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Installation, use and maintenance instructions
Dual fuel light oil/ gas burners
GB
Progressive two stage or modulating operation
20121980
C9161410
20114841
20112654
C9162410
C9162401
20114853
20144501
20143350
20101061
20121979
20075884
20101057
CODE
MODEL
RLS 300/EV FGR
RLS 400/EV FGR
RLS 500/EV FGR
RLS 650/EV FGR
RLS 800/EV FGR
20102963 (6) - 10/2022
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Related Manuals for Riello RLS 300/EV FGR
Summary of Contents for Riello RLS 300/EV FGR
- Page 1 Installation, use and maintenance instructions Dual fuel light oil/ gas burners Progressive two stage or modulating operation CODE MODEL 20121980 C9161410 RLS 300/EV FGR 20114841 20112654 C9162410 RLS 400/EV FGR C9162401 20114853 20144501 RLS 500/EV FGR 20143350 20101061 RLS 650/EV FGR...
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Page 3: Table Of Contents
Contents Information and general instructions ..............3 Information about the instruction manual . - Page 4 Contents 4.14.2 Gas feeding line................33 4.14.3 Gas pressure .
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Page 5: Information And General Instructions
Information and general instructions Information and general instructions Information about the instruction manual 1.1.1 Introduction 1.1.4 Danger: live components The instruction manual supplied with the burner: This symbol indicates operations which, if not car- is an integral and essential part of the product and must not be ried out correctly, lead to electric shocks with lethal separated from it;... -
Page 6: Guarantee And Responsibility
Information and general instructions Guarantee and responsibility The manufacturer guarantees its new products from the installa- 1.2.1 Owner’s responsibility tion date, in accordance with the regulations in force and/or the Please pay attention to the Safety Warnings contained within sales contract. At the moment of the first start-up, check that the this instruction manual. -
Page 7: Safety And Prevention
Safety and prevention Safety and prevention Introduction The burners have been designed and built in compliance with facturer; current regulations and directives, applying the known technical the type and pressure of the fuel, the voltage and frequency of rules of safety and envisaging all the potential danger situations. the electrical power supply, the minimum and maximum deliv- eries for which the burner has been regulated, the pressurisa- It is necessary, however, to bear in mind that the imprudent and... -
Page 8: Technical Description Of The Burner
Technical description of the burner Technical description of the burner Technical data Model RLS 300/EV FGR RLS 400/EV FGR RLS 500/EV FGR Output High 1387 – 4220 (3834*) 1998 – 4995 (4541*) 2775 – 5740 (5217*) MBtu/hr 4732 – 14390 (13082*) 6817 –... -
Page 9: Electrical Data
Technical description of the burner Electrical data Model RLS 300/EV FGR RBNA Code 20121980 C9161410 Control circuit power supply V/Ph/Hz 120/1/60 Main power supply (+/- 10%) V/Ph/Hz 230/3/60 460/3/60 575/3/60 Fan motor 3540 3540 3540 NEMA Premium Efficiency IE3 Pump motor... - Page 10 Technical description of the burner Model RLS 500/EV FGR RBNA Code 20144501 Control circuit power supply V/Ph/Hz 120/1/60 Main power supply (+/- 10%) V/Ph/Hz 230/3/60 460/3/60 575/3/60 Fan motor 3555 3555 3555 NEMA Premium Efficiency IE3 24.8 Pump motor 3515 3515 3515 NEMA Premium Efficiency IE3...
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Page 11: Burner Models Designation
Technical description of the burner Burner models designation Model Code Code RBNA Voltage Fan motor starting Flame safeguard 20121980 230/3/60 RLS 300/EV FGR 20114841 C9161410 460/3/60 Inverter Burner mounted 575/3/60 230/3/60 RLS 400/EV FGR 20114853 C9162410-20112654 460/3/60 Inverter Burner mounted... -
Page 12: Burner Dimensions
R. Bear in mind that inspection of the combustion head requires the burner to be opened by rotating the rear part on the hinge. 20092552 Fig. 2 inch RLS 300/EV FGR ANSI 3” ANSI 4” 16“ 2“ 16“ 16“... -
Page 13: Burner Description
Technical description of the burner Burner description OIL PIPING VIEW 20092554 Fig. 3 Lifting eyebolts 22 Air pressure test point “+” 23 Oil modulator and gas butterfly valve servomotor Fan motor 24 Pump Air gate valve servomotor 25 Pump motor Gas pressure test point 26 Minimum oil pressure switch Combustion head... -
Page 14: Panel Board Description
Technical description of the burner 3.6.1 Panel board description D11449 Fig. 4 “OFF - LOCAL - REMOTE” switch 25 “K5” relay “POWER ON” signal 26 “K3” relay “CALL FOR HEAT” signal 27 Transformer, available for additional actuator or O2 control “OIL - OFF - GAS”... -
Page 15: Firing Rates
Firing rates Maximum output must be selected in the hatched area of the dia- Model MBtu/hr gram (Fig. 5). RLS 300/EV FGR 1387 Minimum output must not be lower than the minimum limit shown RLS 400/EV FGR 1998 in the diagram. -
Page 16: Procedure To Refer Burner Operating Condition At An Altitude And/Or At A Combustion Supporter Air Temperature Different To The Standard Values (328 Ft Above Sea Level, 68 °F)
Technical description of the burner 3.8.1 Procedure to refer burner operating condition at an altitude and/or at a combustion supporter air temperature different to the standard values (328 ft above sea level, 68 °F) AIR TEMPERATURE Altitude Altitude bar. press. bar. -
Page 17: Control Box For The Air/Fuel Ratio (Lmv52
WARNING The LMV52... is a safety device! Do not open, in- terfere with or modify the unit. Riello S.p.A. will not assume responsibility for any damage resulting from unauthorized inter- ference! Risk of explosion! Incorrect configuration can lead to excessive... - Page 18 Technical description of the burner Electrical connection of ionization probe and flame detector • Observe the permissible cable lengths. It is important to achieve practically disturbance- and loss-free • The ionization probe is not protected against electrical shock signal transmission: hazard.
- Page 19 Technical description of the burner Operation sequence of the burner TSA1 Timer 1 Timer 2 TSA1 Fuel 1 (oil) Fuel selection Fuel 2 (gas) Controller - ON (internal + external) Air pressure switch (LP) Fan conductor contact (GSK) (CPI function with LMV52...) Start release - oil Ignition (Z) (alternative start signal)
- Page 20 Technical description of the burner Key to the sequence diagrams: Assignment of times: Depending on the parameter, valve proving takes place: Postpurge lockout position between phase 62 and phase 70 or/and Max. time safety phase between phase 30 and phase 32. Min.
- Page 21 Technical description of the burner Key to the sequence diagrams: Parameter: With / without pressure switch Permissible positioning range Parameter: Short / long preignition time for oil only Short / long oil pump – ON – time In Standby: actuator can travel within the permissible po- Delayed shutdown within TSA1 + TSA2 sitioning range, but is always driven to the home position.
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Page 22: Actuators
Technical description of the burner 3.11 Actuators Warning notes To avoid injury to persons, damage to property or the environment, the following warning notes should be observed! WARNING Do not open, interfere with or modify the actua- tors! All activities (mounting, installation and service work, etc.) must be performed by qualified staff. -
Page 23: Installation
Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner will be The installation of the burner must be carried out by installed, and arranging the correct lighting of the environment, pro- qualified personnel, as indicated in this manual and ceed with the installation operations. -
Page 24: Boiler Plate
Boiler plate Drill the combustion chamber mounting plate as shown in Fig. 11. The position of the threaded holes can be marked using the gasket supplied with the burner. inch RLS 300/EV FGR coarse 32” 64” 4” RLS 400/EV FGR coarse 32”... -
Page 25: Electrode And Ignition Pilot Adjustment
Installation RLS 650 - 800/EV FGR model (Fig. 14) Disconnect the electrical wiring related to oil pump/servomo- While unscrewing, some fuel may leak out. tor, air servomotor and gas pressure switch; WARNING disconnect the leverages related to air damper and head movement;... -
Page 26: Nozzle
In order to guarantee that emissions do not vary, recommended The use of nozzles other than those specified by the and/or alternative nozzles specified by Riello in the Instruction and Manufacturer and inadequate regular maintenance warning booklet should be used. -
Page 27: Nozzle Installation
Installation 4.8.2 Nozzle installation – Fit the nozzle with the box spanner, fitting the spanner through the central hole in the flame stability disk (Fig. 17). – Nozzles with no fuel shut-off needle must be fitted on the noz- zle holder. –... -
Page 28: Combustion Head Setting
screw the spacers 4) onto spacer 1) and screw 5) respectively, once done, refit the tie rod and nuts. 20112601 Fig. 19 D11258 RLS 300/EV FGR RLS 400/EV FGR RLS 500/EV FGR M Bt u/ hr 4545 6060... -
Page 29: Adjustment At The Maximum Output (For Gas)
Installation Only for RLS 400/EV FGR model To achieve operation at minimum output, the com- bustion head’s gas pipes must be adjusted to hole position 5 (Fig. 21). WARNING Fig. 21 D3418 4.9.1 Adjustment at the maximum output (for gas) ... -
Page 30: Fgr Duct System
Installation 4.10 FGR duct system – Normally the duct would connect to the stack as shown in control valves and into the fan. Fig. 23, with a 45° cut facing the flue gas flow and with the In cases of heavy condensation, a condensate drip leg may be center of the cut centered in the stack. -
Page 31: Flue Gas Recirculation Line Sizing
Maximum allowed pipe length (considering smooth steel pipes) is specified for every burner and pipe diameter. Diameter of FGR pipe RLS 300/EV FGR RLS 400/EV FGR RLS 500/EV FGR RLS 650/EV FGR RLS 800/EV FGR 3"... -
Page 32: Hydraulic System
Installation 4.11 Hydraulic system 4.11.1 Double-pipe circuit It is good practice to ensure that the return and suction lines enter the burner from the same height; in this way it will be more improb- The burner is equipped with a self-priming pump which is capable able that the suction line fails to prime or stops priming. -
Page 33: Hydraulic Connections
Installation 4.12 Hydraulic connections The pumps are equipped with a by-pass that connects return line and suction line. The pumps are installed on the burner with the by-pass closed by screw 6)(Fig. 26). It is therefore necessary to connect both hoses to the pump. -
Page 34: Pump
Installation 4.13 Pump 4.13.1 Technical data Pump model (RLS 300-400/EV FGR) (RLS 500/EV FGR) (RLS 650-800/EV FGR) Min. delivery rate at 300 PSI pressure Delivery pressure range 102 - 580 102 - 435 Max. suction pressure Viscosity range 3 - 75 Max. -
Page 35: Gas Supply
Installation 4.14 Gas supply 4.14.1 Gas train The gas train is to be connected on the right of the burner, by flange 1)(Fig. 27). If necessary connect it on the left, proceed as follows: – loosen nuts and screws 3) and 4); –... -
Page 36: Gas Pressure
Installation 4.14.3 Gas pressure 1 p (“WC) 2 p (“WC) MBtu/hr (GCV) The Tab. L shows minimum pressure losses along the gas supply 5112 0.63 line depending on the maximum burner output operation. 5680 0.79 The values shown in the Tab. L refer to natural gas (GCV). 7574 1.38 Column 1... -
Page 37: Electrical Wiring
Installation 4.15 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 carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination. -
Page 38: Installation Of Shielded Cables
Installation 4.15.1 Installation of shielded cables In the case of clamp type A: unscrew the screw until space is created for inserting the shielding of the shielded cable A1)(Fig. 32); insert the shielded cable with the shielding inside the clamp A2);... -
Page 39: Speed Sensor Adjustment
Installation 4.16 Speed sensor adjustment The measurement of speed sensor 1)(Fig. 33) must be respected! WARNING It is important that the disc 2) is installed on the burner as shown in the Fig. 33. WARNING 20072222 Fig. 33 20102963... -
Page 40: Inverter Connection
Installation 4.16.1 Inverter connection Treatment of cables Following, it is reported an example how to con- Countermeasures against cable noise nect the Inverter. For further information, please refer to the relevant The treatment of cables is the most important countermeasure. WARNING Inverter instruction manual. -
Page 41: Thermal Relay Calibration
Installation 4.17 Thermal relay calibration Depending on the burner type, there are two different thermal re- 4.17.2 Electronic thermal relay lays: To reset, in the case of an intervention of the thermal relay, – Electro-mechanical thermal relay (used for single phase mo- press the button “RESET”... -
Page 42: Motor Connection At 208-230 Or 460V
Installation 4.18 Motor connection at 208-230 or 460V Please, pay attention to the indications in case of modification of the motors, manufactured for 208-230/460 IE3 voltage, maintenance, or substitution. NEMA Premium Efficiency voltage, have the same connection than IE2/Epact motors, but differ- ent connection than IE1 motors no more star/delta WARNING but star/double star. -
Page 43: 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 44: Adjustments Before First Firing (Gas Operation)
Start-up, calibration and operation of the burner Adjustments before first firing (gas operation) Adjustment of the combustion head has been illustrated on page 26. In addition, the following adjustments must also be made: open manual valves up-stream from the gas train. ... -
Page 45: Combustion Air Adjustment
Start-up, calibration and operation of the burner 5.6.5 Air/fuel control and power modulation system For the first ignition, you should not activate the re- The air/fuel and power modulation system installed on RLS circulation gas function. See “FGR duct system” on burner series provides, a set of integrated functions ensuring top page 28. -
Page 46: Final Calibration Of The Pressure Switches
Start-up, calibration and operation of the burner Final calibration of the pressure switches 5.7.1 Air pressure switch Adjust the air pressure switch (Fig. 48) after having performed all other burner adjustments with the air pressure switch set to the start of the scale. With the burner operating at min. -
Page 47: Low Oil Pressure Switch
Start-up, calibration and operation of the burner 5.7.4 Low oil pressure switch The low oil pressure switch (Fig. 51) is factory set to 261 PSI (18 bar). If the oil pressure goes down this value in the delivery piping, the pressure switch stops the burner. -
Page 48: Burner Starting
Start-up, calibration and operation of the burner Burner starting Operating control closes, the motor starts. The ignition pilot starts. The pump 18)(Fig. 52) draws the fuel from the tank through Solenoid valves 5) - 6) open; the fuel passes through the pip- the piping 1) and pumps it under pressure for delivery. -
Page 49: Steady State Operation
Start-up, calibration and operation of the burner 5.8.1 Steady state operation At the end of the starting cycle, the servomotor control then passes to load control for boiler pressure or temperature. If the temperature or pressure is low (and the load control is consequently closed), the burner progressively increases out- put up to MAX. -
Page 50: Final Checks (With The Burner Working)
Start-up, calibration and operation of the burner Final checks (with the burner working) Open the control limit operation The burner must stop Open the high limit operation Rotate the maximum gas pressure switch knob to the mini- mum end-of-scale position ... -
Page 51: Maintenance
Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, safe- Before carrying out any maintenance, cleaning or checking opera- ty, yield and duration of the burner. tions: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time. -
Page 52: Safety Components
Maintenance Burner GAS OPERATION Clean the outside of the burner. Clean and grease the cam variable profile. Gas leaks Make sure that there are no gas leaks on the pipework between the Boiler gas meter and the burner. Clean the boiler as indicated in its accompanying instructions in or- der to maintain all the original combustion characteristics intact, es- Gas filter pecially the flue gas temperature and combustion chamber... -
Page 53: Opening The Burner
Maintenance Opening the burner Disconnect the electrical supply from the burner. DANGER Remove the tie rod 1)(Fig. 53) of the head movement lever, loosening nut 2). Disconnect the gas servomotor test point 3). Disconnect the gas pressure switch test point 4). ... -
Page 54: A Appendix - Spare Parts
Appendix - Spare parts 20102963... - Page 55 CODE DESCRIPTION 20042722 • • RLS 300/E US1 HEAD 20042725 • RLS 500/E HEAD 20042726 • RLS 650/E HEAD 20042727 • RLS 800/E HEAD 3013106 • • ELECTRODE 20042714 • ELECTRODE 20011338 • ELECTRODE 20050435 • ELECTRODE 3013794 • • •...
- Page 56 CODE DESCRIPTION 20123147 • • LEVER ASSEMBLY 20103497 • • 20038375 • • • 20103543 • • 20038376 • • • 3013313 • • CYLINDER 3013641 • CYLINDER 20026703 • CYLINDER 20011084 • CYLINDER 20041800 • SHUTTER 20041776 • SHUTTER 20041804 •...
- Page 57 CODE DESCRIPTION 20011191 • • SPRAY NOZZLE 20041674 • • SHUTTER 20042719 • SHUTTER 20011151 • • SHUTTER 3007079 • • • SEAL 3007166 • • SEAL 3013460 • • • CONNECTOR 20011120 • • CONNECTOR 3013553 • • TUBE 3014202 •...
- Page 58 CODE DESCRIPTION 20159557 • • SUPPORT 20033305 • • DIFFUSOR 20033305 • • • • • SEAL A DVISED PARTS = Spare parts for minimum fittings = Spare parts for basic safety fittings A+B+C = Spare parts for extended safety fittings 20102963...
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Page 59: B Appendix - Accessories
Appendix - Accessories Gas train according to UL Standards The installer is responsible for the supply and instal- lation of any required safety device(s) not indicated in this manual. WARNING 20102963... -
Page 60: Appendix - Burner Start Up Report
Appendix - Burner start up report Model number: Serial number: Project name: Start-up date: Installing contractor: Phone number: GAS OPERATION : Low Fire Gas Supply Pressure: High Fire : Low Fire Main Power Supply: High Fire Control Power Supply: CO: Low Fire High Fire : Low Fire Burner Firing Rate:... - Page 64 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.com RIELLO BURNERS NORTH AMERICA http://www.riello.ca 35 Pond Park Road 2165 Meadowpine Blvd Hingham, Massachusetts, Mississauga, Ontario U.S.A. 02043 1-800-4-RIELLO Canada L5N 6H6 Subject to modifications...