Riello RLS 160/M MX Installation, Use And Maintenance Instructions
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Riello RLS 160/M MX Installation, Use And Maintenance Instructions

Riello RLS 160/M MX Installation, Use And Maintenance Instructions

Dual fuel light oil/ gas burners progressive two-stage or modulating operation gas side/two-stage light oil side
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Installation, use and maintenance instructions
Dual fuel light oil/ gas burners
GB
Progressive two-stage or modulating operation gas side/
two-stage light oil side
CODE
20147789
20147790
20147887
20147888
MODEL
RLS 160/M MX
RLS 160/M MX
RLS 160/M MX
RLS 160/M MX
TYPE
781T
781T
781T
781T
20148049 (3) - 11/2020

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Summary of Contents for Riello RLS 160/M MX

  • Page 1 Installation, use and maintenance instructions Dual fuel light oil/ gas burners Progressive two-stage or modulating operation gas side/ two-stage light oil side CODE MODEL TYPE 20147789 RLS 160/M MX 781T 20147790 RLS 160/M MX 781T 20147887 RLS 160/M MX 781T...
  • 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 5.12.2 Gas train ..................................26 5.12.3 Gas train installation ..............................26 5.12.4 Gas pressure ................................26 5.13 Electrical connections ..............................28 5.13.1 Supply cables and external connections passage .....................28 Start-up, calibration and operation of the burner ........................29 Notes on safety for the first start-up ...........................29 Servomotor adjustment ..............................29 Adjustments prior to ignition (light oil) ........................29 Burner start-up (light oil) ............................30...

  • 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

    230V / 50-60Hz 110/50/60 110V / 50-60Hz 3/400/50 230/50 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RLS 160/M MX FS1 3/400/50 Direct 20147789 RLS 160/M MX FS1 3/400/50 Direct 20147790 RLS 160/M MX FS1 3/230/50 Direct 20147887...

  • Page 10: Burner Categories - Countries Of Destination

    2ELL (43.46 ÷ 45.3 MJ/m (0°C)) 2E(R)B LU - PL Tab. B Technical data Model RLS 160/M MX Flame stability disc with Flame stability disc without round sectors 3)(Fig. 17) round sectors 3)(Fig. 17) Output Light oil 2nd stage 965 - 1846...

  • Page 11: Electrical Data

    Technical description of the burner Electrical data Model RLS 160/M MX RLS 160/M MX Code 20147789 - 20147790 20147887 - 20147888 Main electrical supply 3~ 400V +/-10% 3~ 230V +/-10% Auxiliary circuit electrical supply 1N ~ 230V +/-10% - 50Hz...

  • Page 12: Firing Rate

    Technical description of the burner Firing rate During operation, burner output varies between: The firing rate value (Fig. 3) has been obtained  Maximum output, selected from within area A. considering an ambient temperature of 20 °C, an  The minimum output must not be lower than the minimum atmospheric pressure of 1013 mbar (approx.

  • Page 13: Burner Description

    Technical description of the burner 4.11 Burner description 20159592 Fig. 6 Flame stability disc 15 Pipe coupling with flange for fixing to the boiler and the gas Ignition electrodes butterfly valve Combustion head 16 Maximum gas pressure switch Gas pressure test point and head fixing screw 17 Safety valve Screws to secure fan to pipe coupling 18 Servomotor controlling the gas butterfly valve and the air...

  • Page 14: Electrical Panel Description

    Technical description of the burner 4.13 Electrical panel description 20159602 Fig. 7 Ignition transformer 13 Relay A switch for: 14 Dry contact relay automatic-manual-off operation 15 Plug to connect the RWF kit of modulating operation A button for: NOTE output increase - decrease Motor contactor and thermal relay with reset button Two types of burner lockout may occur: Bracket for application of RWF kit...

  • Page 15: Control Box Rfgo-A22

    Technical description of the burner 4.14 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 (Sqn31

    Technical description of the burner 4.15 Servomotor (SQN31...) 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: Calibration Of The Thermal Relay

    Technical description of the burner 4.16 Calibration of the thermal relay The thermal relay (Fig. 10) 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 18: 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 19: Operating Position

    Pierce the closing plate of the combustion chamber, as in (Fig. 14). The position of the threaded holes can be marked using the thermal insulation screen supplied with the burner. RLS 160/M MX 325 - 368 M 16 D455 Fig. 14 5.5.2...

  • Page 20: Securing The Burner To The Boiler

    Installation Securing the burner to the boiler Provide an adequate lifting system.  disconnect the electrode cables, then completely unthread Separate the combustion head from the rest of the burner, the burner from the slide bars. Fig. 15: Fix the pipe coupling with the flange 11)(Fig. 15) to the boiler ...

  • Page 21: Choice Of Nozzles For The 1St And 2Nd Stage

    Installation Choice of nozzles for the 1st and 2nd stage Both nozzles must be chosen from among those listed in Tab. I. kg/h The first nozzle determines the delivery of the burner at the 1st 12 bar 10 bar 12 bar 14 bar stage.

  • Page 22: Nozzle Installation

    Reconnect the light oil pipes by screwing the two fittings 267 standard. In order to guarantee that emissions do not vary, 6)(Fig. 15). recommended and/or alternative nozzles specified by Riello in Reconnect the articulated coupling 7) to the graduated sector the Instruction and warning booklet should be used.

  • Page 23: Combustion Head Adjustment

    (Fig. 22) corresponds with the front part of the flange 6)(Fig. 21). To facilitate the adjustment, loosen the screw 1)(Fig. 17), adjust, then block. ATTENTION Example: Burner RLS 160/M MX D1149 Burner maximum output = 1500 kW. The diagram (Fig. 22) shows that for this output, the adjustment Fig.

  • Page 24: Light Oil Supply

    Installation 5.11 Light oil supply 5.11.2 Loop circuit Explosion danger due to fuel leaks in the The loop circuit is composed of a duct starting from the tank and presence of a flammable source. going back to it, in which an auxiliary pump makes the Precautions: avoid knocking, attrition, sparks and pressurised fuel flow.

  • Page 25: Hydraulic Connections

    Installation 5.11.3 Hydraulic connections The pumps are equipped with a by-pass that connects return line with suction line. They are installed on the burner with the by-pass closed by screw 6)(Fig. 25). It is therefore necessary to connect both hoses to the pump. D3000 The pump will break down immediately if it is run with the return line closed and the by-pass screw inserted.

  • Page 26: Pump

    Installation 5.11.5 Pump  The pump can be considered primed when the light oil starts coming out of the screw 3)(Fig. 26). Stop the burner: set Technical data switch 1)(Fig. 27) to "OFF" and tighten the screw 3)(Fig. 26).  The time required for this operation depends upon the PUMP J7 C diameter and length of the suction tubing.

  • Page 27: Gas Supply

    Installation 5.12 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 28: Gas Train

    Installation 5.12.2 Gas train 5.12.4 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- (mbar) gas train combination"...
  • Page 29 Installation Example with natural gas G20. Operation at maximum modulating output: 1550 kW Gas pressure at test point 1)(Fig. 33) 15.0 mbar Pressure in combustion chamber 3.0 mbar 15.0 + 3.0 = 18.0 mbar S9865 Fig. 33 20148049...

  • Page 30: Electrical Connections

    Installation 5.13 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 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 by qualified personnel, as indicated in this manual Before starting up the burner, refer to section and in compliance with the standards and “Safety test - with no gas supply”...

  • Page 32: Burner Start-Up (Light Oil)

    Start-up, calibration and operation of the burner Burner start-up (light oil) Feed electricity to the burner via the disconnecting switch on the boiler panel. Close the thermostats/pressure switches and turn the switch in Fig. 36 to position “MAN”. As soon as burner starts, check the fan rotation direction through the flame inspection window.

  • Page 33: Adjustments Prior To Ignition (Gas)

    Start-up, calibration and operation of the burner Adjustments prior to ignition (gas) Combustion head adjustment is already described on page 21. The manometer readings are used to calculate MAX burner output using the Tab. L. In addition, the following adjustments must also be made: –...

  • Page 34: Burner Adjustment (Gas)

    Start-up, calibration and operation of the burner Burner adjustment (gas) 6.9.2 Maximum output The optimum adjustment of the burner requires an analysis of flue gases at the boiler outlet. The MAX output must be set within the firing rate indicated in Adjust in sequence: Fig.

  • Page 35: Minimum Output

    Start-up, calibration and operation of the burner 6.9.3 Minimum output MIN output must be selected within the firing rate range indicated Switch off the burner using switch 1)(Fig. 36 on page 30), OFF on Fig. 3 on page 10. Press button 2)(Fig. 39) “Output decrease” position, release the mechanical cam I) (Fig.

  • Page 36: Pressure Switch Adjustment

    Start-up, calibration and operation of the burner 6.10 Pressure switch adjustment 6.10.1 Air pressure switch Adjust the air pressure switch after performing all other burner adjustments with the air pressure switch set to the start of the scale (Fig. 40). With the burner operating at MIN output, increase adjustment pressure by slowly turning the relevant knob clockwise until the burner locks out.

  • Page 37: Operation Sequence Of The Burner (Gas)

    Start-up, calibration and operation of the burner 6.11 Operation sequence of the burner (gas) 6.11.1 Burner start-up 6.11.2 Steady state operation • Control remote control TL closes. Burner without output regulator RWF Fan motor start-up. At the end of the start-up cycle, the servomotor control switches •...

  • Page 38: 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 39: 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 40: Flame Presence Check

    Maintenance 7.2.5 Safety components Check to make sure that no dust has accumulated inside the fan The safety components must be replaced at the end of their life or on its impellers, as this condition will cause a reduction in the cycle indicated in Tab.
  • Page 41 Maintenance LIGHT OIL OPERATION GAS OPERATION Filters (Fig. 46) 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 42: Opening The Burner

    Maintenance Opening the burner  Loosen the screws 1) and remove the hood 2)(Fig. 47).  Disconnect the light oil pipes 7)(Fig. 47). Disconnect the electrical supply from the burner  Disengage the articulated coupling 8) from the graduated by means of the system main switch. sector 9).

  • Page 43: 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 44: 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 45: 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 46 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 47 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 48 Problems - Causes - Remedies signalled by LED indicators Fault explanation Faults Cause Solution Post-diagnostics fault Initial power diagnostics fault Make sure that the status of inlets and Check T12, T13 and T14 outlets is correct upon ignition Local reset The user started the manual reset or the Check T21 inlet or reset for normal reset switch is faulty...
  • Page 49 Problems - Causes - Remedies signalled by LED indicators Faults Cause Solution Not used Internal processor timeout Internal fault Replace the control device Internal processor timeout Internal fault Replace the control device Combustion air check timeout The system could not perform verification tests of the combustion air during the burner Check the wiring or the air pressure switch sequence...

  • Page 50: A Appendix - Accessories

    20099905 0...16 bar 4...20 mA 3010214 Extended head kit Extended head Burner Standard head length (mm) Code length (mm) RLS 160/M MX 3010441 Soundproofing box kit Burner Code Type Reduction of noise levels RLS 160/M MX 3010404 C4/5 10 [dB(A)]...

  • Page 51: B Appendix - Electrical Panel Layout

    Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Functional layout RFGO-A22 Functional layout RFGO-A22 Functional layout RFGO-A22 Electrical wiring that is the responsibility of the installer Functional diagram RWF50... Indication of references / 1 .
  • Page 52 Appendix - Electrical panel layout 20148049...
  • Page 53 Appendix - Electrical panel layout 20148049...
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  • Page 57 Appendix - Electrical panel layout 20148049...
  • Page 58 Appendix - Electrical panel layout 20148049...
  • Page 59 Appendix - Electrical panel layout Wiring layout key Electrical control box XPGM Maximum gas pressure switch connector Filter to protect against radio disturbance Socket for kit XRWF RWF terminal board RWF Output power regulator Current input DC 4...20 mA Burner earth Current input DC 4...20 mA for remote setpoint XVOS Safety valve connector...
  • 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...

This manual is also suitable for:

20147789201477902014788720147888781t

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