Related Manuals for Riello RLS 810/E FGR
Summary of Contents for Riello RLS 810/E FGR
- Page 1 Installation, use and maintenance instructions Dual fuel gas oil/ gas burner Modulating operation CODE MODEL 20170200 RLS 810/E FGR 20171988 (1) - 12/2019...
- Page 2 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 5.13 Gas pressures................................27 5.13.1 Gas feeding line .................................27 5.13.2 Gas train ..................................28 5.13.3 Gas train installation ..............................28 5.13.4 Gas pressure ................................29 5.14 Electrical wiring ................................30 5.14.1 Supply cables and external connections passage .....................30 Start-up, calibration and operation of the burner ........................31 Notes on safety for the first start-up ...........................31 Adjustments prior to ignition (light oil) ........................31 6.2.1...
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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/EC 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: 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
Technical description of the burner Technical description of the burner Burner designation Range: Fuel: Natural gas Gas oil Gas oil / Methane Heavy oil Size Adjustment: Two stage (light oil) / Proportional valve (gas) Electronic cam Electronic cam with variable speed (with Inverter) Proportional air/gas valve Mechanical cam C01 - ... -
Page 10: Models Available
Not intended for operation with induced smoke recirculation (FGR). In order to reduce the nitrogen oxides NOx in case of FGR system, the maximum burner capacity ob- tained, changes within the limits agreed with the Riello Technical Dept. for the specific application. WARNING 20171988... -
Page 11: Electrical Data
The l position is reference for the refractory thickness of the boiler door. 20172264 Fig. 1 RLS 810/E FGR 1200 DN80 629 1442 1360 1055 DN150 1240 Tab. E * The gas adaptor is set also for DN 80 bore. -
Page 12: Firing Rates
1013 mbar (approx. 0 m limit of the diagram: a.s.l.), and with the combustion head adjusted as WARNING shown on page 22. 1080 kW RLS 810/E FGR 1650 kW Tab. F 20176363 Thermal power – kW Fig. 2 NOTE: OIL OPERATION: max 5 kW for smoke index <1. -
Page 13: Burner Description
Technical description of the burner Burner description ASSEMBLY VIEW 20172297 Fig. 4 Cover for electrical panel 27 Flame stability disk Maximum oil pressure switch 28 Ignition electrodes (oil operation) Delivery pressure gauge 29 Gas butterfly valve Minimum oil pressure switch 30 Pump Lifting rings 31 Flue gas entrance flange... -
Page 14: Electrical Panel Description
Technical description of the burner 4.11 Electrical panel description 20175027 VIEW FROM A Fig. 5 20158207 Electrical control box 19 Pump motor contact maker ON/OFF selector 20 Change of fuel selector Output power regulator module (LCM100) 21 Fan motor cables sheath Earth terminal 22 Flame sensor sheath Supply cables and external connections passage. -
Page 15: Control Box For The Air/Fuel Ratio (Bt340)
To avoid accidents, material and/or environmental damage, observe the following instructions! The control box is a safety device! Avoid opening WARNING or modifying it, or forcing its operation. Riello S.p.A. cannot assume any responsibility for dam- age resulting from unauthorised interventions! Risk of explosion! -
Page 16: Burner Operating Sequence (Gas Operation)
Technical description of the burner 4.13 Burner operating sequence (GAS OPERATION) X20+X21 S9612 Fig. 7 Key to layout (Fig. 7) Key to layout (Fig. 7) FGR release Any condition Gas valve 1 Waiting time for safety circuits consent Gas valve 2 (boiler fuel) Pilot valve Ignition transformer... -
Page 17: Burner Operating Sequence (Light Oil Operation)
Technical description of the burner 4.14 Burner operating sequence (LIGHT OIL OPERATION) CPI/POC X20+X21 X32+X34 S9782 CPI= Close Position Indicator POC= Prove Of Closure Oil irrelevance time P323, has an effect on the oil safety chain and on the minimum oil pressure when the air valve is opened. Fig. -
Page 18: Servomotor (662R5
Technical description of the burner 4.15 Servomotor (662R5...) Warnings To avoid accidents, material or environmental damage, observe the following instructions! Avoid opening, modifying or forcing the actua- tors. WARNING 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 is to The installation of the burner must be carried out be installed, and arranging for the environment to be illuminated by qualified personnel, as indicated in this manual correctly, proceed with the installation operations. -
Page 20: Operating Position
2) and the blast tube 4). Ø The refractory can have a conical shape (minimum 60°). This protective fettling must not compromise the extraction of the RLS 810/E FGR blast tube. Tab. K For boilers with a water-cooled front piece, a refractory lining 2)- 5)(Fig. -
Page 21: Access To Head Internal Part
Installation Access to head internal part Disconnect the gas servomotor 1)(Fig. 15), air servomotor 2) unhook the electrodes 7); and FGR servomotor 3); turn the underneath part of the elbow 8) clockwise up to disconnect the socket 4) of the gas pressure switch; release it from its housing;... -
Page 22: Position Of The Electrodes And Central Gas Nozzles
Installation Position of the electrodes and central gas nozzles Check that the electrodes and the ignition pilot are positioned correctly, as in Fig. 16, complying with the dimensions indicated. WARNING Electrodes 20158216 Fig. 16 20171988... -
Page 23: Fgr Duct System
Installation FGR duct system – Normally the duct would connect to the stack as shown in There must be sufficient condensate drip legs and catch Fig. 17, with a 45° cut facing the flue gas flow and with the space (volume of drip legs) to prevent the condensation from centre of the cut centred in the stack. -
Page 24: Flue Gas Recirculation Line Sizing
FGR pipe Diameter Length (m) ly high CO rate. RLS 810/E FGR 8” To calculate the % of recirculated flue gas, use the formula be- low: % IFGR= (CO )/(CO ) x 100. -
Page 25: Nozzle Installation
Installation 5.11 Nozzle installation 5.11.1 Recommended nozzle The burner complies with the emission requirements of the EN 267 standard. • Bergonzo type B5 45° In order to guarantee that emissions do not vary, recommended Alternatively: and/or alternative nozzles specified by the Manufacturer in the In- •... -
Page 26: Light Oil Supply
Installation 5.12 Light oil supply 5.12.1 Double-pipe circuit 5.12.2 The loop circuit The burner is equipped with a self-priming pump which is capable A loop circuit consists of a loop of piping departing from and re- of feeding itself within the limits listed in the table at the side. turning to the tank with an auxiliary pump that circulates the fuel under pressure. -
Page 27: Priming Pump
Vacuometer connection G 1/4” Pressure adjuster By-pass screws Gauge connection G 1/4” Fig. 22 MODEL RLS 810/E FGR Key (Fig. 22) Nozzle delivery pressure gauge TA 5 Nozzle return pressure gauge Min. delivery rate Kg/h 1270 Position indicator (0 ÷ 90) of the pressure variator at 16.5 bar pressure... -
Page 28: Hydraulic Circuit Diagram
Installation 5.12.6 Hydraulic circuit diagram 20172540 Fig. 23 Key (Fig. 23) OPERATION Pump suction Pre-purging phase: Pump return line and nozzle return line valves 5), 6), 13) and 14) closed. Pump by-pass screw Ignition and operation phase: Pump pressure regulator valves 5), 6), 13) and 14) open. -
Page 29: Gas Pressures
Installation 5.13 Gas pressures 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 30: Gas Train
Installation 5.13.2 Gas train Approved according to standard EN 676 and provided separately Pay attention when handling the train: danger of from the burner. crushing of limbs. To select the correct gas train model, refer to the supplied “Burn- er-gas train combination” manual. Make sure that the gas train is properly installed by checking for any fuel leaks. -
Page 31: Gas Pressure
Installation 5.13.4 Gas pressure 1 p (mbar) 1 p (mbar) indicates the minimum pressure drops along the gas supply line, G 20 G 20 depending on the maximum burner output. 5400 43.0 The values shown in refer to: 5000 36.8 –... -
Page 32: Electrical Wiring
Installation 5.14 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: 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 34: Adjustments Prior To Ignition (Gas)
Start-up, calibration and operation of the burner Adjustments prior to ignition (gas) Combustion head adjustment has already been already de- Before starting up the burner, it is good practice to scribed in the section “Combustion head adjustment” on page 22. adjust the gas train so that ignition takes place in In addition, the following adjustments must also be made: conditions of maximum safety, i.e. -
Page 35: Air / Fuel Adjustment
Start-up, calibration and operation of the burner Air / fuel adjustment 6.8.3 Burner adjustment Air/fuel synchronisation is carried out with the relevant air and gas servomotors by logging a calibration curve by using the elec- The optimum adjustment of the burner requires an analysis of tronic cam. -
Page 36: Final Adjustment Of The Pressure Switches
Fig. 32. on the graduated scale corresponds with the arrow pointing On RLS 810/E FGR burners the air pressure switch is fitted in an downwards, and so recovering the hysteresis of the pressure “absolute” mode, that is, connected only to the pressure test point switch (shown by the white mark on a blue background, between “+”... -
Page 37: Pressure Switch Adjustment
Start-up, calibration and operation of the burner 6.10 Pressure switch adjustment 6.10.1 Maximum gas pressure switch Adjust the maximum gas pressure switch (Fig. 33) after perform- ing all other burner adjustments with the maximum gas pressure switch set to the end of the scale. With the burner operating at maximum output, lower the adjust- ment pressure by slowly turning the relative knob anticlockwise until the burner locks out. -
Page 38: Operation
Start-up, calibration and operation of the burner 6.11 Operation Once the start-up cycle is completed, the servomotor command The burner stops when the heat request is less than the heat moves on to the thermostat/pressure switch TR that controls the supplied by the burner at MIN output. -
Page 39: Fan Motor And Pump Motor Lockout
Start-up, calibration and operation of the burner 6.16 Fan motor and pump motor lockout If the motor does not start, it could be because of a thermal relay intervention due to its incorrect calibration or problems with the motor or the main power supply, to release press the button of the thermal relay, see “Calibration of the thermal relay”... -
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: Safety Components
Maintenance Measuring the flame signal LIGHT OIL OPERATION The burner is fitted with a sensor to check that a flame is present. Display shows the intensity of the flame signal. Pump The delivery pressure must comply with the table on page 29. The depression must be less than 0.45 bar. -
Page 42: Opening The Burner
Maintenance GAS OPERATION Air excess EN 676 Max. output. Min. output Gas leaks 1.2 1.3 Make sure that there are no gas leaks on the pipe between the Theoretical max % Calibration gas meter and the burner. mg/kWh ... -
Page 43: Faults - Possible Causes - Solutions
Faults - Possible causes - Solutions Faults - Possible causes - Solutions If faults arise in ignition or operations, the burner performs a In the event of a burner lockout, more than two "safety stop", which is signalled by the red burner lockout LED. consecutive burner reset operations could cause The display of the operator panel visualises alternately the lock- damage to the installation. - Page 44 Faults - Possible causes - Solutions EN67 Fault code P301=0 P301=2 Description P328>0 P328>0 Direction: P 2 = Actuator does not move, i.e. no position feedback. Channel backward, forward If this indication is shown, the monitoring of fault 271 is damaged. Actuator cannot find reference position Channel Direction:...
- Page 45 Faults - Possible causes - Solutions EN67 Fault code P301=0 P301=2 Description P328>0 P328>0 Failure during leakage test: gas pressure still active Failure during leakage test: no gas pressure detected Manual venting of the gas line required CPI/POC signal in unexpected state 1 *1) 1 *1) Invalid drop of the boiler safety interlock chain...
- Page 46 Faults - Possible causes - Solutions EN67 Fault code P301=0 P301=2 Description P328>0 P328>0 Integration of a channel into the fuel/air ratio control takes too long (only one automatic restart possible) Channel Channel is out of 1 monitoring band for too long Channel Channel mode of the fuel/air ratio control does not match to the ac- Channel...
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Page 47: A Appendix - Accessories
Appendix - Accessories Appendix - Accessories Kit for modulating operation Burner Probe Adjustment field Code RLS 810/E FGR PT 100 temperature - 100...+ 500°C 3010110 RLS 810/E FGR 4 - 20 mA pressure 0...2.5 bar 3010213 RLS 810/E FGR 4 - 20 mA pressure 0...16 bar... -
Page 48: Appendix - Electrical Panel Layout
Appendix - Electrical panel layout Appendix - Electrical panel layout Index of layouts Indication of references Layout of unifilar output Layout of unifilar output BT340 operational layout BT340 operational layout BT340 operational layout BT340 operational layout DFM 300 operational layout LCM100 operational layout Electrical wiring that is the responsibility of the installer Electrical wiring that is the responsibility of the installer... - Page 49 Appendix - Electrical panel layout 20171988...
- Page 50 Appendix - Electrical panel layout & & 20171988...
- Page 51 Appendix - Electrical panel layout 20171988...
- Page 52 Appendix - Electrical panel layout 20171988...
- Page 53 Appendix - Electrical panel layout 20171988...
- Page 54 Appendix - Electrical panel layout 20171988...
- Page 55 Appendix - Electrical panel layout 20171988...
- Page 56 Appendix - Electrical panel layout 20171988...
- Page 57 Appendix - Electrical panel layout 20171988...
- Page 58 Appendix - Electrical panel layout 29-4 51/) 29-4 51/) 20171988...
- Page 59 Appendix - Electrical panel layout Wiring layout key Electronic cam Gas adjustment valve + gas safety valve Regulation module Main terminal supply board Fuel management module Valve group terminal board Display and operating unit XPGMax Maximum gas pressure switch connector Oxygen control module XPGMin Minimum gas pressure switch connector...
- Page 60 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...