Riello RLS 800/E MX Quick start guide

20010309 (16) - 06/2021
Installation, use and maintenance instructions
Instructions pour installation, utilisation et entretien
Dual fuel light oil/gas burner
Brûleur mixtes fioul/gaz
Progressive two-stage or modulating operation
Fonctionnement à deux allures progressives ou modulant
CODE MODEL
MODELE TYPE
3911132 RLS 800/E MX 1301 T1
GB
F

1 20010309
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general instructions....................................................................................................................................... 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Danger: live components............................................................................................................................................. 4
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 Overall dimensions...................................................................................................................................................... 9
4.7 Firing rates ................................................................................................................................................................ 10
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Burner description ..................................................................................................................................................... 11
4.10 Description of panel board ........................................................................................................................................ 12
4.11 Burner equipment...................................................................................................................................................... 12
4.12 Control box for the air/fuel ratio (LMV51...) ............................................................................................................... 13
4.13 Actuator (SQM48.4....) .............................................................................................................................................. 15
5 Installation ................................................................................................................................................................................ 16
5.1 Notes on safety for the installation ............................................................................................................................ 16
5.2 Handling .................................................................................................................................................................... 16
5.3 Preliminary checks .................................................................................................................................................... 16
5.4 Operation position ..................................................................................................................................................... 17
5.5 Removal of the locking screws from the shutter........................................................................................................ 17
5.6 Preparing the boiler................................................................................................................................................... 17
5.6.1 Boring the boiler plate ............................................................................................................................................... 17
5.6.2 Blast tube length........................................................................................................................................................ 17
5.7 Securing the burner to the boiler............................................................................................................................... 18
5.8 Accessibility to the interior of the combustion head .................................................................................................. 18
5.9 Position of electrodes................................................................................................................................................ 18
5.10 Nozzle installation ..................................................................................................................................................... 19
5.10.1 Recommended nozzle............................................................................................................................................... 19
5.11 Combustion head setting........................................................................................................................................... 20
5.12 Light oil supply........................................................................................................................................................... 21
5.12.1 Double-pipe circuit..................................................................................................................................................... 21
5.12.2 The loop circuit.......................................................................................................................................................... 21
5.12.3 Hydraulic connections ............................................................................................................................................... 21
5.12.4 Pressure regulator..................................................................................................................................................... 22
5.12.5 Hydraulic system layout ............................................................................................................................................ 22
5.12.6 Pump priming ............................................................................................................................................................ 23
5.12.7 Burner calibration ...................................................................................................................................................... 23
5.13 Gas feeding.............................................................................................................................................................. 24
5.13.1 Gas feeding line ........................................................................................................................................................ 24
5.13.2 Gas train.................................................................................................................................................................... 25
5.13.3 Gas train installation.................................................................................................................................................. 25
5.13.4 Gas pressure............................................................................................................................................................. 25
5.13.5 Pilot - gas train connection ........................................................................................................................................ 26
5.13.6 Ignition pilot burner.................................................................................................................................................... 26

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Contents
5.14 Electrical wiring ..........................................................................................................................................................27
5.14.1 Supply cables and external connections passage .....................................................................................................27
5.15 Calibration of the thermal relay ..................................................................................................................................28
6 Start-up, calibration and operation of the burner ..................................................................................................................29
6.1 Notes on safety for the first start-up...........................................................................................................................29
6.2 Adjustments before first firing ....................................................................................................................................29
6.3 Burner starting ...........................................................................................................................................................29
6.4 Burner firing ...............................................................................................................................................................29
6.5 Fuel change ...............................................................................................................................................................30
6.6 Combustion air adjustment ........................................................................................................................................30
6.7 Air/fuel control and power modulation system ...........................................................................................................30
6.8 Adjustment pressure switches ...................................................................................................................................31
6.8.1 Air pressure switch - CO check..................................................................................................................................31
6.8.2 Max. gas pressure switch ..........................................................................................................................................31
6.8.3 Min. gas pressure switch ...........................................................................................................................................31
6.8.4 Pressure switch PVP kit.............................................................................................................................................31
6.9 Operation sequence of the burner .............................................................................................................................32
6.9.1 Burner starting ...........................................................................................................................................................32
6.9.2 Undesired shutdown during operation .......................................................................................................................32
6.10 Final checks (with the burner working) ......................................................................................................................32
7 Maintenance ..............................................................................................................................................................................33
7.1 Notes on safety for the maintenance .........................................................................................................................33
7.2 Maintenance programme ...........................................................................................................................................33
7.2.1 Maintenance frequency..............................................................................................................................................33
7.2.2 Checking and cleaning...............................................................................................................................................33
7.3 Opening the burner ....................................................................................................................................................34
7.4 Closing the burner......................................................................................................................................................34
8 Faults - Possible causes - Solutions.......................................................................................................................................35
A Appendix - Accessories ...........................................................................................................................................................36
B Appendix - Electrical panel layout...........................................................................................................................................37

3 20010309
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Dual fuel light oil/gas burner
Model: RLS 800/E MX
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
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 management system certified in accordance with ISO 9001:2015.
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard
“1. BImSchV release 26.01.2010”.
Product Type Model Power
Dual fuel light oil/gas burners 1301 T1 RLS 800/E MX 1750 - 8000 kW
Legnago, 03.05.2021 Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. F. Maltempi
CE-0085CL0422 Class 3 (EN 676) - Class 2 (EN 267)

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Information and general instructions
2.1 Information about the instruction manual
2.1.1 Introduction
The 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 for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy 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 the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Danger: live components
Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
The instruction manual is supplied to the user by the system
manufacturer, with the recommendation to keep it in the
room 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 carefully informs the user about:
– the use of the system,
– any further tests that may be necessary before the system
is started up,
– maintenance and the need to have the system checked at
least once a year by the manufacturer or another special-
ised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2 Information and general instructions
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or 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
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
This symbol indicates a list.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................

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Information and general instructions
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 the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
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 non authorised modifications on the equip-
ment;
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 power supply system;
use of the burner even following an error and/or an irregular-
ity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the flame, as structurally
established;
insufficient and inappropriate surveillance and care of those
burner components most subject to wear and tear;
use of non-original components, including spare parts, kits,
accessories and optionals;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and the carrying out of non authorised modifi-
cations will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
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 users expressly named by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion 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 must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine 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;
must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine;
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 knows
the use and safety instructions for his own duties;
must inform the manufacturer if faults or malfunctioning of
the accident prevention systems are noticed, along with any
presumed danger situation.
Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications
given in this manual.
Personnel must follow all the danger and caution indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel are obliged to inform their superiors of every
problem or dangerous 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 therefore
declines any and all responsibility for any damage that may
be caused by the use of non-original parts.
3 Safety and prevention

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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 Electrical supply Starting Code
RLS 800/E MX 3/400/50 Star/Delta 3911132
Series : R
Size
Fuel : Natural gas
Light oil
Light oil / Methane
Setting :
Flame control system :
FS1
FS2
Standard (1 stop every 24 h)
Continuos working (1 stop every 72 h)
Electrical supply to the system :
3/400/50
3/230/50
Auxiliary voltage :
230/50/60
110/50/60
RLS 800 ETC
Emission : ... Class 1 EN267 - EN676
MX Class 1 EN267 - Class 3 EN676
BLU Class 3 EN267 - EN676
MX Class 2 EN267
Class 3 EN676
FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
MX
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Variable speed (with Inverter)
P Air/gas proportioning valve
BP Two-stage (light oil) / Proportioning valve (gas)
M Mechanical cam
S
L
LS
N
Head : TC Standard head
TL Extended head
Country of destination Gas category
SE - 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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Technical description of the burner
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 at test point 5)(Fig. 4) with zero pressure in the combustion chamber and maximum burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
4.5 Electrical data
Tab. B
Model RLS 800/E MX
Output (1)
Delivery (1) min - max kW kg/h
1750/3500 - 8000
147/295 - 674
Fuel
LIGHT OIL, viscosity at 20 °C: 6 mm2/s (1.5 °E - 6 cSt)
NATURAL GAS: G20 (methane) - G21 - G22 - G23 - G25
- GPL: G31 - PCI 26 kWh/Nm3
Gas pressure at maximum delivery (2) -
Gas: G20/G25 mbar 50.6 / 75.4
Operation - Intermittent (min. 1 stop in 24 hours)
- Progressive two-stage or modulating by kit (see accessoires)
Pump Delivery (at 16.5 bar)
Pressure range
Fuel temperature
kg/h
bar
°C max
560
6 - 30
140
Nozzles number 1
Standard applications Boilers: water, steam, diathermic oil
Room temperature °C 0 - 50
Combustion air temperature °C max 60
Noise level (3) Sound pressure
Sound power dB(A) 89.6 100.6
Weight kg 320
Model RLS 800/E MX
Electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
V
kW
A
2950
400/690
22
39.4/22.7
Pump motor IE3
rpm
V
kW
A
2890
220-240/380-415
1.5
5.9/3.4
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 5 kV
1 A - 20 mA
Electrical power consumption Oil
Gas kW max 25.8 24
Protection level IP 54