Riello Burners RLS 70/E Quick start guide

Installation, use and maintenance instructions
Dual Fuel Gas / Light Oil Burners
Electronic cam version
RLS 70 - 100 - 130 /E
Modulating Gas / Low - High Oil Operation
C65050xx - 2915922 (0)
Preliminary
copy
11 / 15 / 2002

2
CONTENTS
FUEL OIL / GAS
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
FUEL OIL
Nozzle selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjustments before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL OIL
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjustment before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL OIL / GAS
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil hydraulic system layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ELECTRICALWIRING
Factory wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix - Burner firing rates according to air density. . . . . . . . 20
Start up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WARNING
If you smell gas:
• Do not touch any electrical items.
• Open all windows.
• Close all gas supply valves.
• Contact your local gas authority immediately.
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. Consulta 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.
(2)
Pressure at test point 18)(A)p.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.
(4)
Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.
Burner model designations:
ACCESSORIES
(optional):
• KIT FOR LENGTHENINGTHE COMBUSTION HEAD
L =Standard length
L1 =Length obtainable with the kit
Code 3010267 L = 9
27/32
” L1 = 15
5/32
” • RLS 70/E
Code 3010268 L = 9
27/32
” L1 = 15
5/32
” • RLS 100/E
Code 3010269 L = 9
27/32
” L1 = 15
5/32
” • RLS 130/E
• KIT FOR LPG OPERATION - Code 3010305: The kit allows the RLS 70-100-130/E burners to operate on LPG .
• GASTRAIN ACCORDINGTO UL STANDARDS: see page 11.
Model RLS 70/E RLS 100/E RLS 130/E
Output
(1)
Delivery
(1)
Maximum MBtu/hr
(4)
1750 - 3094 2646 - 4396 3500 - 5292
kW 513 - 907
12.5 - 22.1 775 - 1288 18.9 - 31.4 1026 - 1551 25 - 37.8
GPH
Minimum MBtu/hr
(4)
854 1330 1750
kW 250
6.1 390 9.5 513 12.5
GPH
Fuel #2 Fuel oil
Natural gas / Propane gas
Gas pressure at maximum delivery
(2)
Gas: Natural gas “WC 2.44 3.94 4.29
Operation Low-high light oil
Low-high-low / modulating gas
Nozzles number 2
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
Electric motors rpm 3400
Fan motor V
W - HP
A
208 - 230 / 460 / 575
1100 - 1.5
4.8 - 2.8 - 2.3
208 - 230 / 460 / 575
1800 - 2.5
6.7 - 3.9 - 3.2
208 - 230 / 460 / 575
2200 - 3
8.8 - 5.1 - 4.1
Pump motor V
W - HP
A
208 - 230 / 460 / 575
550 - 0.75
2.6 - 1.5 - 1.2
Ignition transformer Oil V1 - V2
I1 - I2 120V - 2 x 5 kV 3.7 A - 35 mA
Gas V1 - V2
I1 - I2 120V - 1 x 7 kV 1.6 A - 23 mA
Pump delivery (at 174 PSI)
pressure range
fuel temperature
GPH
PSI
° F max
52.5
145 - 290
140 (60 °C)
Electrical power consumption W max 2200 3000 3400
Electrical protection NEMA 1
Noise levels
(3)
dBA 74 77.5 80
Model Code Voltage Control panel with
electronic cam
Code
RLS 70/E Cxxxxxxx
(3485074)
Cxxxxxxx (3485074) 208-230/460/3/60 575/3/60
301xxxxRLS 100/E Cxxxxxxx
(3485274)
Cxxxxxxx (3485274) 208-230/460/3/60 575/3/60
RLS 130/E Cxxxxxxx
(3485474)
Cxxxxxxx (3485474) 208-230/460/3/60 575/3/60
Important:
tThe installer is responsible for the supply and installation of any required safety device(s) not indicated in this manual.

4
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrodes
3 Screw for combustion head adjustment
4 Sleeve
5Cover
6 Fan motor
7 Motors contactors and thermal cut-out with reset but-
ton
8 UV scanner
9 Terminal strip
10 Knockouts for electrical connections by installer
11 Servomotor controlling gas butterfly valve
12 Screw securing fan to sleeve
13 Flame inspection window
14 Low air pressure switch
(differential operating type)
15 Slide bars for opening the burner and inspecting the
combustion head
16 Safety solenoid valve
17 Low and high fire oil valves
18 Gas pressure test point and head fixing screw
19 Air pressure test point
20 Servomotor controlling air damper
21 Pump motor
22 Low oil pressure switch
23 Pilot attachment
24 Pump
25 Gas input connection
26 Boiler mounting flange
27 Flame stability disk
Motor trip: release by pressing the pushbutton on the
thermal overload 7)(A).
PACKAGING -WEIGHT (B)
- Approximate measure-
ments
• The burners are skid mounted. Outer dimensions of
packaging are indicated in (B).
• The weight of the burner complete with packaging is
indicated in Table (B).
MAX. DIMENSIONS (C)
- Approximate measure-
ments
The maximum dimensions of the burners are given in
(C).
Inspection of the combustion head requires the burner
to be opened and the rear part withdrawn on the slide
bars.
The maximum dimension of the burner when open, with-
out casing, is give in measurement I.
STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
4 - Flange fixing screws
1 - Burner head gasket
4 - Screws to secure the burner flange to the boiler:
1/2
W x 1
3/8
”
1 - Adaptor G
1/8
“ /
1/8
“ NPT
2 - Flexible hoses
1 - Instruction booklet
1 - Spare parts list
(A)
inch A B C lbs
RLS 70/E 50“ 2525/32“34
3
/
4
“159
RLS 100/E 50“ 2525/32“34
3
/
4
“165
RLS 130/E 50“ 2525/32“34
3
/
4
“170
(B)
RLS A B C D E F G H I L M N O
70/E 271/2“113/8“161/8“2127/32“333/32“927/32“71/16“1615/16“4523/32“87/16“59/32”823/32“2“
100/E 287/8“1225/32“161/8“2127/32“333/32“927/32“71/16“1615/16“4523/32“87/16“59/32”823/32“2“
130/E 287/8“1225/32“161/8“2127/32“333/32“927/32“77/16“1615/16“4523/32“87/16“59/32”823/32“2“
(C)
D2985
D36
D2300

5
FIRING RATES (A)
MAXIMUM OUTPUT must be selected in area A.
In order to increase to area B (RLS 130/E) it is neces-
sary to perform the calibration of the combustion head
as explained on page 6.
MINIMUM OUTPUT must not be lower than the mini-
mum limit shown in the diagram:
RLS 70/E = 854 MBtu/hr = 6.1 GPH
RLS 100/E = 1330 MBtu/hr = 9.5 GPH
RLS 130/E = 1750 MBtu/hr = 12.5 GPH
Important:
The FIRING RATE area values have been obtained con-
sidering an ambient temperature of 68 °F, and an atmos-
pheric pressure of 394” WC and with the combustion
head adjusted as shown on page 7.
Note:
The FIRING RATE areas given in figure (A) have been
reduced by 10% with respect to the maximum range that
can be reached.
Consult Appendix on page 20 for operation at different
ambient temperatures and/or altitudes.
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 2579 MBtu/hr:
diameter 24 inch - length 6.6 ft.
(A)
RLS 70/E
RLS 100/E
RLS 130/E
Combustion chamber pressure
“WC
Combustion chamber pressure
“WC
Combustion chamber pressure
“WC
A B
D2301
(B) D2919
A
A
ft
Diameter (inches)
Length (ft)
Furnace dimensions

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 gasket supplied with the burner.
BLASTTUBE LENGTH (B)
The length of the blast tube must be selected according
to the indications provided by the manufacturer of the
boiler, it must be greater than the thickness of the boiler
door complete with its insulation. The range of lengths
available, L (inch), is as follows:
Blast tube 10): RLS 70/E RLS 100/E RLS 130/E
• short 927/32“9
27/32“9 27/32“
• long 155/32“15
5
/
32“15
5
/
32“
For boilers with front flue passes 13) or flame inversion
chambers, insulation material 11) must be inserted
between the refractory 12) and the blast tube 10).
This protective insulation must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front, the insulation
11)-12)(B) is not required unless it is required by the
boiler manufacturer.
SECURINGTHE BURNERTOTHE BOILER (B)
Detach the combustion head from the burner, fig.(B):
- Disconnect the oil pipes by unscrewing the two con-
nectors 6)
- Loosen the 4 screws 3) and remove the cover 1)
- Remove the screws 2) from the slide bars 5)
- Remove the 2 screws 4) and pull the burner back on
slide bars 5) by about 4”.
- Disconnect the electrode wires and then pull the
burner completely off the slide bars.
COMBUSTION HEAD CALIBRATION
At this point check, on model RLS 130/E, whether the
maximum delivery of the burner is contained in area A or
in area B of the firing rate.See page 5.
If it is in area A then no adjustment is required.
If it is in area B:
- Unscrew the screws 1)(C) and disassemble the blast
tube 2).
- Move the fixing of the rod 3)(C) from position A to
position B, thereby causing the shutter 4) to retract.
- Now refit the blast tube 2)(C) and the screws 1).
Once this operation has been carried out, secure the
flange 9)(B) to the boiler plate, inserting the gasket 7)(B)
supplied with the burner. Use the 4 screws, also sup-
plied with the unit, after first protecting the thread with an
anti-seize product.Tighten the seal between burner and
boiler.
NOZZLE SELECTION
Both nozzles must be chosen from among those listed
in Table (D).
The first nozzle determines the delivery of the burner in
low fire.
The second nozzle combines together with the 1st noz-
zle to determine the total firing rate at high fire.
The total firing rates of low and high fire must be con-
tained within the value range indicated on page 3.
Use nozzles with a 60° spray angle at the recommended
pressure of 174 PSI.
The two nozzles have equal deliveries rates
(D)
inch A B C
RLS 70/E 79/32“10
27/32“ - 1225/32“1/2W
RLS 100/E 721/32“10
27/32“ - 1225/32“1/2W
RLS 130/E 721/32“10
27/32“ - 1225/32“1/2W
D455
(A)
(B)
(E)
D2986
Nozzle
size
GPH MBtu/hr
174 PSI
145 PSI 174 PSI 203 PSI
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.30
8.50
9.00
9.50
10.0
10.5
11.0
12.0
12.3
13.0
13.8
14.0
15.0
15.3
16.0
17.0
6.15
6.76
7.4
8.01
8.61
9.22
9.86
10.21
10.47
11.08
11.69
12.3
12.94
13.54
14.76
15.15
16.01
17.0
17.23
18.48
18.83
19.69
20.94
6.79
7.46
8.17
8.84
9.51
10.18
10.86
11.27
11.56
12.23
12.90
13.58
14.28
14.95
16.3
16.71
17.64
18.73
19.02
20.37
20.78
21.74
23.09
7.4
8.13
8.87
9.61
10.34
11.08
11.82
12.26
12.55
13.29
14.03
14.76
15.49
16.23
17.71
18.16
19.18
20.27
20.65
22.16
22.57
23.63
25.1
951
1044
1144
1238
1331
1425
1520
1578
1618
1712
1806
1901
1999
2093
2282
2339
2470
2622
2663
2852
2909
3044
3514
D1122
(C) D1192

7
NOZZLE ASSEMBLY
Remove screw 1)(E) and extract the nozzle assembly
2)(E) (see page 6). Install both nozzles 1)(A), after hav-
ing removed the plastic plugs 2)(A), fitting the wrench
through the central hole in the flame stability disk or
loosen screws 1)(B), remove disk 2)(B) and replace the
nozzles using the wrench 3)(B).
Do not use any sealing products such as gaskets, seal-
ing compound, or tape. Be careful to avoid damaging
the nozzle sealing seat. The nozzles must be screwed
into place tightly but carefully.
The nozzle for low fire operation is the one lying beneath
the firing electrodes Fig. (C).
Make sure that the electrodes are positioned as shown
in Figure (C).
Refit the burner to the slide bars 3)(G) at approximately
4” from the sleeve 4) - burner positioned as shown in fig.
(B)p. 6 - insert the ignition electrode cables and then
slide the burner up to the sleeve so that it is positioned
as shown in fig.(G).
Refit screws 2)(G) on slide bars 3).
Secure the burner to the sleeve by tightening screws 1).
Connect the oil pipes again by screwing on the two con-
nectors 6)(B)p.6.
Important
When fitting the burner on the two slide bars, it is advis-
able to gently draw out the high tension cables until they
are slightly stretched.
ADJUSTMENTS BEFORE FIRST FIRING
(light-oil operation)
• Combustion head setting
The setting of the combustion head depends exclusively
on the maximum delivery of the burner.
Turn screw 5)(E) until the notch shown in diagram (F) is
level with the front surface of flange 6)(E).
Example: Burner RLS 100/E
maximum burner delivery = 23.1 GPH.
If diagram (F) is consulted it is clear that for this delivery,
the combustion head must be adjusted using notch 3, as
shown in fig.(E).
• Pump adjustment
No settings are required for the pump, which is set to
174 PSI by the manufacturer. This pressure must be
checked and adjusted (if required) after the burner has
been ignited.
The only operation required in this phase is the applica-
tion of a pressure gauge on the appropriate pump
attachment.
• Air damper adjustment
The first time the burner is fired leave the factory setting
unchanged for both low and high fire operation.
• Ignition pilot adjustment
Place the pilot and electrode as shown in fig. (D).
The pilot works correctly at pressures ranging from 6 -
12”WC.
(A)
(D)
D1146 D1147
D2539
D1149
N° Notches
Maximum fuel oil delivery USGPH
D2304
(B)
D2987
ELECTRODE POSITION (for OIL operation)
(G)
(F)
(C)
(E)
Ignition pilot
Electrode
D2591
3/32”
1/32”

8
PUMP (A)
1 - Suction 1/4” NPT
2 - Return 1/4” NPT
3 - Pressure gauge attachment G 1/8”
4 - Vacuum gauge attachment G 1/8”
5 - Pressure regulator
A - Min. delivery rate at 174 PSI pressure
B - Delivery pressure range
C - Max. suction
D - Viscosity range
E - Max fuel oil temperature
F - Max. suction and return pressure
G - Pressure calibration in the factory
H - Filter mesh width
(A)
PUMP
SUNTEC AJ6 CC
AJ6 CC
A
B
C
D
E
F
G
H
GPH
PSI
“Hg
cSt
°F - °C
PSI
PSI
inch
52.5
145 - 290
13
2.8 - 75
140 - 60
29
174
0.006
D2306

9
FUEL SUPPLY (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 left.
The tank higher than the burner A
The distance "P" must not exceed 33 ft in order to avoid
subjecting the pump's seal to excessive strain; the dis-
tance "V" must not exceed 13 ft in order to permit pump
self-priming even when the tank is almost completely
empty.
The tank lower than the burner B
Pump suction pressures 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 more improbable that the suction line fails to
prime or stops priming.
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 and suction line. The pumps are installed on
the burner with the by-pass closed by screw 6), see dia-
gram page 15.
It is therefore necessary to connect both hoses to the
pump.
Damage to the pump seal will occur 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 and
where they do not hamper the opening of the burner.
Now connect the other end of the hoses to the suction
and return lines.
PUMP PRIMING
-Before starting the burner, make sure that the
tank return line is not clogged. Obstructions in
the line could cause damage to the pump seal.
(The pump leaves the factory with the by-pass
closed).
- Also check to make sure that the valves located on
the suction line are open and that there is sufficient
fuel in the tank.
- For self-priming to take place, one of the screws 3) of
the pump (See fig.(A) page 8) must be loosened in
order to bleed off the air contained in the suction line.
(A)
6
7
53
2
1
4
- H
315/16
+ H V
P
5
7A
B
6
D2988
+ H
- H
ft
L ft
RLS 70 - 100 - 130/E
Ø inch
1/2”9/16”5/8”
+ 13
+ 10
+ 6.6
+ 3.3
+ 1.6
234
204
174
145
132
454
401
349
296
270
493
493
493
493
493
0 118 243 451
- 1.6
- 3.3
- 6.6
- 10
- 13
105
92
63
33
-
217
191
138
86
33
405
359
266
174
82
D2989
(B)

10
GAS PRESSURE
The adjacent tables show minimum pressure losses
along the gas supply line depending on the maximum
burner output.
Column 1
Pressure loss at combustion head.
Gas pressure measured at test point 1)(B), with:
• Combustion chamber at 0”WC
• Burner operating at maximum output
• Natural gas
Column 2
Pressure loss at butterfly valve.
Calculate the approximate high fire output of the burner
as follows:
- subtract the combustion chamber pressure from the
gas pressure measured at test point 1)(B).
- Find the nearest pressure value to your result in col-
umn 1 of the table for the burner in question.
- Read off the corresponding output on the left.
Example - RLS 100/E
• Maximum output operation
• Natural gas
• Gas pressure at test point 1)(B) = 4.41” WC
• Pressure in combustion chamber = 0.79” WC
4.41 - 0.79 = 3.62” WC
A maximum output of 3616 MBtu/hr shown inTable RLS
100 corresponds to 3.62” WC pressure, column 1, natu-
ral gas.
This value serves as a rough guide, the effective deliv-
ery must be measured at the gas meter.
To calculate the required gas pressure at test point
1)(B), set the maximum output required from the burner:
- find the nearest output value in the table for the burner
in question.
- Read off the pressure at test point 1)(B) on the right in
column 1.
- Add this value to the estimated pressure in the com-
bustion chamber.
Example - RLS 100/E
• Maximum required burner output: 3616 MBtu/hr
• Natural gas
• Gas pressure at burner output of 3616 MBtu/hr, taken
from table RLS 100, column 1, natural gas = 3.62” WC
• Pressure in combustion chamber = 0.79” WC
3.62 + 0.79 = 4.41”WC
pressure required at test point 1)(B).
(A)
(B)
RLS 70/E ∆p (“ WC)
RLS 100/E ∆p (“ WC)
RLS 130/E ∆p (“ WC)
MBtu/hr 1 2
1750 2.17 0.08
1950 2.20 0.08
2140 2.24 0.12
2329 2.28 0.12
2519 2.32 0.12
2708 2.36 0.16
2897 2.40 0.16
3094 2.44 0.16
MBtu/hr 1 2
2646 3.15 0.16
2878 3.27 0.16
3125 3.39 0.20
3371 3.50 0.20
3616 3.62 0.24
3863 3.70 0.28
4109 3.82 0.31
4396 3.94 0.31
MBtu/hr 1 2
3500 3.66 0.39
3825 3.74 0.43
4128 3.82 0.51
4431 3.90 0.59
4734 4.09 0.67
5037 4.29 0.71
D2990
1
2

11
GAS LINE
• The main gas train must be connected to the gas
attachment 1)(A), using flange 2), gasket 3) and
screws 4) supplied with the burner.
• The main gas train can enter the burner from the
right or left side, see fig. (A).
• Gas safety shut-off valves 5)-6)(B) must be as close
as possible to the burner to ensure gas reaches the
combustion head within the safety time range.
• The pilot gas train must be connected to the gas
attachment 5)(A) and can enter the burner from the
right or left side.
GASTRAIN (B)
It must be type-approved according to required Stand-
ards and is supplied separately from the burner.
Note
See the accompanying instructions for the gas train lay
out.
KEYTO LAYOUT (B)
1 - Gas input pipe
2 - Manual valve
3 - Pressure regulator
4 - Low gas pressure switch
5 - 1st safety shut off valve
6 - 2nd safety shut off valve
7 - Standard issue burner gasket with flange
8 - Gas butterfly valve
9 - Burner
(A)
(B)
D2310
D2311
TYPICAL UL SCHEMATIC GAS PIPING
GAS PILOT LINE
MAIN GAS LINE

12
ADJUSTMENTS BEFORE FIRST FIRING
Adjustment of the combustion head has been illustrated
on page 7.
In addition, the following adjustments must also be
made:
- Open manual valves up-stream from the gas train.
- Adjust the low gas pressure switch to the start of the
scale (A).
- Adjust the high gas pressure switch to the upper limit
of the scale (B).
- Adjust the air pressure switch to the zero position of
the scale (C).
- Purge the air from the gas line.
- Fit a U-type manometer (D) to the gas pressure test
point on the sleeve.
The manometer readings are used to calculate MAX.
burner power using the tables on page 10.
Before starting up the burner it is good practice to adjust
the gas train so that ignition takes place in conditions of
maximum safety, i.e. with gas delivery at the minimum.
(A)
(D)
LOW GAS PRESSURE SWITCH AIR PRESSURE SWITCH HIGH GAS PRESSURE SWITCH
(B) (C)
D2991

13
AIR PRESSURE SWITCH (A)
Adjust the air pressure switch after having performed all
other burner adjustments with the air pressure switch set
to the start of the scale (A).
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.
Attention:
as a rule, the air pressure switch must prevent the forma-
tion of CO.
To check this, insert a combustion analyser into the
chimney, slowly close the fan suction inlet (for example
with cardboard) and check that the burner locks out,
before the CO in the fumes exceeds 400 ppm.
The air pressure switch may operate in "differential"
operation in two pipe system. If a negative pressure in
the combustion chamber during pre-purging prevents
the air pressure switch from switching, switching may be
obtained by fitting a second pipe between the air pres-
sure switch and the suction inlet of the fan. In such a
manner the air pressure switch operates as differential
pressure switch.
HIGH GAS PRESSURE SWITCH (B)
Adjust the high gas pressure switch after having per-
formed all other burner adjustments with the maximum
gas pressure switch set to the end of the scale (B).
With the burner operating at MAX output, reduce the
adjustment pressure by slowly turning the adjustment
dial anticlockwise until the burner locks out.
Then turn the dial clockwise by 0.8” WC and repeat
burner firing.
If the burner locks out again, turn the dial again clock-
wise by 0.4”WC.
LOW GAS PRESSURE SWITCH (C)
Adjust the low gas pressure switch after having per-
formedall the otherburner adjustments withthe pressure
switch set at the start of the scale (C).
With the burner operating at MAX output, increase ad-
justment pressure by slowly turning the relative dial
clockwise until the burner locks out.
Then turn the dial anti-clockwise by 0.8” WC and repeat
burner starting to ensure it is uniform.
If the burner locks out again, turn the dial anti-clockwise
again by 0.4”WC.
(A)
(B)
AIR PRESSURE SWITCH
(C)
HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH
D2548
D2547
D2547

14
MAINTENANCE
Combustion
The optimum calibration of the burner requires an analy-
sis of the flue gases. Significant differences with respect
to the previous measurements indicate the points where
more care should be exercised during maintenance.
Gas leaks
Make sure that there are no gas leaks on the pipework
between the gas meter and the burner.
Flame inspection window
Clean the flame inspection window (A).
Combustion head
Open the burner and make sure that all components of
the combustion head are in good condition, not
deformed by the high temperatures, free of impurities
from the surroundings and correctly positioned. If in
doubt, disassemble the elbow fitting 7)(C).
Nozzles (fuel oil)
Do not clean the nozzle orifices. The nozzle filters how-
ever may be cleaned or replaced as required.
Replace the nozzles every 2-3 years or whenever nec-
essary. Combustion must be checked after the nozzles
have been changed.
UV scanner
Clean the glass cover from any dust that may have
accumulated. The scanner 1)(B) is held in position by a
pressure fit and can therefore be removed by pulling it
outward forcefully.
Flexible hoses (fuel oil)
Check to make sure that the flexible hoses are still in
good condition and that they are not crushed or other-
wise deformed.
Burner
Check for excess wear or loose screws. Also make sure
that the screws securing the electrical leads in the
burner connections are fully tightened.
Clean the outside of the burner.
Combustion
Adjust the burner if the combustion values found at the
beginning of the operation do not comply with the regu-
lations in force, or at any rate, do not correspond to good
combustion.
TO OPENTHE BURNER (C):
- Switch off the electrical power
- Loosen screws 1) and withdraw the cover 2)
- Disengage the swivel coupling 7) from the graduated
sector.
- Disconnect the light-oil pipes.
- Remove screws 3) and pull the burner back by about
4” on the slide bars. Disconnect the electrode leads
and then pull the burner fully back.
Now extract the internal part 5) after having removed the
screw 6).
TO CLOSETHE BURNER (C):
- Push the burner until it is about 4” from the sleeve.
- Re-connect the leads and slide in the burner until it
comes to a stop.
- Refit screws 3) and pull the leads gently out until they
are slightly stretched.
- Re-couple the swivel coupling 7) to the graduated sec-
tor.
- Reconnect the light-oil pipes.
FLAME SIGNAL MEASUREMENT
Min value for a good signal: 70 µA.
If the value is lower, it can be due to:
• Worn scanner;
• 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, with a capacitor of 100 µF - 1V c.c. at the same
level of the instrument. See fig. (A).
(A)
(B)
(C)
FLAME INSPECTION WINDOW
D484
UV SCANNER
OPENING THE BURNER
D2992
D2993
1
(D) D1143

15
OIL HYDRAULIC SYSTEM LAYOUT (A)
1 Pump suction
2 Filter
3 Pump
4 Pressure regulator
5 Return pipe
6 By-pass screw
7 Pump return
8 Safety solenoid
9 Low fire valve
10 High fire valve
11 Filter
M Pressure gauge
P low oil pressure switch
V Vacuum gauge
OIL PRESSURE SWITCH
The oil pressure switch 22)(A) page 4 is factory set to
145 PSI (10 bar). If the oil pressure goes down to this
value, the pressure switch stops the burner.
(A) D2592

16
Factory Wiring Diagram RLS 70 - 100 - 130/E
Layout of electric panel board
1
2
4
5
CONTENTS
References layout
Functional diagram
Functional diagram
3Functional diagram
2References layout
N. Page
/1.A1
Coordinates
Key to layouts
B7 - QRI detector
F1 - Fan motor thermal overload
F2 - Pump motor thermal overload
K1 - Fan motor contactor
K2 - Pump motor contactor
M1 - Fan motor
M2 - Pump motor
SM1 - Servomotor
SM2 - Servomotor
S10 - Air pressure switch
S12 - Maximum gas pressure switch
S14 - Minimum oil pressure switch
T1 - Gas ignition transformer
T2 - Oil ignition transformer
T8 - Burner ground
XMB - Burner terminal strip
XQ - 32-pin plug
Y20 - Safety valve
Y21 - 1st stage oil valve
Y22 - 2nd stage oil valve
NOTES
• The setting of the thermal overload must be according to the total
burner amperage draw.
• The RLS 70-100-130/E burners leave the factory preset for 208-
230 V power supply. If 460 V power supply is used, change the
fan motor connection from delta to star and change the setting of
the thermal overload as well.
For the installation, electrical connections, start-up and set-
ting of the LMV51... electronic cam, see the instructions
supplied with the control panel.

17

18

19

20
The FIRING RATE area values have been obtained considering a surround-
ing temperature of 68°F (20°C), and an atmospheric pressure of 398” W.C.
and with the combustion head adjusted as shown on page 7.
The burner may be required to operate with combustion air at a higher tem-
perature and/or at higher altitudes.
Heating of air and increase in altitude produce the same effect: the expan-
sion of the air volume, i.e. the reduction of air density.
The burner fan's delivery remains substantially the same, but the oxygen
content per cubic meter and the fan's head are reduced.
It is therefore important to know if the maximum output required of the burner
at a given combustion chamber pressure remains within the burner's firing rate range even at different temperature and altitude con-
ditions. Proceed as follows to check the above:
1-Find the correction factor F in the Table (A) for the plant's air temperature and altitude.
2-Divide the burner's delivery Q by F in order to obtain the equivalent delivery Qe:
3-In the firing rate range of the burner, Fig. (B), indicate the work point defined by:
Qe = equivalent delivery
H1 = combustion chamber pressure
The resulting point A must remain within the firing rate range.
4-Plot a vertical line from Point A as shown in Figure (B) and find the maximum pressure H2 of the firing rate.
5-Multiply H2 by F to obtain the maximum reduced pressure H3 of the firing rate.
If H3 is greater than H1, as shown in Fig. (B), the burner delivers the output required.
If H3 is lower than H1, the burner's delivery must be reduced. A reduction in delivery is accompanied by a reduction of the pressure in
the combustion chamber:
Qr = reduced delivery
H1r = reduced pressure
Example, a 5% delivery reduction:
Qr = Q x 0.95
H1r = H1 x (0.95)2
Steps 2 - 5 must now be repeated using the new Qr and H1r values.
Important: the combustion head must be adjusted in respect to the equivalent delivery Qe.
Qe = Q : F (MBtu/hr)
H3= H2x F (“ W.C.)
Qe MBTU/h
A
H2
H1
H3
“W.C.
(B)
D2617
APPENDIX
- Burner firing rates according to air density
above sea level average barom.
pressure
CORRECTION FACTOR F
Air temperature
°F (°C)
ft m “ W.C. mbar 0 (0°C) 41 (5°C) 50 (10°C) 59 (15°C) 68 (20°C) 77 (25°C) 86 (30°C) 104 (40°F)
0
329
658
987
1316
1645
1974
2303
2632
2961
3290
3947
4605
5263
5921
6579
0
100
200
300
400
500
600
700
800
900
1000
1200
1400
1600
1800
2000
399
394
389
385
380
376
372
367
363
358
354
346
337
329
321
313
1013
1000
989
978
966
955
944
932
921
910
898
878
856
836
815
794
1,087
1,073
1,061
1,050
1,037
1,025
1,013
1,000
0,988
0,977
0,964
0,942
0,919
0,897
0,875
0,852
1,068
1,054
1,042
1,031
1,018
1,007
0,995
0,982
0,971
0,959
0,946
0,925
0,902
0,881
0,859
0,837
1,049
1,035
1,024
1,013
1,000
0,989
0,977
0,965
0,954
0,942
0,930
0,909
0,886
0,866
0,844
0,822
1,031
1,017
1,006
0,995
0,983
0,972
0,960
0,948
0,937
0,926
0,914
0,893
0,871
0,851
0,829
0,808
1,013
1,000
0,989
0,978
0,966
0,955
0,944
0,932
0,921
0,910
0,898
0,878
0,856
0,836
0,815
0,794
0,996
0,983
0,972
0,962
0,950
0,939
0,928
0,916
0,906
0,895
0,883
0,863
0,842
0,822
0,801
0,781
0,980
0,967
0,956
0,946
0,934
0,923
0,913
0,901
0,891
0,880
0,868
0,849
0,828
0,808
0,788
0,768
0,948
0,936
0,926
0,916
0,904
0,894
0,884
0,872
0,862
0,852
0,841
0,822
0,801
0,783
0,763
0,743
(A)
H1r = H1x ()
Qr
Q2