Table of Contents
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Installation, use and maintenance instructions
Dual fuel light oil/ gas burners
GB
Progressive two stage or modulating operation
C9131000
C9131010
C9131001
C9132010
C9132001
C9133010
C9133001
C9134010
C9134001
C9135010
C9135001
CODE
MODEL
RLS 300/E
RLS 400/E
RLS 500/E
RLS 650/E
RLS 800/E
20036644 (9) - 02/2014
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Table of Contents
Related Manuals for Riello RLS 300/E
Summary of Contents for Riello RLS 300/E
- Page 1 Installation, use and maintenance instructions Dual fuel light oil/ gas burners Progressive two stage or modulating operation CODE MODEL C9131000 C9131010 RLS 300/E C9131001 C9132010 RLS 400/E C9132001 C9133010 RLS 500/E C9133001 C9134010 RLS 650/E C9134001 C9135010 RLS 800/E C9135001...
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Page 3: Table Of Contents
Contents Information and general instructions ..............3 Information about the instruction manual . - Page 4 Motor connection at 208-230 or 460V only for RLS 300/E .......
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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 the type and pressure of the fuel, the voltage and frequency of current regulations and directives, applying the known technical the electrical power supply, the minimum and maximum deliv- rules of safety and envisaging all the potential danger situations. -
Page 8: Technical Description Of The Burner
Technical description of the burner Technical description of the burner Technical data Model RLS 300/E RLS 400/E RLS 500/E Output High 1387 – 4220 (3834*) 1998 – 4995 (4541*) 2775 – 5740 (5217*) MBtu/hr 4732 – 14390 (13082*) 6817 – 17042 (15494*) 9468 –... -
Page 9: Electrical Data
Technical description of the burner Electrical data Fan motor and pump motor IE1 Model RLS 300/E RBNA Code C9131000 C9131010 C9131001 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... - Page 10 Technical description of the burner Fan motor and pump motor IE2/EPACT Model RLS 300/E RBNA Code C9131000 C9131010 C9131001 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 3500 3500...
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Page 11: Burner Models Designation
Electrical protection NEMA 1 Tab. C Burner models designation Model Code Code RBNA Voltage Fan motor starting Flame safeguard 20041484 C9131000 208 - 220/3/60 RLS 300/E C9131010 460/3/60 Direct Burner mounted 20061830 C9131001 575/3/60 20055022 C9132010 460/3/60 RLS 400/E Star/Delta... -
Page 12: Burner Dimensions
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. D3505 Fig. 2 inch RLS 300/E ANSI 3” 16“ 2“ 16“ 16“ 32“... -
Page 13: Burner Description
Technical description of the burner Burner description O IL P IP IN G V IE W D11281 Fig. 3 Lifting eyebolts 21 QRI flame detector 22 Air pressure test point “+” Fan motor 23 Oil modulator and gas butterfly valve servomotor Air gate valve servomotor 24 Pump Gas pressure test point... -
Page 14: Panel Board Description
Technical description of the burner 3.7.1 Panel board description STAR/DELTA START DIRECT START D11175 Fig. 4 “OFF - LOCAL - REMOTE” switch 32 Holes for cables grommets for electrical wirings, accessories and power supply (to be carried out by the installer) “POWER ON”... -
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/E 4,732 Minimum output must not be lower than the minimum limit shown RLS 400/E 6,817 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 (Lmv51
WARNING The LMV51... 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.
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Page 20: Operation Sequence Of The Burner
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 In Standby: actuator can travel within the permissible po- Parameter: Short / long preignition time for oil only Short / sitioning range, but is always driven to the home position. long oil pump –...
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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: Removal Of The Locking Screws From The Shutter
Fig. 11 Boiler plate Drill the combustion chamber mounting plate as shown in Fig. 12. The position of the threaded holes can be marked using the gasket supplied with the burner. inch RLS 300/E coarse 32” 64” 4” RLS 400/E coarse 32”... -
Page 26: Accessibility To The Interior Of The Combustion Head
Installation 4.7.3 Accessibility to the interior of the combustion head In order to reach inside the combustion head proceed as follows: RLS 300 - 400 - 500/E model (Fig. 14) open burner at hinge (Fig. 14) after removing the 4 screws 1); ... -
Page 27: Electrode And Ignition Pilot Adjustment
Installation Electrode and ignition pilot adjustment Place the electrode and the ignition pilot observing the dimensions RLS 650 - 800/E model (Fig. 17) in Fig. 16 and Fig. 17. RLS 300 - 400 - 500/E model (Fig. 16) 27/ 32" 5/ 8"... -
Page 28: 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 29: Nozzle Installation
Installation 4.9.2 Nozzle installation – Fit the nozzle with the box spanner, fitting the spanner through the central hole in the flame stability disk (Fig. 18). – Nozzles with no fuel shutoff needle must be fitted on the nozzle holder. –... -
Page 30: Combustion Head Setting
screw the spacers 4) onto spacer 1) and screw 5) respectively, once done, refit the tie rod and nuts. D3409 Fig. 20 D11258 RLS 300/E RLS 400/E RLS 500/E M Bt u/ hr 4545 6060... -
Page 31: Adjustment At The Maximum Output (For Gas)
Installation Only for RLS 400/E model To achieve operation at minimum output, the com- bustion head’s gas pipes must be adjusted to hole position 5 (Fig. 22). WARNING Fig. 22 D3418 4.10.1 Adjustment at the maximum output (for gas) unscrew the screws and remove the 8 tangential tubes 1); Only for RLS 650/E model ... -
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/E) (RLS 500/E) (RLS 650-800/E) Min. delivery rate at 300 PSI pressure Delivery pressure range 102 - 580 102 - 435 Max. suction pressure Viscosity range 3 - 75 Max. oil temperature °F 302 (150 °C) 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. J 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. J 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: Thermal Relay Calibration
Installation 4.16 Thermal relay calibration Depending on the burner type, there are two different thermal re- 4.16.2 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 “RESET”... -
Page 39: Motor Connection At 208-230 Or 460V Only For Rls 300/E
Installation 4.17 Motor connection at 208-230 or 460V only for RLS 300/E 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. -
Page 40: Motor Connection At 208-230 Or 460V Only For Rls 400-500-650-800/E
Installation 4.20 Motor connection at 208-230 or 460V only for RLS 400-500-650-800/E 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 41: 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 42: 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 28. In addition, the following adjustments must also be made: open manual valves up-stream from the gas train. ... -
Page 43: Combustion Air Adjustment
Start-up, calibration and operation of the burner 5.6.1 Combustion air adjustment Fuel/combustion air must be synchronized with the relevant servo- motors (air and gas) by storing a setting curve by means of the electronic cam. To reduce pressure loss and to have a wider adjustment range, it is best to set the servomotor to the maximum output used, as near to maximum opening (90°) as possible. -
Page 44: 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. 46) 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 45: 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. 49) 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 46: 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. 50) 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 47: 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 48: 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 49: 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 50: A Appendix - Spare Parts
Appendix - Spare parts Appendix - Spare parts 20036644... - Page 51 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 52 Appendix - Spare parts CODE DESCRIPTION • • • • • 3013320 GEAR • • • • • 3012795 BEARING • • • • • 3008663 VIEWING PORT • • • • • 3000858 SEAL • • • • • 20014103 PRESSURE SWITCH •...
- Page 53 Appendix - Spare parts CODE DESCRIPTION • • • • • 20036019 WHITE SIGNAL LIGHT • • • • • 20010962 BUTTON • • • • • 3013354 SIGNAL BUTTON • • • • • 20013115 COVER • • • • • 20006151 QRI PROBE •...
- Page 54 Appendix - Spare parts CODE DESCRIPTION • • 3006410 PUMP • • • • • 3006896 CONNECTOR • • • • • 3012384 OIL PRESSURE SWITCH • • • • • 20042844 TUBE • • • • • 3006140 PRESSURE GAUGE •...
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Page 55: 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 20036644... -
Page 56: 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.rielloburners.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-burners.com Subject to modifications...