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Riello RLS 800/M MX Installation, Use And Maintenance Instructions

Dual fuel light oil/ gas burner
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Installation, use and maintenance instructions
Dual fuel light oil/ gas burner
GB
Progressive two-stage or modulating operation
CODE
MODEL
TYPE
20147802
RLS 800/M MX
1301 T
20148124 (2) - 11/2020

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Summary of Contents for Riello RLS 800/M MX

  • Page 1 Installation, use and maintenance instructions Dual fuel light oil/ gas burner Progressive two-stage or modulating operation CODE MODEL TYPE 20147802 RLS 800/M MX 1301 T 20148124 (2) - 11/2020...
  • Page 2 Translation of the original instructions...

  • Page 3: Table Of Contents

    Contents Declarations....................................3 Information and general warnings............................4 Information about the instruction manual ........................4 2.1.1 Introduction.................................. 4 2.1.2 General dangers................................4 2.1.3 Other symbols ................................4 2.1.4 Delivery of the system and the instruction manual...................... 5 Guarantee and responsibility............................5 Safety and prevention................................
  • Page 4 Contents 5.14 Electrical connections ..............................26 5.14.1 Supply cables and external connections passage .....................26 5.15 Calibration of the thermal relay ..........................27 5.16 Motor rotation ................................27 Start-up, calibration and operation of the burner ........................28 Notes on safety for the first start-up ...........................28 Burner adjustment..............................28 Adjustments prior to ignition............................28 Burner start-up ................................29...

  • Page 5: Declarations

    The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015. Manufacturer's Declaration RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BImSchV revision 26.01.2010”. Product...

  • Page 6: 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 7: Delivery Of The System And The Instruction Manual

    Information and general warnings 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 safety rules and envisaging all the potential danger situations.

  • Page 9: Technical Description Of The Burner

    230/50 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RLS 800/M MX 3/400/50 Star/Triangle 20147802 Tab. A Burner categories - Countries of destination Country of destination Gas category SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO 2ELL (43.46 ÷...

  • Page 10: Technical Data

    Technical description of the burner Technical data Model RLS 800/M MX TC FS1 Type 1301 T Output min - max 1750/3500 ÷ 8000 Delivery kg/h 147/295 ÷ 674 Fuels - LIGHT OIL, max. viscosity at 20 °C: 6 mm /s (1.5 °E - 6 cSt)

  • Page 11: Maximum Dimensions

    Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part turned on the hinge. The l position is reference for the refractory thickness of the boiler door. D9251 Fig. 1 RLS 800/M MX 1333 DN80 1187 1061 Tab. E...

  • Page 12: Firing Rates

    The MINIMUM OUTPUT must not be lower than the minimum atmospheric pressure of 1013 mbar (approx. 0 m limit of the diagram: a.s.l.), and with the combustion head adjusted as ATTENTION RLS 800/M MX = 1750 kW shown on page 19. D10725 Class 3 EN676 Class 1 EN267...

  • Page 13: Burner Description

    Technical description of the burner Burner description D9242 Fig. 4 Lifting rings 23 Pump 24 Pump motor Fan motor 25 Minimum oil pressure switch Servomotor 26 Maximum oil pressure switch Combustion head gas pressure test point 27 Nozzle return pressure gauge Combustion head 28 Nozzle delivery pressure gauge Ignition pilot...

  • Page 14: Electrical Panel Description

    Technical description of the burner 4.10 Electrical panel description 20160527 Fig. 5 Terminal board for kits 20 Plug/socket valves/motor Dry contact relay output 21 Fan motor thermal relay Ignition transformer 22 Pump motor contactor and thermal relay Bracket to apply the RWF output regulator kit 23 Oil/Gas selection relay Stop push-button 24 Plug/socket maximum gas pressure switch...

  • Page 15: Control Box Rfgo-A22

    Technical description of the burner 4.12 Control box RFGO-A22 Important notes To avoid accidents, material or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening ATTENTION or modifying it, or forcing its operation. The Manufacturer cannot assume any responsibility for damage resulting from unauthorised work! ...

  • Page 16: Servomotor (Sqm10.1

    Technical description of the burner 4.13 Servomotor (SQM10.1..) Important notes To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying forcing ATTENTION actuators.  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 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 18: Operating Position

    For boilers with front flue passes 1)(Fig. 12) or flame inversion chamber, a protection in refractory material 5) must be inserted between the boiler fettling 2) and the blast tube 4). RLS 800/M MX M 18 This protection must not compromise the extraction of the blast Tab.

  • Page 19: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler Prepare a suitable lifting system using rings 3)(Fig. 12).  Fit the heat insulation supplied onto the blast tube 4) (Fig. 12).  Fit the entire burner onto the boiler hole prepared previously, as in Fig.

  • Page 20: Nozzle Installation

    The burner complies with the emission requirements of the EN 267 standard. In order to guarantee that emissions do not vary, • Bergonzo type B5 45° recommended and/or alternative nozzles specified by Riello in • Fluidics type N4 45° the Instruction and warning booklet should be used.

  • Page 21: Combustion Head Adjustment

    Installation 5.11 Combustion head adjustment The air damper servomotor 4)(Fig. 4), beyond varying the air Proceed as follows (Fig. 17): output according to the output demand, through a leverage varies  unscrew the nuts 2) and remove the tie-rod 3); the combustion head adjustment.

  • Page 22: Light Oil Supply

    Installation 5.12 Light oil supply Explosion danger due to fuel leaks in the presence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure the fuel shut-off valve is closed before performing any operation on the burner. The fuel supply line must be installed by qualified personnel, in compliance with current standards and laws.

  • Page 23: Pressure Variator

    Installation 5.12.4 Pressure variator 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 Circuit Diagram

    Installation 5.12.5 Hydraulic circuit diagram 5.12.6 Priming pump Before starting the burner, make sure that the tank return line is not clogged. Obstructions in the line could cause the sealing ATTENTION organ located on the pump shaft to break.  In order for the pump (Fig. 22) to self-prime, it is vital that the screw 4) of the pump be loosened to vent the air contained in the suction line.

  • Page 25: Gas Supply

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

  • Page 26: Gas Train

    Installation 5.13.2 Gas train 5.13.4 Gas pressure Type-approved in accordance with EN 676 and supplied Tab. L indicates the pressure drops of the combustion head and separately from the burner. gas butterfly valve depending on the burner operating output. To select the correct gas train model, refer to the manual "Burner- 1 p (mbar) 2 p (mbar) gas train combination"...

  • Page 27: Pilot - Gas Train Connection

    Installation Example with natural gas G20: 5.13.5 Pilot - gas train connection Operation at maximum modulating output The burner is equipped with a dedicated gas train fixed to the Gas pressure at test point 1) (Fig. 28) = 35.2 mbar sleeve.

  • Page 28: Electrical Connections

    Installation 5.14 Electrical connections 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 29: Calibration Of The Thermal Relay

    Installation 5.15 Calibration of the thermal relay The thermal relay (Fig. 31) serves to avoid damage to the motor due to an excessive absorption increase or if a phase is missing. For calibration 2), refer to the table indicated in the electrical layout (electrical wiring by the installer).

  • Page 30: 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, by qualified personnel, as indicated in this manual command and safety devices.

  • Page 31: Burner Start-Up

    Start-up, calibration and operation of the burner Burner start-up Turn off the remote controls and set the switch 1)(Fig. 34) to “MAN”. Check that the lamps or testers connected to the solenoid valves, 0 AUTO MAN or the pilot lights on the solenoid valves, indicate that no voltage is present.

  • Page 32: Maximum Output

    Start-up, calibration and operation of the burner The values in the table can be useful as reference for good fuel calibration. EN 676 Air excess Max. output Min. output   1.2   1.3 GAS Theoretical max % Calibration mg/kWh ...

  • Page 33: Air / Fuel Adjustment

    Start-up, calibration and operation of the burner Air / fuel adjustment During the operations for calibrating the air/fuel ratio for oil Burner calibration procedure burners, the following adjustments need to be made:  Install the nozzle suitable to achieve the maximum desired output.

  • Page 34: Servomotor

    Start-up, calibration and operation of the burner Servomotor The servomotor (Fig. 38) simultaneously adjusts, through driving gears, the output and pressure of the air, and the flow rate of the fuel being used. It is equipped with adjustable cams which operate as many switches.

  • Page 35: Pressure Switch Adjustment

    Start-up, calibration and operation of the burner 6.10 Pressure switch adjustment 6.10.1 Air pressure switch - check CO Adjust the air pressure switch after performing all other burner adjustments with the air pressure switch set to the start of the scale (Fig.

  • Page 36: Operation Sequence Of The Burner

    Start-up, calibration and operation of the burner 6.11 Operation sequence of the burner 6.11.1 Burner start-up 6.11.2 Steady state operation  Burner without output regulator RWF • 0s TL thermostat/pressure switch closure. Once the start-up cycle is completed, the servomotor command Fan motor start-up.

  • Page 37: Final Checks (With Burner Operating)

    Start-up, calibration and operation of the burner 6.12 Final checks (with burner operating)   Open the thermostat/pressure switch TL The burner must stop  Open the thermostat/pressure switch TS  Turn the knob of the gas maximum pressure switch to the ...

  • Page 38: 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 safety, yield and duration of the burner. operations: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.

  • Page 39: Safety Components

    Maintenance Check Mode With burner flame on:  hold the reset button on the flame control pressed for at least 3 sec.;  the button colour will change from green to yellow;  each operating status signalling LED will be compared to 20% of the maximum brightness;...
  • Page 40 Maintenance LIGHT OIL OPERATION GAS OPERATION Filters (Fig. 44) Gas leaks Check the filtering baskets on line 1) and at nozzle 2) present in Make sure that there are no gas leaks on the pipe between the the system. gas meter and the burner. Clean or replace if necessary.

  • Page 41: Opening The Burner

    Maintenance Opening the burner  Remove the tie-rods 1) and 6)(Fig. 45) of the lever for moving the head and opening the dampers, loosening the Disconnect the electrical supply from the burner nuts 2). by means of the system main switch. ...

  • Page 42: Led Indicator And Special Function

    LED indicator and special function LED indicator and special function Description of LED lamps It turns on when the fan motor is powered (T6) and blinks when RUN/CHECK switch is set to “CHECK” during damper movement phases, PTFI AND MTFI. S9740 It blinks when the air damper is moving towards the maximum opening position until the Damper...

  • Page 43: Led Lamps: Burner Operating Status

    LED indicator and special function LED lamps: burner operating status OPERATING STATUSES INDICATED BY LEDS DURING NORMAL OPERATION AND CHECK MODE Operation Damper Damper Modulation Ignition Flame Status LED ● = ON open closed Icon S9740 S9741 S9742 S9743 S9744 S9745 S9746 Power OFF/ON...

  • Page 44: Problems - Causes - Remedies Signalled By Led Indicators

    Problems - Causes - Remedies signalled by LED indicators Problems - Causes - Remedies signalled by LED indicators When an emergency stop occurs, the control device LEDs Thermal unit’s operation, maintenance and indicate the cause of the stop. troubleshooting interventions must be carried out The terminal T3 is not powered.
  • Page 45 Problems - Causes - Remedies signalled by LED indicators Error / RFGO LED lock-out codes Faults LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Operation Open Closed Auto Ignition Flame Status LED ● = ON damper damper Icon...
  • Page 46 Problems - Causes - Remedies signalled by LED indicators Faults LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Off-specification mains voltage ● ● ● ● ● UV: Internal fault ● ● Supervisor processor fault ●...
  • Page 47 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution UV: no flame at the end of the Inspect the system, check the gas pressure, No flame at the end of the 2 safety time check the UV scanner, check the wiring, safety time (MTFI) etc.
  • Page 48 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution Internal processor fault Internal fault Replace the control device UV: false flame during operation False flame detected before ignition Check the scanner FR: false flame during operation False flame detected before ignition Check the wiring Check the scanner Make sure that earthing is appropriate...

  • Page 49: A Appendix - Accessories

    • the analogue signal converter; • the potentiometer Burner Potentiometer Analogue Signal Converter Type Code Type Code RLS 800/M MX ASZ... 3010402 E5202 3010390 Spacer kit Burner Thickness (mm) Code RLS 800/M MX 20008903 Potentiometer kit for load position indication...

  • Page 50: Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Single-wire output layout Functional layout star/triangle starter Functional layout RFGO-A22 Functional layout RFGO-A22 Functional layout RFGO-A22 Functional layout RFGO-A22 Electrical wiring kit RWF50 internal Electrical wiring that is the responsibility of the installer Functional layout for kit RWF50 Electrical wiring kit RWF50 external...
  • Page 51 Appendix - Electrical panel layout 20148124...
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  • Page 57 Appendix - Electrical panel layout 20148124...
  • Page 58 Appendix - Electrical panel layout 20148124...
  • Page 59 Appendix - Electrical panel layout 20148124...
  • Page 60 Appendix - Electrical panel layout 20148124...
  • Page 61 Appendix - Electrical panel layout Wiring layout key Electrical control box Servomotor Output power regulator RWF50 internal Ignition transformer Limit thermostat/pressure switch Output regulator RWF50 external Probe with output under current Adjustment thermostat/pressure switch Output device in current to modify remote Safety thermostat/pressure switch setpoint Flame sensor...
  • Page 64 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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