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Riello RLS 500/M MX Installation, Use And Maintenance Instructions

Dual fuel light oil/gas burners, progressive two-stage or modulating operation
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Installation, use and maintenance instructions
Dual fuel light oil/gas burners
GB
Progressive two-stage or modulating operation
CODE
MODEL
TYPE
3899602 - 3899612
RLS 500/M MX
1300 T
20009655 (10) - 12/2014

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Summary of Contents for Riello RLS 500/M MX

  • Page 1 Installation, use and maintenance instructions Dual fuel light oil/gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 3899602 - 3899612 RLS 500/M MX 1300 T 20009655 (10) - 12/2014...
  • Page 2 Translation of the original instructions...

  • Page 3: Table Of Contents

    Contents Declarations ................3 Information and general instructions .
  • Page 4 Contents 5.14 Electrical wiring..................27 5.14.1 Supply cables and external connections passage .

  • Page 5: Declarations

    The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001. Manufacturer's Declaration RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BImSchV release 26.01.2010”.

  • Page 6: Information And General Instructions

    Information and general instructions Information and general instructions Information about the instruction manual 2.1.1 Introduction WARNING: MOVING PARTS The instruction manual supplied with the burner: This symbol indicates that you must keep limbs ➤ is an integral and essential part of the product and must not away from moving mechanical parts;...

  • Page 7: Delivery Of The System And The Instruction Manual

    Information and general instructions 2.1.4 Delivery of the system and the instruction ➤ The system supplier must carefully inform the user about: – the use of the system; manual – any further tests that may be required before activating the When the system is delivered, it is important that: system;...

  • Page 8: Safety And Prevention

    Safety and prevention Safety and prevention Introduction The burners have been designed and built in compliance with the type and pressure of the fuel, the voltage and frequency of the current regulations and directives, applying the known technical electrical power supply, the minimum and maximum deliveries for rules of safety and envisaging all the potential danger situations.

  • Page 9: Technical Description Of The Burner

    BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Electrical supply Starting Code RLS 500/M MX 3/400/50 Star/Delta 3899602 - 3899612 Burner categories - Countries of destination Country of destination Gas category SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO...

  • Page 10: Technical Data

    Technical description of the burner Technical data Model RLS 500/M MX Type 1300 T Output 1120/2500 - 5050 MIN - MAX Delivery kg/h 95/211 - 425 LIGHT OIL, viscosity at 20 °C: 6 mm /s (1.5 °E - 6 cSt)

  • Page 11: Overall Dimensions

    Technical description of the burner Model RLS 500/M MX Electrical supply 3N ~ 400 V +/-10% 50 Hz 2880 400/690 Fan motor IE3 21,8/12,6 2870 220-240/380-415 Pump motor 5,9/3,4 V1 - V2 230 V - 2 x 5 kV Ignition transformer...

  • Page 12: Firing Rates

    20 °C, and an atmospheric pressure of 1013 mbar shown in the diagram: (approx. 0 m above sea level) and with the com- WARNING RLS 500/M MX = 1120 kW bustion head adjusted as shown on page 19. D8899 Thermal output - kW Fig.

  • Page 13: Burner Description

    Technical description of the burner Burner description 20 25 30 29 23 D8355 Fig. 4 Lifting eyebolts 26 Maximum oil pressure switch 27 Pressure gauge for pressure on nozzle return Fan motor 28 Nozzle delivery pressure gauge Servomotor 29 Oil modulator Gas pressure test point 30 Pressure gauge attachment Combustion head...

  • Page 14: Description Of Panel Board

    Technical description of the burner 4.10 Description of panel board D8787 10 11 Fig. 5 Terminal strip for kits 18 Auxiliary circuits fuse Relay outlet - clean contacts 19 Servomotor plug/socket Ignition transformer 20 Plug-socket valve /Pump motor Bracket for mounting the power regulator RWF40 21 Fan motor Stop push-button 22 Pump motor contactor and thermal cut-out...

  • Page 15: Control Box (Lfl1.333

    The control box LFL1.333... is a safety device! WARNING Avoid opening or modifying it, or forcing its opera- tion. Riello S.p.A. cannot assume any responsibil- ity for damage resulting from unauthorised interventions! ➤ All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel.

  • Page 16: Servomotor (Sqm10.1

    Technical description of the burner 4.13 Servomotor (SQM10.1..) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying or forcing the actua- WARNING tors. ➤ All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ➤...

  • Page 17: Installation

    Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner will The installation of the burner must be carried out be installed, and arranging the correct lighting of the environ- by qualified personnel, as indicated in this manual ment, proceed with the installation operations.

  • Page 18: Operation Position

    Fig. 11 plete with its fettling. For boilers with front flue passes 1) (Fig. 12) or flame inversion RLS 500/M MX M 18 chambers, protective fettling in refractory material 5) must be in- serted between the boiler fettling 2) and the blast tube 4).

  • Page 19: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler Prepare an adequate system of hoisting by hook- The burner-boiler seal must be airtight. ing onto the rings 3)(Fig. 12). WARNING ➤ Slip the thermal protection (standard equipment) onto the blast tube 4)(Fig. 12). ➤...

  • Page 20: Position Of Electrodes

    267 standard. In order to guarantee that emissions do not vary, zle return line fuel pressure must be adjusted according to the ta- recommended and/or alternative nozzles specified by Riello in ble. the Instruction and warning booklet should be used.

  • Page 21: Combustion Head Setting

    Installation 5.11 Combustion head setting In addition to varying air flow depending on the output requested, Proceed as follows (Fig. 17): the air gate valve servomotor 4) (Fig. 4) by means of a lifting as- ➤ first unscrew nuts 2), remove tie rod 3). sembly - varies the setting of the combustion head.

  • Page 22: Light Oil Supply

    Installation 5.12 Light oil supply 10 = Check valve (only Italy) Explosion danger due to fuel leaks in the pres- ence of a flammable source. 5.12.2 The loop circuit Precautions: avoid knocking, attrition, sparks and heat. 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 Make sure the fuel interception tap is closed be- under pressure.

  • Page 23: Pressure Regulator

    Installation 5.12.4 Pressure regulator Calibration pressure on return line With a servomotor position of 20°, the nut and the corresponding lock nut 6)(Fig. 20), are fixed in contact with the eccentric 8). During the rotation towards 130° of the servomotor, the eccentric will push the modulator shaft, taking the pressure, read on the pressure gauge 3)(Fig.

  • Page 24: Hydraulic System Layout

    Installation 5.12.5 Hydraulic system layout 5.12.6 Pump priming Before starting the burner, make sure that the tank return line is not clogged. Obstructions in the line could cause the sealing WARNING organ located on the pump shaft to break. ➤ In order for self-priming to take place, one of the screw 4) (Fig.

  • Page 25: Burner Calibration

    Installation The a.m. operation is possible because the pump is already full of fuel when it leaves the factory. If the pump has been drained, fill it with fuel through WARNING the opening on the vacuum meter 4) (Fig. 22) prior to starting;...

  • Page 26: Gas Feeding

    Installation 5.13 Gas feeding Explosion danger due to fuel leaks in the pres- MBC “threaded” ence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure the fuel interception tap is closed be- fore performing any operation on the burner. The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws.

  • Page 27: Gas Train

    Installation 5.13.2 Gas train 5.13.4 Gas pressure Approved according to standard EN 676 and provided separately Tab. I indicates the pressure drop of the combustion head and from the burner. the gas butterfly valve depending on the operating output of the burner.
  • Page 28 Installation To calculate the required gas pressure at test point 1) (Fig. 29), set the maximum output required from the burner operation: – find the nearest output value in the table for the burner in question. – Read off the pressure at test point 1) (Fig. 29) on the right in column 1.

  • Page 29: Electrical Wiring

    Installation 5.14 Electrical wiring Notes on safety for the electrical wiring ➤ The electrical wiring must be carried out with the electrical supply disconnected. ➤ Electrical wiring must be made in accordance with the regulations currently in force in the country of destination and by qualified personnel.

  • Page 30: Calibration Of The Thermal Relay

    Installation 5.15 Calibration of the thermal relay The thermal relay (Fig. 31) is used to avoid damage to the motor owing to a strong increase in absorption or the lack of a phase. For the calibration 2), refer to the table given in electrical layout (Electrical connections set by installer).

  • Page 31: Start-Up, Calibration And Operation Of The Burner

    Start-up, calibration and operation of the burner Start-up, calibration and operation of the burner Notes on safety for the first start-up The first start-up of the burner must be carried out Check the correct working of the adjustment, com- by qualified personnel, as indicated in this manual mand and safety devices.

  • Page 32: Fuel Change

    Start-up, calibration and operation of the burner Fuel change There are two possible options for changing fuel: By setting selector 3) (Fig. 33) to EXT, you activate the remote using selector 3) (Fig. 33); fuel selection facility. using a remote selector connected to the main terminal In this position, if no remote selector is fitted, the display shows board.

  • Page 33: Intermediate Outputs

    Start-up, calibration and operation of the burner 6.6.3 Intermediate outputs Once you have adjusted the burner’s maximum and minimum output, the next step is to adjust air and gas at the various inter- mediate servomotor positions. You can switch from one position to the next by holding selector 2) (Fig.

  • Page 34: Servomotor

    Start-up, calibration and operation of the burner Procedures for setting the burner automatic return selection switch on the control panel. Stop ➤ Fit the suitable nozzle to obtain the maximum required deliv- when the servomotor has turned by 15° and then effect a ery.

  • Page 35: Adjustment Pressure Switches

    Start-up, calibration and operation of the burner Adjustment pressure switches 6.9.1 Air pressure switch - CO check Adjust the air pressure switch after having performed all other burner adjustments with the air pressure switch set to the start of the scale (Fig. 39). With the burner operating at minimum output, increase adjust- ment pressure by slowly turning the relative knob clockwise until the burner locks out.

  • Page 36: Operation Sequence Of The Burner

    Start-up, calibration and operation of the burner 6.10 Operation sequence of the burner 6.10.1 Burner starting NORMAL FIRING Thermostat/pressure switch TL closes. Fan motor starts. Motor starts. Servomotor starts: 130° rotation to right, until contact is made on cam 1) with light oil operation, or cam 4) with gas operation.

  • Page 37: Final Checks (With The Burner Working)

    Start-up, calibration and operation of the burner 6.11 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.

  • Page 38: Maintenance

    Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, safety, yield and duration of the burner. Disconnect the electrical supply from the burner It allows you to reduce consumption and polluting emissions and by means of the main system switch.
  • Page 39 Maintenance Filters (Fig. 45) GAS OPERATION Check the filtering baskets on line 1) and at nozzle 2) present in the system. Gas leaks Clean or replace if necessary. Make sure that there are no gas leaks on the pipework between If rust or other impurities are observed inside the pump, use a the gas meter and the burner.

  • Page 40: Opening The Burner

    Maintenance Opening the burner Disconnect the electrical supply from the burner by means of the main system switch. DANGER Turn off the fuel interception tap. DANGER Wait for the components in contact with heat sources to cool down completely. ➤ Remove the tie rods 1) and 6) (Fig. 46) of the head move- ment and damper opening lever by loosening nuts 2).

  • Page 41: Faults - Possible Causes - Solutions

    Faults - Possible causes - Solutions Faults - Possible causes - Solutions The LFL1.333... control box is equipped with a lockout indicator Lockout indicator (Fig. 47) that turns during the start-up programme, and is visible Start-up sequence from the small lockout window. b-b’...
  • Page 42 Faults - Possible causes - Solutions GAS OPERATION Symbol Fault Probable cause Suggested remedy The burner does not start No electrical power supply Close all switches and check connections A limiter or safety control device is open Adjust or replace Control box lock-out Reset control box Replace...
  • Page 43 Faults - Possible causes - Solutions GAS OPERATION Symbol Fault Probable cause Suggested remedy The burner repeats the Mains gas pressure is near the valve to which starting cycle without themin. gas pressure switch gas is adjusted. lock out The repeated drop in pressure which follows valve opening causes temporary opening of Reduce operating pressure of minimum the pressure switch itself, the valve immediate-...
  • Page 44 Faults - Possible causes - Solutions LIGHT OIL OPERATION Symbol Fault Probable cause Suggested remedy The burner does not start A limit or safety control device is open Adjust or replace Control box lock-out Reset Fan motor blocked Reset thermal cut-out Adjust pressure switch or eliminate over- Oil pressure switch intervenes pressure...
  • Page 45 Faults - Possible causes - Solutions LIGHT OIL OPERATION Symbol Fault Probable cause Suggested remedy Smoke in flame - dark Not enough air Adjust head and fan gate Bacharach Erroneous pump pressure Adjust Nozzle filter clogged Clean or replace Boiler room air vents insufficient Increase Nozzle worn or dirty Replace...

  • Page 46: A Appendix - Accessories

    Analogic signal converter; • the Potentiometer Burner Potentiometer Analogic signal converter Type Code Type Code RLS 500/M MX ASZ... 3010402 E5202 3010390 Potentiometer kit for the indication of load position Burner Code RLS 500/M MX 3010402 Soundproofing box kit...

  • Page 47: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts References layout Layout of unifilar output Operational layout star-powered starter/delta-powered starter Operational layout LFL 1... Operational layout LFL 1... Operational layout LFL 1... Operational layout LFL 1... Operational layout Electrical connections set by installer Electrical connections for internal RWF40 kit...
  • Page 48 Appendix - Electrical panel layout 20009655...
  • Page 49 Appendix - Electrical panel layout 20009655...
  • Page 50 Appendix - Electrical panel layout 20009655...
  • Page 51 Appendix - Electrical panel layout 20009655...
  • Page 52 Appendix - Electrical panel layout 20009655...
  • Page 53 Appendix - Electrical panel layout 20009655...
  • Page 54 Appendix - Electrical panel layout 20009655...
  • Page 55 Appendix - Electrical panel layout 20009655...
  • Page 56 Appendix - Electrical panel layout 20009655...
  • Page 57 Appendix - Electrical panel layout 20009655...
  • Page 58 Appendix - Electrical panel layout Wiring layout key Control box Flame sensor Internal output power regulator RWF40 Gas adjustment valve + gas safety valve External output power regulator RWF40 YVPS Gas valve leak detection control device Probe with current output Main supply terminal strip Device with current output for editing remote setpoint RWF40 terminal strip...
  • Page 60 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...

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