Related Manuals for Riello RLS 160/E MX
Summary of Contents for Riello RLS 160/E MX
- Page 1 Installation, use and maintenance instructions Dual fuel gas oil/ gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 20073920 RLS 160/E MX 781T1 20081721 RLS 200/E MX LS002 T1 20121303 (4) -03/2021...
- 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 5.15.1 Supply cables and external connections passage .....................32 5.16 Thermal relay calibration of the fan motor .........................33 5.17 Thermal relay calibration of the pump motor ......................33 Start-up, calibration and operation of the burner ........................34 Notes on safety for the first start-up ...........................34 Adjustments prior to ignition (light oil) ........................34 6.2.1 Nozzle ..................................34...
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Page 5: Declarations
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015. 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... -
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 rules of safety and envisaging all the potential danger situations. -
Page 9: Technical Description Of The Burner
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 160/E MX FS1 3/400/50 Direct 20073920 RLS 200/E MX FS1 3/400/50 Direct 20081721 Tab. A 20121303... -
Page 10: Burner Categories - Countries Of Destination
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO 2ELL (43,46 ÷ 45,3 MJ/m (0°C)) 2E(R)B LU - PL Tab. B Technical data Model RLS 160/E MX FS1 RLS 200/E MX FS1 Power 421/947 - 1845 401/1400 - 2322 min - max Delivery kg/h 35/80 - 155... -
Page 11: Electrical Data
Technical description of the burner Electrical data Modello RLS 160/E MX FS1 RLS 200/E MX FS1 Main electrical supply 3~ 400V - 50Hz +/-10% Auxiliary circuit electrical supply 1N~230V - 50Hz Fan motor IE3 2895 2935 230/400 230/400 4500 5500 15.0/8.7... -
Page 12: Firing Rates
Technical description of the burner Firing rates The maximum output should be chosen within area A)(Fig. 2) of The firing rate was obtained with an ambient tem- the diagram. perature of 20°C and a barometric pressure of The minimum output must not be lower than the minimum limit 1013 mbar (approx. -
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” 42-43 20126922 45 33 Fig. 5 Combustion head 27 Gas input pipe Ignition electrodes 28 Gas butterfly valve Screw for combustion head adjustment 29 Boiler fixing flange Maximum gas pressure switch 30 Flame stability disc Pipe coupling 31 Bracket for application of output power regulator RWF50... -
Page 15: 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 16 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...
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Page 17: Operation Sequence Of The Burner (Gas Operation)
Technical description of the burner 4.12.1 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 18: Operation Sequence Of The Burner (Light Oil Operation)
Technical description of the burner 4.12.2 Operation sequence of the burner (light oil operation) Operation Start-up Switching off Phase number Timer - Resolution - Ratio 30 s Timer 1 (parameters) Timer 2 (parameters) Timer 3 = max. phase time RAST plug Input signals PIN number X3-04 Pin 1/2... -
Page 19: List Of The Phases (Gas Operation)
Technical description of the burner 4.12.3 List of the phases (gas operation) 4.12.4 List of the phases (light oil operation) Phase Description Phase Description Ph00 Lockout phase Ph00 Lockout phase Ph02 Safety phase Ph02 Safety phase Ph10 Closing paused Ph10 Closing paused Ph12 Standby... -
Page 20: Description Of The Symbols On The Display
Technical description of the burner 4.13.1 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 21: Servomotors
Technical description of the burner 4.14 Servomotors Introduction The servomotors are commanded by the control box, which con- stantly checks their position by means of a return signal from the optic sensor inside the servomotor. For this reason it is absolutely forbidden to re- move the cover of the servomotors. -
Page 22: 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 23: Operating Position
D455 Fig. 14 plete with its fettling. The available lengths L are those indicated in the table below. RLS 160/E MX 325-368 M 16 Blast tube (mm) Short... -
Page 24: Securing The Burner To The Boiler
Installation Securing the burner to the boiler Before fixing the burner to the boiler, check from the opening of the blast tube if the electrodes are positioned correctly as in Fig. 26. If in the previous check the position was not correct, remove the screw 1)(Fig. -
Page 25: 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 26: Shutter Movement
Installation 5.7.3 Shutter movement For model RLS 200/E MX only Necessary for the operation within area B) of the “Firing rates” flame funnel 1); on page 10. unscrew the 4 screws 2) and remove the flame funnel; Withdraw the inner part of the combustion head as ... -
Page 27: Combustion Head Adjustment
Installation Combustion head adjustment The adjustment of the combustion head depends only on the maximum output of the burner. Turn the screw 5)(Fig. 24) until the notch indicated by the dia- gram (Fig. 25) corresponds with the front part of the flange 6). To facilitate the adjustment, loosen the screw 1)(Fig. -
Page 28: Closing The Burner
Installation 5.11 Closing the burner Once the combustion head adjustment is completed: replace screws 2) and lifting rings on the two slide bars 3); reassemble the burner on the guides 3) at about 100 mm connect the light oil pipes by screwing the two fittings 16); from the pipe coupling 4) - burner in the position shown in ... -
Page 29: Light Oil Supply
Installation 5.12 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 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 30: Hydraulic Connections
Installation 5.12.3 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. 30). It is necessary to connect both flexible hoses to the pump (Fig. 29). The pump will break down immediately if it is run with the return line closed and the by-pass screw inserted. -
Page 31: Pump
Installation 5.13.1 Pump Technical data SUNTEC TA2 pump Min. delivery rate at 20 bar pressure 350 kg/h Delivery pressure range 7 - 40 bar Max. suction depression 30 cm Hg Viscosity range 4 - 75 cSt 20108975 Max. light oil temperature 150 °C Fig. -
Page 32: Gas Feeding
Installation 5.14 Gas feeding Explosion danger due to fuel leaks in the pres- 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 33: Gas Pressure
Find, in related to the burner concerned, the pressure value 1468 closest to the result of the subtraction. 1682 10.6 Read off the corresponding output on the left. 1895 13.2 Example with G 20 natural gas - RLS 160/E MX: 2109 11.4 16.0 Maximum output operation 2322 13.6 19.0 Gas pressure at test point 1)(Fig. -
Page 34: Electrical Wiring
Installation 5.15 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 35: Thermal Relay Calibration Of The Fan Motor
Installation 5.16 Thermal relay calibration of the fan motor The thermal relay (Fig. 40) 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 36: 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 37: Burner Start-Up
Fig. 44 signed to exclude the operation with light oil and to activate the gas operation. WARNING This modification must be made by qualified Riello personnel. There are two change of fuel options: with the “OIL-EXT-GAS” selector (Fig. 43); with a remote selector connected to the main terminal Fig. -
Page 38: 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 39: 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 (Fig. 49) after making all other burner adjustments with the maximum gas pressure switch set to the end of the scale. To calibrate the maximum gas pressure switch, open the tap and then connect a pressure gauge to its pressure test point. -
Page 40: Visualisation And Programming Mode
Start-up, calibration and operation of the burner Visualisation and programming mode 6.8.1 Normal mode 6.8.1.4 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 41: Info Mode
Start-up, calibration and operation of the burner 6.8.1.5 Reset procedure Releasing the “F” key, the standard visualisation appears, with the current load percentage flashing: this means that the burner The burner is in lockout when the red indicator light on the oper- is working in Manual mode (any outside adjustment is excluded ator panel is lit up, and the display visualises the lockout code (in and only the safety devices are active). -
Page 42: Service Mode
Start-up, calibration and operation of the burner The list of parameters (in the sequence in which they are dis- 6.8.3.1 Operating mode on Info Mode and Service Mode played) is shown in Tab. P. After access to these levels, the display visualises the number of the parameter (flashing) on the left, and the corresponding value Parameter on the right. - Page 43 Start-up, calibration and operation of the burner Once you have confirmed, the sign “–” will appear. 6.8.4.2 Assigning parameter levels Continue in the same way for the other characters. The parameters level is subdivided into groups as shown in Tab. After inserting the last character of the password, confirm by pressing the key “i/reset”: if the password inserted is correct you Parameter...
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Page 44: Parameter Modification Procedure
Start-up, calibration and operation of the burner Parameter modification procedure After accessing the level and group of parameters, the display visualises the number of the parameter (flashing) on the left, and The set value does not require confirmation. the corresponding value on the right. WARNING If the value is not visualised, press the key “i/reset”... - Page 45 Start-up, calibration and operation of the burner 6.9.0.2 CALC function The diagram (Fig. 53) shows how the fuel modulation curve is modified if the values of point “P5” are changed. By keeping the “+” key pressed for more than 3 s, the points from “P6”...
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Page 46: Start-Up Procedure
Start-up, calibration and operation of the burner 6.10 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 The burner goes to its switch-on position, point “P0”, defined in it is necessary to set the modulation curve of the burner. - Page 47 Start-up, calibration and operation of the burner Solve the problem, referring to the paragraph Ignition failure. Halfway through the procedure (i.e. around point P4 or P5), you are advised to measure gas delivery and check that the output is To unlock, see Reset procedure. The display shows “OFF UP0” about 50% of the maximum output.
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Page 48: Backup / Restore Procedure
Start-up, calibration and operation of the burner 6.11 Backup / Restore procedure At the end of the Start-up procedure it is wise to carry out a The parameter bAC_UP appears on the display screen: backup, creating a copy of the data memorised on the LMV 26..., in the RDI 21 display panel. -
Page 49: Restore
Start-up, calibration and operation of the burner NOTE: The parameter bAC_UP appears on the display screen: If an error occurs during the backup process, the display screen shows a negative value. Refer to diagnostic code 137 to determine the cause of the error (see section List of parameters). -
Page 50: List Of Parameters
Start-up, calibration and operation of the burner After approx 8 seconds (it depends on the duration of the pro- NOTE: gramme), the 0 value appears on the display screen, this is to in- When the restore process is successfully completed, the 0 dicate that the restore process has been completed correctly. - Page 51 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 Standby time before a new attempt in event of com- munication fault Set values: Modification 7200s...
- Page 52 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 Uphill train fan motor Modification 0.2s Service Mode Maximum time to reach low flame Modification 0.2s 10 min...
- Page 53 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 operation mode (fuel supply line, modulating/ stage, servomotors, etc.) -- = not defined (eliminate curves) 1 = Gmod 2 = Gp1 mod 3 = Gp2 mod...
- Page 54 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: Post-purging time (no extraneous light Modification 0.2s 108 min 0.2s 0.2s Service Mode...
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Page 55: 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 Result of the sampling of the contact (codified in bits) Bit 0.0 = 1: Minimum pressure switch Bit 0.1 = 2: Maximum pressure switch Bit 0.2 = 4: Pressure switch control valves Bit 0.3 = 8: Air pressure switch... -
Page 56: Burner Flame Goes Out During Operation
Start-up, calibration and operation of the burner 6.15 Burner flame goes out during operation If the flame accidentally goes out during operation, the control If the flame is still absent, the control box goes into lockout. box carries out a recycle (i.e. it repeats the start-up phase once, and makes a further ignition attempt). -
Page 57: 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 Turn off the burner's electrical supply using the to keep the product in a reliable state over time. - Page 58 Maintenance Electrical current to flame sensor Combustion Clean the glass cover from any dust that may have accumulated. In case the combustion values found at the beginning of the inter- To remove the flame sensor, pull out outwards; it is only pressed vention do not respect the standards in force or, in any case, do not correspond to a proper combustion, contact the Technical As- Min value for a good work: 70 µA.
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Page 59: Safety Components
Maintenance 7.2.4 Safety components 7.2.5 Checking the air and gas pressure on the combustion head The safety components must be replaced at the end of their life cycle indicated in Tab. X. The specified life cycles do not refer to To carry out this operation it is necessary to use a pressure gauge the warranty terms indicated in the delivery or payment to measure the air and gas pressure at the combustion head, as... -
Page 60: Opening The Burner
Maintenance Opening the burner Loosen the 4 screws 1)(Fig. 58) and remove the hood 2). Turn off the burner's electrical supply using the Disconnect the light oil pipes using the fittings 3). main system switch. Disconnect the tie-rod 4) from the sector 5). Make sure that both electrical supplies have been ... -
Page 61: Faults - Probable Causes - Solutions
Faults - Probable causes - Solutions Faults - Probable 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 62 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Leak test Check if the valve on the side of the burner has any leaks. V2 leaks Check if the pressure switch for the leak test (PGVP) is closed when gas pressure is not present.
- Page 63 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Safety circuit open /Burner flange open, extraneous light, air pressure, POC - Alarm lockout at start Safety circuit open /Burner flange, air pressure, fuel pressure, POC - Alarm lockout at start Safety circuit open /Burner flange, extraneous light, air pressure, fuel pressure, POC - Alarm lockout at start...
- Page 64 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code It was not possible to reach the target position within the Position error requested tolerance range. 1. Check if the servomotor is blocked or overloaded. Circuit open shown on the servomotor connection.
- Page 65 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code 0 Min. pressure switch 1 Max. pressure switch 2 Valve operation test pressure switch 3 Air pressure 4 Load controller open 5 Load controller on/off Can be caused by capacitive loads or presence of DC voltage 6 Load controller closed Blocked upon irregularity...
- Page 66 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Backup – the data comparison between the internal 243 (-13) Repeat the reset and backup microprocessors is irregular The backup data are incompatible with the current version of 244 (-12) The backup data are incompatible the software;...
- Page 67 Faults - Probable causes - Solutions Error Diagnostic code Meaning of the LMV 26... system Recommended measures code Redefine the operation mode (parameter 201) Internal error Carry out a reset; if the error arises repeatedly, replace the control box Phase number Program stop The program stop is active (no error) Carry out a reset;...
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Page 68: A Appendix - Accessories
3010094 Soundproofing box kit Burner Code RLS 160-200/E MX 3010404 Tubes kit Burner Code RLS 160/E MX 3010249 RLS 200/E MX 20035848 Software interface kit (ACS410 + OCI410.30) - Service Level Burner Code RLS 160-200/E MX 3010436 Modbus interface kit... -
Page 69: B Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output LMV26..operational layout LMV26..operational layout LMV26..operational layout LMV26..operational layout LMV26..operational layout Electrical connections set by installer Electrical connections set by installer RWF50... - Page 70 Appendix - Electrical panel layout 20121303...
- Page 71 Appendix - Electrical panel layout 20121303...
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- Page 73 Appendix - Electrical panel layout 20121303...
- Page 74 Appendix - Electrical panel layout 20121303...
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- Page 77 Appendix - Electrical panel layout 20121303...
- Page 78 Appendix - Electrical panel layout 20121303...
- Page 79 Appendix - Electrical panel layout 20121303...
- Page 80 Appendix - Electrical panel layout Wiring layout key Burner components Air servomotor Boiler components Gas servomotor Ignition transformer Control box for the air/fuel ratio Operator panel Limit thermostat/pressure switch Filter to protect against radio disturbance Adjustment thermostat/pressure switch Output regulator RWF50 Safety thermostat/pressure switch Fuel meter VFOil...
- Page 84 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...