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Installation, use and maintenance instructions
Dual fuel light oil/ gas burners
GB
Progressive two stage or modulating operation
C9161400
C9161410
C9161401
C9162400
C9162410
C9162401
C9163400
C9163410
C9163401
C9164400
C9164410
C9164401
C9165400
C9165410
C9165401
CODE
MODEL
RLS 300/EV FGR
RLS 400/EV FGR
RLS 500/EV FGR
RLS 650/EV FGR
RLS 800/EV FGR
20037168 (10) - 09/2014
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Table of Contents
Related Manuals for Riello C9161400
Summary of Contents for Riello C9161400
- Page 1 Installation, use and maintenance instructions Dual fuel light oil/ gas burners Progressive two stage or modulating operation CODE MODEL C9161400 C9161410 RLS 300/EV FGR C9161401 C9162400 C9162410 RLS 400/EV FGR C9162401 C9163400 C9163410 RLS 500/EV FGR C9163401 C9164400 C9164410 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 4.14.3 Gas pressure ................35 4.15 Electrical wiring .
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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 C9161400 C9161410 C9161401 Control circuit power supply V/Ph/Hz 120/1/60 Main power supply (+/- 10%) V/Ph/Hz 208 - 220/3/60 460/3/60 575/3/60 Fan motor 3510 3510 3510 208 - 230 11.5... - Page 10 Technical description of the burner Model RLS 500/EV FGR RBNA Code C9163400 C9163410 C9163401 Control circuit power supply V/Ph/Hz 120/1/60 Main power supply (+/- 10%) V/Ph/Hz 208 - 220/3/60 460/3/60 575/3/60 Fan motor 3550 3550 3550 208 - 230 57.6 28.8 Pump motor 3470...
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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 C9161400 208 - 220/3/60 RLS 300/EV FGR 20039966 C9161410 460/3/60 Inverter Burner mounted C9161401 575/3/60 C9162400 208 - 220/3/60 RLS 400/EV FGR... -
Page 12: Burner Dimensions
Technical description of the burner Burner dimensions The maximum dimensions of the burner are given in Fig. 2. The overall dimensions of the burner when open are indicated by L and R. Bear in mind that inspection of the combustion head requires the burner to be opened by rotating the rear part on the hinge. -
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 26 “K3” relay “POWER ON” signal 27 Transformer, available for additional actuator or O2 control “CALL FOR HEAT” signal 28 “K2” relay “OIL - OFF - GAS”... -
Page 15: Firing Rates
Technical description of the burner 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 In High Altitude Plants
Technical description of the burner 3.8.1 Procedure to refer burner operating condition Example in high altitude plants Rated capacity = 3000 MBtu/hr - Rated air pressure = 1.5” WC Find the CORRECTED BURNER CAPACITY for the plant’s alti- Real altitude = 5000 ft - Real temperature = 108°F tude in chart 1 and the CORRECTED PRESSURE in chart 2. -
Page 17: Minimum Furnace Dimensions
Technical description of the burner CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE Altitude m a.s.l. 1220 1525 1830 2135 2440 Rated Pressure ft a.s.l 1000 2000 3000 4000 5000 6000 7000 8000 0.50 0.49 0.50 0.51 0.53 0.55 0.57 0.59 0.62 0.64 0.67... -
Page 18: 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 19 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 20 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 21 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 22 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 23: 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 24: 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 25: Boiler Plate
Installation 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 26: 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 ➤... -
Page 27: 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 28: 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 shutoff needle must be fitted on the nozzle holder. –... -
Page 29: Combustion Head Setting
Installation Combustion head setting In addition to varying air flow depending on the output requested, the air gate valve servomotor 4)(Fig. 3) by means of a lifting as- sembly - varies the setting of the combustion head. This system allows an optimal setting even at a minimum firing rate. -
Page 30: 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 31 Installation – Duct expansion and contraction can be managed by using two tion. The supports may need to be anchored to provide this sta- relatively long duct runs that are 90° apposed to each other. bility in the FGR duct. A small movement in the angle between these two legs will pro- Uncontrolled condensation can cause premature vide the space needed to absorb the expansion and contrac-...
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Page 32: Flue Gas Recirculation Line Sizing
Installation 4.10.1 Flue gas recirculation line sizing Maximum allowed pipe length (considering smooth steel pipes) is specified for every burner and pipe diameter. The Tab. G can be helpful to correctly size the FGR pipes taking To prepare the Tab. G a flue gas maximum temperature of 500°F flue gases from boiler stack base up to the burner intake port. -
Page 33: 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 34: 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 35: 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 36: 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 37: Gas Pressure
Installation 4.14.3 Gas pressure 1 ∆p (“WC) 2 ∆p (“WC) MBtu/hr (GCV) The Tab. K 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. K refer to natural gas (GCV). 7574 1.38 Column 1... -
Page 38: 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 39: Other Connection
Installation 4.15.1 Other connection It is very important to shield the motor cable 1) as The connection from the Inverter to LMV52..must be done shown in Fig. 31. as shown in Fig. 32. WARNING The connection from the speed sensor to LMV52..must be done as shown in Fig. -
Page 40: Inverter Connection
Installation 4.16.1 Inverter connection Treatment of cables Countermeasures against cable noise Following, it is reported an example how to con- nect the Inverter. The treatment of cables is the most important countermeasure. For further information, please refer to the relevant The machinery manufacturers are requested 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 termal relay (used for single phase motors) press the button “... -
Page 42: Motor Connection At 208-230 Or 460V
Installation 4.18 Motor connection at 208-230 or 460V WARNING : the motors, manufactured for 208-230/460V IE2/Epact voltage, have a different connection than IE1 motors, no more star/delta but star/double star. Please, pay attention to the indications in case of modification of voltage, maintenance, or substitution. IE2/Epact S8407 S8406... -
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 27. 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 ➤ burner power is modulated according to the load required by For the first ignition, you should not activate the re- the system, while boiler pressure or temperature is main- circulation gas function. See “FGR duct system” on tained at set operating values;... -
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: Opening The Burner
Maintenance Flexible hoses GAS OPERATION Check to make sure that the flexible hoses are still in good condi- tion. Gas leaks Make sure that there are no gas leaks on the pipework between the Fuel tank gas meter and the burner. Approximately every 5 years, or whenever necessary, suck any water or other impurities present on the bottom of the tank using a Gas filter... -
Page 53: A Appendix - Spare Parts
Appendix - Spare parts Appendix - Spare parts 20037168... - Page 54 Appendix - Spare parts CODE DESCRIPTION • 20042722 OIL/GAS HEAD • 20042723 OIL/GAS HEAD • 20042725 OIL/GAS HEAD • 20042726 OIL/GAS HEAD • 20042727 OIL/GAS HEAD • • 3013106 ELECTRODE • 20042714 ELECTRODE • • 20011338 ELECTRODE • • 20013159 ELECTRODE CONNECTION •...
- Page 55 Appendix - Spare parts CODE DESCRIPTION • • • • • 3013320 GEAR • • • • • 3012795 BEARING • • • • • 3008663 VIEWING PORT • • • • • 3000858 SEAL • • • • • 20014103 PRESSURE SWITCH •...
- Page 56 Appendix - Spare parts CODE DESCRIPTION • • • • • 20010963 SWITCH • • • • • 20036020 GREEN SIGNAL LIGHT • • • • • 20036019 WHITE SIGNAL LIGHT • • • • • 20010962 BUTTON • • • • • 3013354 SIGNAL BUTTON •...
- Page 57 Appendix - Spare parts CODE DESCRIPTION • • • • • 20042836 PUMP MOTOR 2HP 230/460V • • • • • 20041732 PUMP MOTOR 2HP 575V • • 3006158 PUMP • 3006236 PUMP • • 3006410 PUMP • • • • • 3006896 CONNECTOR •...
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Page 58: B Appendix - Accessories
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 20037168... -
Page 59: Appendix - Burner Start Up Report
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... - Page 60 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com RIELLO BURNERS NORTH AMERICA 1-800-4-RIELLO 35 Pond Park Road 2165 Meadowpine Blvd Hingham, Massachusetts, 1-800-474-3556 Mississauga, Ontario U.S.A. 02043 Canada L5N 6H6 http://www.riello.ca Subject to modifications...