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Riello RLS 310/E MX Installation, Use And Maintenance Instructions

Dual fuel gas oil/ gas burners
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Installation, use and maintenance instructions
Dual fuel gas oil/ gas burners
GB
Progressive two-stage or modulating operation
CODE
20082946 - 20087643
20087644
20084376 - 20087645
20087646
20083562
20080180
MODEL
RLS 310/E MX
RLS 410/E MX
RLS 510/E MX
RLS 610/E MX
TYPE
1161T1
1162T1
1163T1
1164T1
20081825 (4) - 12/2015

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Summary of Contents for Riello RLS 310/E MX

  • Page 1 Installation, use and maintenance instructions Dual fuel gas oil/ gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 20082946 - 20087643 RLS 310/E MX 1161T1 20087644 20084376 - 20087645 RLS 410/E MX 1162T1 20087646 20083562 RLS 510/E MX 1163T1...
  • Page 2 Original instructions...

  • Page 3: Table Of Contents

    Contents Declarations....................................4 Information and general warnings............................5 Information about the instruction manual ........................5 2.1.1 Introduction.................................. 5 2.1.2 General dangers................................5 2.1.3 Other symbols ................................5 2.1.4 Delivery of the system and the instruction manual...................... 6 Guarantee and responsibility............................6 Safety and prevention................................
  • Page 4 Contents 5.12.3 Hydraulic connections ..............................29 5.12.4 Priming pump ................................30 5.12.5 Pressure variator................................30 5.12.6 Hydraulic circuit diagram............................31 5.13 Gas pressures................................32 5.13.1 Gas feeding line .................................32 5.13.2 Gas train ..................................33 5.13.3 Gas train installation ..............................33 5.13.4 Gas pressure ................................34 5.14 Electrical wiring ................................35 5.14.1 Supply cables and external connections passage .....................35 Start-up, calibration and operation of the burner ........................36...
  • Page 5 Contents 7.2.1 Maintenance frequency ............................. 59 7.2.2 Checking and cleaning .............................. 59 7.2.3 Safety components..............................59 7.2.4 Measuring the flame signal ............................60 Opening the burner ..............................61 Closing the burner ..............................61 7.4.1 Checking the air and gas pressure on the combustion head ..................61 Faults - Possible causes - Solutions ............................

  • Page 6: 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. BIm- SchV revision 26.01.2010”.

  • Page 7: Information And General Warnings

    Information and general warnings Information and general warnings 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 8: Delivery Of The System And The Instruction Manual

    Information and general warnings  The system supplier must carefully inform the user about: 2.1.4 Delivery of the system and the instruction – 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 9: 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 10: Technical Description Of The Burner

    Technical description of the burner Technical description of the burner Burner designation Range: Fuel: Natural gas Gas oil Light oil / Gas Heavy oil Size Adjustment: Two stage (light oil) / Proportional valve (gas) Electronic cam Electronic cam with variable speed (with Inverter) Proportional air/gas valve Mechanical cam Emission:...

  • Page 11: Models Available

    Technical description of the burner Models available Designation Voltage Start-up Code 3/400/50 Star/Triangle 20082946 RLS 310/E MX 3/230/50 Direct 20087643 3/400/50 Direct 20087644 3/400/50 Star/Triangle 20084376 RLS 410/E MX 3/230/50 Direct 20087645 3/400/50 Direct 20087646 RLS 510/E MX 3/400/50 Star/Triangle...

  • Page 12: Technical Data

    Technical description of the burner Technical data Model RLS 310/E MX RLS 410/E MX RLS 510/E MX RLS 610/E MX Type 1161T1 1162T1 1163T1 1164T1 Power 600/1200 - 3600 640/ 1500 - 4200 660/1800 - 5170 1000/2200 - 6155 min - max...

  • Page 13: Electrical Data

    Technical description of the burner Electrical data DIRECT START UP Model RLS 310/E MX RLS 410/E MX RLS 310/E MX RLS 410/E MX Main electrical supply 3 ~ 230V +/-10% 50 Hz 3N ~ 400V +/-10% 50 Hz 2900 2920...

  • Page 14: Burner Weight

    Technical description of the burner Burner weight The weight of the burner complete with its packaging is shown in Tab. F on page 12. Model RLS 310/E MX RLS 410/E MX RLS 510/E MX 20086678 RLS 610/E MX Tab. F Fig.

  • Page 15: Firing Rates

    0 m a.s.l.), and with the combustion head adjusted as shown on page 27. Model RLS 310/E MX Pre-calibration of the combustion head only for the burner model RLS 310/E MX: RLS 410/E MX RLS 510/E MX If the maximum burner output of the burner falls WARNING...

  • Page 16: Test Boiler

    ......No. 4 Gas nozzles (only for version RLS 310/E MX)..No. 8 Instructions.

  • Page 17: Burner Description

    Technical description of the burner 4.11 Burner description ASSEMBLY VIEW 20086686 Fig. 5 Lifting rings 32 Pump motor 33 Minimum oil pressure switch Fan motor 34 Maximum oil pressure switch Air damper servomotor 35 Nozzle return pressure gauge Combustion head gas pressure test point 36 Nozzle delivery pressure gauge Combustion head Ignition electrodes...

  • Page 18: Electrical Panel Description

    Technical description of the burner 4.12 Electrical panel description 20095670 VIEW A 20096208 Fig. 6 Electrical control box 20 Triangle contactor (Star/triangle start up) ON/OFF selector 21 Star contactor (Star/triangle start up) Output power regulator (if present) 22 Auxiliary contacts Earth terminal 23 Timer for star/triangle start up Supply cables and external connections passage.

  • Page 19: Control Box For The Air/Fuel Ratio (Lmv 26

    To avoid accidents, material and/or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening WARNING or modifying it, or forcing its operation. Riello S.p.A. cannot assume any responsibility for dam- age resulting from unauthorised interventions! Risk of explosion!
  • Page 20 Technical description of the burner Technical data Control box Mains voltage AC 230 V -15% / +10% Mains frequency 50 / 60 Hz ±6% Power absorption < 30 W Safety class I, with components in compliance with II and III, ac- cording to DIN EN 60730-1 Load on ‘input’...

  • Page 21: Operation Sequence Of The Burner (Gas Operation)

    Technical description of the burner 4.14 Operation sequence of the burner (gas operation) Operation Checking of Start-up Switching off seal TSA1 Phase number Timer - Resolution - Ratio 0.6s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max. phase time RAST plug Input signals PIN number...

  • Page 22: Operation Sequence Of The Burner (Light Oil Operation)

    Technical description of the burner 4.15 Operation sequence of the burner (light oil operation) Operation Start-up Switching off Phase number 30 s Timer - Resolution - Ratio Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max. phase time RAST plug Input signals PIN number X3-04 Pin 1/2...

  • Page 23: List Of The Phases (Gas Operation)

    Technical description of the burner 4.15.1 List of the phases (gas operation) Phase Description Phase Description Ph44 t44 = interval time 1 Ph00 Lockout phase Ph60 Operation Ph02 Safety phase Ph62 The burner moves to the switching off position Ph10 Closing paused Ph70 t13 = post-combustion time...

  • Page 24: Description Of The Symbols On The Display

    Technical description of the burner 4.16.1 Description of the symbols on the display Ignition transformer Valve powered powered Flame presence Fan motor powered Pre-heater active Lockout only for light oil burners Heat request Lock-out lamp Parameter mode active Info mode active Service mode active V h min s D9000...

  • Page 25: Servomotor (Sqm33

    Technical description of the burner 4.17 Servomotor (SQM33..) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Do not open, modify or force the actuators. WARNING  All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel.

  • Page 26: Installation

    Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner is to The installation of the burner must be carried out be installed, and arranging for the environment to be illuminated by qualified personnel, as indicated in this manual correctly, proceed with the installation operations.

  • Page 27: Operating Position

    For boilers with front flue passes 1)(Fig. 17 on page 25) or flame inversion chamber, a protection in refractory material 5) must be inserted between the boiler fettling 2) and the blast tube 4). RLS 310/E MX RLS 410/E MX The refractory can have a conical shape (minimum 60°).

  • Page 28: Access To Head Internal Part

    Installation Access to head internal part The burner leaves the factory set for opening to the right, there- fore maintaining the pin 1)(Fig. 18 on page 26) in its housing. To open the burner towards the right, proceed as follows: A Remove the screws 2);...

  • Page 29: Gas Butterfly Valve

    Maximum burner output (kW) Fig. 20 The combustion head can be adjusted within the following fields: RLS 310/E MX: 0 - 11; WARNING RLS 410/E MX: 5 - 16; RLS 510/E MX: 2 - 16; RLS 610/E MX: 0 - 6.

  • Page 30: Nozzle Installation

    Installation 5.11 Nozzle installation The burner complies with the emission requirements of the EN 5.11.1 Recommended nozzle 267 standard. • Fluidics type N2 45° In order to guarantee that emissions do not vary, recommended Alternatively: and/or alternative nozzles specified by the Manufacturer in the In- •...

  • Page 31: Light Oil Supply

    Installation 5.12 Light oil supply 5.12.1 Double-pipe circuit 5.12.2 The loop circuit The burner is equipped with a self-priming pump which is capable A loop circuit consists of a loop of piping departing from and re- of feeding itself within the limits listed in the table at the side. turning to the tank with an auxiliary pump that circulates the fuel under pressure.

  • Page 32: Priming Pump

    Installation 5.12.4 Priming pump 5.12.5 Pressure variator The pressure variator (Fig. 26 on page 30), allows the pressure Before starting the burner, make sure that the tank on the return line of the nozzle to be varied according to the re- return line is not clogged.

  • Page 33: Hydraulic Circuit Diagram

    Installation 5.12.6 Hydraulic circuit diagram 20086806 Fig. 27 Key (Fig. 27 on page 31) Pump suction Pump return line and nozzle return line Pump by-pass screw Pump pressure regulator Safety valve Safety valve Nozzle delivery line Nozzle without interception rod Nozzle return line 10 Pressure variator on nozzle return line 11 Pressure variator servomotor...

  • Page 34: Gas Pressures

    Installation 5.13 Gas pressures 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 35: Gas Train

    Installation 5.13.2 Gas train Approved according to standard EN 676 and provided separately Pay attention when handling the train: danger of from the burner. crushing of limbs. To select the correct gas train model, refer to the supplied “Burn- er-gas train combination” manual. Make sure that the gas train is properly installed by checking for any fuel leaks.

  • Page 36: Gas Pressure

    Installation 5.13.4 Gas pressure 1 p (mbar) 2 p (mbar) Tab. O on page 34 indicates the minimum pressure drops along G 20 G 25 G 20 G 25 the gas supply line, depending on the maximum burner output. 1200 The values shown in Tab.

  • Page 37: 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 38: 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 39: Adjustments Prior To Ignition (Gas)

    Start-up, calibration and operation of the burner Adjustments prior to ignition (gas) Combustion head adjustment has already been already de- Before starting up the burner, it is good practice to scribed in the section “Combustion head adjustment” on page 27. adjust the gas train so that ignition takes place in In addition, the following adjustments must also be made: conditions of maximum safety, i.e.

  • Page 40: Change Of Fuel

    Start-up, calibration and operation of the burner Change of fuel There are two change of fuel options: with selector 27)(Fig. 6 on page 16); with a remote selector connected to the main terminal board. Positioning the selector 27)(Fig. 6 on page 16) to “EXT” acti- vates the remote selection of the fuel.

  • Page 41: Air / Fuel Adjustment

    Start-up, calibration and operation of the burner Air / fuel adjustment Air/fuel synchronisation is carried out with the relevant air, gas 6.8.4 Output upon ignition and light oil servomotors by logging a calibration curve using the Ignition must occur at a lower output than the max. operation out- electronic cam.

  • Page 42: Final Adjustment Of The Pressure Switches

    Start-up, calibration and operation of the burner Final adjustment of the pressure switches 6.9.1 Air pressure switch on the graduated scale corresponds with the arrow pointing downwards, and so recovering the hysteresis of the pressure Adjust the air pressure switch (Fig. 39 on page 40) after perform- switch (shown by the white mark on a blue background, between ing all other burner adjustments with the air pressure switch set the two arrows).

  • Page 43: Pressure Switch Adjustment

    Start-up, calibration and operation of the burner 6.10 Pressure switch adjustment 6.10.1 Maximum gas pressure switch Adjust the maximum gas pressure switch (Fig. 40 on page 41) af- ter performing all other burner adjustments with the maximum gas pressure switch set to the end of the scale. With the burner operating at maximum output, lower the adjust- ment pressure by slowly turning the relative knob anticlockwise until the burner locks out, the display shows “Loc c22 d0”.

  • Page 44: Visualisation And Programming Mode

    Start-up, calibration and operation of the burner 6.11 Visualisation and programming mode 6.11.1 Normal mode 6.11.1.4 Error state message, display of the errors and information The Normal mode is the standard operation mode visualised on the operator panel display. It is the main level of the menu. The display visualises alternately the error code (in the example ...

  • Page 45: Info Mode

    Start-up, calibration and operation of the burner 6.11.1.5 Reset procedure The burner is in lockout when the red indicator light on the oper- ator panel is lit up, and the display visualises the lockout code (in the example alongside c: 4) and the relative diagnostics (in the example d: 3) alternately.

  • Page 46: Service Mode

    Start-up, calibration and operation of the burner 6.11.3 Service mode 6.11.4 Parameters Mode The Service mode (SEr) visualises the error log and certain The Parameters Mode (PArA) displays and allows you to modi- technical information about the system. To access this level you fy/programme the parameters list on page 52.

  • Page 47: Parameter Modification Procedure

    Start-up, calibration and operation of the burner 6.11.4.2 Assigning parameter levels The password must only be communicated to the The parameters level is subdivided into groups as shown on page qualified personnel or the Technical Assistance Service, and must be kept in a safe place. WARNING Parameter 100: ParA...
  • Page 48 Start-up, calibration and operation of the burner 6.12.0.1 Procedure for inserting and adjusting points on Select another point, or exit this area by pressing the keys “+” and “-” (ESC) simultaneously. the modulation curve Nine adjustment/calibration points (P1 - P9) can be inserted in the control box for each servomotor, varying their position by de- grees and, consequently, the quantity of air and fuel introduced.

  • Page 49: Start-Up Procedure

    Start-up, calibration and operation of the burner 6.13 Start-up procedure Check that the Operator panel display shows the heat request Phase 36: and “OFF UP0” for fuel 0 or “OFF UPr1” for fuel 1: this means it The burner goes to its switch-on position, point “P0”, defined in is necessary to set the modulation curve of the burner.
  • Page 50 Start-up, calibration and operation of the burner Press the button “+”: the display visualises the indicator “P1” If you want to make the burner work on just a part of the modula- flashing and proposes the same settings as point “P0”. tion curve, modify the parameters “546”...

  • Page 51: Backup / Restore Procedure

    Start-up, calibration and operation of the burner 6.14 Backup / Restore procedure At the end of the “Start-up procedure” it is wise to carry out a We suggest that this operation be carried out at backup, creating a copy of the data memorised on the REC, in the end of any intervention that involves modifica- the RDI 21 display panel.

  • Page 52: Restore

    Start-up, calibration and operation of the burner NOTE: It is advisable to perform a backup every time If an error occurs during the backup process, the display that a parameter is changed, after checking screen shows a negative value. that the modification carried out is correct. Refer to diagnostic code 137 to determine the cause of the WARNING error (see section “List of parameters”...
  • Page 53 Start-up, calibration and operation of the burner The value 1 appears on the display screen: h min s After approx 8 seconds (it depends on the duration of the pro- gramme), the 0 value appears on the display screen, this is to in- dicate that the restore process has been completed correctly.

  • Page 54: List Of Parameters

    Start-up, calibration and operation of the burner 6.14.3 List of parameters Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment INTERNAL PARAMETERS Start backup/restore process via RDI21... / PC TOOL (set the parameter to 1) Index 0 = create backup Modification...
  • Page 55 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Peripheral address for Modbus Set values: Modification Service Mode 1 ... 247 Baud Rate for Modbus Set values: Modification...
  • Page 56 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Maximum repeats of safety circuit 1 = No repetition Modification Service Mode 2...15 = Number of repetitions 16 = Constant repetitions Gas: selection of flame sensor...
  • Page 57 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment BURNER CHECKS (FUEL 1) Burner operation mode (fuel supply line, modulating/ stage, servomotors, etc.) -- = not defined (eliminate curves) 1 = Gmod...
  • Page 58 Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment (Fuel 1) Oil: pre-purging time Modification 60 min 0.2s Service Mode (Fuel 1) Oil: Spark pre-ignition time Modification 0.6s...

  • Page 59: Operation

    Start-up, calibration and operation of the burner Parameter Unit of Values interval No. of Modifica- Degree of Predefined measure- Access mode elements tion precision setting Description Min. Max. ment Heat source active 1 = output during the definition of the curves 2 = manual output Reading only Service mode...

  • Page 60: Ignition Failure

    Start-up, calibration and operation of the burner 6.16 Ignition failure If the burner does not switch on, there is a lockout within 3s of the In the event there are further lockouts or faults electrical supply reaching the fuel valve. with the burner, the maintenance interventions It may be that the fuel does not arrive at the combustion head must only be carried out by qualified, authorised...

  • Page 61: Maintenance

    Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, Before carrying out any maintenance, cleaning or checking oper- safety, yield and duration of the burner. ations: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.

  • Page 62: Measuring The Flame Signal

    Maintenance 7.2.4 Measuring the flame signal The burner is fitted with a sensor to check that a flame is present. The minimum current for control box operation is 70 µA. The op- erator Panel displays “30%” (see “List of parameters” on page 52, parameter 954).

  • Page 63: Opening The Burner

    Maintenance Fuel tank LIGHT OIL OPERATION Approximately every 5 years, suck any water on the bottom of the tank using a separate pump. Pump The delivery pressure must comply with the table on page 34. Combustion The depression must be less than 0.45 bar. In case the combustion values found at the beginning of the inter- Unusual noise must not be evident during pump operation.

  • Page 64: Faults - Possible Causes - Solutions

    Faults - Possible causes - Solutions Faults - Possible causes - Solutions If faults arise in ignition or operations, the burner performs a In the event the burner stops, in order to prevent “safety stop”, which is signalled by the red burner lockout LED. any damage to the installation, do not unblock the The display of the operator panel visualises alternately the lock- burner more than twice in a row.
  • Page 65 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Valve leak detection control Leak test V1 leaks Check if the valve on the side of the gas has any leaks. Check the wiring and make sure that the circuit is open. Leak test Check if the valve on the side of the burner has any leaks.
  • Page 66 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Safety circuit/Burner flange OFF S Safety circuit open /Burner flange open Safety circuit open /Burner flange open - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light - Alarm lockout at start Safety circuit open /Burner flange open, extraneous light -...
  • Page 67 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Fuel/air ratio internal checking error: cyclical data check Check synchronisation data, different current load Check synchronisation data, different target load Check synchronisation data, different target positions Check synchronisation data, different positions reached Carry out a reset;...
  • Page 68 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Relay supervision error Check the contacts: 1. Control box connected to the power supply: the fan output must be without voltage. The safety relay contacts have joined together or the 2.
  • Page 69 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Carry out a reset, repeat and check the last setting of the EEPROM access internal error parameters. Restore the group of parameters: if the error arises repeatedly, replace the control box.
  • Page 70 Faults - Possible causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Manual lockout The control box has been manually blocked (no error) Manual lockout from remote reset command Manual lockout from RDI21… Manual lockout from PC interface During a regulation of the curve via the operating panel Manual lockout from RDI21…...

  • Page 71: Appendix - Accessories

    Appendix - Accessories Appendix - Accessories Kit for modulating operation Burner Output regulator Code All models RWF 50.2 3-POINT OUTLET 20085417 All models RWF 55.5 COMPLETE WITH RS-485 INTERFACE 20074441 RWF 55.6 COMPLETE WITH INTERFACE All models 20074442 RS-485/PROFIBUS Burner Probe Adjustment field Code...

  • Page 72: B Appendix - Electrical Panel Layout

    Index of layouts Indication of references Single line output diagram (RLS 310/E MX 230 V - Direct Start Up) Single line output diagram (RLS 310/E MX 400 V - Direct Start Up) Single line output diagram (RLS 410/E MX 230 V - Direct Start Up)
  • Page 73 Appendix - Electrical panel layout 20081825...
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  • Page 82 Appendix - Electrical panel layout & & 20081825...
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  • Page 93 Appendix - Electrical panel layout Wiring layout key Electronic cam PGVP Gas pressure switch for valve leak detection control device Display and calibration unit POILMax Maximum oil pressure switch Output power regulator RWF... internal POILMin Minimum oil pressure switch Fuel level measurer Flame sensor Output probe in current Burner reset switch...
  • Page 96 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...

This manual is also suitable for:

Rls 410/e mxRls 510/e mxRls 610/e mx

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