dual fuel gas oil/gas burners

Installation, use and maintenance instructions

20061317 (7) - 12/2015

Dual fuel gas oil/gas burners

Modulating operation

CODE MODEL TYPE

20057529 RLS 1000/E MX 1311 T1

20057530 RLS 1200/E MX 1312 T1

GB

Translation of the original instructions

1 20061317GB

Contents

1 Declarations...................................... .......................................................................................................................................... 3

2 Information and general warnings.................. .......................................................................................................................... 4

2.1 Information about the instruction manual .................................................................................................................... 42.1.1 Introduction.................................................................................................................................................................. 42.1.2 General dangers.......................................................................................................................................................... 42.1.3 Other symbols ............................................................................................................................................................. 42.1.4 Delivery of the system and the instruction manual...................................................................................................... 5

2.2 Guarantee and responsibility....................................................................................................................................... 5

3 Safety and prevention.............................. .................................................................................................................................. 6

3.1 Introduction.................................................................................................................................................................. 6

3.2 Personnel training ....................................................................................................................................................... 6

4 Technical description of the burner ............... .......................................................................................................................... 7

4.1 Burner designation ...................................................................................................................................................... 7

4.2 Models available.......................................................................................................................................................... 7

4.3 Burner categories - Countries of destination ............................................................................................................... 7

4.4 Technical data ............................................................................................................................................................. 8

4.5 Electrical data.............................................................................................................................................................. 8

4.6 Maximum dimensions.................................................................................................................................................. 9

4.7 Firing rates ................................................................................................................................................................ 10

4.8 Test boiler.................................................................................................................................................................. 10

4.9 Burner description ..................................................................................................................................................... 11

4.10 Electrical panel description........................................................................................................................................ 12

4.11 Burner equipment...................................................................................................................................................... 12

4.12 Control box for the air/fuel ratio (LMV51...) ............................................................................................................... 13

4.13 Servomotor................................................................................................................................................................ 15

5 Installation ...................................... .......................................................................................................................................... 16

5.1 Notes on safety for the installation ............................................................................................................................ 16

5.2 Handling .................................................................................................................................................................... 16

5.3 Preliminary checks .................................................................................................................................................... 16

5.4 Operating position ..................................................................................................................................................... 17

5.5 Removal of the locking screws from the shutter........................................................................................................ 17

5.6 Preparing the boiler ................................................................................................................................................... 175.6.1 Boring the boiler plate ............................................................................................................................................... 175.6.2 Blast tube length........................................................................................................................................................ 17

5.7 Securing the burner to the boiler ............................................................................................................................... 18

5.8 Access to head internal part...................................................................................................................................... 18

5.9 Nozzle installation ..................................................................................................................................................... 195.9.1 Recommended nozzle............................................................................................................................................... 19

5.10 Electrode position...................................................................................................................................................... 20

5.11 Combustion head adjustment.................................................................................................................................... 20

5.12 Light oil supply........................................................................................................................................................... 215.12.1 Double-pipe circuit..................................................................................................................................................... 215.12.2 Loop circuit ................................................................................................................................................................ 215.12.3 Hydraulic connections ............................................................................................................................................... 225.12.4 Hydraulic circuit diagram ........................................................................................................................................... 225.12.5 Pressure variator ....................................................................................................................................................... 22

5.13 Pump ......................................................................................................................................................................... 235.13.1 Technical data ........................................................................................................................................................... 235.13.2 Priming pump ............................................................................................................................................................ 23

5.14 Gas feeding ............................................................................................................................................................... 245.14.1 Gas feeding line ........................................................................................................................................................ 245.14.2 Gas train.................................................................................................................................................................... 255.14.3 Gas train installation.................................................................................................................................................. 25

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Contents

5.14.4 Gas pressure .............................................................................................................................................................255.14.5 Pilot - gas train connection.........................................................................................................................................265.14.6 Ignition pilot burner ....................................................................................................................................................26

5.15 Activation of the burner lance ....................................................................................................................................27

5.16 Electrical connections ................................................................................................................................................285.16.1 Supply cables and external connections passage .....................................................................................................28

5.17 Calibration of the thermal relay ..................................................................................................................................29

6 Start-up, calibration and operation of the burner .. ................................................................................................................30

6.1 Notes on safety for the first start-up...........................................................................................................................30

6.2 Adjustments prior to ignition (light oil) ........................................................................................................................306.2.1 Nozzle ........................................................................................................................................................................306.2.2 Combustion head.......................................................................................................................................................306.2.3 Pump pressure...........................................................................................................................................................30

6.3 Burner ignition (light oil) .............................................................................................................................................30

6.4 Adjustments prior to ignition (gas) .............................................................................................................................31

6.5 Burner start-up (gas) ..................................................................................................................................................31

6.6 Check motor rotation..................................................................................................................................................31

6.7 Burner ignition............................................................................................................................................................31

6.8 Change of fuel............................................................................................................................................................32

6.9 Combustion air adjustment ........................................................................................................................................326.9.1 Air / gas adjustment and output modulation...............................................................................................................32

6.10 Pressure switch adjustment .......................................................................................................................................336.10.1 Air pressure switch - check CO..................................................................................................................................336.10.2 Maximum gas pressure switch...................................................................................................................................336.10.3 Minimum gas pressure switch....................................................................................................................................336.10.4 PVP pressure switch kit .............................................................................................................................................336.10.5 Oil pressure switch.....................................................................................................................................................34

6.11 Final checks (with burner operating) ..........................................................................................................................34

7 Maintenance ....................................... .......................................................................................................................................35

7.1 Notes on safety for the maintenance .........................................................................................................................35

7.2 Maintenance programme ...........................................................................................................................................357.2.1 Maintenance frequency..............................................................................................................................................357.2.2 Checking and cleaning...............................................................................................................................................35

7.3 Opening the burner ....................................................................................................................................................37

7.4 Closing the burner......................................................................................................................................................37

8 Faults - Possible causes - Solutions................ .......................................................................................................................38

A Appendix - Accessories ............................ ...............................................................................................................................39

B Appendix - Electrical panel layout................. ..........................................................................................................................40

3 20061317GB

Declarations

1 Declarations

Declaration of conformity in accordance with ISO / I EC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 737045 Legnago (VR)

Product: Dual fuel gas oil/ gas burners

Model: RLS 1000/E MXRLS 1200/E MX

These products are in compliance with the following Technical Standards:

EN 676

EN 267

EN 12100

and according to the European Directives:

GAD 2009/142/EC Gas Devices Directive

MD 2006/42/EC Machine Directive

LVD 2014/35/UE Low Voltage Directive

EMC 2014/30/UE Electromagnetic Compatibility

Such products are marked as follows:

The quality is guaranteed by a quality and manageme nt system certified in accordance with UNI EN ISO 90 01.

Manufacturer's Declaration

RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BImSchVrevision 26.01.2010 ”.

Product Type Model Output

Dual fuel gas oil/ gas burners 1311 T1 RLS 1000/E MX 1200 - 10600 kW1312 T1 RLS 1200/E MX 1500 - 11500 kW

Legnago, 01.12.2015 Executive General ManagerRIELLO S.p.A. - Burner Department

Research & Development DirectorRIELLO S.p.A. - Burner Department

Mr. U. Ferretti Mr. F. Comencini

RLS 1000/E MX EC-0085CN0119 Class 2 (EN 267) - Class 3 (EN 676)

RLS 1200/E MX EC-0085CN0120 Class 2 (EN 267) - Class 3 (EN 676)

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Information and general warnings

2.1 Information about the instruction manual

2.1.1 IntroductionThe instruction manual supplied with the burner:➤ is an integral and essential part of the product and must not

be separated from it; it must therefore be kept carefully forany necessary consultation and must accompany the burnereven if it is transferred to another owner or user, or toanother system. If the manual is lost or damaged, anothercopy must be requested from the Technical Assistance Ser-vice of the area;

➤ is designed for use by qualified personnel;➤ offers important indications and instructions relating to the

installation safety, start-up, use and maintenance of theburner.

Symbols used in the manual

In some parts of the manual you will see triangular DANGERsigns. Pay great attention to these, as they indicate a situation ofpotential danger.

2.1.2 General dangersThe dangers can be of 3 levels , as indicated below.

2.1.3 Other symbols

Abbreviations used

Ch. ChapterFig. FigurePage PageSec. SectionTab. Table

2 Information and general warnings

DANGER

Maximum danger level!This symbol indicates operations which, if not car-ried out correctly, cause serious injury, death orlong-term health risks.

WARNING

This symbol indicates operations which, if not car-ried out correctly, may cause serious injury, deathor long-term health risks.

CAUTION

This symbol indicates operations which, if not car-ried out correctly, may cause damage to the ma-chine and/or injury to people.

DANGER

DANGER: LIVE COMPONENTS

This symbol indicates operations which, if not car-ried out correctly, lead to electric shocks with le-thal consequences.

DANGER: FLAMMABLE MATERIAL

This symbol indicates the presence of flammablematerials.

DANGER: BURNING

This symbol indicates the risks of burns due tohigh temperatures.

DANGER: CRUSHING OF LIMBS

This symbol indicates the presence of movingparts: danger of crushing of limbs.

WARNING: MOVING PARTS

This symbol indicates that you must keep limbsaway from moving mechanical parts; danger ofcrushing.

DANGER: EXPLOSION

This symbol signals places where an explosive at-mosphere may be present. An explosive atmos-phere is defined as a mixture - under atmosphericconditions - of air and flammable substances inthe form of gases, vapours, mist or dust in which,after ignition has occurred, combustion spreads tothe entire unburned mixture.

PERSONAL PROTECTION EQUIPMENT

These symbols indicate the equipment that mustbe worn and kept by the operator for protectionagainst threats against safety and/or health whileat work.

OBLIGATION TO ASSEMBLE THE HOOD ANDALL THE SAFETY AND PROTECTION DEVIC-ES

This symbol signals the obligation to reassemblethe hood and all the safety and protection devicesof the burner after any maintenance, cleaning orchecking operations.

ENVIRONMENTAL PROTECTION

This symbol gives indications for the use of themachine with respect for the environment.

IMPORTANT INFORMATION

This symbol indicates important information thatyou must bear in mind.

➤ This symbol indicates a list.

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Information and general warnings

2.1.4 Delivery of the system and the instruction manual

When the system is delivered, it is important that:➤ the instruction manual is delivered to the user by the system

manufacturer, with the recommendation to keep it in theroom where the heat generator is to be installed.

➤ The instruction manual shows:– the serial number of the burner;

– the address and telephone number of the nearest Assis-tance Centre.

➤ The system supplier must carefully inform the user about:– the use of the system; – any further tests that may be required before activating the

system; – maintenance, and the need to have the system checked at

least once a year by a representative of the manufactureror another specialised technician.To ensure a periodic check, the manufacturer recom-mends the drawing up of a Maintenance Contract.

2.2 Guarantee and responsibility

The manufacturer guarantees its new products from the installa-tion date, in accordance with the regulations in force and/or thesales contract. At the moment of the first start-up, check that theburner is integral and complete.

In particular, the rights to the guarantee and the responsibility willno longer be valid, in the event of damage to things or injury topeople, if such damage/injury was due to any of the followingcauses:➤ incorrect installation, start-up, use and maintenance of the

burner;➤ improper, incorrect or unreasonable use of the burner;➤ intervention of unqualified personnel;➤ carrying out of unauthorised modifications on the equipment;➤ use of the burner with safety devices that are faulty, incor-

rectly applied and/or not working;➤ installation of untested supplementary components on the

burner;➤ powering of the burner with unsuitable fuels;➤ faults in the fuel supply system;➤ use of the burner even following an error and/or an irregularity;➤ repairs and/or overhauls incorrectly carried out;➤ modification of the combustion chamber with inserts that

prevent the regular development of the structurally estab-lished flame;

➤ insufficient and inappropriate surveillance and care of thoseburner components most likely to be subject to wear and tear;

➤ the use of non-original components, including spare parts,kits, accessories and optional;

➤ force majeure.

The manufacturer furthermore declines any and every re-sponsibility for the failure to observe the content s of thismanual.

.........................................................................................

.........................................................................................

.........................................................................................

.........................................................................................

WARNING

Failure to observe the information given in thismanual, operating negligence, incorrect installa-tion and carrying out of non authorised modifica-tions will result in the annulment by themanufacturer of the guarantee that it supplies withthe burner.

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Safety and prevention

3.1 Introduction

The burners have been designed and built in compliance withcurrent regulations and directives, applying the known technicalrules of safety and envisaging all the potential danger situations.

It is necessary, however, to bear in mind that the imprudent andclumsy use of the equipment may lead to situations of death riskfor the user or third parties, as well as the damaging of the burneror other items. Inattention, thoughtlessness and excessive confi-dence often cause accidents; the same applies to tiredness andsleepiness.

It is a good idea to remember the following:➤ The burner must only be used as expressly described. Any

other use should be considered improper and therefore dan-gerous.

In particular:

it can be applied to boilers operating with water, steam, diather-mic oil, and to other uses expressly named by the manufacturer;

the type and pressure of the fuel, the voltage and frequency of theelectrical power supply, the minimum and maximum deliveries forwhich the burner has been regulated, the pressurisation of thecombustion chamber, the dimensions of the combustion cham-ber and the room temperature must all be within the values indi-cated in the instruction manual.➤ Modification of the burner to alter its performance and desti-

nations is not allowed.➤ The burner must be used in exemplary technical safety con-

ditions. Any disturbances that could compromise safety mustbe quickly eliminated.

➤ Opening or tampering with the burner components is notallowed, apart from the parts requiring maintenance.

➤ Only those parts envisaged by the manufacturer can bereplaced.

3.2 Personnel training

The user is the person, body or company that has acquired themachine and intends to use it for the specific purpose. He is re-sponsible for the machine and for the training of the people work-ing around it.

The user:➤ undertakes to entrust the machine exclusively to suitably

trained and qualified personnel;➤ undertakes to inform his personnel in a suitable way about

the application and observance of the safety instructions.With that aim, he undertakes to ensure that everyone knowsthe use and safety instructions for his own duties;

➤ Personnel must observe all the danger and caution indica-tions shown on the machine.

➤ Personnel must not carry out, on their own initiative, opera-tions or interventions that are not within their province.

➤ Personnel must inform their superiors of every problem ordangerous situation that may arise.

➤ The assembly of parts of other makes, or any modifications,can alter the characteristics of the machine and hence com-promise operating safety. The manufacturer thereforedeclines any and every responsibility for any damage thatmay be caused by the use of non-original parts.

In addition:

3 Safety and prevention

WARNING

The manufacturer guarantees safety and properfunctioning only if all burner components are intactand positioned correctly.

➤ the user must take all the measures neces-sary to prevent unauthorised people gainingaccess to the machine;

➤ the user must inform the manufacturer iffaults or malfunctioning of the accident pre-vention systems are noticed, along with anypresumed danger situation.

➤ Personnel must always use the personal pro-tective equipment envisaged by legislationand follow the indications given in this man-ual.

7 20061317GB

Technical description of the burner

4.1 Burner designation

4.2 Models available

4.3 Burner categories - Countries of destination

4 Technical description of the burner

Designation Voltage Start-up CodeRLS 1000/E MX TC 3/400/50 Star/Triangle 20057529RLS 1200/E MX TC 3/400/50 Star/Triangle 20057530

Class 2 EN267 - Class 3 EN676

Series : R

Size

Fuel : Natural gas

Gas oil

Gas oil / Methane

Adjustment :

Flame control system:FS1FS2

Standard (1 stop every 24 h)Continuos working (1 stop every 72 h)

Electrical supply of the system :3/400/503/230/50

Auxiliary voltage :230/50/60110/50/60

R LS 1000 E TC

Emission : C11 or... Class 1 EN267 - EN676C22 or MZ Class 2 EN267 - EN676

C33 or BLU Class 3 EN267 - EN676

FS1 3/400/50 230/50/60

BASIC DESIGNATION

EXTENDED DESIGNATION

MX

3N / 400V / 50Hz3 / 230V / 50Hz

230V / 50-60Hz110V / 50-60Hz

Heavy oil

E Electronic camEV Electronic cam with variable speed (with Inverter)P Proportional air/gas valve

BP Two stage (light oil) / Proportional valve (gas)

M Mechanical cam

S

L

LS

N

Head : TC Standard headTL Extended head

C23 or MX

MX Class 1 EN267 - Class 3 EN676

Country of destination Gas categorySE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H

DE I2ELL

NL I2L

FR I2Er

BE I2E(R)B

LU - PL I2E

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4.4 Technical data

Tab. A(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.

(2) Pressure on the test point 28(Fig. 4) with zero pressure in the combustion chamber and at maximum burner output.

(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The soundpower is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out inEN ISO 3746.

4.5 Electrical data

Tab. B

Model RLS 1000/E MX RLS 1200/E MX

Type 1311 T1 1312 T1

Output (1)Delivery (1)

min - maxkWkg/h

1200/3750 ÷ 10600 100/315 ÷ 867

1500/5500 ÷ 11500171/462 ÷ 942

Fuels – Light oil, max. viscosity at 20 °C: 6 mm2/s (1.5 °E - 6 cSt)– Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25

Gas pressure at max. output (2) - Gas: G20/G25

mbar 67.8/101.1 97.2/145

Operation – Intermittent (min. 1 stop in 24 hours)– Modulating

Pump Output at 30 barPressure rangeFuel temperature

kg/hbar

°C max

14009/40140

18269/40140

Nozzles number 1

Standard applications Boilers: water, steam, diathermic oil

Ambient temperature °C 0 - 50

Combustion air temperature °C max 60

Noise levels (3) Sound pressureSound power

dB(A)85.4

100.684.499.7

Weight kg 500 540


Electrical supply 3N ~ 400V 50 Hz

Fan motor IE2 rpmV

kWA

2935400/690

2238.6/22.3

2964400/690

2141.8/24.2

2920400/690

2544.1/25.5

Pump motor rpmV

kWA

1458230/400

2.29.3/5.4

1400400

48.2

Ignition transformer V1 - V2I1 - I2

230 V - 1 x 8 kV1 A - 20 mA

Electrical power consumption Light oilGas

kW max2624

3127

Protection level IP 55

9 20061317GB


Tab. C

4.6 Maximum dimensions

The maximum dimensions of the burner are given in Fig. 1.

Bear in mind that inspection of the combustion head requires theburner to be opened and the rear part turned on the hinge.

The maximum dimensions of the open burner are indicated bythe L and R positions.

The l position is reference for the refractory thickness of the boilerdoor.

Tab. D


Electrical supply 3N ~ 400V 50 Hz

Fan motor IE3 rpmV

kWA

2880400/690

2238.1/22

2880400/690

2138.2/22.3

2880400/690

2543.4/25.1

Pump motor rpmV

kWA

1458230/400

2,29.3/5.4

1400400

48.2

Ignition transformer V1 - V2I1 - I2

230 V - 1 x 8 kV1 A - 20 mA

Electrical power consumption Light oilGas

kW max2724

3227.2

Protection level IP 55

Fig. 1

20053383

mm A B C D E F G H I L R

RLS 1000/E MX 1637 674 200 413 885 DN80 1206 1338 484 1425 1350

RLS 1200/E MX 1637 658 200 456 885 DN80 1250 1338 465 1425 1350

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4.7 Firing rates

The MAXIMUM OUTPUT is chosen from within the continuousdiagram area (Fig. 2).

The MINIMUM OUTPUT must not be lower than the minimumlimit of the diagram:RLS 1000/E MX = 3750 kWRLS 1200/E MX = 5500 kW

4.8 Test boiler

The burner/boiler combination does not pose any problems if theboiler is EC approved and its combustion chamber dimensionsare similar to those indicated in the diagram (Fig. 3).

If the burner must be combined with a boiler that has not been ECapproved and/or its combustion chamber dimensions are clearlysmaller than those indicated in the diagram, consult the manufac-turer.

The firing rates were set in relation to special test boilers, accord-ing to EN 676 regulations.

In Fig. 3 you can see the diameter and length of the test combus-tion chamber.

Example: Output 7000 kW - diameter 120 cm - length 6 m.

MODULATING RATIO

The modulating ratio, obtained in the test boilers, according tostandard (EN 676 for gas, EN 267 for light oil), is of 4:1

WARNING

The firing rate value (Fig. 2) has been obtainedconsidering an ambient temperature of 20C, anatmospheric pressure of 1013 mbar (approx. 0 ma.s.l.), and with the combustion head adjusted asshown on pag. 20.

1000 1800 2600 3400 4200 5000 5800 6600 7400 8200 9000 106000

2

4

6

8

10

12

14

16

18

20

22

24

26

9800 11400 12200

D11552

Com

bust

ion

cham

ber

pres

sure

- m

bar

Thermal power – kW Fig. 2

RLS 1200/E MXRLS 1000/E MX

Fig. 3

Com

bust

ion

cham

ber

m

D2448

11 20061317GB


4.9 Burner description

1 Lifting rings2 Fan3 Fan motor4 Air damper servomotor5 Oil modulator6 Combustion head7 Ignition pilot8 Flame stability disc9 Electrical panel casing10 Hinge for opening the burner11 Fan air inlet12 Pipe coupling13 Gasket for boiler fixing14 Nozzle return pressure gauge15 Shutter16 Combustion head movement lever17 Air damper movement lever18 Air pressure switch (differential operating type)19 Combustion head air pressure test point20 Maximum gas pressure switch with pressure test point21 QRI cell22 Pressure test point for air pressure switch “+”23 Gas butterfly valve and oil modulator servomotor24 Pump

25 Pump motor26 Maximum oil pressure switch27 Minimum oil pressure switch28 Combustion head gas pressure test point29 Gas regulator30 3-way valve for the mechanical activation of the burner

lance31 Locking screws of the shutter during the transport (replace

them with the screws M12x25 supplied with the burner).

Fig. 4

20053384

CAUTION

The burner can be opened to the right or to the leftwithout links to the fuel supply side.

When the burner is closed, the hinge can be refit-ted on the opposite side.

WARNING

The gas can only enter from the right side of theburner as shown in Fig. 4.

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4.10 Electrical panel description

1 Terminal board for kits2 Clean contacts output relay3 Electronic cam transformer4 Electronic control box5 Ignition transformer6 Shielding terminals7 Stop push-button8 Off-automatic selector9 Light signalling of main fuel valve open 10 Fuel selector and enable signal to remote fuel selector11 Light signalling of mains live state12 Light signalling of fan motor lockout and pump motor13 Light signalling of burner lockout and reset switch14 Heat request signal 15 Fan motor contactor and thermal relay, star-triangle starter16 Timer17 Pump motor contactor and thermal relay

18 Main terminal supply board19 Air pressure switch20 Supply cables, external connections and kits21 Auxiliary circuits fuse22 Plug/socket servomotor23 Flame sensor plug/sensor socket24 Oil valve plug/socket/Pump motor/PGm (Deriv. unit)25 AZL display

NOTE

Two types of burner failure may occur:➤ Control box lockout: if the pushbutton 13)(Fig. 5) (red led )

lights up, it indicates that the burner is in lockout. release bypressing the pushbutton 13)(Fig. 5).

➤ Motors lockout : release by pressing the button on the rele-vant thermal relay.

4.11 Burner equipment

Gasket for gas train flange . . . . . . . . . . . . . . . . . . . . . . . . No. 1

M 16 x 70 gas flange fastener screws . . . . . . . . . . . . . . . . No. 8

Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

M 20 x 70 screws to secure the burner flange to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4

Pressure switch (for leak detection control) . . . . . . . . . . . No. 1

Light gas flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2

Fitting 1” 1/2 - 3/4” (RLS 1200/E MX). . . . . . . . . . . . . . . . . No. 1

Fitting 3/4” - 1/2” (RLS 1200/E MX) . . . . . . . . . . . . . . . . . . No. 1

Rotating elbow 1/2” (RLS 1000/E MX) . . . . . . . . . . . . . . . . No. 1

Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

20063856

Fig. 5

13 20061317GB


4.12 Control box for the air/fuel ratio (LMV51...)

Warnings

➤ All interventions (assembly and installation operations,assistance, etc.) must be carried out by qualified personnel.

➤ Before modifying the wiring in the LMV52 control box con-nection area, fully disconnect the system from the powersupply (omnipolar separation). Check the system is notpowered and cannot be accidentally reconnected. Failure todo this will lead to the risk of electrocution.

➤ Protection against electrocution from the LMV5... control boxand all connected electric components is obtained with cor-rect assembly.

➤ Before any intervention (assembly and installation opera-tions, assistance, etc.), ensure the wiring is in order and thatthe parameters are correctly set, then make the safetychecks.

➤ Falls and collisions can negatively affect the safety func-tions. In this case, the control box must not be operated, even if itdisplays no evident damage.

➤ In programming mode, the position check of actuators andVSD (checking electronic fuel / air ratio control) is differentfrom the check during automatic operation.As for automatic operation, the actuators are guidedtogether to the positions requested and, if an actuator doesnot reach the position requested, adjustments are madeuntil the position is actually reached. However, in contrast toautomatic operation, there are no time limits to these cor-rective actions. The other actuators maintain their positions until all actua-tors have reached the positions currently required. This is absolutely important to set the fuel / air ratio controlsystem. During the time the fuel / air ratio curves are being pro-grammed, the person making the plant settings must contin-uously monitor the quality of the combustion process (e.g. bymeans of a flue gas analyzer). Also, if combustion levels are poor, or in the event of dan-gerous situations, the commissioning engineer must takeappropriate action (e.g. switching off manually).

To ensure the safety and reliability of the LMV5... system, thefollowing instructions must also be followed:– avoid conditions that can favour the development of conden-

sate and humidity. Otherwise, before switching on again,make sure that the entire control box is perfectly dry!

– Static charges must be avoided since they can damage thecontrol box’s electronic components when touched.

Mechanical structureThe LMV5... control box is a system to check the burners, basedon a microprocessor and equipped with components to adjustand monitor medium and large capacity forced draught burners.The base control box of the LMV5... system incorporates the fol-lowing components:

• Burner control with gas valve proving system

• Electronic fuel / air ratio control with a maximum of 4 (LMV51…)or 6 (LMV52…) actuators

• Optional PID temperature / pressure controller (load controller)

• Optional VSD module Mechanical design

Installation notes

• Check the electric wiring inside the boiler complies with the na-tional and local safety regulations.

• Do not confuse the powered conductors with the neutral ones.

• Make certain that strain relief of the connected cables is incompliance with the relevant standards (e.g. as per DIN EN60730 and DIN EN 60 335).

• Ensure that spliced wires cannot get into contact with neigh-bouring terminals. Use adequate ferrules.

• Arrange the HV ignition cables separately, as far as possiblefrom the control box and the other cables.

• The burner manufacturer must protect unused AC 230 V ter-minals with dummy plugs (refer to sections Suppliers of otheraccessory items).

• When wiring the unit, make sure that AC 230 V mains voltagecables are run strictly separate from extra low-voltage cablesto avoid risks of electrical shock hazard.

WARNING

To avoid accidents, material or environmentaldamage, observe the following instructions!

The LMV51... is a safety device! Avoid opening ormodifying it, or forcing its operation. Riello S.p.A.cannot assume any responsibility for damage re-sulting from unauthorised interventions!

Risk of explosion!

An incorrect configuration can provoke fuel over-charging, with the consequential risk of explosion!Operators must be aware that incorrect settingsmade on the AZL5… display and operating unitand incorrect settings of the fuel and / or air actu-ator positions can lead to dangerous burner oper-ating conditions.

Fig. 6D9301

20061317 14 GB


Electrical connection of flame detector

It is important for signal transmission to be almost totally freeof any disturbances or loss:

• always separate the detector cables from the other cables:– Line capacitance reduces the magnitude of the flame signal.– Use a separate cable.

• Respect the allowed cable lengths.

Technical data

Tab. E

LMV51... basic unit Mains voltage AC 230 V -15 % / +10 %

Mains frequency 50 / 60 Hz ±6 %

Power absorption < 30W (normal)

Safety class I, with components in compliance with II and III, according to DIN EN 60730-1

Load on‘input’ terminals

F1 unit fuse (internal) 6.3 AT

Main fuse of perm. network (external) Max. 16 AT

Undervoltage• Safety switch-off from operating position to

mains voltage• Restart when mains voltage picks up

< AC 186 V

> AC 188 V

Oil pump / magnetic clutch (nominal voltage)• Nominal current• Power factor

2Acosϕ > 0.4

Air pressure switch test valve (nominal voltage)• Nominal current• Power factor

0.5Acosϕ > 0.4

Load on 'output'terminals

Total load on the contacts:• Mains voltage• Total unit input current

(safety circuit) load on contacts due to:- Fan motor contactor- Ignition transformer- Valve- Oil pump / magnetic clutch

AC 230 V -15 % / +10 %Max. 5 A

Single contact loading:Fan motor contactor (nominal voltage)• Nominal current• Power factor

1A cosϕ > 0.4

Alarm output (nominal voltage)• Nominal current• Power factor

1Acosϕ > 0.4

Ignition transformer (nominal voltage)• Nominal current• Power factor

2A cosϕ > 0.2

Fuel gas valve (nominal voltage)• Nominal current• Power factor

2A cosϕ > 0.4

Fuel oil valve (nominal voltage)• Nominal current• Power factor

1A cosϕ > 0.4

Cable lengths Main line Max. 100 m (100 pF/m)

Environmental conditions

OperationClimatic conditionsMechanical conditionsTemperature rangeHumidity

DIN EN 60721-3-3Class 3K3Class 3M3-20...+60°C< 95% RH

15 20061317GB


4.13 Servomotor

Warnings

➤ All interventions (assembly and installation operations,assistance, etc.) must be carried out by qualified personnel.

➤ Before modifying the wiring in the SQM4... system connec-tion area, fully disconnect the burner control device from thepower supply (omnipolar separation).

➤ To avoid the risk of electrocution, protect the connection ter-minals in a suitable manner and correctly fix the cover.

➤ Check the wiring is in order.➤ Falls and collisions can negatively affect the safety func-

tions. In this case, the unit must not be operated, even if itdisplays no evident damage.

Assembly notes

• Check the relevant national safety standards are respected.

• The connection between the actuator command shaft and thecontrol element must be rigid, without any mechanical play.

• To avoid an excessive load on the bearings due to rigid hubs,the use of compensation clutches without any mechanicalplay is recommended (e.g. metal bellows-type clutches).

Installation notes

• Arrange the H.V. ignition cables separately, as far as possiblefrom the control box and the other cables.

• To avoid the risk of electrocution, make sure that the 230V ACsection of the SQM4... unit is fully separated from the function-al low-voltage section.

• The static torque is reduced when the electrical supply of theactuator is switched off.

• The housing cover may only be removed for short periods oftime for wiring or when making the addressing. In similar cas-es, make sure that dust or dirt does not penetrate inside theactuator.

• The actuator comprises a PCB with ESD-sensitive compo-nents.

• The top side of the board carries a cover which affords pro-tection against direct contact. This protective cover must notbe removed! The underside side of the board must not betouched.

Technical data

Tab. F

WARNING

To avoid accidents, material or environmen-tal damage, observe the following instruc-tions!

Avoid opening, modifying or forcing the ac-tuators.

WARNING

During the maintenance or replacement of theactuators, be careful not to invert the connec-tors.

Operating voltage AC 2 x 12V via bus cable from thebase unit or via a separate trans-former

Safety class extra low-voltage with safe isolationfrom mains voltage

Power absorption– SQM45...– SQM48...

9...15 VA 26...34 VA

Degree of protection to EN 60 529, IP 54, provided ade-quate cable entries are used

Cable connection RAST3,5 connectors

Rotation direction - Anticlockwise (standard) - Clockwise (inverted rotation)

Nominal torque (max)– SQM45...– SQM48...

3 Nm20 Nm

Holding torque (max) – SQM45...– SQM48...

1.5 Nm20 Nm

Running time (min.) for 90°– SQM45...– SQM48...

10 s.30 s.

Weight – SQM45...– SQM48...

1 kg approx.1.6 kg approx.

Environmental conditions:

OperationClimatic conditionsMechanical conditionsTemperature rangeHumidity

DIN EN 60 721-3-3Class 3K3Class 3M3-20...+60°C< 95% RH

D8271 Fig. 7

20061317 16 GB

Installation

5.1 Notes on safety for the installation

After carefully cleaning all around the area where the burner willbe installed, and arranging the correct lighting of the environ-ment, proceed with the installation operations.

5.2 Handling

The packaging of the burner includes a wooden platform, so it ispossible to move the burner (still packaged) with a transpallettruck or fork lift truck.

5.3 Preliminary checks

Checking the consignment

Checking the characteristics of the burner

Check the identification label of the burner, showing:➤ the model (A)(Fig. 8) and type of burner (B);➤ the year of manufacture, in cryptographic form (C);➤ the serial number (D);➤ the data for electrical supply and the protection level (E);➤ the absorbed electrical power (F);➤ the types of gas used and the relative supply pressures (G);➤ the data of the burner's minimum and maximum output pos-

sibilities (H) (see Firing rate)Warning. The burner output must be within the boiler's firingrate;

➤ the category of the appliance/countries of destination (I).➤ light oil maximum viscosity (L).

5 Installation

DANGER

All the installation, maintenance and disassemblyoperations must be carried out with the electricitysupply disconnected.

WARNING

The installation of the burner must be carried outby qualified personnel, as indicated in this manualand in compliance with the standards and regula-tions of the laws in force.

DANGER

Combustion air inside the boiler must be free fromhazardous mixes (e.g.: chloride, fluoride, halo-gen); if present, it is highly recommended to carryout cleaning and maintenance more frequently.

WARNING

The handling operations for the burner can behighly dangerous if not carried out with the great-est attention: keep any unauthorised people at adistance; check the integrity and suitableness ofthe available means of handling.Check also that the area in which you are workingis empty and that there is an adequate escapearea (i.e. a free, safe area to which you can quick-ly move if the burner should fall).When handling, keep the load at not more than20-25 cm from the ground.

After positioning the burner near the installationpoint, correctly dispose of all residual packaging,separating the various types of material.

CAUTION

Before proceeding with the installation operations,carefully clean all around the area where the burn-er will be installed.

CAUTION

After removing all the packaging, check the integ-rity of the contents. In the event of doubt, do notuse the burner; contact the supplier.

The packaging elements (wooden cage or card-board box, nails, clips, plastic bags, etc.) must notbe abandoned as they are potential sources ofdanger and pollution; they should be collected anddisposed of in the appropriate places.

WARNING

A burner label that has been tampered with, re-moved or is missing, along with anything else thatprevents the definite identification of the burnerand makes any installation or maintenance workdifficult.

R.B.L.

GAS-KAASUGAZ-AEPIO

0085RIELLOS.p.A.I-37045Legnago(VR) CE

HEIZÖLFUEL

Fig. 8D9243

A B CED F

HGG H

I

L

17 20061317GB

Installation

5.4 Operating position

5.5 Removal of the locking screws from the shutter

Remove the screws and the nuts 1) and 2)(Fig. 10), before in-stalling the burner on the boiler. Replace them with the screws 3)M12x25 supplied with the burner.

5.6 Preparing the boiler

5.6.1 Boring the boiler plateDrill the combustion chamber locking plate as shown in Fig. 11.The position of the threaded holes can be marked using the ther-mal screen supplied with the burner.

5.6.2 Blast tube lengthThe length of the blast tube must be selected according to the in-dications provided by the manufacturer of the boiler, and in anycase it must be greater than the thickness of the boiler door com-plete with its fettling.

For boilers with front flue passes 1)(Fig. 12) or flame inversionchamber, a protection in refractory material 5) must be insertedbetween the boiler fettling 2) and the blast tube 4).

This protective fettling must not compromise the extraction of theblast tube.

For boilers with a water-cooled frontpiece, a refractory lining 2)-5)(Fig. 12) is not necessary, unless expressly requested by theboiler manufacturer.

Tab. G

WARNING

➤ The burner is designed to operate only inpositions 1, 2, 3 and 4 (Fig. 9).

➤ Installation 1 is preferable, as it is the onlyone that allows the maintenance operationsas described in this manual.

➤ Installations 2, 3 and 4 permit operation butmake maintenance and inspection of thecombustion head more difficult.

DANGER

➤ Any other position could compromise the cor-rect operation of the appliance.

➤ Installation 5 is prohibited for safety reasons.

Fig. 9

2 3 4 51

D7739

Fig. 1020061924

mm A B CRLS 1000/E MX 460 608 M 20RLS 1200/E MX 500 608 M 20

Fig. 11D455

20061317 18 GB

Installation

5.7 Securing the burner to the boiler

➤ 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.

5.8 Access to head internal part

In order to reach inside the combustion head (Fig. 13) proceed asfollows:➤ disconnect the derivation unit socket 1) and the QRI photo-

cell 2); ➤ disconnect the fuel servomotor socket;➤ disconnect the leverage of the head motor drive 3);➤ remove the 4 fixing screws 4); ➤ open the burner on the hinge;➤ disconnect the cable of the pilot electrode 5);➤ release the ignition pilot fitting 6);➤ remove the screw/gas pressure socket 7) of the head;➤ disconnect the light oil pipes unscrewing the two pipe fit-

tings 8); ➤ remove the oil lance lockout screw 9);➤ release the oil lance from the combustion head 10);➤ pull out the inner part of the head 11).

Prepare a suitable lifting system using rings 3)(Fig. 12).

WARNING

The seal between burner and boiler must beairtight.

Fig. 12

20053388

Be careful as some drops of fuel may leak out dur-ing this phase.

Fig. 1320053390

19 20061317GB

Installation

5.9 Nozzle installation

The burner complies with the emission requests specified instandard EN 267. To guarantee a constant level of emissions, itis necessary to use the nozzles recommended and/or alterna-tives indicated by Riello in the instructions and warnings.

Fit the nozzle with a 24 mm (for RLS 1000/E MX) and 41 mm (forRLS 1200/E MX) box wrench, passing from the centre opening ofthe flame stability disc (Fig. 14).

Fit the nozzles with the fuel interception rod on the nozzle holder.To calibrate the delivery range of operation of the nozzle, adjustthe fuel pressure on the nozzle return line, according to Tab. H.

5.9.1 Recommended nozzle

Complete range of nozzles:

• Bergonzo type B5 60°350 - 375 - 400 - 425 - 450 - 475 - 500 - 525 - 550 - 575 - 600650 - 700 - 750 - 800 - 850 - 900.

• Bergonzo type C3 - C5 60°700 - 800 - 900 - 1000 - 1100

• Fluidics type W2 60°:375 - 400 - 450 - 500 - 550 - 600 - 650 - 700 - 750.

Tab. H

WARNING

It is advisable to replace the nozzle once a yearduring periodical maintenance.

CAUTION

The use of nozzles other than those specified byRiello S.p.A. and inadequate regular maintenancemay result into emission limits non-conforming tothe values set forth by the regulations in force, andin extremely serious cases, into potential hazardsto people and objects.

The manufacturing company shall not be liable forany such damage arising from nonobservance ofthe requirements contained in this manual.

WARNING

➤ Do not use any sealing products such as gas-kets, sealing compound, or tape.

➤ Be careful to avoid damaging the nozzle seal-ing seat.

➤ The nozzle must be screwed into place tightlybut not to the maximum torque value pro-vided by the wrench.

11. 4 mm

Fig. 14D11310

Model Nozzle

RLS 1000/E MX – Bergonzo type B5 60°– Fluidics type W2 60°

RLS 1200/E MX – Bergonzo type C3 - C5 60°

Noz

zle

kg/hDelivery pressure

(bar)

Return pressure

(bar)kg/h kW

Ber

gonz

o B

5 60

°350

18 8 100 1200

20 17.5 315 3750

60020 6 140 1675

22 16 563 6700

75020 6.5 180 2150

22 19 722 8600

90016 4 168 2000

20 15 867 10300

Ber

gonz

o C

3 -

C5

60° 700

18 3 172 2043

20 16 462 5500

70018 3 172 2043

20 19 635 7550

90017 5 237 2815

18 17.5 791 9400

110016 6 273 3242

18 16.5 961 11425

20061317 20 GB

Installation

5.10 Electrode position

5.11 Combustion head adjustment

The air damper servomotor 4)(Fig. 4), beyond varying the air out-put according to the output demand, through a leverage variesthe combustion head adjustment.

This system allows an optimum adjustment also at minimum fir-ing rate. Similarly to servomotor rotation, it is possible to vary theopening of the combustion head moving the tie-rod on the holes(5-6-7-8-10)(Fig. 16).

The selection of the hole to be used is determined based on themaximum output requested, as illustrated in Tab. I.

In the factory, the adjustment is adjusted for the maximum stroke(hole 10, Fig. 16).

Tab. I

WARNING

Place the electrode on the ignition pilot observingthe dimensions specified in Fig. 15.

Fig. 15

18.5 0- 2

71.5 ± 1

DiffuserElectrode

D9218

Fig. 1620062792

Leverage holeOutput (kW)

From A

RLS

100

0 5 1200 3750

5 3750 6700

8 6700 8600

8 8600 10600

RLS

120

0 5 1500 5500

5 5500 7500

6 7500 9600

10 9600 11500

WARNING

The gas pipes leave the factory calibrated atnotch 1.

The adjustment shown in Fig. 17 allows the gaspipes to be positioned in the best way for the ap-plication on which the burner is installed (e.g. boil-ers with flame inversion chamber).

Fig. 1720077710

21 20061317GB

Installation

5.12 Light oil supply

5.12.1 Double-pipe circuitThe burner is equipped with a self-priming pump which is capableof feeding itself within the limits listed in Tab. J.

Tank higher than burner A (Fig. 18)Distance "P" must not exceed 10 meters in order to avoid strain-ing the pump's seal; distance "V" must not exceed 4 meters in or-der to allow pump self-priming even when the tank is almostempty.

Tank lower than burner B (Fig. 18)Pump depression values higher than 0.45 bar (35 cm Hg) mustnot be exceeded because at higher levels gas is released fromthe fuel, the pump starts making noise and its working life-span decreases.It is good practice to ensure that the return and suction lines enterthe burner from the same height; in this way it will be less proba-ble that the suction line fails to prime or stops priming.

5.12.2 Loop circuitA loop circuit consists of a loop of piping departing from and re-turning to the tank with an auxiliary pump that circulates the fuelunder pressure. A branch connection from the loop feeds theburner.

This circuit is extremely useful whenever the burner pump doesnot succeed in self-priming because the tank distance and/orheight difference are higher than the values listed in Tab. J.

Tab. J

Key (Fig. 18)

H = Pump/Foot valve height differenceØ = Inside pipe diameter1 = Burner2 = Pump3 = Filter4 = Manual on/off valve5 = Suction line6 = Foot valve7 = Quick closing manual valve with remote control (Italy only)8 = On/off solenoid valve (Italy only). See electrical layout.

Connections to be carried out by the installer (SV).

9 = Return line10 = Check valve (only Italy)

Explosion danger due to fuel leaks in the pres-ence of a flammable source.

Precautions: avoid knocking, attrition, sparks andheat.

Make sure that the fuel interception tap is closedbefore performing any operation on the burner.

WARNING

The fuel supply line must be installed by qualifiedpersonnel, in compliance with current standardsand laws. +/- H

[m]

RLS 1000/E MX RLS 1200/E MX

Ø [mm] Ø [mm]

20 22 24 27 22 24 27 36

4.0 26 45 73 138 19 33 65 300

3.0 22 39 63 120 16 28 55 260

2.0 18 33 53 102 13 23 45 220

1.0 15 26 44 84 10 18 38 185

0.5 13 23 39 75 9 16 33 165

0 11 20 34 66 7 13 30 145

-4.0 - - - - - - - -

-3.0 - - - 12 - - - 30

-2.0 - 7 14 30 - - 11 70

-1.0 7 14 24 48 - 9 20 108

-0.5 9 17 29 57 5 11 25 125

0 11 20 34 66 7 13 29 145

Fig. 18

20053391

20061317 22 GB

Installation

5.12.3 Hydraulic connections

5.12.4 Hydraulic circuit diagramKey (Fig. 19)1 Pump suction2 Pump return line and nozzle return line3 Pump pressure regulator4 Delivery safety valve5 Delivery safety valve6 Nozzle delivery line7 Nozzle without interception rod8 Nozzle return line9 Pressure variator on nozzle return line10 Pressure variator servomotor11 Pressure switch on nozzle return line12 Safety valve on nozzle return line13 Safety valve on nozzle return line14 Pressure switch on pump delivery lineM Pressure gaugesV Vacuometer connection

OPERATION

Pre-purging phase :valves 4), 5), 12) and 13) closed.

Ignition and operation phase :valves 4), 4), 12) and 13) open.

Stop: all valves closed.

5.12.5 Pressure variator The pressure variator (Fig. 20), incorporated in the oil circuitvalve group, makes it possible to vary the pressure on the nozzlereturn line depending on the output required.

The pressure on the return line is adjusted by varying a sectionby means of the rotation of the servomotor 23)(Fig. 4), which alsocontrols the gas butterfly valve at the same time.➤ Regulator to 0° (maximum opening) = minimum pressure on

nozzle return line.➤ Regulator to 90° (minimum opening) = maximum pressure

on nozzle return line.

The servomotor is controlled by the electronic cam 3) (Fig. 5);thanks to this device, it is possible to set different curves for oiland gas on the same servomotor (also for the air damper servo-motor 4)(Fig. 4).➤ When adjusting the gas , it is recommended to adjust the

servomotor to about 90° to reduce leaks from the gas butter-fly valve.

➤ When adjusting the oil , the adjustment is done based onthe nozzle fitted and on the required degree of modulation;in a situation of minimum firing rate, a rotation of 20° can be

enough.

Key (Fig. 20)15 Nozzle return pressure gauge16 Position indicator (0 ÷ 90) of the pressure variator17 Maximum oil pressure switch on return circuit

CAUTION

➤ Make sure that the flexible hoses to the pumpsupply and return line are installed correctly.

WARNING

Follow the instructions below:➤ Tighten the flexible hoses with the supplied

gaskets. ➤ Take care that the hoses are not stretched or

twisted during installation.➤ Place the pipes so that they are not crushed

or are in contact with hot parts of the boilerand so it is possible to open the burner.

➤ Finally, connect the other end of the flexiblehoses to the suction and return pipes.

Fig. 19

20053392

20053394

Fig. 20

23 20061317GB

Installation

5.13 Pump

5.13.1 Technical data

Tab. K

Key (Fig. 21)1 Suction line G 3/4” (RLS 1000/E)1 G 1” 1/2 (RLS 1200/E)2 Return line G 1”3 Vacuometer connection G 1/4”4 Gauge connectionG 1/4”5 Pressure adjuster

5.13.2 Priming pump

➤ In order for self-priming to take place, the screw 4) on thepump (Fig. 21) must be loosened to bleed off the air con-tained in the suction line.

➤ Start the burner by closing the remote controls. As soon asthe burner starts, check the direction of rotation of the fanblade.

➤ The pump can be considered to be primed when the light oilstarts coming out of the screw 4).

➤ Close the burner and undo the screws 4).

The time required for this operation depends upon the diameterand length of the suction tubing. If the pump fails to prime at first start-up and the burner locks out,wait approx. 15 seconds, reset the burner, and then repeat thestart-up operation. And so on. After 5 or 6 starting operations allow 2 or 3 minutes for the trans-former to cool.

Do not illuminate the QRI cell or the burner will lock out; the burn-er should lock out anyway about 10 seconds after it starts.

Pump RLS 1000/E MXVBHRG

RLS 1200/E MX VBHGRP

Min. delivery rate at 40 bar pressure 1160 kg/h 1660 kg/hDelivery pressure range 9 - 40 bar 9 - 40 bar

Max. suction depression 0.6 bar 0.6 barViscosity range 6 - 800 cSt 6 - 800 cStMax. light oil temperature 140°C 140°C

Max. suction and return pressure 5 bar 5 barPressure calibration in the factory 22 bar 22 bar

Fig. 21

D11321

WARNING

Before starting the burner, make sure that the tankreturn line is not clogged.

Obstructions in the line could cause the sealingorgan located on the pump shaft to break.

WARNING

The a.m. operation is possible because the pumpis already full of fuel when it leaves the factory.

If the pump has been drained, fill it with fuel throughthe opening on the vacuometer 4)(Fig. 21) prior tostarting; otherwise, the pump will seize.

Whenever the length of the suction piping ex-ceeds 20-30 meters, the supply line must be filledusing a separate pump.

20061317 24 GB

Installation

5.14 Gas feeding

5.14.1 Gas feeding lineKey (Fig. 22 - Fig. 23 - Fig. 24 - Fig. 25)1 Gas input pipe2 Manual valve3 Vibration damping joint4 Pressure gauge with pushbutton cock5 Filter

6A Includes:– filter– working valve– safety valve– pressure adjuster

6B Includes– working valve– safety valve– pressure adjuster

6C Includes– safety valve– working valve

6D Includes:– safety valve– working valve

7 Minimum gas pressure switch

8 Leak detection control, provided as an accessory or integrat-ed, based on the gas train code. In compliance with the EN676 standard, the leak detection control is compulsory forburners with maximum outputs over 1200 kW.

9 Gasket, for "flanged" versions only

10 Pressure adjuster

11 Train-Burner adaptor, supplied separately

P2 Upline pressure of valves/adjuster

P3 Upstream pressure of the filter

L Gas train, supplied separately

L1 The responsibility of the installer

Explosion danger due to fuel leaks in the pres-ence of a flammable source.

Precautions: avoid knocking, attrition, sparks andheat.

Make sure that the fuel interception tap is closedbefore performing any operation on the burner.

WARNING

The fuel supply line must be installed by qualifiedpersonnel, in compliance with current standardsand laws.

L1 L

6AP2

7

4

P3

321

8

Fig. 22D11854

MBC “threaded”

LL1

P2 6B

7

9

8

4

P3

321 5

11

Fig. 23D11855

MBC “flanged”

LL1

5

6C

P2

7

321

8

10

119

Fig. 24D11856

DMV “flanged or threaded”

LL1

5

6D

P2

7

321

8

10

119

Fig. 25D11857

CB “flanged or threaded”

25 20061317GB

Installation

5.14.2 Gas trainApproved according to standard EN 676 and provided separatelyfrom the burner.

To select the correct gas train model, refer to the supplied "Burn-er-gas train combination" manual.

5.14.3 Gas train installation

The gas train is prearranged to be connected to the burner by theflange 1) (Fig. 26).

5.14.4 Gas pressure The Tab. L indicates the pressure drop of the combustion headand the gas butterfly valve depending on the operating output ofthe burner.

Tab. L

The values shown in Tab. L refer to: – Natural gas G 20 NCV 9.45 kWh/Sm3 (8.2 Mcal/Sm3)– Natural gas G 25 NCV 8.13 kWh/Sm3 (7.0 Mcal/Sm3)

Column 1

Pressure loss at combustion head.Gas pressure measured at test point 1)(Fig. 27), with:• combustion chamber at 0 mbar;• burner working at maximum modulating output;• combustion head set as in pag. 20.

Column 2Pressure loss at gas butterfly valve 2)(Fig. 27) with maximumopening: 90°.

Calculate the approximate output of the burner thus:– Subtract the combustion chamber pressure from the gas

pressure measured at test point 1) (Fig. 27).– Find, in the table Tab. L related to the burner concerned, the

pressure value closest to the result of the subtraction.– Read off the corresponding output on the left.

DANGER

Disconnect the electrical power using the mainsystem switch.

Check that there are no gas leaks.

Beware of train movements: danger of crushing oflimbs.

Make sure that the gas train is properly installedby checking for any fuel leaks.

The operator must use appropriate tools for instal-lation.

Fig. 2620053395

kW1 ∆p (mbar) 2 ∆p (mbar)

G 20 G 25 G 20 G 25

RLS

100

0/E

MX

3750 9.2 13.7 1.0 1.4

4000 10.8 16.0 1.1 1.6

4500 13.9 20.7 1.4 2.1

5000 17.0 25.4 1.7 2.5

5500 20.2 30.1 2.1 3.1

6000 23.3 34.8 2.4 3.7

6500 26.4 39.4 2.9 4.3

7000 30.4 45.3 3.3 5.0

7500 34.8 51.9 3.8 5.7

8000 39.2 58.5 4.4 6.5

8500 43.6 65.1 4.9 7.3

9000 49.2 73.3 5.5 8.2

9500 55.0 82.0 6.1 9.2

10000 60.8 90.7 6.8 10.1

10600 67.8 101.1 7.6 11.4

RLS

120

0/E

MX

5500 23.1 34.5 2.1 3.1

6000 27.9 41.6 2.4 3.7

6500 32.6 48.7 2.9 4.3

7000 37.4 55.7 3.3 5.0

7500 42.1 62.8 3.8 5.7

8000 48.3 72.1 4.4 6.5

8500 54.5 81.3 4.9 7.3

9000 60.7 90.6 5.5 8.2

9500 67.0 99.8 6.1 9.2

10000 74.3 110.8 6.8 10.2

10500 81.9 122.2 7.5 11.2

11000 89.6 133.6 8.2 12.3

11500 97.2 145.0 9.0 13.4

20061317 26 GB

Installation

Example RLS 1000/E MX with natural gas G20:Operation at maximum modulating outputGas pressure at test point 1)(Fig. 27) = 44.2 mbarPressure in combustion chamber = 5 mbar

44.2 - 5 = 39.2 mbar

A pressure of 39.2 mbar, column 1, corresponds in Tab. L to anoutput of 8000 kW.

This value serves as a rough guide; the effective output must bemeasured at the gas meter.

To calculate the required gas pressure at test point 1) (Fig. 27),set the maximum modulating output required from the burner op-eration:– find the nearest output value in the table Tab. L for the burner

in question.– read, on the right (column 1), the pressure at the test point 1)

(Fig. 27).– Add this value to the estimated pressure in the combustion

chamber.

Example RLS 1000/E MX with natural gas G20:Operation at maximum modulating outputGas pressure at an output of 8000 kW = 39.2 mbarPressure in combustion chamber = 5 mbar

39.2 + 5 = 44.2 mbarpressure required at test point 1)(Fig. 27).

5.14.5 Pilot - gas train connectionThe burner is fitted with a dedicated gas train that is fixed to thepipe coupling. ➤ It should be connected to the main train downstream the fil-

ter or the pressure regulator (depending on configuration).

5.14.6 Ignition pilot burnerFor proper operation, adjust gas pressure (measured at pressuretest point 1)(Fig. 28) as follows:

Tab. M

In the case of ignition problems check:➤ correct positioning of the ignition electrode;➤ the gas pressure, according to indications.

+

WARNING

Supply pressure 68 ÷ 500 mbar

Model Gas mbar Sm 3/hRLS 1000/E MX G20 1.5 12.3

G31 1.4 3.2RLS 1200/E MX G20 40 14.3

G31 30 7.1

WARNING

Check pilot flame stability before starting up themain burner.

20053396

Fig. 27

Fig. 28

D11317

27 20061317GB

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 activationof the burner lance and the point at which the compressed air in-put A) must be connected.It must operate at 6 - 7 bar.

A

Fig. 29D12066S8484

“VU VALVE”

“OIL LANCE”

“Delivery line”

“PUMP”

“Return line”

“Oil regulator”

“Compressed air”

20061317 28 GB

Installation

5.16 Electrical connections

Notes on safety for the electrical wiring

Before carrying out any maintenance, cleaning or checking oper-ations:

If the hood is still present, remove it and proceed with the electri-cal wiring according to the wiring diagrams.

Use flexible cables in compliance with the EN 60 335-1 standard.

5.16.1 Supply cables and external connections passage

All the cables to be connected to the burner should be passedthrough cable grommets, as shown in Fig. 30.

Key (Fig. 30)1 Electrical supply2 Minimum gas pressure switch3 Pressure switch for VPS gas valve leak detection4 Gas train5 Consents/Safety6 Available7 Plug

DANGER

➤ 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. Refer to the wiring diagrams.➤ The manufacturer declines all responsibility for modifications or connections different from those shown in the wir-

ing diagrams➤ Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man-

ual.➤ The burner has been type-approved for intermittent use (FS1).

This means they should compulsorily be stopped at least once every 24 hours to enable the control box to per-form checks of its own start-up efficiency. Normally, burner stopping is guaranteed by the boiler's thermostat/pres-sure switch. If this is not the case, a time switch should be fitted in series to TL to stop the burner at least onceevery 24 hours. Refer to the wiring diagrams.

➤ The burner is factory set for FS1 operation (1 stop every 24 hours); it can be converted to FS2 operation (continu-ous - 1 stop every 72 hours), by changing the parameters using the menu of the AZL Display.

➤ The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,made according to current standards. It is necessary to check this fundamental safety requirement. In the event ofdoubt, have the electrical system checked by qualified personnel. Do not use the gas tubes as an earthing systemfor electrical devices.

➤ The electrical system must be suitable for the maximum power absorption of the device, as indicated on the labeland in the manual, checking in particular that the section of the cables is suitable for that level of power absorption.

➤ For the main power supply of the device from the electricity mains:- do not use adapters, multiple sockets or extensions;- use a multiple pole switch with at least a 3 mm gap between the contacts (overvoltage category III), as envis-

aged by the present safety standards.➤ Do not touch the device with wet or damp body parts and/or in bare feet.➤ Do not pull the electric cables.

DANGER

Disconnect the electrical supply from the burnerby means of the main system switch.

DANGER

Close the fuel interception tap.

DANGER

Avoid condensate, ice and water leaks from form-ing.

WARNING

To guarantee the protection level of the burner, itis necessary to close any holes that are still free,using the plugs supplied.

After carrying out maintenance, cleaning orchecking operations, reassemble the hood and allthe safety and protection devices of the burner.

Fig. 30

1

2

5

45

6

7

7

7

5

6

6

7

7

3

20062902

29 20061317GB

Installation

5.17 Calibration of the thermal relay

The thermal relay (Fig. 31) serves to avoid damage to the motordue 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).

To reset, in case of an intervention of the thermal relay, press but-ton "RESET" 1).

The button “STOP” 3) opens the NC contact (95-96) and stopsthe motor.

Insert a screwdriver in the window “TEST/TRIP” 4) and move it inthe arrow direction (to the right) to carry out the thermal relay test.

WARNING

The automatic reset can be dangerous.

This operation is not foreseen in the burner oper-ation.

Fig. 31D11301

20061317 30 GB

Start-up, calibration and operation of the burner

6.1 Notes on safety for the first start-up

6.2 Adjustments prior to ignition (light oil)

The optimum calibration of the burner requires an analysis of theflue gases at the boiler outlet and interventions on the followingpoints.

6.2.1 NozzleSee information on pag. 19.

6.2.2 Combustion head The adjustment of the combustion head already carried out onpag. 20 need not be altered unless the 2nd stage delivery of theburner is changed.

6.2.3 Pump pressure In order to change pump pressure, act on screw 5) (Fig. 21).See information on pag. 19.

6.3 Burner ignition (light oil)

Position the selector 1)(Fig. 32) in “AUTO”.

Position the selector 2) in “OIL” to select light oil fuel.

When the limit thermostat (TL) is closed, the “HEAT REQUEST”3) signal must be switched on.

At first ignition, there is a momentary drop in fuel pressure due tothe filling of the nozzle piping. This lowering of the fuel pressure

can cause the burner to lockout and can sometimes give rise topulsations.

Once the following adjustments have been made, the ignition ofthe burner must generate a noise similar to the noise generatedduring operation.

If a burner lockout occurs, refer to the “Release procedure” givenin the equipment manual supplied.

6 Start-up, calibration and operation of the burner

WARNING

The first start-up of the burner must be carried outby qualified personnel, as indicated in this manualand in compliance with the standards and regula-tions of the laws in force. WARNING

Check the correct working of the adjustment, com-mand and safety devices.

WARNING

It is recommended to adjust first the light oil burnerand then the gas burner.

Carry out the fuel change with burner off.

Fig. 32S8384

1 2 3

4

31 20061317GB


6.4 Adjustments prior to ignition (gas)

In addition, the following adjustments must also be made:➤ Slowly open the manual valves situated upstream from the

gas train.➤ Adjust the minimum gas pressure switch (Fig. 37) to the start

of the scale.➤ Adjust the maximum gas pressure switch (Fig. 36) to the end

of the scale.➤ Adjust the air pressure switch (Fig. 35) to the start of the

scale.➤ Purge the air from the gas line.

We recommend using a plastic tube routed outside the build-ing and to purge air until gas is smelt.

➤ Fit a U-type pressure gauge or a differential pressure gauge(Fig. 33), with socket (+) on the gas pressure of the pipecoupling and (-) in the combustion chamber. The manometer readings are used to calculate MAX burneroutput.

➤ Connect two lamps or testers to the two gas line solenoids tocheck the exact moment in which voltage is supplied.This operation is unnecessary if each of the two solenoidvalves is equipped with a pilot light that signals voltage pass-ing through.

6.5 Burner start-up (gas)

Close the remote controls and position the selector 1)(Fig. 32) to“AUTO”.

Position the selector 2) to “GAS” to select gas as fuel.

Make sure that the lights or testers connected to the solenoids, orthe pilot lights on the solenoids themselves, indicate that no volt-

age is present. If voltage is present, stop the burner immediatelyand check the electrical connections.

When the limit thermostat (TL) closes, the “CALL FOR HEAT ” 3)signal must come on. The burner will subsequently begin its start-ing cycle.

6.6 Check motor rotation

If this is not the case:➤ turn the burner switch to position “0” (OFF) and wait for the

control box to carry out the switch-off phase;➤ disconnect the power supply to the main panel;➤ invert the phases on the three-phase power supply;➤ if necessary, carry out the same operation for the pump

motor.

6.7 Burner ignition

The burner should light after having performed the above steps.

If the motor starts up, but the flame does not appear and the con-trol box goes into lockout, reset it and wait for a new ignition at-tempt.

If ignition is still not achieved, it may be that gas is not reachingthe combustion head within the safety time period of 3 seconds.In this case increase gas ignition delivery.

The arrival of gas at the sleeve is indicated by the U-type manom-eter (Fig. 33).

If further burner lockouts occur, refer to the “Release procedure”given in the equipment manual supplied.

CAUTION

Before starting up the burner, it is good practice toadjust the gas train so that ignition takes place inconditions of maximum safety, i.e. with gas deliv-ery at the minimum.

Fig. 3320053397

WARNING

As soon as the burner starts up, go in front of thefan motor cooling fan and check it is rotating anti-clockwise (Fig. 34).

DANGER

This operation must be carried out with the electri-cal supply disconnected.

Fig. 3420079199

20061317 32 GB


Once the burner has fired, now proceed with global calibrationoperations.

6.8 Change of fuel

There are three options of change of fuel: 1 with the AZL device 4)(Fig. 32);2 with selector 2);3 with a remote selector connected to the main terminal

board.

The AZL device sets the priority fuel; the display shows the se-lected fuel.

Positioning the selector 2)(Fig. 32) to “EXT” activates the remoteselection of the fuel. In this position, if there is no remote selector,the display shows the priority fuel.

6.9 Combustion air adjustment

Fuel/combustion air synchronisation is done with the relevantservomotors (air and gas) by logging a calibration curve bymeans of the electronic cam.

It is advisable, to reduce the loss and for a wide calibration field,to adjust the servomotors to the maximum of the output used, thenearest possible to the maximum opening (90°).

On the gas butterfly valve, fuel step according to the burner out-put required, with servomotor completely open, is carried out bythe pressure stabiliser placed on the gas train.

The values indicated in Tab. N and Tab. O can be a reference fora good combustion calibration.

Tab. N

Tab. O

6.9.1 Air / gas adjustment and output modulationThe air/gas adjustment and output modulation system with whichthe RLS range burners are equipped carries out a series of inte-grated functions in order to optimise burner functioning, both forsingle operation and together with other units (e.g. double fur-nace boiler or more than one generator in parallel).

The basic system functions control:1 The dosage of the air and fuel through positioning using

direct servocommands of the relevant valves eliminating thepossible play in the calibration systems with mechanicalcam lever mechanisms, used on traditional modulatingburners.

2 The modulation of the burner output in accordance with theload required by the system, with maintenance of the pres-sure or temperature of the boiler at the operating values set.

3 The sequence (cascade adjustment) of more than oneboiler through the suitable connection of the various unitsand the activation of the internal software of the individualsystems (option).

Further interfaces and communication functions with computers,for remote control or integration in central supervision systemsare available on the basis of the configuration of the system.

The first start-up and curve synchronisation manual is suppliedwith the burner.

At request, the complete manual for the control and setting of allparameters is available.

WARNING

In the event of a burner lockout, more than twoconsecutive burner reset operations could causedamage to the installation. On the third lockout,contact the Aftersales Service. DANGER

If further lockouts or burner faults occur, interven-tions must only be made by qualified, authorisedpersonnel (as indicated in this manual, and incompliance with the laws and regulations current-ly in force).

EN 676Air excess

COMax. outputλ ≤ 1.2

Max. outputλ ≤ 1.3

GASTheoretical max. CO2

0 % O2

CO2 % Calibrationmg/kWh

λ = 1.2 λ = 1.3

G 20 11.7 9.7 9 ≤ 1000

G 25 11.5 9.5 8.8 ≤ 1000

G 30 14.0 11.6 10.7 ≤ 1000

G 31 13.7 11.4 10.5 ≤ 1000

EN 267Air excess


Min. outputλ ≤ 1.3

Theoretical max. CO 20 % O2


λ = 1.2 λ = 1.3

15.2 12.6 11.5 ≤ 1000

WARNING

The first start up and every further internal settingoperation of the adjustment system or the expan-sion of the base functions require access bymeans of password and are to be carried out byservice personnel who are especially trained forthe internal programming of the instrument andthe specific application created with this burner.

33 20061317GB


6.10 Pressure switch adjustment

6.10.1 Air pressure switch - check COAdjust the air pressure switch after performing all other burneradjustments with the air pressure switch set to the start of thescale (Fig. 35).

With the burner working at MIN output, insert a combustionanalyser in the stack, slowly close the suction inlet of the fan (forexample, with a piece of cardboard) until the CO value does notexceed 100 ppm.

Slowly turn the appropriate knob clockwise until the burner goesinto lockout.

Check the indication of the arrow pointing upwards on the gradu-ated scale.

Turn the knob clockwise again, until the value shown on the grad-uated scale corresponds with the arrow pointing downwards, andso recovering the hysteresis of the pressure switch (shown by thewhite mark on a blue background, between the two arrows). Nowcheck the correct start-up of the burner.

If the burner locks out again, turn the knob anticlockwise a littlebit more.

6.10.2 Maximum gas pressure switchAdjust the maximum gas pressure switch after having performedall the other burner adjustments with the maximum gas pressureswitch set at the end of the scale (Fig. 36).

With the burner operating at maximum output, lower the adjust-ment pressure by slowly turning the relative knob anticlockwiseuntil the burner locks out.

Now turn the knob clockwise by 0,2 kPa (2 mbar) and repeat thestart-up of the burner.

If the burner locks out again, turn the knob clockwise again by0,1 kPa (1 mbar).

6.10.3 Minimum gas pressure switchAdjust the minimum gas pressure switch after performing all theother burner adjustments with the pressure switch set to the startof the scale (Fig. 37).

With the burner operating at maximum output, increase adjust-ment pressure by slowly turning the relative knob clockwise untilthe burner stops.

Now turn the knob anticlockwise by 0,2 kPa (2 mbar) and repeatburner start-up to ensure it is uniform.

If the burner locks out again, turn the knob anti-clockwise againby 0,1 kPa (1 mbar).

6.10.4 PVP pressure switch kitAdjust the pressure switch for the leak detection control (PVP kit)(Fig. 38) according to the instructions supplied with the kit.

WARNING

1 kPa = 10 mbar

Fig. 35D3854

Fig. 36D3856

Fig. 37D3855

Fig. 38D3855

20061317 34 GB


6.10.5 Oil pressure switchCheck the calibration of the maximum and minimum oil pressureswitches, using the adjustment screw as shown in Fig. 39.

The check should be carried out by individually varying the cali-bration of each pressure switch.

Maximum oil pressure switchTurning the screw anti-clockwise lowers the setting and the burn-er should go into lockout.Once this control has been carried out, it is necessary to reset thefactory setting of the maximum oil pressure switch to about 4/5bar.

Minimum oil pressure switchTurning the screw clockwise increases the setting and the burnershould not start.Once this control has been carried out, it is necessary to reset thefactory setting of the minimum oil pressure switch to about 16/18bar.

Any other pressure values should be adjusted to the burner out-put.

6.11 Final checks (with burner operating)

Tab. P

Fig. 39

20079898

➤ Open the thermostat/pressure switch TL➤ Open the thermostat/pressure switch TS ➮ The burner must stop

➤ Turn the gas maximum pressure switch knob to the mini-mum end of scale position

➤ Turn the air pressure switch to the maximum end of scaleposition

➮ The burner must stop in lockout

➤ Check the maximum oil pressure switch➤ Check the minimum oil pressure switch ➮ The burner must stop in lockout

➤ Turn off the burner and cut off the power➤ Disconnect the minimum gas pressure switch connector ➮ The burner must not start

➤ Disconnect the QRI cell wire ➮ The burner must stop in lockout due to ignition failure

WARNING

Make sure that the mechanical locking systemson the various adjustment devices are fully tight-ened.

35 20061317GB

Maintenance

7.1 Notes on safety for the maintenance

The periodic maintenance is essential for the good operation,safety, yield and duration of the burner.

It allows you to reduce consumption and polluting emissions andto keep the product in a reliable state over time.

Before carrying out any maintenance, cleaning or checking oper-ations:

7.2 Maintenance programme

7.2.1 Maintenance frequency

7.2.2 Checking and cleaning

CombustionCarry out an analysis of the combustion discharge gases. Significant differences with respect to the previous check indicatethe points where more care should be exercised during mainte-nance.

Combustion headOpen the burner and make sure that all components of thecombustion head are in good condition, not deformed by thehigh temperatures, free of impurities from the surroundingsand correctly positioned.

Voltage on the QRI cell

Minimum value for correct operation: 3.5 Vdc (value on AZL dis-play at about 50%).

If the value is lower, it could be due to:– cell not positioned correctly– low voltage (lower than 187 V)– bad regulation of the burner

In order to measure, use a voltmeter with a 10 Vdc scale connect-ed as in the diagram (Fig. 40).

BurnerClean the outside of the burner.

FanCheck to make sure that no dust has accumulated inside the fanor on its blades, as this condition will cause a reduction in the airflow rate and provoke polluting combustion.

BoilerClean the boiler as indicated in its accompanying instructions inorder to maintain all the original combustion characteristics in-tact, especially the flue gas temperature and combustion cham-ber pressure.

PumpThe delivery pressure must comply with Tab. H, a pag. 19. The depression must be less than 0.45 bar.Unusual noise must not be evident during pump operation.If the pressure is found to be unstable or if the pump runs noisily,the flexible hose must be detached from the line filter and the fuelmust be sucked from a tank located near the burner. This measure permits the cause of the anomaly to be traced toeither the suction piping or the pump.If the problem lies in the suction line, check the filter is clean andthat air is not entering the piping.

Filters (Fig. 41)Check the filtering baskets on line 1) and at nozzle 2) present inthe system.Clean or replace if necessary.

If rust or other impurities are observed inside the pump, use aseparate pump to lift any water and other impurities that may

have deposited on the bottom of the tank.

7 Maintenance

DANGER

The maintenance interventions and the calibrationof the burner must only be carried out by qualified,authorised personnel, in accordance with the con-tents of this manual and in compliance with thestandards and regulations of current laws.

DANGER


DANGER


Wait for the components in contact with heatsources to cool down completely.

The gas combustion system should be checked atleast once a year by a representative of the man-ufacturer or another specialised technician.

The operator must use the required equipmentduring maintenance.

GAS OIL OPERATION

0...10 V

Ri > 10 M

X10-02 / 6

X10-02 / 4

X10-02 / 2

LMV...

+D9174

Fig. 40

20061317 36 GB

Maintenance

NozzlesIt is advisable to replace nozzles once a year during periodicalmaintenance.Do not clean the nozzle openings;

HosesCheck that these are in good conditions.

Fuel tankApproximately every 5 years, suck any water on the bottom of thetank using a separate pump.

CombustionIf the combustion values found at the start of the intervention donot satisfy current standards or anyway indicate a poor state ofcombustion (consult the table below), contact the Technical As-sistance Service for the necessary adjustments.

Tab. Q

Gas leaksMake sure that there are no gas leaks on the pipework betweenthe gas meter and the burner.

Gas filterChange the gas filter when it is dirty.

CombustionIf the combustion values found at the start of the intervention donot satisfy current standards or anyway indicate a poor state ofcombustion (consult the table below), contact the Technical As-sistance Service for the necessary adjustments.

Tab. R

EN 267Air excess


Min. outputλ ≤ 1.3

Theoretical max. CO 20 % O2


λ = 1.2 λ = 1.3

15.2 12.6 11.5 ≤ 1000

Fig. 41

20062799

GAS OPERATION

EN 676Air excess


Max. outputλ ≤ 1.3

GASTheoretical max.

CO20 % O2


λ = 1.2 λ = 1.3

G 20 11.7 9.7 9 ≤ 1000

G 25 11.5 9.5 8.8 ≤ 1000

G 30 14.0 11.6 10.7 ≤ 1000

G 31 13.7 11.4 10.5 ≤ 1000

37 20061317GB

Maintenance

7.3 Opening the burner

➤ Disconnect the derivation unit socket and the QRI photocell;➤ disconnect the electrode cable;➤ remove the tie-rod 1)(Fig. 42) of the head movement lever,

undoing the nut 2);➤ disconnect the socket 4) of the fuel servomotor;➤ remove the screws 5).➤ At this point, it is possible to open the burner on the hinge.

7.4 Closing the burner

Refit following the steps described but in reverse order; refit allburner components as they were originally assembled.

DANGER


DANGER


Wait for the components in contact with heatsources to cool down completely.

Fig. 4220053398

After carrying out maintenance, cleaning orchecking operations, reassemble the hood and allthe safety and protection devices of the burner.

20061317 38 GB

Faults - Possible causes - Solutions

If faults arise in ignition or operations, the burner performs a"safety stop", which is signalled by the red burner lockout LED.

The display visualises alternately the lockout code and the rela-tive diagnostic. To reset the start-up conditions, refer to the “Re-set procedure” indicated in the control box manual supplied.

When the burner starts again, the red LED goes out and the con-trol box is reset.

8 Faults - Possible causes - Solutions

WARNING

In the event of a burner lockout, more than twoconsecutive burner reset operations could causedamage to the installation. On the third lockout,contact the Aftersales Service.

DANGER

If further lockouts or burner faults occur, interven-tions must only be made by qualified, authorisedpersonnel (as indicated in this manual, and incompliance with the laws and regulations current-ly in force).

39 20061317GB

Appendix - Accessories

Software interface kit

Soundproofing box kit

AZL kit (display and operating unit) (Russia only)

Pressure switch kit for leak detection control (supplied as standard)

Probe for checking temperature/pressure

Gas trains in compliance with EN 676

Please refer to manual.

A Appendix - Accessories

Burner Code


3010388

Burner Code


3010401

Burner Code


3010469

Burner Code


3010344

Parameter to be checked Probe

Adjustment field Type Code

Temperature - 100...+ 500°C PT 100 3010110

Pressure0...2.5 bar0...16 bar

Output probe4....20 mA

30102133010214

20061317 40 GB

Appendix - Electrical panel layout

B Appendix - Electrical panel layout

Index of layouts

2 Indication of references

3 Single-wire output layout

4 Functional layout star/triangle starter

5 LMV51.... functional layout







12 Electrical wiring that the installer is responsible for



1

2

Sheet no.

/1 .A1

Coordinates

Indication of references

41 20061317GB


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Wiring layout key

A5 Control boxAZL Display for control boxBA Output probe in currentBA1 Output device in current to modify remote setpointBA2 Load indicator at current inputBA3 Device with current output for remote modulationBP Pressure probeBP1 Pressure probeBT3 Probe Pt100, 3 wiresBT4 Probe Pt100, 3 wiresBT5 PT 1000 probe, 2 wires BV Output probe in voltageBV1 Output devicein voltage to modify remote setpointBV2 Device with voltage current output for remote modulationF1 Fan motor thermal relayF2 Pump motor thermal relayF3 Auxiliary fuseH1 Light signalling burner onH2 Light signalling fan motor lockout and pump motorH3 Heat request lighting signal H4 Burner working lighting signalKL1 Star/triangle starter line contactor and direct start-upKMP Pump motor contact makerKT1 Star/triangle starter triangle contactorKS1 Start/triangle starter star contactorKST1 Star/triangle starter timerK3 Clean contacts output relay burner lockoutK4 Output relay for light oil operation clean contactsK5 Output relay for gas operation clean contactsK6 Clean contacts for gas output relay burner switched onK7 Output relay for 'light oil burner on' clean contactsMP Pump motorMV Fan motorPA Air pressure switchPE Burner earthPGMax Maximum gas pressure switchPGMin Minimum gas pressure switchPGVP Pilot valves gas pressure switchPO Oil pressure switchPO1 Maximum oil pressure switch on return lineQRI Flame sensorRS Remote burner reset buttonS1 Emergency stop buttonS2 0 / AUTO selectorS5 Fuel selector and enable signal to remote fuel selectorSH3 Burner reset button and lock-out signalSM1 Servomotor SM2 Fuel servomotorSV Remote safety light oil valveTA Ignition transformerTL Limit thermostat/pressure switchTR Adjustment thermostat/pressure switchTS Safety thermostat/pressure switchT1 Control box transformerVF Light oil operation valveVP1 Pilot valve 1VP2 Pilot valve 2VR Light oil return valveVR1 Light oil return valveVS Safety light oil valveVU Nozzle valve XAZL AZL display connectorXAUX Auxiliary terminal boardXGD Derivation unit connectorXPGM Maximum gas pressure switch connectorXPO Oil pressure switch connector

XPO1 Oil return pressure switch connector XS Flame sensor connectorXSM Servomotor connectorX1 Main terminal supply boardX4 Derivation unit terminal boardX10 Kit terminal board Y Gas adjustment valve + gas safety valve

Subject to modifications

RIELLO S.p.A.

I-37045 Legnago (VR)

Tel.: +39.0442.630111

http:// www.riello.it

http:// www.riello.com

dual fuel gas oil/gas burners

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