Riello Burners RL 190/M Quick start guide

Installation, use and maintenance instructions
Light Oil Burners
RL 190/M
Low - High or Modulating Operation
C6505049 - 2916051 (5) - 03/2008

2
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3
Burner models designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 6
Choice of nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Burner calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Procedure to refer burner operating condition
in high altitude plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flame signal measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Siemens LAL control sequence of operations . . . . . . . . . . . . . . 16
Siemens LAL control troubleshooting guide. . . . . . . . . . . . . . . . 17
Factory wiring diagram - burner mounted LAL . . . . . . . . . . . . . . 18
Field wiring diagram- burner mounted LAL . . . . . . . . . . . . . . . . 19
Factory wiring diagram - remote panel. . . . . . . . . . . . . . . . . . . . 20
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Start up reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
N.B.
Figures mentioned in the text are identified as follows:
1)(A) =part 1 of figure A, same page as text;
1)(A)p.4 =part 1 of figure A, page number 4.
WARNING
Do not store flammable or hazardous materials in the vicinity
of fuel burning appliances.
Improper installation, adjustment, alteration, service or main-
tenance can cause property damage, personal injury or
death. Refer to this manual for instructional or additional in-
formation. Consult a certified installer, service representative
or the gas supplier for further assistance.
Burner shall be installed in accordance with manufacturers
requirements as outlined in this manual, local codes and au-
thorities having jurisdiction.

3
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394” WC - Altitude 329 ft a.s.l.
(2) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
(3) Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.
Burner models designations:
ACCESSORIES (optional):
• Available auxiliary panels
• Flame inversion boiler kit cod. 3010241
Model RL 190/M
Output (1)
Delivery (1)
High MBtu/hr (3)
GPH
5376 - 9184
38.4 - 65.6
Low MBtu/hr (3)
GPH
1792 - 5376
12.8 - 38.4
Fuel #2 fuel oil
Operation Low - high or modulating
Nozzle number 1 (return flow nozzle)
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Main power supply (+/- 10%) V/Ph/Hz 208 - 230 / 460 / 575 / 3 / 60
Fan motor rpm
W - HP
V
A
3400
4000 - 5.5
208 - 230 / 460 / 575
15.8 - 9.1 - 6
Ignition transformer V1 - V2
I1 - I2
120 V - 2 x 5 kV
3.7 A - 35 mA
Pump TA3 delivery (at 290 PSI)
pressure range
fuel temperature
GPH
PSI
°F max
213
101.5 - 580
284
Electrical power consumption W max 5500
Electrical protection NEMA1
Noise levels (2) dBA 83.9
Model Code Voltage Flame safeguard
RL 190/M
C9517300 (3477870)
C9517301 (3477875)
C9717300 (3477873)
C9717301 (3477873)
208-230/460/3/60
575/3/60
208-230/460/3/60
575/3/60
Burner mounted
Burner mounted
In an auxiliary panel (see Accessories)
In an auxiliary panel (see Accessories)
Auxiliary panel code Flame safeguard type
3010330 Fireye
3010334 Landis
Important:
The installer is responsible for the supply and installation of any safety device(s) not indicated in this manual.

4
BURNER DESCRIPTION (A)
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Screw for fixing fan to flange
5 Pressure gauge for pressure on nozzle return
6 Pressure gauge for pressure on nozzle delivery
7Pump
8 Air inlet to fan
9 Air damper
10 Fan pressure test point
11 Boiler mounting flange
12 Flame stability disk
13 Slide bars for opening the burner and inspecting the
combustion head
14 Extensions for slide bars 13) (with kit)
15 High oil pressure switch
16 Ignition transformer
17 Motor contactor and thermal cut-out with reset button
18 Power switch for different operations:
automatic - manual - off.
Button for:
power increase - power reduction
19 Terminal strip
20 Knockouts for electrical connections by installer
21 Flame safeguard with lock-out pilot light and lock-out
reset button
22 Flame inspection window
23 Air pressure switch
24 Valve assembly with pressure regulator on nozzle
return
25 Photocell (cad cell)
26 Servomotor, provides adjustment of fuel delivery reg-
ulator and of air damper.
When the burner is not operating the air damper is
fully closed in order to reduce to a minimum heat dis-
persion from the boiler.
Two types of burner failure may occur:
Flame safeguard Lock-out: if the flame relay 21)(A)
pushbutton lights up, it indicates that the burner is in
lock-out.
To reset, press the pushbutton, no sooner than 10 s
after the lock-out.
Motor trip: release by pressing the pushbutton on ther-
mal overload 17)(A).
PACKAGING - WEIGHT (B) -
Approximate measurements
• The burners are shipped skid mounted. Outer dimen-
sions of packaging are indicated in (B).
• The weight of the burner complete with packaging is
indicated in Table (B).
MAX. DIMENSIONS (C) -
Approximate measurements
The maximum dimensions of the burners are given in
(C).
Bear in mind that inspection of the combustion head
requires the burner to be opened and the rear part with-
drawn on the slide bars.
The maximum dimension of the burner when open, with-
out casing, is give in measurement I.
STANDARD EQUIPMENT
2 - Flexible hoses (L = 36”)
2 - Gaskets for flexible hoses
1 - Head gasket
4 - Screws to secure the burner flange to the boiler:
5/8 Wx 137/64”
1 - Adaptor G 1/8“ / 1/8“ NPT
1 - Instruction booklet
1 - Spare parts list
(A)
inch ABClbs
RL 190/M 471/4”33
15/32”31 1/2”209
(B)
(C)
D3932
D36
D1217
ABCDEFGH I
RL 190/M 32” 1413/32”17
19
/32”21
27/32”28 1/32”14 9/16”8 3/4”16 15/16”45 29/32”

5
FIRING RATES (A)
During operation, burner output varies between:
•MINIMUM OUTPUT: area A;
•MAXIMUM OUTPUT: area B.
The firing rate may be found by plotting a vertical line
from the desired delivery and a horizontal line from the
pressure in the combustion chamber. The intersection of
these two lines is the firing rate which must lie within
area A, for MIN output, and within area B, for MAX out-
put.
Note:
The FIRING RATE areas given in figure (A) have been
reduced by 10% with respect to the maximum range that
can be reached.
Important:
The FIRING RATE area values have been obtained con-
sidering an ambient temperature of 68 °F (20°C), and an
atmospheric pressure of 394” WC with the combustion
head adjusted as shown on page 7.
Consult Procedure on page 15 to refer burner operating
condition in high altitude plants.
MINIMUM FURNACE DIMENSIONS (B)
The firing rates were set in relation to certified test boil-
ers.
Figure (B) indicates the diameter and length of the test
combustion chamber.
Example:
Output 6400 MBtu/hr:
diameter = 31.5 inch; length 10.4 ft
Whenever the burner is operated in a much smaller
commercially-available combustion chamber, a prelimi-
nary test should be performed to verify operation.
(A) D2422
RL 190/M
(B) D2920
Diameter (inches)
Length (ft)
Furnace dimensions
A B
comb. chamber “ WC

6
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber mounting plate as shown
in (A). The position of the threaded holes can be marked
using the head gasket supplied with the burner.
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected according
to the indications provided by the manufacturer of the
boiler, and it must be greater than the thickness of the
boiler door complete with its insulation.
The length available, L (mm), is 149/16”.
For boilers with front flue passes 12) or flame inversion
chambers, protective insulation 10) must be inserted
between the boiler refractory 11) and the blast tube 9).
This protective insulation must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the insulation
11)(B) is not required unless it is required by the boiler
manufacturer.
SECURING THE BURNER TO THE BOILER (B)
Disassemble the blast tube 9) from the burner 6) by pro-
ceeding as follows:
- Loosen the four screws 3) and remove the cover 1).
- Remove the screws 2) from the two slide bars 5).
- Remove the two screws 4) fixing the burner 6) to the
flange 7).
- Withdraw the blast tube 9) complete with flange 7) and
slide bars 5).
Secure flange 7)(B) to the boiler plate inserting the sup-
plied gasket 8)(B). Use the 4 screws provided after hav-
ing protected the thread with an anti-seizing product.
The burner-boiler seal must be airtight.
D455
(B)
(A)
inch A B C
RL 190/M 91/6”12
25/32” - 1415/32”5/8 W
D1976

7
CHOICE OF NOZZLE (A)
See diagrams (B) page 11.
In case an intermediate delivery between the two values
indicated in the diagrams (B) page 11 is required, a noz-
zle with higher delivery must be chosen. Delivery reduc-
tion will be obtained by means of the pressure regulator.
RECOMMENDED NOZZLES:
Type A4 return flow nozzles - 45° angle
NOZZLE ASSEMBLY
At this stage of installation the burner is still disassem-
bled from the blast tube; At this point install the nozzle
with the box wrench 1)(A), fitting the wrench through the
central hole in the flame stability disk. Do not use any
sealing products such as gaskets, sealing compound, or
tape. Be careful to avoid damaging the nozzle sealing
seat.
Make sure that the electrodes are positioned as shown
in Figure (B).
Finally remount the burner 3)(C) on the slide bars 2) and
slide it up to the flange 5), keeping it slightly raised to
prevent the flame stability disk from pressing against the
blast tube.
Tighten the screws 1) on the slide bars 2) and screws 4)
fixing the burner to the flange.
If it proves necessary to change a nozzle with the burner
already fitted to the boiler, proceed as outlined below:
- Pull back the burner on its slide bars as shown in fig.
(D)p.14.
- Remove the nuts 1)(D) and the disk 2)
- Use wrench 3)(D) to change the nozzles.
COMBUSTION HEAD SETTING
The setting of the combustion head depends exclusively
on the maximum burner delivery at which it will be oper-
ating.
Turn screw 4)(E) until the notch shown in diagram (F) is
level with the front surface of flange 5)(E).
Example:
RL 190/M, maximum light oil delivery = 48 GPH
Diagram (F) indicates that for a delivery of 48 GPH the
RL 190/M Model requires the combustion head to be set
to approx. three notches, as shown in Figure (E).
(D)
(B)
(A) D1220
D2528
(C)
D1222
D462
(E)
N° Notches
Max Fuel oil delivery USGPH
D2424
(F)
D1977

8
HYDRAULIC SYSTEM
FUEL SUPPLY
Double-pipe circuit (A)
The burner is equipped with a self-priming pump which
is capable of feeding itself within the limits listed in the
table at the side.
The tank higher than the burner A
Distance "P" must not exceed 33 ft in order to avoid sub-
jecting the pump's seal to excessive strain; distance "V"
must not exceed 13 ft in order to permit pump self-prim-
ing even when the tank is almost completely empty.
The tank lower than the burner B
Pump suction values higher than 13 “Hg must not be
exceeded because at higher levels gas is released from
the fuel, the pump starts making noise and its working
life-span decreases.
It is good practice to ensure that the return and suction
lines enter the burner from the same height; in this way it
will be less probable that the suction line fails to prime or
stops priming.
The oil loop circuit
A loop main circuit consists of a loop of piping departing
from and returning to the tank with an auxiliary pump
that circulates the fuel under pressure. A branch con-
nection from the loop goes to feed the burner. This cir-
cuit is extremely useful whenever the burner pump does
not succeed in self-priming because the tank distance
and/or height difference are higher than the values listed
in the Table.
Key
H = Pump/foot valve height difference
L = Piping length
Ø = Inside pipe diameter
1 = Burner
2=Pump
3 = Filter
4 = Manual on/off valve
5 = Suction line
6 = Foot valve
7 = Return line
HYDRAULIC CONNECTIONS (B)
The pumps are equipped with a by-pass that separates
return line with suction line. The pumps are installed on
the burner with the by-pass closed by screw 6)(A)p.13.
It is therefore necessary to connect both hoses to the
pump.
The pump seal will be damaged immediately if it is
run with the return line closed and the by-pass
screw inserted.
Remove the plugs from the suction and return connec-
tions of the pump.
Insert the hose connections with the supplied seals into
the connections and screw them down.
Take care that the hoses are not stretched or twisted
during installation.
Install the hoses where they cannot be stepped on or
come into contact with hot surfaces of the boiler.
Now connect the other end of the hoses to the suction
and return lines.
(B)
(A)
A
B
1
2
3
7
5
6
6
4
75
- H + H V
P
D737
315/16”
D1978
+ H
- H
(ft)
L (ft)
Ø (inch)
1/2” 5/8”
+ 13 197 263
+ 10 164 230
+ 6.6 132 197
+ 4.8 115 181
+ 3.3 99 164
+ 1.6 82 148
0 66 132
- 1.6 59 115
- 3.3 49 99
- 4.8 43 82
- 6.6 33 66
- 10 16 33
- 13 - 20

9
PUMP (A)
1 - Suction 1/2" NPT
2 - Return 1/2" NPT
3 - Pressure gauge attachment G 1/8"
4 - Vacuum gauge attachment G 1/8"
5 - Pressure adjustment screw
6 - By-pass screw
A - Min. delivery rate at 290 PSI pressure
B - Delivery pressure range
C - Max. suction pressure
D - Viscosity range
E - Max fuel oil temperature
F - Max. suction and return pressure
G - Pressure calibration in the factory
PUMP PRIMING
- Before starting the burner, make sure that the tank
return line is not clogged. Obstructions in the line
could cause the seal located on the pump shaft to
break.
The time required for this operation depends upon the
diameter and length of the suction tubing. If the pump
fails to prime at the first starting of the burner and the
burner locks out, wait approx. 15 seconds, reset the
burner, and then repeat the starting operation as often
as required. After 5 or 6 starting operations allow 2 or 3
minutes for the transformer to cool.
Important: the priming operation is possible because
the pump is already full of fuel when it leaves the factory.
If the pump has been drained, fill it with fuel through the
opening for the vacuum gauge prior to starting; other-
wise, the pump will seize. Whenever the length of the
suction piping exceeds 66 - 98 ft, the supply line must be
filled using a separate pump.
AIR PRESSURE SWITCH (B)
Adjust the air pressure switch after having performed all
other burner adjustments with the air pressure switch set
to the start of the scale (B).
With the burner operating at min. output, increase adjust-
ment pressure by slowly turning the relative dial clock-
wise until the burner locks out.
Then turn the dial anti-clockwise by about 20% of the set
point and repeat burner starting to ensure it is correct.
If the burner locks out again, turn the dial anti-clockwise
a little bit more.
(A)
PUMP SUNTEC TA 3
D2352
D1979
TA 3
A
B
C
D
E
F
G
GPH
PSI
“Hg
cSt
°F
PSI
PSI
213
101.5 - 580
13
4 - 800
284 (140 °C)
72.5
435
(B)
AIR PRESSURE SWITCH
D2548

10
SERVOMOTOR (A)
The servomotor gives simultaneous regulation of the air
damper through the adjustable profile cam 4)(F) and the
pressure controller (A) pag. 11.
It rotates by 130° in approx. 35 s.
The factory settings must not be changed for the first fir-
ing, just check that they comply with the details below.
To open the servomotor, remove the screws and pull the
cover outward, fig. (A).
CAMS AND TRIM POTENTIOMETERS FUNC-
TIONS
Cam 1: 130°
Limits rotation towards maximum.
Cam 2: 0°
Limits rotation towards minimum, air damper closed on
stand by.
Cam 3: 20°
Limits ignition position.
Cams 4 - 5 - 6 - 7 - 8: not used
Trim potentiometer MAX
Limits maximum modulation.
It must be set near the stroke end (cam 1) to exploit as
far as possible the variable profile cam.
Trim potentiometer MIN
Limits minimum modulation.
It must be set near the stroke end (cam 2) to exploit as
far as possible the variable profile cam.
Trim potentiometer POS
Limits an intermediate operating position between MAX
and MIN, supplying power to the "P" terminal in the ser-
vomotor (through an external command). This function
cuts out any external signals.
Note
Using the slide switch to select MAX or MIN, the servo-
motor goes into the position for the respective settings of
the MAX and MIN TRIM POTENTIOMETERS.
When the settings are complete, place the slide switch
on OPE.(operate)
(A)
(D)
(F)
D2277
(E)
1Servomotor
2 Adjustable profile cam
3 Adjustment screws for cam
starting profile
4 Adjustment fixing screws
5 Adjustment screws for cam
and profile
D1229
(B)
D2585
NO
Figure above shows how the servo-
motor is released to manually check
there is no binding though its motion.
Don’t release the button indi-
cated in this figure: the syn-
cronization of the cams
made in factory would be
changed.
YES
(C)
Slide switch
Trim potentiometers
Position jumpers

11
BURNER CALIBRATION
The optimum calibration of the burner requires an analy-
sis of the flue gases at the boiler outlet.
The following settings that have already been made do
not require modification under normal circumstances:
• Combustion head;
• Servomotor, cams I - II - III
ADJUSTING THE NOZZLE FLOW RATE
The nozzle flow rate varies according to the fuel pres-
sure on the nozzle return.
Diagram (B) indicates this relationship for type A4 return
flow nozzles with pump delivery pressure of 290 PSI.
Diagrams (B):
Horizontal axis : PSI, nozzle return pressure
Vertical axis : GPH, nozzle flow rate
NOTE: with a pump delivery pressure of 290 PSI, the
pressure on the nozzle return must not exceed 246.5
PSI.
The pressure difference between pump delivery and
nozzle return must be at least 43.5 PSI. With smaller
pressure differences, the pressure on the nozzle return
can be unstable.
The nozzle delivery pressure value is indicated by the
pressure gauge 1)(A).
The nozzle return pressure value is indicated by the
pressure gauge 2)(A).
The output and the pressure of the nozzle are at maxi-
mum when the servomotor is positioned on maximum.
The fine adjustment of the pressure in the return line
may be carried out by changing the setting of the eccen-
tric 7)(A), of the nut and lock-nut 5)(A).
The eccentric setting should be carried out by loosening
screws 8), and turning the screw 6) to obtain the desired
eccentricity. Turn clockwise the screw 6) to increase the
eccentricity, increasing the difference between the min.
and max. capacity of the nozzle; turn counter-clockwise
the screw 6) to decrease the eccentricity and, conse-
quently the difference between the min. and max.
capacity of the nozzle.
NOTE
• The proper setting of the eccentric 7) is possible when
its operation field follows the servomotor operation
field (20° ÷ 130°): so, that every variation of the servo-
motor position corresponds to a pressure variation.
• Do not let the piston bottom out repeatedly: the
stop ring 4) (A) determines the max. stroke.
• When the setting is carried out, verify manually that no
slow-down occurs between 0° and 130° and that the
maximum and minimum pressures correspond to
those chosen as per diagrams (B).
• If you wish to check the delivery capacity of the nozzle,
open the burner, attach the nozzle, simulate the start-
up and then proceed with observation of the maximum
and minimum pressures of the fuel.
• If at the maximum capacity of the nozzle (maximum
pressure in the return line) pressure fluctuations are
detected on the gauge 1), slightly decrease the pres-
sure in the return line until they are completely elimi-
nated.
(A)
1 - Gauge for pressure in delivery line
2 - Gauge for pressure in return line
3 - Oil pressure switch
3 - Ring for piston stop
4 - Nut and lock-nut for piston setting
5 - Eccentric adjusting screw
6 - Variable eccentric
7 - Eccentric locking screws
D1984
PRESSURE CONTROLLER
D2427
(B)
Delivery pressure 290 PSI
Type A4 return flow nozzle (45°)
Nozzle flow rate GPH
Return pressure PSI
The values indicated in the right side of the diagram, refer to the data printed
on the nozzle.

12
BURNER STARTING
Close the control circuit, with the switches in fig. (C) and
(E) in the AUTO position.
On firing turn the switch (C) to MAN.
MAXIMUM OUTPUT
Using button (B), "increase output" until it stops at app.
130° (cam 1).
Place the slide switch on MAX and set the relative MAX
trim potentiometer (setting must be very near to 130°) to
exploit as far as possible the variable profile cam 2)(D).
The setting of the oil delivery must be made on the vari-
able eccentric 7)(A) page 11 by turning the screw
6)(A)pag. 11.
The air setting must be made on the variable profile cam
2)(D) after loosening the screws 4) by turning the screws
3).
MINIMUM OUTPUT
With the slide switch on the OPE position, use button (B)
"decrease output" until it stops at app. 20° (cam 3).
Put the slide switch in the MIN position and set the mod-
ulation minimum using the relative MIN trim potentiome-
ter .
The setting of the oil delivery must be made on the nut
and lock-nut 5)(A)page.11 and, if necessary, on the var-
iable eccentric 7)(A) page 11
Important
When the eccentricity is modified, it is necessary to bring
back to MAX and check the setting again.
The setting must be made on the adjustable profile cam
2)(D).
INTERMEDIATE OUTPUTS
With the switch (C) in the AUTO position, the slide switch
in the OPE position and the switch 1)(E) in the MAN po-
sition, move the button 2)(E) in various intermediate lev-
els between maximum and minimum and set the variable
profile cam 2)(D) to achieve optimum combustion, by
turning the screws 3).
If possible, do not change the previously set maximum
and minimum levels.
Do not change the eccentric, already adjusted for MAX
and MIN.
Check the various setting levels with a combustion anal-
ysis.
Important
Make a progressive setting of the profile, without sharp
changes.
When the setting is complete, lock the cam profile using
screws 4)(D).
Turn the burner off, release the servomotor as shown in
fig. (B) page 10 and manually turn cam 2)(D) to check for
smooth operation.
(E)
12
D791
(B) (C)
(D)
(A)
Slide switch
Trim potentiometers
Position jumpers
1Servomotor
2 Adjustable profile cam
3 Adjustment screws for cam starting profile
4 Adjustment fixing screws
5 Adjustment screws for cam end profile
D1229
D2593

13
BURNER OPERATION
BURNER STARTING (A) - (B)
• Operating control closes, the motor starts.
The pump 3) draws the fuel from the tank through the
piping 1) and pumps it under pressure for delivery. The
piston 4) rises and the fuel returns to the tank through
the piping 5) - 7). The screw 6) closes the by-pass
heading towards suction and the de-energized sole-
noid valves 2) - 8) - 9) close the passage to the nozzle.
• Servomotor starts: 130° rotation to right, until contact is
made on cam 1. The air damper is positioned on MAX.
output.
• Pre-purge stage with air delivery at MAX. output.
• Servomotor rotates to left until contact is made on cam
3.
• Air damper and pressure regulator are positioned on
MIN output.
• Ignition electrodes spark.
• Solenoid valves 2) - 8) - 9) open; the fuel passes
through the piping 10) and filter 11), and enters the
nozzle.
A part of the fuel is then sprayed out through the noz-
zle, igniting when it comes into contact with the spark:
flame at a low output level; the rest of the fuel passes
through piping 12 at the pressure adjusted by the regu-
lator 13, then, through piping 7), it goes back into the
tank.
• The spark goes out.
• The starting cycle ends.
STEADY STATE OPERATION
At the end of the starting cycle, the servo-motor control
then passes to load control for boiler pressure or tem-
perature.
• If the temperature or pressure is low (and the load con-
trol is consequently closed), the burner progressively
increases output up to MAX.
• If subsequently the temperature or pressure increases
until the load control opens, the burner progressively
decreases output down to MIN.
• The burner shuts down when demand for heat is less
than the heat supplied by the burner in the MIN output.
The servomotor returns to the 0° angle limited by con-
tact with cam 2. The air damper closes completely to
reduce thermal dispersion to a minimum.
Every time output is changed, the servomotor automati-
cally modifies oil delivery (pressure regulator) and air
delivery (fan damper).
FIRING FAILURE
If the burner does not fire, it goes into lock-out within 5 s
of the opening of the light oil valve.
FLAME FAILURE
If the flame should go out for accidental reasons during
operation, the burner will lock out in 1 s.
OIL PRESSURE SWITCH
The oil pressure switch 15)(A) page 4 is factory set to
43.5 PSI (3 bar). If the oil pressure reaches this value in
the return piping, the pressure switch stops the burner.
Burner starts again automatically if the pressure goes
down under 43.5 PSI (3 bar) after burner shut down. If a
loop circuit with Px pressure feeds the burner, the pres-
sure switch should be adjusted to Px + 43.5 PSI.
(A) D2444

14
FINAL CHECKS
• Obscure the photocell and switch on the control circuit:
the burner should start and then lock-out about 5 s
after starting.
• Illuminate the photocell and switch off the control
devices: burner should go into lock-out.
• Obscure the photocell while the burner is operating:
flame should go out and burner lock out within 1 s.
• Switch off control devices while the burner is operat-
ing: the burner should stop.
MAINTENANCE
Combustion
An analysis of the flue gases at the boiler outlet is
required . Significant differences with respect to the pre-
vious measurements indicate the points where more
care should be exercised during maintenance.
Pump
The pump delivery pressure must be stable at 290 PSI.
The suction must be less than 6.5 PSI.
Unusual noise must not be evident during pump opera-
tion.
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 fuel must be sucked from a tank
located near the burner. This measure permits the
cause of the problem to be traced to either the suction
line or the pump.
If the problem lies in the suction line, check to make sure
that the filter is clean and that air is not entering the pip-
ing.
Filters (A)
Check the following filter boxes:
• on line 1)
• at nozzle 2)
and clean or replace as required. If rust or other impuri-
ties are observed inside the pump, use a separate pump
to suck out any water and other impurities that may have
deposited on the bottom of the tank.
Fan
Check to make sure that no dust has accumulated
inside the fan or on its blades, as this condition will
cause a reduction in the air flow rate and create polluting
combustion.
Combustion head
Check to make sure that all the parts of the combustion
head are in good condition, positioned correctly, free of
all impurities, and that no deformation has been caused
by operation at high temperatures.
Nozzles
Do not clean the nozzle orifices.
Replace the nozzles every 2-3 years or whenever nec-
essary. Combustion must be checked after the nozzles
have been changed.
Photocell (cad cell) (B)
Clean the glass cover from any dust that may have
accumulated. Photocell 1) can be removed by pulling it
outward forcefully.
Flame inspection window (C)
Clean the glass.
Flexible hoses
Check to make sure that the flexible hoses are still in
good condition.
Boiler
Clean the boiler as indicated in its accompanying
instructions in order to maintain all the original combus-
tion characteristics intact, especially the flue gas tem-
perature and combustion chamber pressure. Lastly,
check the condition of the flue gas stack.
TO OPEN THE BURNER (D)
- Switch off the electrical power
- Loosen screws 1) and withdraw the cover 2)
- Unscrew screws 3)
- Fit the two extensions 4), supplied with a kit, onto the
slide bars 5)
- Pull part A backward keeping it slightly raised to avoid
damaging the disk 6) on blast tube 7).
FUEL PUMP AND/OR COUPLINGS REPLACEMENT
(E)
As per fig. (E), dimension X should be set at 3/32”.
(A)
(B)
(D)
(C)
D2012
D1254
D709
D1980
(E)
dimension
D2854
X

15
PROCEDURE TO REFER BURNER OPERATING CONDITION IN HIGH ALTITUDE PLANTS
- Find the corrected burner capacity for the plant’s altitude in chart 1 and the corrected pressure in chart 2.
- Check in the firing rate graph of the burner (page 5), if the working point defined by the values above is within the range limits.
If not, higher burner size is needed.
Reference conditions (Charts 1-2): Ambient temperature 68 °F (20 °C) - Barometric pressure 394” WC (1000 mbar) - Altitude 328 ft a.s.l. (100 m a.s.l.)
Note
Charts are based only on altitude variation
(reference temperature = 68°F , 20°C)
To get the combined correction in case of different
air temperature, a compensation of 1000 ft each
20°F (305 m each 11°C) is applicable.
Example
Rated capacity = 3000 MBtu/hr - Rated air pressure = 1.5”w.c.
Real altitude = 5000 ft - Real temperature = 108°F
∆= 108°F - 68°F (reference temp.) = 40°F (equivalent 2000 ft variation)
Proceeding as descripted above and considering a “virtual altitude” of (5000 + 2000) ft:
- the corrected capacity is 3847 MBtu/hr;
- the corrected burner air pressure is 1.92. Burner RL 190/M is OK
m. a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000
500 494 500 512 530 551 571 593 616 641 669
1000 987 1000 1023 1061 1101 1142 1186 1232 1282 1337
1500 1481 1500 1535 1591 1652 1713 1778 1848 1924 2006
2000 1974 2000 2046 2121 2202 2284 2371 2464 2565 2675
2500 2468 2500 2558 2652 2753 2855 2964 3079 3206 3343
3000 2962 3000 3069 3182 3303 3425 3557 3695 3847 4012
3500 3455 3500 3581 3712 3854 3996 4149 4311 4488 4680
4000 3949 4000 4092 4243 4404 4567 4742 4927 5130 5349
4500 4442 4500 4604 4773 4955 5138 5335 5543 5771 6018
5000 4936 5000 5116 5303 5505 5709 5928 6159 6412 6686
5500 5429 5500 5627 5834 6056 6280 6520 6775 7053 7355
6000 5923 6000 6139 6364 6606 6851 7113 7391 7694 8024
6500 6417 6500 6650 6894 7157 7422 7706 8006 8335 8692
7000 6910 7000 7162 7425 7708 7993 8299 8622 8977 9361
7500 7404 7500 7673 7955 8258 8564 8892 9238 9618 10029
8000 7897 8000 8185 8485 8809 9135 9484 9854 10259 10698
8500 8391 8500 8697 9016 9359 9705 10077 10470 10900 11367
9000 8885 9000 9208 9546 9910 10276 10670 11086 11541 12035
9500 9378 9500 9720 10076 10460 10847 11263 11702 12183 12704
10000 9872 10000 10231 10607 11011 11418 11855 12318 12824 13373
Average barometric
Pressure
(
20°C
)
mbar 1013 1000 977,4 942,8 908,2 875,8 843,5 811,85 779,8 747,8
Average barometric
Pressure
(
68°F
)
"w.c. 399 394 385 371 358 345 332 320 307 294
Rated Capacity
Altitude
CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE
1
m. a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000
0,50 0,49 0,50 0,51 0,53 0,55 0,57 0,59 0,62 0,64 0,67
1,00 0,99 1,00 1,02 1,06 1,10 1,14 1,19 1,23 1,28 1,34
1,50 1,48 1,50 1,53 1,59 1,65 1,71 1,78 1,85 1,92 2,01
2,00 1,97 2,00 2,05 2,12 2,20 2,28 2,37 2,46 2,56 2,67
2,50 2,47 2,50 2,56 2,65 2,75 2,85 2,96 3,08 3,21 3,34
3,00 2,96 3,00 3,07 3,18 3,30 3,43 3,56 3,70 3,85 4,01
3,50 3,46 3,50 3,58 3,71 3,85 4,00 4,15 4,31 4,49 4,68
4,00 3,95 4,00 4,09 4,24 4,40 4,57 4,74 4,93 5,13 5,35
4,50 4,44 4,50 4,60 4,77 4,95 5,14 5,33 5,54 5,77 6,02
5,00 4,94 5,00 5,12 5,30 5,51 5,71 5,93 6,16 6,41 6,69
5,50 5,43 5,50 5,63 5,83 6,06 6,28 6,52 6,77 7,05 7,35
6,00 5,92 6,00 6,14 6,36 6,61 6,85 7,11 7,39 7,69 8,02
6,50 6,42 6,50 6,65 6,89 7,16 7,42 7,71 8,01 8,34 8,69
7,00 6,91 7,00 7,16 7,42 7,71 7,99 8,30 8,62 8,98 9,36
7,50 7,40 7,50 7,67 7,96 8,26 8,56 8,89 9,24 9,62 10,03
8,00 7,90 8,00 8,18 8,49 8,81 9,13 9,48 9,85 10,26 10,70
8,50 8,39 8,50 8,70 9,02 9,36 9,71 10,08 10,47 10,90 11,37
9,00 8,88 9,00 9,21 9,55 9,91 10,28 10,67 11,09 11,54 12,04
9,50 9,38 9,50 9,72 10,08 10,46 10,85 11,26 11,70 12,18 12,70
10,00 9,87 10,00 10,23 10,61 11,01 11,42 11,86 12,32 12,82 13,37
Average barometric
Pressure
(
20°C
)
mbar 1013 1000 977,4 942,8 908,2 875,8 843,5 811,85 779,8 747,8
Average barometric
Pressure
(
68°F
)
"w.c. 399 394 385 371 358 345 332 320 307 294
Rated Pressure
Altitude
CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE
2

16
FLAME SIGNAL MEASUREMENT (A)
Min value for a good signal: 8 µA.
If the value is lower, it can be due to:
• Worn photocell;
• Low current;
• Bad set up of the burner.
In order to measure the current, use a microammeter of
100 µA c.c., connected to the scanner, as in the dia-
gram.
SEQUENCE OF OPERATION - LAL CONTROL
See fig. (B) - (C).
Switching times are given in seconds, in the burner star-
tup sequence.
Legend for the times
t1 Pre-purge time with air damper open
t2 Safety time
t3 Pre-ignition time, short (“Z” connected to
terminal “16”)
t4 Interval between voltage at terminals “18” and
“20”
t5 Air damper running time to OPEN position
t6 Air damper running time to low-flame position
(MIN)
t7 Permissible after-burn time
t8 Interval to the OPEN command for the air damper
Min. detector current required at AC 230 V 8 µA
Max. detector current required without
flame 0.8 µA
Max. detector current that can occur 35 µA
Instrument’s + pole to term. 22
Length of detector line
In the same cable as the control lines not perm.
Separate cable in the cable duct 20 m
Three-wire cable ---
Two-wire cable for the detector line (bl,
sw); separate single-wire cable for the line
(br)
---
Shielded cable (e.g. RG62, shielding insu-
lated) 200 m
Shielding to term. 23
LAL 2.25
t1
t2
t3
t4
18
4
2
12
t5
t6
t7
t8
optional
optional
12
4
(B)
(C)
Full modulation
High - low
D2871
D2883
(A)
D3206
LAL2... Sub-base

17
BURNER FAULTS
(1) When the burner does not fire or stops following a fault, the symbol which appears on control box after lockout indicates type of problem.
(2) The fuse is located in the rear part of the control box. A spare fuse is also available located under a break off tang.
SYMBOL (1) FAULT PROBABLE CAUSE SUGGESTED REMEDY
The burner does not start 1 - A limit or safety control device is open . . . . . . . . . . . . . . . . Adjust or replace
2 - Control box lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset control box
3 - Oil pressure switch tripped . . . . . . . . . . . . . . . . . . . . . . . . . Adjust pressure switch or eliminate pressure
4 - Motor protection tripped . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset thermal cut-out
5 - No electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . Close all switches - Check connections
6 - Flame safeguard fuse blown . . . . . . . . . . . . . . . . . . . . . . . . Replace
7 - Contact II of servomotor does not operate,. . . . . . . . . . . . . Adjust cam II or replace servomotor
flame safeguard terminals 11 - 8
8 - Pump is jammed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
9 - Defective motor command control device . . . . . . . . . . . . . . Replace
10 - Defective Flame safeguard . . . . . . . . . . . . . . . . . . . . . . . . . Replace
11 - Defective electrical motor . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
The burner does not start and a
function lock-out occurs 12 - Flame simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace control box 13 - Photocell short-circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace photocell
14 - Missing phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset thermal cut-out
thermal cut-out trips when third phase is re-connected
The burner starts but stops at
maximum air damper setting 15 - Contact I of servomotor does not operate, . . . . . . . . . . . . . Adjust cam I or replace servomotor flame safeguard terminals 9-8
The burner starts and then goes
into lock-out 16 - Fault in flame detection circuit. . . . . . . . . . . . . . . . . . . . . . . Replace flame safeguard
The burner remains in pre-purging
phase 17 - Contact III of servomotor does not operate, . . . . . . . . . . . . Adjust cam III or replace servomotor flame safeguard terminals 10-8
After pre-purge and the safety
time, the burner goes to lock-out
and the flame does not appear
18 - No fuel in tank; water on tank bottom . . . . . . . . . . . . . . . . . Top up fuel level or suck up water
19 - Inappropriate head and air damper adjustments . . . . . . . . Adjust
20 - Light oil solenoid valves fail to open . . . . . . . . . . . . . . . . . . Check connections; replace coil
21 - Nozzle clogged, dirty, or deformed . . . . . . . . . . . . . . . . . . . Replace
22 - Dirty or poorly adjusted firing electrodes. . . . . . . . . . . . . . . Adjust or clean
23 - Grounded electrode due to broken insulation . . . . . . . . . . . Replace
24 - High voltage cable defective or grounded. . . . . . . . . . . . . . Replace
25 - High voltage cable deformed by high temperature . . . . . . . Replace and protect
26 - Ignition transformer defective . . . . . . . . . . . . . . . . . . . . . . . Replace
27 - Poor electrical connections of valves or transformer . . . . . Check
28 - Defective flame safeguard . . . . . . . . . . . . . . . . . . . . . . . . . Replace
29 - Pump unprimed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prime pump and see "Pump unprimes”
30 - Pump/motor coupling broken . . . . . . . . . . . . . . . . . . . . . . . Replace
31 - Pump suction line connected to return line . . . . . . . . . . . . . Correct connection
32 - Valves up-line from pump closed . . . . . . . . . . . . . . . . . . . . Open
33 - Filters dirty: line - pump - nozzle . . . . . . . . . . . . . . . . . . . . . Clean
34 - Incorrect motor rotation direction . . . . . . . . . . . . . . . . . . . . Change motor electrical connections
The flame ignites normally but the
burner locks out when the safety
time has elapsed
35 - Defective photocell or flame safeguard. . . . . . . . . . . . . . . . Replace photocell or flame safeguard
36 - Dirty photocell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean
Firing with pulsations or flame
detachment, (lift off) delayed firing 37 - Poorly adjusted head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust 38 - Poorly adjusted or dirty firing electrodes . . . . . . . . . . . . . . . Adjust
39 - Poorly adjusted fan air gate: too much air . . . . . . . . . . . . . Adjust
40 - Nozzle unsuited for burner or boiler . . . . . . . . . . . . . . . . . . See Nozzle Table
41 - Defective nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
42 - Inappropriate pump pressure . . . . . . . . . . . . . . . . . . . . . . . Adjust
The burner does not pass to 2nd
stage 43 - Control device TR does not close . . . . . . . . . . . . . . . . . . . . Adjust or replace 44 - Defective control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
Uneven fuel supply 45 - Check if cause is in pump or . . . . . . . . . . . . . . . . . . . . . . . . Feed burner from tank
fuel supply system located near burner
Internally rusted pump 46 - Water in tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remove water from tank bottom with separate pump
Noisy pump, unstable pressure 47 - Air has entered the suction line . . . . . . . . . . . . . . . . . . . . . Tighten connectors
- Depression value too high (higher than 35 cm Hg):
48 - Tank/burner height difference too great . . . . . . . . . . . . . . . Feed burner with loop circuit
49 - Piping diameter too small . . . . . . . . . . . . . . . . . . . . . . . . . . Increase
50 - Suction filters clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean
51 - Suction valves closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open
52 - Paraffin solidified due to low temperature . . . . . . . . . . . . . . Add additive to light oil
Pump loses prime after prolonged
pause 53 - Return pipe not immersed in fuel . . . . . . . . . . . . . . . . . . . . Bring to same height as suction pipe 54 - Air enters suction piping . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten connectors
Pump leaks light oil 55 - Leakage from sealing organ . . . . . . . . . . . . . . . . . . . . . . . . Replace pump
Smoke in flame - dark Bacharach
- yellow Bacharach
56 - Not enough air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust head and fan damper
57 - Nozzle worn or dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
58 - Nozzle filter clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean or replace
59 - Erroneous pump pressure. . . . . . . . . . . . . . . . . . . . . . . . . . Adjust
60 - Flame stability disk dirty, loose, or deformed . . . . . . . . . . . Clean, tighten in place, or replace
61 - Boiler room air vents insufficient . . . . . . . . . . . . . . . . . . . . . Increase
62 - Too much air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust head and fan damper
Dirty combustion head 63 - Nozzle or filter dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
64 - Unsuitable nozzle delivery or angle . . . . . . . . . . . . . . . . . . See recommended nozzles
65 - Loose nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten
66 - Impurities on flame stability disk . . . . . . . . . . . . . . . . . . . . . Clean
67 - Wrong head adjustment or not enough air . . . . . . . . . . . . . Adjust, open air damper
68 - Blast tube length unsuited to boiler. . . . . . . . . . . . . . . . . . . Contact boiler manufacturer
During operation, the burner stops
in lock out 69 - Dirty or defective photocell . . . . . . . . . . . . . . . . . . . . . . . . . Clean or replace
1
2
I

18
D2815
LAYOUT (A)
Burner RL 190/M
Key to Layout (A)
CMV - Motor contactor
DA - Control box
FR - Photocell
MB - Terminal strip
MV - Fan motor
PA - Air pressure switch
PO - High oil pressure switch
RT - Thermal overload
S1 - Switch for following operations :
MAN = manual
AUT = automatic
OFF
S2 - Button for :
- = power reduction
+ = power increase
SM - Servomotor
TA - Ignition transformer
TB - Burner ground (earth) connection
VM - Delivery pump valve
VS - Delivery pump valve (safety valve)
VR - Valve on nozzle return
Factory Wiring Diagram
RL 190/M with burner mounted Siemens LAL control
(A) D2873
Continuous fan operation
Change the wire connection from terminal 7 to terminal 1, move the jumper from terminals 12-13 to terminals 4-12 and
remove the wire from terminal 13 of control box.

19
(A)
FIELD WIRING CONNECTIONS
set by installer
Use flexible cables according to local regulation.
LAYOUT (A)
RL 190/M electrical connection three-phase 208 - 230/460 V
power supply
Key to wiring layouts (A)
H1 - Remote lock-out signal
H2 - Burner on signal
H4 - Power on signal
H5 - Limit satisfied
IN - Manual burner stop switch
MB - Terminal strip
PS - Remote lock-out reset
OC - Operating control.
HL - High limit control.
N.B.
• The setting of the thermal overload must be according to the total
burner amperage draw.
• The RL190/M burners leave the factory preset for:
- 208-230 V power supply: only in this case, if 460 V power sup-
ply is required, change the fan and the pump motor connection
from delta to star and change the setting of the thermal overload
as well;
-or 575 V power supply;
depending on the burner model (see page 3).
• The RL 190/M burner has been type-approved for intermittent
operation. This means it should be stopped at least once every 24
hours to enable the control box to perform self checks at start-up.
Burner halts are normally provided for automatically by the boiler
load control system.
Field Wiring Diagram
RL 190/M with burner mounted LAL flame safeguard
RL 190/M
208 -
230 V 460 V 575 V
FAT25T20T15
S AWG 12 12 12
D2291
Motor Connection
D3686

20
Factory Wiring Diagram RL 190/M
With auxiliary panel
(A)