Table of Contents
Related Manuals for Riello RLS 1000/M MX
Summary of Contents for Riello RLS 1000/M MX
- Page 1 Installation, use and maintenance instructions Dual fuel gas oil/gas burners Progressive two-stage or modulating operation CODE MODEL TYPE 20057525 RLS 1000/M MX 1311 T 20053012 RLS 1200/M MX 1312 T 20061348 (7) - 12/2015...
- 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 5.14.4 Gas pressure ................................24 5.14.5 Pilot - gas train connection............................25 5.14.6 Ignition pilot burner ..............................25 5.15 Activation of the burner lance ............................26 5.16 Electrical wiring ................................27 5.16.1 Supply cables and external connections passage .....................27 5.17 Calibration of the thermal relay ..........................28 Start-up, calibration and operation of the burner ........................29 Notes on safety for the first start-up ...........................29 Adjustments prior to ignition (light oil) ........................29...
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Page 5: Declarations
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001. Manufacturer's Declaration RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BIm- SchV revision 26.01.2010”. -
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
110V / 50-60Hz 1000 3/400/50 230/50/60 BASIC DESIGNATION EXTENDED DESIGNATION Models available Designation Voltage Start-up Code RLS 1000/M MX 3/400-230/50 Star/Triangle 20057525 RLS 1200/M MX 3/400-230/50 Star/Triangle 20053012 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/M MX RLS 1200/M MX Type 1311 T 1312 T Output 1200/3750 ÷ 10600 1500/5500 ÷ 11500 min - max Delivery kg/h 100/315 ÷ 867 171/462 ÷ 942 Fuels – Light oil, viscosity max. 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. 20062787 Fig. 1 RLS 1000/M MX 1637 DN80 1206 1338 1425... -
Page 12: Firing Rates
1013 mbar (approx. 0m limit of the diagram: above sea level), and with the combustion head WARNING RLS 1000/M MX = 3750 kW adjusted as shown on page 19. RLS 1200/M MX = 5500 kW D11552 RLS 1000/M MX... -
Page 13: Burner Description
Technical description of the burner Burner description 20062788 Fig. 4 Lifting rings 23 Pump 24 Pump motor Fan motor 25 Maximum oil pressure switch Air damper servomotor 26 Minimum oil pressure switch Combustion head gas pressure test point 27 Nozzle return pressure gauge Combustion head 28 Screws to lock the shutter during transportation (replace Ignition pilot burner... -
Page 14: Electrical Panel Description
Light gas flexible hoses ......No. 2 Fitting 1” 3/4” (RLS 1000/M MX) ....No. 1 Fitting 1”... -
Page 15: Control Box (Lfl1.333
The control box LFL1.333... is a safety device! WARNING Avoid opening or modifying it, or forcing its opera- tion. Riello S.p.A. cannot assume any responsibil- ity for damage resulting from unauthorised interventions! ➤ All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. -
Page 16: Servomotor (Sqm10.1
Technical description of the burner 4.13 Servomotor (SQM10.1..) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying or forcing the actua- WARNING tors. ➤ All interventions (assembly and installation operations, assistance, etc.) must be carried out by qualified personnel. ➤... -
Page 17: 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 18: Operating Position
For boilers with a water-cooled front piece, a refractory lining 2)- 5)(Fig. 12) is not necessary, unless expressly requested by the boiler manufacturer. D455 Fig. 11 RLS 1000/M MX M 20 RLS 1200/M MX M 20 Tab. G 20061348... -
Page 19: Securing The Burner To The Boiler
Installation Securing the burner to the boiler Prepare a suitable lifting system using rings 3)(Fig. 12). ➤ Insert the thermal protection supplied with the blast tube 4). ➤ Insert the entire burner on the boiler hole, previously fitted, as in Fig. 11, and fix it with the screws supplied. The seal between burner and boiler must be airtight. -
Page 20: Nozzle Installation
Return kg/h pressure pressure kg/h Fit the nozzle with a 24 mm (for RLS 1000/M MX) and 41 mm (for (bar) RLS 1200/MX M) box wrench, passing from the centre opening 1200 of the flame stability disc (Fig. 15). 17.5 3750 Fit the nozzles with the fuel interception rod on the nozzle holder. -
Page 21: Combustion Head Adjustment
Installation 5.11 Combustion head adjustment The air damper servomotor 4)(Fig. 4), beyond varying the air out- The selection of the hole to be used is determined based on the put according to the output demand, through a leverage varies maximum output requested, as illustrated in Tab. I. the combustion head adjustment. -
Page 22: 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/M MX RLS 1200/M MX and laws. +/- H Ø... -
Page 23: Hydraulic Connections
Installation 5.12.3 Hydraulic connections 5.12.5 Pressure variator ➤ Make sure that the flexible hoses to the pump Calibration pressure on return line supply and return line are installed correctly. With a servomotor position of 20°, the nut and the corresponding lock nut 6)(Fig. -
Page 24: Pump
2), slightly reduce the pressure until they disappear. 5.13 Pump 5.13.1 Technical data Pump RLS 1000/M MX RLS 1200/M MX VBHRG VBHGRP Min. delivery rate at 40 bar pressure 1160 kg/h... -
Page 25: Gas Feeding
Installation 5.14 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 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 26: Gas Train
Installation 5.14.2 Gas train 5.14.4 Gas pressure Approved according to standard EN 676 and provided separately Tab. L indicates the pressure drop of the combustion head and from the burner. the gas butterfly valve depending on the operating output of the burner. -
Page 27: Pilot - Gas Train Connection
Installation Example RLS 1000/M MX with natural gas G20: Operation at maximum modulating output Gas pressure at test point 1)(Fig. 27) = 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. -
Page 28: Activation Of The Burner Lance
Installation 5.15 Activation of the burner lance The burner is equipped with a spray lance for light oil. Fig. 29 shows the 3-way valve used for the mechanical activation of the burner lance and the point at which the compressed air input A) must be connected. -
Page 29: Electrical Wiring
Installation 5.16 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 30: Calibration Of The Thermal Relay
Installation 5.17 Calibration of the thermal relay The thermal relay (Fig. 31) serves to avoid damage to the motor due to an excessive absorption increase or if a phase is missing. For calibration 2), refer to the table indicated in the electrical lay- out (electrical wiring in charge of the installer). -
Page 31: 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 32: Adjustments Prior To Ignition (Gas)
Start-up, calibration and operation of the burner Adjustments prior to ignition (gas) In addition, the following adjustments must also be made: Before starting up the burner, it is good practice to ➤ Slowly open the manual valves situated upstream from the adjust the gas train so that ignition takes place in gas train. -
Page 33: Servomotor Adjustment
Start-up, calibration and operation of the burner Servomotor adjustment The servomotor (Fig. 34) adjusts simultaneously, through driving gears, the output and pressure of the air and the delivery of the fuel in use. It is equipped with adjustable cams which operate as many switches. -
Page 34: Burner Adjustment And Output Modulation
Start-up, calibration and operation of the burner 6.10 Burner adjustment and output modulation 6.10.1 Maximum output For better adjustment repeatability, take care to stop the rotation of the cam unit when the upper bearing that slides on the profile The servomotor (Fig. 34 on page 31) must be adjusted to the 4)(Fig. -
Page 35: Burner Calibration Procedure
Start-up, calibration and operation of the burner 6.11.1 Burner calibration procedure ➤ Install the nozzle suitable to achieve the maximum desired output. ➤ Verify that the eccentricity of the oil cam is such to make a travel of about 8 mm on the shaft of oil modulator. Normally, with a shaft travel of 8 mm, the pressure variation needed for the modulation of the minimum to maximum out- put is obtained. -
Page 36: Pressure Switch Adjustment
Start-up, calibration and operation of the burner 6.12 Pressure switch adjustment 6.12.1 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 37: Operation Sequence Of The Burner
Start-up, calibration and operation of the burner 6.13 Operation sequence of the burner 6.13.1 Burner start-up NORMAL IGNITION TL thermostat/pressure switch closure. Fan motor starts up. Servomotor start: 130° rotation to the right, until the acti- vation of the contact on cam 1). If it's operating with oil or cam 4) if it's operating with gas. -
Page 38: Final Checks (With Burner Operating)
Start-up, calibration and operation of the burner 6.14 Final checks (with burner operating) ➮ ➤ Open the thermostat/pressure switch TL The burner must stop ➤ Open the thermostat/pressure switch TS ➤ Turn the gas maximum pressure switch knob to the mini- ➮... -
Page 39: Maintenance
Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, safety, yield and duration of the burner. Disconnect the electrical supply from the burner It allows you to reduce consumption and polluting emissions and by means of the main system switch. - Page 40 Maintenance If rust or other impurities are observed inside the pump, use a GAS OPERATION separate pump to lift any water and other impurities that may have deposited on the bottom of the tank. Gas leaks Make sure that there are no gas leaks on the pipe between the gas meter and the burner.
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Page 41: Opening The Burner
Maintenance Opening the burner ➤ Remove the tie-rods 1) and 4)(Fig. 45) of the head move- ment and damper opening lever, loosening nut 2); Disconnect the electrical supply from the burner ➤ disconnect the socket 3) of the servomotor; by means of the main system switch. ➤... -
Page 42: Faults - Probable Causes - Solutions
Faults - Probable causes - Solutions Faults - Probable causes - Solutions The LFL1.333... control box is equipped with a lockout indicator Lockout indicator (Fig. 46) that turns during the start-up programme, and is visible Start-up sequence from the small lockout window. b-b’... -
Page 43: Light Oil Operation
Faults - Probable causes - Solutions Light oil operation Symbol Problem Possible cause Recommended remedy Limiter or safety control device open Adjust or replace Control box lockout Release Fan motor lockout Release the thermal relay Adjust the pressure switch or eliminate Intervention of maximum oil pressure switch overpressure No electrical power supply... - Page 44 Faults - Probable causes - Solutions Symbol Problem Possible cause Recommended remedy Little air Adjust the fan head and damper Incorrect pump pressure Adjust Nozzle filter clogged Clean or replace Smoke in flame (dark Bacharach) Insufficient boiler room ventilation openings Increase Dirty or worn nozzle Replace...
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Page 45: Gas Operation
Faults - Probable causes - Solutions Gas operation Symbol Problem Possible cause Recommended remedy No electrical power supply Close all switches and check connections A limit or safety thermostat/pressure switch Adjust or replace open Control box lockout Release the control box Control box fuse interrupted Replace it Incorrect electrical wiring... - Page 46 Faults - Probable causes - Solutions Symbol Problem Possible cause Recommended remedy The VP1 solenoid lets too little gas through Increase The solenoid VP1 or VP2 does not open Replace the coil or the rectifier panel Gas pressure too low Increase pressure at governor Ignition electrode incorrectly adjusted Adjust it...
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Page 47: A Appendix - Accessories
Two components should be ordered: • the analogue signal converter • the potentiometer Burner Potentiometer Analogue Signal Converter Type Code Type Code RLS 1000/M MX RLS 1200/M MX ASZ... 3013532 E5202 3010390 Soundproofing box kit Burner Code RLS 1000/M MX 3010401 RLS 1200/M MX... -
Page 48: Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Single-wire output layout Functional layout star/triangle starter Functional layout LFL 1... Functional layout LFL 1... Functional layout LFL 1... Functional layout LFL 1... Functional diagram Electrical wiring that the installer is responsible for Electrical wiring that the installer is responsible for Electrical wiring kit RWF40 internal... - Page 49 Appendix - Electrical panel layout 20061348...
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- Page 51 Appendix - Electrical panel layout & & 20061348...
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- Page 61 Appendix - Electrical panel layout 20061348...
- Page 62 Appendix - Electrical panel layout Wiring layout key Control box XAUX Auxiliary terminal board Output regulator RWF40 internal Derivation unit connector Output regulator RWF40 external XPGM Maximum gas pressure switch connector Probe with output under current Oil pressure switch connector Device with output undercurrent, for modifying remote XPO1 Oil return pressure switch 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...