Riello RLS 70 Quick start guide

20079454 (2) - 01/2014

Installation, use and maintenance instructions

安装、使用和维护手册

Dual fuel light oil/gas burners

双燃料轻油 / 燃气燃烧器

Two-stage operation

两段火运行

CODE - 代码 MODEL - 型号 TYPE - 类型

20079208 RLS 70 687 T1

20079215 RLS 100 688 T1

20079217 RLS 130 689 T1

Original instructions

说明书原文翻译

CONTENTS

DECLARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Choice of nozzles for the 1st and 2nd stage . . . . . . . . . . . . . . . . . .7

Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Adjustments before first firing (light oil operation) . . . . . . . . . . . . . .7

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Burner calibration (light oil operation). . . . . . . . . . . . . . . . . . . . . . .12

Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Gas feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Adjustment before firing (gas operation) . . . . . . . . . . . . . . . . . . . .16

Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

LPG - Propane - Butane operation. . . . . . . . . . . . . . . . . . . . . . . . .18

Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Gas combustion checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

FAULTS - POSSIBLE CAUSES - SOLUTIONS . . . . . . . . . . . . . .22

ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Declaration of conformity in accordance with ISO / IEC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 7

37045 Legnago (VR)

Product: Dual fuel light oil/gas burner

Model: RLS 70 - 100 - 130

These products are in compliance with the following Technical Standards:

EN 676

EN 267

EN 12100

and according to the European Directives:

MD 2006/42/EC Machine Directive

LVD 2006/95/EC Low Voltage Directive

EMC 2004/108/EC Electromagnetic Compatibility

The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.

Legnago, 10.10.2013 Executive Director

RIELLO S.p.A. - Burner Department Research & Development Director

RIELLO S.p.A. - Burner Department

Mr. G. Conticini Mr. R. Cattaneo

TECHNICAL DATA

(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m s.l.m.

(2 Upstream pressure of the gas train 1)(A)p.13 as indicated by EN676 Standard, with 0 mbar in the combustion chamber and at the maximum

burner output.

(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The

sound power is evaluated, in line with the regulations, on a spherical surface centred on the burner and with a radius of 1 metre.

ELECTRICAL DATA

BURNER CATEGORIES

MODEL RLS 70 RLS 100 RLS 130

Output (1)

Delivery (1)

2nd stage kW

kg/h 465 - 817

39 - 69 698 - 1163

59 - 98 930 - 1512

78 - 130

min. 1st stage kW

kg/h 232

19 349

29,5 465

Fuel LIGHT OIL, viscosity at 20 °C: 6 mm2/s max (1,5 °E - 6 cSt)

NATURAL GAS: G20 (methane) - G21 - G22 - G23 - G25

GPL - G30 (propane) - G31 (butane)

Gas pressure at maximum delivery (2)

Gas: G20/G25/G31 mbar 7.4/10.6/9.4 11.5/17.0/13.1 14.1/12.1/18.8

Operation - Intermittent (min. 1 stop in 24 hours)

- Two-stage (high and low flame) and single-stage (all - nothing)

Nozzles number 2

Standard applications Boilers: water, steam, diathermic oil

Ambient temperatur °C 0 - 40

Combustion air temperature °C max 60

Pump delivery (at 12 bar)

pressure range

fuel temperatur

kg/h

bar

° C max

220

10 - 20

Noise levels (3) Sound pressure

Sound power dBA 74

85 77.5

89.5 80

MODEL RLS 70 RLS 100 RLS 130

Main electrical supply

Control circuit power supply 3 ~ 230/400V 50Hz

1N ~ 230V 50Hz

Fan motor IE2 rpm

2880

230 / 400

1100

4.3 - 2.5

2870

230 / 400

1500

5.9 - 3.4

2900

230 / 400

2200

7.9 - 4.6

Pump motor

Pump motor capacitor

rpm

µF

2700

230

550

3.6

Ignition transformer V1 - V2

I1 - I2 230 V - 2 x 5 kV

1,9 A - 30 mA

Absorbed electrical power W max 2000 2400 3200

Protection level IP 44

COUNTRY CATEGORY

IT - AT - GR - DK - FI - SE II2H3B / P

ES - GB - IE - PT II2H3P

NL II2L3B / P

FR II2Er3P

DE II2ELL3B /P

BE I2E(R)B, I3P

LU - PL II2E3B/P

BURNER DESCRIPTION (A)

1 Combustion head

2 Ignition electrodes

3 Screw for combustion head adjustment

4 Sleeve

5 Relay

6 Fan motor

7 Motor contactor and thermal cut-out with

reset button

8LEDPANEL

9 Terminal strip

10 Fairleads for electrical connections by

installer

11 Two switches:

- one “burner off - on”

- one for “1st - 2nd stage”

12 Control box with lock-out pilot light and lock-

out reset button

13 Flame inspection window

14 Minimum air pressure switch

(differential operating type)

15 Slide bars for opening the burner and

inspecting the combustion head

16 Safety solenoid valve

17 1st and 2nd stage valves

18 Gas pressure test point and head fixing

screw

19 Air pressure test point

20 Servomotor. When the burner is not operat-

ing the air gate valve is fully closed in order

to reduce to a minimum heat dispersion from

the boiler due to the flue draught which

draws air from the fan suction inlet.

21 Pump motor

22 Air gate valve

23 Air inlet to fan

24 Pump

25 Gas input pipework

26 Boiler mounting flange

27 Flame stability disk

28 Screw securing fan to sleeve

29 Cell UV

30 OIL/GAS selector

Two types of burner failure may occur:

Control Box Lock-out: if the control box 12)(A)

pushbutton lights up, it indicates that the burner

is in lock-out.

To reset, press the pushbutton.

Motor trip: release by pressing the pushbutton

on thermal relay 7)(A).

PACKAGING - WEIGHT (B) - Approximate

measurements

• The burners stands on a wooden base which

can be lifted by fork-lifts. Outer dimensions of

packaging are indicated in (B).

• The weight of the burner complete with pack-

aging is indicated in Table (B).

MAX. DIMENSIONS (C) -Approximate meas-

urements

The maximum dimensions of the burner are

given in (C).

Bear in mind that inspection of the combustion

head requires the burner to be opened and the

rear part withdrawn on the slide bars.

The maximum dimension of the burnerwhen

open, without casing, is give in measurement I.

STANDARD EQUIPMENT

1 - Gas train flange

1 - Flange gasket

4 - Flange fixing screws M 10 x 35

1 - Thermal insulation screen

4 - Screws to secure the burner flange to the

boiler: M 12 x 35

2 - Flexible hoses

2 - Nipples for flexible hoses with gasket

1 - KIT for LPG operation

1 - Label for LPG operation

1 - Instruction booklet

1 - Spare parts list

(A)

mm ABCkg

RLS 70 1405 1000 660 70

RLS 100 1405 1000 660 73

RLS 130 1405 1000 660 76

(1) Blast tube: short-long

mm ABCDE F(1) GH I LMNO

RLS 70 691 296 395 555 840 250-385 179 430 1161 214 134 221 2”

RLS 100 707 312 395 555 840 250-385 189 430 1161 214 134 221 2”

RLS 130 733 338 395 555 840 250-385 189 430 1161 214 134 221 2”

D1175

D36

D1176

(B)

(C)

FIRING RATES (A)

The burners can work in two ways: one-stage

and two-stage.

MAXIMUM OUTPUT must be selected in area

In order to utilize also area B (RLS 130) it is nec-

essary to perform the calibration of the combus-

tion head as explained on page 8.

MINIMUM OUTPUT must not be lower than the

minimum limit shown in the diagram:

RLS 70 = 232 kW = 19.0 kg/h

RLS 100 = 349 kW = 29.5 kg/h

RLS 130 = 465 kW = 39.0 kg/h

Important:

The firing rate area values have been obtained

considering a surrounding temperature of 20°C,

and an atmospheric pressure of 1000 mbar

(approx. 100 m above sea level) and with the

combustion head adjusted as shown on page 8.

TEST BOILER (B)

The firing rates were set in relation to special

test boilers, according to EN 676 and EN 267

regulations.

Figure (B) indicates the diameter and length of

the test combustion chamber.

Example: Output 650 Mcal/h:

diameter 60 cm - length 2 m.

COMMERCIAL BOILERS

The burner/boiler combination does not pose

any problems if the boiler is CE type-approved

and its combustion chamber dimensions are

similar to those indicated in diagram (B).

If the burner must be combined with a commer-

cial boiler that has not been CE type-approved

and/or its combustion chamber dimensions are

clearly smaller than those indicated in diagram

(B), consult the manufacturer.

(A)

RLS 70

RLS 100

RLS 130

D1194

D715

(B)

Combustion chamber

pressure - mbar

Combustion chamber

pressure - mbar

Combustion chamber

pressure - mbar

Combustion chamber

lenght - m

INSTALLATION

BOILER PLATE (A)

Drill the combustion chamber locking plate as

shown in (A). The position of the threaded holes

can be marked using the thermal screen sup-

plied with the burner.

BLAST TUBE LENGTH (B)

The length of the blast tube must be selected

according to the indications provided by the

manufacturer of the boiler, and in any case it

must be greater than the thickness of the boiler

door complete with its fettling. The range of

lengths available, L (mm), is as follows:

Blast tube 10): RLS 70 RLS 100 RLS 130

• short 250 250 250

• long 385 385 385

For boilers with front flue passes 13) or flame

inversion chambers, protective fettling in refrac-

tory material 11) must be inserted between the

boiler fettling 12) and the blast tube 10).

This protective fettling must not compromise the

extraction of the blast tube.

For boilers having a water-cooled front the

refractory fettling 11)-12)(B) is not required

unless it is expressly requested by the boiler

manufacturer.

SECURING THE BURNER TO THE BOILER

(B)

Detach the combustion head from the burner,

fig. (B):

- Disconnect the oil pipes by unscrewing the two

connectors 6).

- Loosen the 4 screws 3) and remove the cover 1).

- Remove the screws 2) from the slide bars 5).

- Remove the 2 screws 4) and pull the burner

back on slide bars 5) by about 100 mm.

- Disconnect the electrode wires and then pull

the burner completely off the slide bars.

COMBUSTION HEAD CALIBRATION

At this point check, for model RLS 130, whether

the maximum delivery of the burner in 2nd stage

operation is contained in area A or in area B of

the firing rate. See page 5.

If it is in area A then no operation is required.

If, on the other hand, it is in area B:

- unscrew the screws 1)(C) and disassemble

the blast tube 2).

- Move the fixing of the rod 3)(C) from position

A to position B, thereby causing the shutter

4) to retract.

- Now refit the blast tube 2)(C) and the screws 1).

Once this operation has been carried out (if it

was required):

- secure the flange 9)(B) to the boiler plate,

interposing the thermal insulating screen

7)(B) supplied with the burner.

- Use the 4 screws, also supplied with the unit,

after first protecting the thread with an anti-

locking product.

The seal between burner and boiler

must be airtight.

mm A B C

RLS 70 185 275-325 M 12

RLS 100 195 275-325 M 12

RLS 130 195 275-325 M 12

(A)

(B)

(C)

D455

D1172

D1192

WARNING

CHOICE OF NOZZLES FOR 1ST AND 2ND

STAGE

The burner complies with the emission require-

ments of the EN 267 standard.

In order to guarantee that emissions do not vary,

recommended and/or alternative nozzles speci-

fied by Riello in the Instruction and warning

booklet should be used.

Both nozzles must be chosen from among those

listed in Table (A).

The first nozzle determines the delivery of the

burner in the 1st stage.

The second nozzle works together with the 1st

nozzle to determine the delivery of the burner in

the 2nd stage.

The deliveries of the 1st and 2nd stages must

be contained within the value range indicated on

page 3.

Use nozzles with a 60° spray angle at the rec-

ommended pressure of 12 bar.

The two nozzles usually have equal deliveries.

NOZZLE ASSEMBLY

Remove screw 1)(B) and extract the internal

part 2)(B).

Fit two nozzles with the box spanner 1)(C) (16

mm), after having removed the plastic plugs

2)(C), fitting the spanner through the central

hole in the flame stability disk or loosen screws

1)(D), remove disk 2)(D) and replace the noz-

zles using the wrench 3)(D).

Do not use any sealing products such as gas-

kets, sealing compound, or tape. Be careful to

avoid damaging the nozzle sealing seat. The

nozzles must be screwed into place tightly but

not to the maximum torque value provided by

the wrench.

The nozzle for the 1st stage of operation is the

one lying beneath the firing electrodes.

It is advisable to replace the nozzle

once a year during periodical mainte-

nance.

The use of nozzles other than those

specified by Riello S.p.A. and inade-

quate regular maintenance may re-

sult into emission limits non-

conforming to the values set forth by

the regulations in force, and in ex-

tremely serious cases, into potential

hazards to people and objects.

The manufacturing company shall not

be liable for any such damage arising

from nonobservance of the require-

ments contained in this manual.

Make sure that the electrodes are

positioned as shown in figure (E).

WARNING

CAUTION

(A)

GPH kg/h kW

12 bar

10 bar 12 bar 14 bar

5.00

5.50

6.00

6.50

7.00

7.50

8.00

8.30

8.50

9.00

9.50

10.0

10.5

11.0

12.0

12.3

13.0

13.8

14.0

15.0

15.3

16.0

17.0

19.2

21.1

23.1

25.0

26.9

28.8

30.8

31.9

32.7

34.6

36.5

38.4

40.4

42.3

46.1

47.3

50.0

53.1

53.8

57.7

58.8

61.5

65.4

21.2

23.3

25.5

27.6

29.7

31.8

33.9

35.2

36.1

38.2

40.3

42.4

44.6

46.7

50.9

52.2

55.1

58.5

59.4

63.6

64.9

67.9

72.1

23.1

25.4

27.7

30.0

32.3

34.6

36.9

38.3

39.2

41.5

43.8

46.1

48.4

50.7

55.3

56.7

59.9

63.3

64.5

69.2

70.5

73.8

78.4

251.4

276.3

302.4

327.3

352.3

377.2

402.1

417.5

428.2

453.1

478.0

502.9

529.0

553.9

603.7

619.1

653.5

693.8

704.5

754.3

769.7

805.3

855.1

D1122

(B)

D1146 D1147

(E) D1124

WARNING

Refit the burner to the slide bars 3)(C) at

approximately 100 mm from the sleeve 4) -

burner positioned as shown in fig. (B)p.6 - insert

the ignition electrode cables and then slide the

burner up to the sleeve so that it is positioned as

shown in fig. (C).

Refit screws 2)(C) on slide bars 3).

Secure the burner to the sleeve by tightening

screws 1).

Connect the oil pipes again by screwing on the

two connectors 6)(B)p.6.

ADJUSTMENTS BEFORE FIRST FIRING

(light oil operation)

• Combustion head setting

The setting of the combustion head depends

exclusively on the delivery of the burner in the

2nd stage.

Turn screw 5)(A) until the notch shown in dia-

gram (B) is level with the front surface of flange.

Example: Burner RLS 100

2nd stage burner delivery = 72 kg/h.

If diagram (B) is consulted it is clear that for this

delivery, the combustion head must be adjusted

using notch 3, as shown in fig. (B).

• Pump adjustment

No settings are required for the pump, which is

set to 12 bar by the manufacturer. This pressure

must be checked and adjusted (if required) after

the burner has been ignited.

The only operation required in this phase is the

application of a pressure gauge on the appropri-

ate pump attachment.

• Fan gate adjustment

The first time the burner is fired leave the factory

setting unchanged for both 1st stage and 2nd

stage operation.

When fitting the burner on the two

slide bars, it is advisable to gently

draw out the high tension cables

until they are slightly stretched.

SETTING THE COMBUSTION HEAD

(B)

No. notches

Light oil delivery in 2nd stage - kg/h

D1149

D1193

D1173

(C)

(A)

WARNING

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