception tap Wait for the components in contact with heat sourc es to cool down completely 5 4 1 2 3 A 6 7 1 Fig 46 20111946 After carrying out ...

Страница 37: ... 14 15 20 21 22 23 25 28 29 30 31 32 33 34 36 37 8 41 42 44 47 53 57 58 60 63 64 65 66 67 69 71 73 74 76 8 8 8 56 54 50 49 78 79 35 73 6 9 8 10 11 12 5 5 16 35 59 2 2 35 35 16 48 69 39 39 8 10 52 77 17 46 18 27 45 51 55 62 61 70 26 19 82 81 80 4 80 75 72 68 40 24 43 38 ...

Страница 38: ...E COUPLING A 24 3014106 FUSE A 25 3013531 EXHAUST VALVE C 26 20031413 HORN 27 3013940 CONNECTORS ASSEMBLY B 28 3006140 PRESSURE GAUGE 29 3003204 SEAL B 30 3007150 O RING B 31 3003200 NUT 32 3003287 COIL B 33 3012357 BEARING C 34 20086579 FLAME SENSOR 35 3013937 HUB 36 3012976 FAN C 37 3003005 CONNECTOR C 38 20086561 COVER B 39 3014079 SPACER 40 3012012 HALF SHELL 41 3013867 TUBE 42 3013868 TUBE 43...

Страница 39: ...3495 U BOLT 64 3003796 ELECTRODE A 65 3013908 CONNECTION A 66 20111155 NUT 67 3012461 BRACKET 68 20027021 SELECTOR SWITCH A 69 3004821 DRIVE DISK A 70 3020071 BASE 71 3013681 SCREW 72 20027422 SELECTOR SWITCH B 73 20008601 SERVOMOTOR B 74 3012384 OIL PRESSURE SWITCH A 75 20010962 BUTTON C 76 20008598 MOTOR C 77 20027917 OVERLOAD C 78 3012088 CONNECTOR C 79 3013947 TUBE 80 20036017 GREEN SIGNAL LIG...

Страница 40: ...pendix Accessories Flame inversion boiler kit B Appendix Accessories Burner Code RL 190 E 3010241 WARNING The installer is responsible for the supply and instal lation of any safety device s not indicated in this manual ...

Страница 41: ...igh Fire Control Power Supply CO Low Fire High Fire Burner Firing Rate NOX Low Fire High Fire Low Fire Flame Signal Net Stack Temp Low Fire High Fire High Fire Flame Signal Comb Efficiency Low Fire High Fire Low Fire Nozzle Size Overfire Draft High Fire Nozzle Size Smoke number CONTROL SETTINGS Operating Setpoint Low Oil Pressure High Limit Setpoint High Oil Pressure Low Gas Pressure Flame Safegua...

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Страница 44: ...RTH AMERICA 35 Pond Park Road http www riello ca 2165 Meadowpine Blvd Hingham Massachusetts Mississauga Ontario U S A 02043 1 800 4 RIELLO Canada L5N 6H6 RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...

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