Related Manuals for Riello RLS 120/E FGR
Summary of Contents for Riello RLS 120/E FGR
- Page 1 Installation, use and maintenance instructions Dual fuel light oil/gas burner Modulating operation CODE MODEL 20166921 RLS 120/E FGR 20168262 (3) - 01/2020...
- Page 2 Translation of the original instructions...
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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 5.14.2 Gas pressure ................................29 5.15 Electrical connections ..............................30 5.15.1 Supply cables and external connections passage .....................30 Start-up, calibration and operation of the burner ........................31 Notes on safety for the first start-up ...........................31 Adjustments prior to ignition (light oil) ........................31 6.2.1 Nozzle ..................................31 6.2.2...
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Page 5: Declarations
Electromagnetic Compatibility Quality is ensured by means of an ISO 9001:2015 certified quality and management system. Legnago, 21.04.2018 General Manager Research and Development Director RIELLO S.p.A. - Burners Department RIELLO S.p.A. - Burners Department Eng. U. Ferretti Eng. F. Comencini 20168262... -
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 Background The burners have been designed and built in compliance with which the burner has been regulated, the pressurisation of the current regulations and directives, applying the known technical combustion chamber, the dimensions of the combustion cham- rules of safety and envisaging all the potential danger situations. -
Page 9: Technical Description Of The Burner
3/400/50 3 / 230V / 50Hz 3/230/50 Voltage of auxiliaries: 230V / 50-60Hz 230/50/60 110V / 50-60Hz 110/50/60 3/400/50 230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RLS 120/E FGR FS1 3/400/50 Direct 20166921 Tab. A 20168262... -
Page 10: Burner Categories - Countries Of Destination
EN ISO 3746. To reduce the NOx of the nitric oxides in the event of an FGR system, the maximum burner output obtained chases based on the specific application and within the limits agreed upon with the Riello WARNING WARNING Technical Office. -
Page 11: Electrical Data
Bear in mind that inspection of the combustion head requires the burner to be opened and the rear part drawn back on the slide bars. 20169315 Fig. 1 RLS 120/E FGR 886 330 556 640 950 189 218 1482 2” DN65 Tab. -
Page 12: Firing Rate
Technical description of the burner Firing rate The maximum output should be chosen within area A)(Fig. 2) of For the operation inside the area B)(Fig. 2) the diagram. remove the gas nozzle as shown (“Removing The minimum output must not be lower than the minimum limit the nozzles”... -
Page 13: Commercial Boilers
Technical description of the burner Commercial boilers The burner is suitable for operating on both flame inversion boil- ers (*), as well as on boilers with a combustion chamber with run- off from the bottom (three flue passes) on which the best results 250 mm MAX for low NO emissions are obtained. -
Page 14: Burner Description
Technical description of the burner 4.11 Burner description Seen from “A” 20169319 Fig. 5 Combustion head 30 Flame stability disc Ignition electrode for pilot 31 Connector G1/4 Screw for combustion head adjustment 32 Lifting rings Maximum gas pressure switch 33 Flue gas recirculation butterfly valve Pipe coupling 34 Flue gas recirculation servomotor Gas servomotor... -
Page 15: Control Box For Controlling The Air/Fuel Ratio (Bt340)
The control box is a safety device! Avoid opening WARNING 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! An incorrect configuration can provoke fuel over-... -
Page 16: Operation Sequence Of The Burner (Gas Operation)
Technical description of the burner 4.13 Operation sequence of the burner (GAS operation) X20+X21 S9612 Fig. 7 Key to layout (Fig. 7) Key to layout (Fig. 7) FGR enabling Any position Gas valve 1 Safety circuits enabling standby time Gas valve 2 (boiler and fuel) Pilot valve Gas valve opening time (with valve leak... -
Page 17: Operation Sequence Of The Burner (Light Oil Operation)
Technical description of the burner 4.14 Operation sequence of the burner (LIGHT OIL operation) CPI/POC X20+X21 X32+X33 S9782 CPI= Closed Position Indicator POC= Proof Of Closure Oil irrelevance time P323, has an effect on the oil safety chain and on the minimum oil pressure when the air valve is opened. Fig. -
Page 18: Servomotor (662R5
Technical description of the burner 4.15 Servomotor (662R5...) Warning To avoid accidents, material or environmental damage, observe the following instructions! Do not open, modify or force the actuators. WARNING WARNING All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ... -
Page 19: 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 20: Operating Position
D455 plete with its fettling. Fig. 13 The available lengths L are those indicated in the table below. Blast tube (mm) Short RLS 120/E FGR 325-368 M 16 RLS 120/E FGR Tab. K Tab. J For boilers with a front flue gas passes 13)(Fig. 15 on page 19) -
Page 21: Positioning Electrode And Pilot
Installation Positioning electrode and pilot 2 3 m m Before fixing the burner to the boiler, check the correct positioning of the electrodes and pilot as indicated Fig. 25. WARNING WARNING The following is required to perform the check: remove the screw 1)(Fig. 15); 3 5 m m ... -
Page 22: Securing The Burner To The Boiler
Installation Securing the burner to the boiler pull back the burner on the guides 5) by about 100 mm; disconnect the electrode leads, then unthread the burner Provide an adequate lifting system of the burner. completely from the guides; ... -
Page 23: Nozzle
267 standard. In order to guarantee that emissions do not vary, Remove the screw 1)(Fig. 19) and the internal part 2); recommended and/or alternative nozzles specified by Riello in remove the nozzle 1)(Fig. 20) using a wheel spanner;... -
Page 24: Removing The Nozzles
Installation 5.8.3 Removing the nozzles Necessary for the operation within area B) of the Fig. 2 on page 10. extract the internal part of the combustion head as described in paragraph “Nozzle installation” on page 21; unscrew screws 1)(Fig. 22) and nuts 2); ... -
Page 25: Flue Gases Recirculation Piping System
Installation 5.11 Flue gases recirculation piping system – Normally the pipe would be connected to the flue stack as – Establish whether reduction joints are needed to connect the shown in Fig. 26, forming an angle of 45° facing the flow of flue gases recirculation control valve and the relative shut-off the flue gases and with the centre of the angle located at the valve. -
Page 26: Flue Gas Recirculation Line Sizing
Installation 5.11.1 Flue gas recirculation line sizing The Tab. L can be helpful to correctly size the FGR pipes taking Where: flue gases from boiler stack base up to the burner intake port. – ) is the percentage of CO measured at the burner coupling –... -
Page 27: Light Oil Supply
Installation 5.13 Light oil supply Explosion danger due to fuel leaks in the pres- ence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure that the fuel interception tap 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: Hydraulic Circuit Diagram
Installation 5.13.4 Hydraulic circuit diagram 20159817 Fig. 30 Key (Fig. 30) Pump suction OPERATION Pump return line and nozzle return line Pre-purging phase: Pump by-pass screw valves 5), 6), 13) and 14) closed. Pump pressure regulator Ignition and operation phase: Safety valve valves 5), 6), 13) and 14) open. -
Page 29: Pump
Installation 5.13.5 Pump Technical data After 5 or 6 starting operations allow 2 or 3 minutes for the trans- Pump former to cool. Min. delivery rate at 20 bar pressure 195 kg/h Do not illuminate the flame sensor or the burner will lock out; the Delivery pressure range 10 - 21 bar burner should lock out anyway about 10 seconds after it starts. -
Page 30: Gas Supply
Installation 5.14 Gas supply Explosion danger due to fuel leaks in the pres- ence of a flammable source. Precautions: avoid knocking, attrition, sparks and heat. Make sure that the fuel interception tap 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 31: Gas Pressure
Installation 5.14.2 Gas pressure 1 p (mbar) 2 p (mbar) Indicates the pressure drop of the combustion head and the gas butterfly valve depending on the operating output of the burner. The values shown the table refer to: – natural gas G 20 NCV 10 kWh/Nm (8.6 Mcal/Nm –... -
Page 32: Electrical Connections
Installation 5.15 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 33: 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 34: Burner Start-Up
Start-up, calibration and operation of the burner Burner start-up Feed electricity to the burner via the disconnecting switch on the boiler panel. Close the thermostats/pressure switches and set the selec- tor 9)(Fig. 5 on page 12) to “ON”. ... -
Page 35: Burner Adjustment
Start-up, calibration and operation of the burner Burner adjustment 6.6.1 Gas/air delivery adjustment 6.6.2 Light oil/air delivery adjustment Slightly move towards the maximum flow rate (butterfly valve Position the selector for selecting the light oil fuel. fully open); ... -
Page 36: Maximum Gas Pressure Switch
Start-up, calibration and operation of the burner 6.7.2 Maximum gas pressure switch Adjust the maximum gas pressure switch after having performed all the other burner adjustments with the maximum gas pressure switch set at the end of the scale (Fig. 43). With the burner operating at maximum output, lower the adjust- ment pressure by slowly turning the relative knob anticlockwise until the burner locks out. -
Page 37: Start-Up The Flue Gases Recirculation System
Start-up, calibration and operation of the burner Start-up the flue gases recirculation system The flue gases recirculation function has the task of reducing the Once the settings of the fuel/air ratio of the curves without flue quantity of NOx contained in the combustion gases. To this end, gases recirculation, it is possible to pass to the settings of the a part of the combustion gases is put back into the combustion FGR servomotor. -
Page 38: Burner Flame Goes Out During Operation
Start-up, calibration and operation of the burner 6.11 Burner flame goes out during operation If the flame accidentally goes out during operation, the control box carries out a recycle (i.e. it repeats the start-up phase once, and makes a further ignition attempt). If the flame is still absent, the control box goes into lockout. -
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 oper- safety, yield and duration of the burner. ations: It allows you to reduce consumption and polluting emissions and Disconnect the burner's electrical supply using the to keep the product in a reliable state over time. -
Page 40: Safety Components
Maintenance 7.2.4 Safety components Check to make sure that no dust has accumulated inside the fan The safety components should be replaced at the end of their life or on its impellers, as this condition will cause a reduction in the cycle indicated in the Tab. -
Page 41: Checking The Air And Gas Pressure On The Combustion Head
Maintenance 7.2.5 Checking the air and gas pressure on the GAS OPERATION combustion head Gas leaks To carry out this operation it is necessary to use a pressure gauge Make sure that there are no gas leaks on the pipe between the to measure the air and gas pressure at the combustion head, as gas meter and the burner. -
Page 42: Opening The Burner
Maintenance Opening the burner Loosen the 4 screws 1)(Fig. 49) and remove the hood 2). Disconnect the burner's electrical supply using the Disconnect the light oil pipes using the fittings 3). main system switch. Disconnect the pipe 4). Make sure that both electrical supplies have been ... -
Page 43: 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 there are further lockouts or faults "safety stop", which is signalled by the red burner lockout LED. with the burner, the maintenance interventions The operator panel display shows the lockout code. - Page 44 Faults - Possible causes - Solutions EN67 Error P301=0 P301=2 Description code P328>0 P328>0 Unlimited Fuel/air ration command blocked: Channel Channel Direction: P 2 = The actuator does not move, namely no position feedback. Channel backward, forward If this indication appears, the monitoring of fault 271 is damaged. The actuator does not find the reference position Channel Direction:...
- Page 45 Faults - Possible causes - Solutions EN67 Error P301=0 P301=2 Description code P328>0 P328>0 Fault during the seal test: gas pressure still active Fault during the seal test: no gas pressure detected Request for manual vent of the gas line CPI/POC in unexpected state signal 1 *1) 1 *1)
- Page 46 Faults - Possible causes - Solutions EN67 Error P301=0 P301=2 Description code P328>0 P328>0 The channel remains outside the 1 monitoring band for too long Channel The channel mode of the air/fuel ratio control does not correspond Channel to the type of activation Channel + The direct control channel moves to an invalid position, i.e.
- Page 47 Faults - Possible causes - Solutions EN67 Error P301=0 P301=2 Description code P328>0 P328>0 Secure parameter writing could not be completed. Device is blocked contact the After Sales Service Tab. T *1) The system will not be restarted until the condition that generated the fault is eliminated (i.e.
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Page 48: Appendix - Accessories
0...2.5 bar Output probe 3010213 Pressure 0...16 bar 4...20 mA 3010214 Software interface kit Burner Code RLS 120/E FGR 20130843 O2 control kit - CO Burner Code RLS 120/E FGR 20101753 O2 - CO high efficiency control kit Burner Code... -
Page 49: B Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Single-wire output layout Functional layout BT340 Functional layout BT340 Functional layout BT340 Functional layout BT340 Functional layout LCM100 Functional layout LCM100 Electrical wiring that is the responsibility of the installer Electrical wiring that is the responsibility of the installer Indication of references / 1 . - Page 50 Appendix - Electrical panel layout 20168262...
- Page 51 Appendix - Electrical panel layout 20168262...
- Page 52 Appendix - Electrical panel layout 20168262...
- Page 53 Appendix - Electrical panel layout 20168262...
- Page 54 Appendix - Electrical panel layout 20168262...
- Page 55 Appendix - Electrical panel layout 20168262...
- Page 56 Appendix - Electrical panel layout 20168262...
- Page 57 Appendix - Electrical panel layout 20168262...
- Page 58 Appendix - Electrical panel layout 29-4 51/) 29-4 51/) 20168262...
- Page 59 Appendix - Electrical panel layout Wiring layout key Burner components VS-VS1 Oil circuit valves Boiler components Burner terminal strip Valve group terminal board Control box for the air/fuel ratio Adjustment module XPGM Maximum gas pressure switch connector Fuel management module XPGMin Minimum gas pressure switch connector Operator panel...
- 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...