Related Manuals for Riello RLS 1000/E FGR
Summary of Contents for Riello RLS 1000/E FGR
- Page 1 Installation, use and maintenance instructions Dual fuel gas oil/gas burners Modulating operation CODE MODEL 20169821 RLS 1000/E FGR 20170346 RLS 1200/E FGR 20170641 (1) - 10/2019...
- 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 Guarantee and responsibility............................5 Safety and prevention................................6 Introduction.................................. 6 Personnel training ............................... 6 Technical description of the burner ............................7 Burner designation ..............................7 Models available................................ - Page 4 Contents Burner ignition ................................34 Change of fuel................................34 Combustion air adjustment ............................34 6.10 FGR commissioning..............................35 6.11 Pressure switch adjustment ............................36 6.12 Final checks (with burner operating) ..........................37 Maintenance ....................................38 Notes on safety for the maintenance .........................38 Maintenance programme ............................38 Opening the burner ..............................41 Closing the burner..............................41 Faults - Possible causes - Solutions............................42 Appendix - Accessories ................................43...
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Page 5: Declarations
Declarations Declarations Declaration of Conformity in accordance with ISO / IEC 17050-1 These products are in compliance with the following Technical Standards: • EN 12100 • EN 676 • EN 267 According to the European Directives: 2006/42/CE Machine Directive 2014/35/EU Low Voltage Directive EMC 2014/30/EU Electromagnetic Compatibility... -
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: Guarantee And Responsibility
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
110V / 50-60Hz 1000 3/400/50 230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RLS 1000/E FGR 3/400/50 Star/Triangle 20169821 RLS 1200/E FGR 3/400/50 Star/Triangle 20170346 Burner categories - Countries of destination Country of destination Gas category SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO... -
Page 10: Technical Data
Technical description of the burner Technical data Model RLS 1000/E FGR RLS 1200/E FGR Output 1200/3750 ÷ 10600 1500/5500 ÷ 11500 min - max Delivery kg/h 100/315 ÷ 867 171/462 ÷ 942 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. 20171799 Fig. 1 RLS 1000/E FGR 1637 DN80 1678 1376 1498... -
Page 12: Firing Rates
1013 mbar (approx. 0 m limit of the diagram: a.s.l.), and with the combustion head adjusted as WARNING RLS 1000/E FGR = 3750 kW shown on page 21. RLS 1200/E FGR = 5500 kW D11552 RLS 1000/E FGR... -
Page 13: Burner Description
Technical description of the burner Burner description 30 31 20171802 Fig. 4 Lifting rings 25 Pump motor 26 Maximum oil pressure switch Fan motor 27 Minimum oil pressure switch Air damper servomotor 28 Combustion head gas pressure test point Oil modulator 29 Gas regulator Combustion head 30 3-way valve for the mechanical activation of the burner... -
Page 14: Electrical Panel Description
Fitting 3/4” - 1/2” (RLS 1200/E FGR) ....No. 1 Rotating elbow 1/2” (RLS 1000/E FGR)....No. 1... -
Page 15: 4.12 Azl Display
The AZL... display is a safety device! Avoid open- WARNING ing or modifying it, or forcing its operation. Riello S.p.A. cannot assume any responsibility for dam- age resulting from unauthorised interventions! The electronic cam is operated and programmed through the AZL5 interface... -
Page 16: Control Box For The Air/Fuel Ratio (Lmv51
To avoid accidents, material or environmental damage, observe the following instructions! The LMV51... is a safety device! Avoid opening or WARNING modifying it, or forcing its operation. Riello S.p.A. cannot assume any responsibility for damage re- sulting from unauthorised interventions! Risk of explosion! - Page 17 Technical description of the burner Electrical connection of flame detector • always separate the detector cables from the other cables: – Line capacitance reduces the magnitude of the flame signal. It is important for signal transmission to be almost totally free –...
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Page 18: Servomotor (Sqm 48
Technical description of the burner 4.14 Servomotor (SQM 48..) Warnings To avoid accidents, material or environmen- tal damage, observe the following instruc- tions! WARNING Avoid opening, modifying or forcing the ac- tuators. 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 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 20: Operating Position
For boilers with front flue passes 1)(Fig. 13) or flame inversion chamber, a protection in refractory material 5) must be inserted between the boiler fettling 2) and the blast tube 4). RLS 1000/E FGR M 20 This protective fettling must not compromise the extraction of the... -
Page 21: Securing The Burner To The Boiler
Installation Securing the burner to the boiler Prepare a suitable lifting system using rings 3) (Fig. 13). Insert the thermal protection supplied with the blast tube 4). Insert the entire burner on the boiler hole, previously fitted, as in Fig. 12, and fix it with the screws supplied. The seal between burner and boiler must be airtight. -
Page 22: Nozzle Installation
Return kg/h pressure pressure kg/h Fit the nozzle with a 24 mm (for RLS 1000/E FGR) and 41 mm (bar) (bar) (for RLS 1200/E FGR) box wrench, passing from the centre 1200 opening of the flame stability disc (Fig. 15). -
Page 23: Electrode Position
Installation 5.10 Electrode position 71.5 ± 1 Place the electrode on the ignition pilot observing the dimensions specified in Fig. 16. WARNING 18.5 D9218 Diffuser Electrode Fig. 16 5.11 Combustion head adjustment The air damper servomotor 4)(Fig. 4, a pag. 11) varies the air output according to the output demand, while manually a lever- age varies the combustion head adjustment. -
Page 24: Light Oil Supply
The fuel supply line must be installed by qualified height difference are higher than the values listed in Tab. J. personnel, in compliance with current standards RLS 1000/E FGR RLS 1200/E FGR and laws. +/- H Ø... - Page 25 Installation 5.12.3 Hydraulic connections Make sure that the flexible hoses to the pump supply and return line are installed correctly. CAUTION Follow the instructions below: Tighten the flexible hoses with the supplied gaskets. Take care that the hoses are not stretched or WARNING twisted during installation.
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Page 26: Fgr Duct System
Installation 5.13 FGR duct system – Normally the duct would connect to the stack as shown in through the control valves and into the fan. Fig. 22, with a 45° cut facing the flue gas flow and with the In cases of heavy condensation, a condensate drip leg may center of the cut centered in the stack. -
Page 27: Pump
Installation 5.14 Pump 5.14.1 Technical data Pump RLS 1000/E FGR RLS 1200/E FGR VBHRG VBHGRP Min. delivery rate at 40 bar pressure 1160 kg/h 1660 kg/h Delivery pressure range 9 - 40 bar 9 - 40 bar Max. suction depression 0.6 bar... -
Page 28: Gas Feeding
Installation 5.15 Gas feeding 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 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 29 Installation 5.15.2 Gas train 5.15.4 Gas pressure Approved according to standard EN 676 and provided separately The Tab. L indicates the pressure drop of the combustion head from the burner. and the gas butterfly valve depending on the operating output of the burner.
- Page 30 Installation Example RLS 1000/E FGR with natural gas G20: Operation at maximum modulating output Gas pressure at test point 1)(Fig. 29) = 44.2 mbar Pressure in combustion chamber 5 mbar 44.2 - 5 = 39.2 mbar A pressure of 39.2 mbar, column 1, corresponds in Tab. L to an output of 8000 kW.
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Page 31: Activation Of The Burner Lance
Installation 5.16 Activation of the burner lance The burner is equipped with a spray lance for light oil. Fig. 31 shows the 3-way valve used for the mechanical activation of the burner lance and the point at which the compressed air in- put A) must be connected. -
Page 32: Electrical Wiring
Installation 5.17 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 33: Calibration Of The Thermal Relay
Installation 5.17.2 Supply cables and external connections Key (Fig. 33) Electrical supply passage Minimum gas pressure switch All the cables to be connected to the burner should be passed Pressure switch for VPS gas valve leak detection through cable grommets, as shown in Fig. 33. Gas train To guarantee the protection level of the burner, it Consents/Safety... -
Page 34: 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 35: Burner Ignition (Light Oil)
Start-up, calibration and operation of the burner Burner ignition (light oil) Position the selector 1)(Fig. 36) in “AUTO”. This lowering of the fuel pressure can cause the burner to lockout and can sometimes give rise to pulsations. Position the selector 2) in “OIL” to select light oil fuel. Once the following adjustments have been made, the ignition of When the limit thermostat (TL) is closed, the “HEAT REQUEST”... -
Page 36: Burner Ignition
Start-up, calibration and operation of the burner Burner ignition The burner should light after having performed the above steps. In the event of a burner lockout, more than two If the motor starts up, but the flame does not appear and the con- consecutive burner reset operations could cause trol box goes into lockout, reset it and wait for a new ignition at- damage to the installation. -
Page 37: Fgr Commissioning
Start-up, calibration and operation of the burner 6.10 FGR commissioning The flue gas recirculation (FGR) function is used to reduce the First time FGR set up NOx content of flue gases. This is accomplished by feeding a cer- Modify the factory preset: FGR-Mode = time (Auxiliary actuator 3 tain proportion of the flue gas back to the combustion chamber, is held in the ignition position until an adjustable time is reached). -
Page 38: Pressure Switch Adjustment
Start-up, calibration and operation of the burner 6.11 Pressure switch adjustment 6.11.1 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 39: Final Checks (With Burner Operating)
Start-up, calibration and operation of the burner 6.11.5 Oil pressure switch Check the calibration of the maximum and minimum oil pressure switches, using the adjustment screw as shown in Fig. 42. The check should be carried out by individually varying the cali- bration of each pressure switch. -
Page 40: 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 41 Maintenance Burner 7.2.5 Pump unit Clean the outside of the burner. Prior to performing any operations/maintenance on the pump unit, make sure the electrical power supply to the burner is turned off by means of the Check to make sure that no dust has accumulated inside the fan system's main switch.
- Page 42 Maintenance GAS OIL OPERATION GAS OPERATION Pump Gas leaks The delivery pressure must comply with Tab. H, a pag. 20. Make sure that there are no gas leaks on the pipework between The depression must be less than 0.45 bar. the gas meter and the burner.
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Page 43: Opening The Burner
Maintenance Opening the burner Disconnect the derivation unit socket and the QRI photocell; disconnect the electrode cable; Disconnect the electrical supply from the burner disconnect the socket 4) of the fuel and FGR servomotor; by means of the main system switch. ... -
Page 44: Faults - Possible Causes - Solutions
Faults - Possible causes - Solutions Faults - Possible causes - Solutions If faults arise in ignition or operations, the burner performs a "safety stop", which is signalled by the red burner lockout LED. The display visualises alternately the lockout code and the rela- tive diagnostic. -
Page 45: A Appendix - Accessories
Appendix - Accessories Appendix - Accessories Software interface kit Burner Code RLS 1000/E FGR 3010388 RLS 1200/E FGR Soundproofing box kit Burner Code RLS 1000/E FGR 3010401 RLS 1200/E FGR Pressure switch kit for leak detection control (supplied as standard) -
Page 46: Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output Functional layout star/triangle starter LMV51..functional layout LMV51..functional layout LMV51..functional layout LMV51..functional layout LMV51..functional layout LMV51..functional layout LMV51.. - Page 47 Appendix - Electrical panel layout 20170641...
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- Page 49 Appendix - Electrical panel layout & & 20170641...
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- Page 60 Appendix - Electrical panel layout 20170641...
- Page 61 Appendix - Electrical panel layout Wiring layout key Control box Derivation unit connector Display for control box XPGM Maximum gas pressure switch connector Output probe in current Oil pressure switch connector Output device in current to modify remote setpoint XPO1 Oil return pressure switch connector Load indicator at current input Flame sensor connector...
- 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...