Riello RL 190 Instruction Manual

20044168 (1) - 03/2012
Installation, use and maintenance instructions
安装、使用及维护手册
Light oil burners
轻油燃烧器
Two-stage operation
两段火运行
CODE-编码 MODEL-型号 TYPE-类型
20042310 RL 190 673 T1
GB
CN

1 20044168
GB
Contents
1 Declarations................................................................................................................................................................................ 2
2 Information and general instructions....................................................................................................................................... 3
2.1 Information about the instruction manual ..................................................................................................................................................3
2.1.1 General dangers........................................................................................................................................................................................3
2.1.2 Danger: live components...........................................................................................................................................................................3
2.2 Guarantee and responsibility.....................................................................................................................................................................4
3 Safety and prevention................................................................................................................................................................ 5
3.1 Introduction................................................................................................................................................................................................5
3.2 Personnel training .....................................................................................................................................................................................5
4 Technical description of the burner ......................................................................................................................................... 6
4.1 Technical data...........................................................................................................................................................................................6
4.1.1 Accessories (optional):..............................................................................................................................................................................6
4.1.2 Variants .....................................................................................................................................................................................................6
4.2 Burner description .....................................................................................................................................................................................7
4.2.1 Weight - approximate measurements .......................................................................................................................................................7
4.2.2 Max. dimensions - approximate measurements........................................................................................................................................8
4.2.3 Standard equipment..................................................................................................................................................................................8
4.3 Firing rates ................................................................................................................................................................................................8
4.3.1 Test boiler..................................................................................................................................................................................................8
5 Installation .................................................................................................................................................................................. 9
5.1 Handling....................................................................................................................................................................................................9
5.2 Preliminary checks ....................................................................................................................................................................................9
5.3 Boiler plate ..............................................................................................................................................................................................10
5.4 Blast tube length......................................................................................................................................................................................10
5.5 Securing the burner to the boiler.............................................................................................................................................................10
5.6 Choice of nozzles for 1st and 2nd stage .................................................................................................................................................11
5.7 Nozzle assembly .....................................................................................................................................................................................11
5.8 Combustion head setting.........................................................................................................................................................................12
6 Electrical system...................................................................................................................................................................... 13
6.1 Electrical system (factory set) .................................................................................................................................................................14
6.1.1 Electrical connections..............................................................................................................................................................................14
7 Hydraulic system...................................................................................................................................................................... 16
7.1 Fuel supply..............................................................................................................................................................................................16
7.2 Hydraulic connections.............................................................................................................................................................................17
7.3 Pump.......................................................................................................................................................................................................17
7.3.1 Pump priming ..........................................................................................................................................................................................17
8 Burner calibration .................................................................................................................................................................... 18
8.1 Firing .......................................................................................................................................................................................................18
8.2 Operation.................................................................................................................................................................................................18
8.2.1 Burner starting.........................................................................................................................................................................................19
8.2.2 Steady state operation ............................................................................................................................................................................20
8.2.3 Firing failure.............................................................................................................................................................................................20
8.2.4 Undesired shutdown during operation.....................................................................................................................................................20
8.2.5 Final checks ............................................................................................................................................................................................20
9 Maintenance.............................................................................................................................................................................. 21
9.1 Burner start-up cycle diagnostics ............................................................................................................................................................23
9.2 Resetting the control box and using diagnostics.....................................................................................................................................23
9.3 Resetting the control box.........................................................................................................................................................................23
9.4 Visual diagnostics....................................................................................................................................................................................23
9.5 Software diagnostics ...............................................................................................................................................................................24
10 STATUS (optional).................................................................................................................................................................... 26
10.1 Assembly.................................................................................................................................................................................................26
10.2 The STATUS unit has three functions:....................................................................................................................................................26
10.2.1 Key to symbols (STATUS) ......................................................................................................................................................................27

20044168 2
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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: Light oil burners
Model: RL 190
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
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
Light oil burner 673 T1 RL 190 759 - 2443 kW
Legnago, 15.03.2010 Mr. G. Conticini
Burners Division Department
RIELLO S.p.A.

3 20044168
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Information and general instructions
2.1 Information about the instruction manual
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 Assist-
ance Service 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.
2.1.1 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.2 Danger: live components
Other symbols
This symbol indicates a list.
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 Assist-
ance Centre;
The system supplier carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the sys-
tem is started up,
- maintenance and the need to have the system checked
at least once a year by the manufacturer or another spe-
cialised technician.
To ensure a periodic check, recommends 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.

20044168 4
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Information and general instructions
2.2 Guarantee and responsibility
guarantees its new products from the installation date, in
accordance with the regulations in force and/or the sales con-
tract. 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 irregu-
larity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the flame, as structur-
ally 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.
furthermore declines any and every responsibility
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 of
the guarantee that it supplies with the burner.

5 20044168
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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 tech-
nical rules of safety and envisaging all the potential danger situ-
ations.
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
dangerous.
In particular:
it can be applied to boilers operating with water, steam, dia-
thermic oil, and to other users expressly named by the man-
ufacturer;
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 chamber and the room temperature must
all be within the values indicated 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

20044168 6
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Technical description of the burner
4.1 Technical data
(1) Reference conditions: Ambient temperature 20 °C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.
(2) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated
output.
4.1.1 Accessories (optional):
•STATUS (see pag. 26): code 3010322
•RADIO DISTURBANCEPROTECTION KIT
If the burner is installed in places particularly subject to
radio disturbance (emission of signals exceeding 10 V/m)
owing to the presence of an INVERTER, or in applications
where the length of the thermostat connections exceeds 20
metres, a protection kit is available as an interface between
the control box and the burner.
4.1.2 Variants
4 Technical description of the burner
MODEL RL 190
CODE 20042310
OUTPUT (1)
DELIVERY (1)
2nd stage kW
Mcal/h
kg/h
1423 - 2443
1224 - 2100
120 - 206
1st stage kW
Mcal/h
kg/h
759 - 1423
653 - 1224
64 - 120
FUEL LIGHT OIL
- Net calorific value kWh/kg
Mcal/kg 11,8 10,2 (10.200 kcal/kg)
- Density kg/dm30,82 - 0,85
- Viscosity at 20 °C mm2/s max 6 (1,5 °E - 6 cSt)
OPERATION Intermittent (min. 1 stop in 24 hours).
Two-stage (high and low flame) and single-stage (all - nothing).
NOZZLES number 2
STANDARD APPLICATIONS Boilers: water, steam, diathermic oil
AMBIENT TEMPERATURE °C 0 - 40
COMBUSTION AIR TEMPERATURE °C max 60
POWER SUPPLY V
Hz 400 with neutral ~ +/- 10% 50 - three-phase
ELECTRICAL MOTOR rpm
W
V
2800
4500
400
Operating current A9,1
Acceleration current A72,8
IGNITION TRASFORMER V1 - V2
I1 - I2 230 V - 2 x 5 kV 1,9 A - 35 mA
Control box RMO88.53A2
PUMP J7C delivery (at 12 bar)
pressure range
fuel temperature
kg/h
bar
°C max
230
10 - 21
90
ELECTRICAL POWER CONSUMPTION W max 5870
ELECTRICAL PROTECTION IP 44
NOISE LEVELS (2) dBA 83,9
BURNER RL 190
Code 3010386
Model Code Power supply
electrical
RL 190 20042310 400 V

7 20044168
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Technical description of the burner
4.2 Burner description
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Screw for fixing fan to flange
5Pump
6 Hydraulic cylinder for regulation of the air gate valve in 1st
and 2nd stage positions. When the burner is not operating
the air gate valve is fully closed in order to reduce heat dis-
persion from the boiler due to the flue draught which draws
air from the fan suction inlet.
7 Air inlet to fan
8Airgatevalves
9 Fan pressure test point
10 Boiler mounting flange
11 Flame stability disk
12 Slide bars for opening the burner and inspecting the com-
bustion head
13 Extensions for slide bars 12)
14 Electrical motor
15 Ignition transformer
16 Motor contactor and thermal cut-out with reset button
17 1st stage valve
18 Terminal strip
19 Two switches:
- one "burner off - on"
- one for "1st - 2nd stage operation"
20 Fairleads for wiring carried out by the installer
21 Control box with lock-out pilot light and lock-out reset button
22 Flame inspection window
23 Photoresistor for flame presence control
24 2nd stage valve
25 Safety solenoid valve
Two types of burner failure may occur:
Control box lock-out: if the control box 22)(Fig. 1) pushbutton
(red led) lights up, it indicates that the burner is in lock-out.
To reset, hold the pushbutton down for between 1 and 3 seconds.
Motor trip: release by pressing the pushbutton on thermal cut-
out 17)(Fig. 1).
Tab. A
4.2.1 Weight - approximate measurements
• The weight of the burner complete with its packaging is
shown in table (Tab. A)
Fig. 1
D3930
kg
RL 190 75

20044168 8
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Technical description of the burner
4.2.2 Max. dimensions -
approximate measurements The maximum dimensions of the burner are given in (Fig. 2).
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the guides.
The dimensions of the open burner are indicated by position I.
4.2.3 Standard equipment
2 - Flexible hoses (L = 1350 mm)
2 - Gaskets for flexible hoses
2 - Nipples for flexible hoses
1 - Thermal insulation screen
4 - Extensions 13)(Fig. 1) for slide bars 12)(Fig. 1)
4 - Screws to secure the burner flange to the boiler: M 16 x 40
1 - Instruction booklet
1 - Spare parts list
4.3 Firing rates
The RL 190 Model burners can work in two ways: one-stage and
two-stage.
1st stage DELIVERY must be selected within area A of the ad-
jacent diagrams.
2nd stage DELIVERY must be selected within area B. This area
provides the maximum delivery of the burner in relation to the
pressure in the combustion chamber.
4.3.1 Test boiler
The firing rates were set in relation to special test boilers in ac-
cordance with the methods defined in EN 267 standards.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example:
delivery 65 kg/hour:
diameter = 60 cm; length = 2 m.
Whenever the burner is operated in a much smaller commercial-
ly-available combustion chamber, a preliminary test should be
performed.
Fig. 2
D1217
mm A BCDEFGH I
RL 190 756 366 390 555 712 370 222 430 1166
combustionchamberpressure
Fig. 3
D1246
WARNING
The FIRING RATE area values have been ob-
tained considering a surrounding temperature of
20 °C, and an atmospheric pressure of 1000 mbar
(approx. 100 m above sea level) and with the
combustion head adjusted as shown on pag. 12.
D688 Fig. 4
combustion chamber pressure mbar

9 20044168
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Installation
Notes on safety for the installation
After carefully cleaning all around the area where the burner will be installed, and arranging the correct lighting of the environment,
proceed with the installation operations.
5.1 Handling
The packaging of the burner includes a wooden platform, so it is possible to move the burner (still packaged) with a transpallet truck
or fork lift truck.
5.2 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model (see A in Fig. 5) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the electrical input power (E);
the types of fuel used and the relative supply pressures (F);
the data of the burner’s minimum and maximum output pos-
sibilities (G) (see Firing rate)
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
WARNING
The handling operations for the burner can be highly dangerous if not carried out with the greatest attention: keep any
unauthorised people at a distance; check the integrity and suitableness of the available means of handling.
Check also that the area in which you are working is empty and that there is an adequate escape area (i.e. a free, safe
area to which you can quickly move if the burner should fall).
During the handling, keep the load at not more than 20-25 cm from the ground.
CAUTION
After positioning the burner near the installation point, correctly dispose of all residual packaging, separating the various
types of material.
Before proceeding with the installation operations, carefully clean all around the area where the burner will be installed.
CAUTION
After removing all the packaging, check the integrity of the contents. In the event of doubt, do not use the burner; con-
tact the supplier.
The packaging elements (wooden cage or cardboard box, nails, clips, plastic bags, etc.) must not be abandoned as
they are potential sources of danger and pollution; they should be collected and disposed of in the appropriate places.
D8965
RIELLO S.p.A.
I−37045 Legnago (VR) 0036
A
BC
DE
G
F
Fig. 5
WARNING
The output of the burner must be within the boil-
er’s firing rate;
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.

20044168 10
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Installation
5.3 Boiler plate
Drill the combustion chamber locking plate as shown in (Fig. 6).
The position of the threaded holes can be marked using the ther-
mal screen supplied with the burner.
5.4 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its refractory. The length available, L (mm), is 370 mm.
For boilers with front flue passes 12) or flame inversion cham-
bers, protective fettling in refractory material 10) must be inserted
between the boiler’s fettling 11) and the blast tube 9).
This protection must not compromise the extraction of the blast
tube.
For boilers having a water-cooled front the refractory fettling 10)-
11) (Fig. 7) is not required unless it is expressly requested by the
boiler manufacturer.
5.5 Securing the burner to the boiler
Disassemble the blast tube 9) from the burner 6) by proceeding
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) (Fig. 7) to the boiler plate interposing the sup-
plied gasket 8) (Fig. 7). Use the 4 screws provided after having
protected the thread with antiscruffing products.
The burner-boiler seal must be airtight.
D455 Fig. 6
mm A B C
RL 190 230 325-368 M 16
Fig. 7
D1247

11 20044168
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Installation
5.6 Choice of nozzles for 1st and 2nd stage
Both nozzles must be chosen from among those listed in table
(Tab. B).
The first nozzle determines the delivery of the burner in the 1st
stage.
The second nozzle works together with the 1st nozzle to deter-
mine the delivery of the burner in the 2nd stage.
The deliveries of the 1st and 2nd stages must be contained within
the value range indicated on pag. 6.
Use nozzles with a 60° spray angle at the recommended pres-
sure of 12 bar.
As a rule the two nozzles have equal deliveries but the 1st stage
nozzle may have a delivery less than 50% of the total delivery
when a reduction of the counter-pressure peak is desired at the
moment of starting (the burner allows good combustion rates
also with a 40 - 100 % ratio between the 1st and 2nd stage).
Example
Boiler output = 1630 kW - efficiency 90 %
Output required by the burner =
1630 : 0,9 = 1812 kW;
1812 : 2 = 906 kW per nozzle;
therefore, two equal, 60°, 12 bar nozzles are required:
1° = 18 GPH - 2° = 18 GPH,
or the following two different nozzles:
1° = 16 GPH - 2° = 20 GPH.
Tab. B
(1) light oil: density 0.84 kg/dm3- viscosity 4.2 cSt/20 °C - tem-
perature 10 °C
5.7 Nozzle assembly
At this stage of installation the burner is still disassembled from
the blast tube; it is therefore possible to fit the nozzle with the box
spanner 1) (Fig. 8) (16 mm), after having removed the plastic
plugs 2) (Fig. 8), fitting the spanner through the central hole in the
flame stability disk. Do not use any sealing products such as gas-
kets, sealing compound, or tape. Be careful to avoid damaging
the nozzle sealing seat. The nozzles must be screwed into place
tightly but not to the maximum torque value provided by the
wrench.
The nozzle for the 1st stage of operation is the one lying beneath
the firing electrodes (Fig. 9)
Make sure that the electrodes are positioned as shown in (Fig. 9)
Finally refit the burner 3) (Fig. 10) to 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:
– Retract the burner on its slide bars as shown in (Fig. 7
pag. 10).
– Remove the nuts 1) (Fig. 11) and the disk 2).
– Use spanner 3) (Fig. 11) to change the nozzles.
GPH kg/h (1) kW
12 bar
10 bar 12 bar 14 bar
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.30
8.50
9.00
9.50
10.0
10.5
11.0
12.0
12.3
13.0
13.8
14.0
15.0
15.3
16.0
17.0
17.5
18.0
19.0
19.5
20.0
21.5
22.0
19.2
21.1
23.1
25.0
26.9
28.8
30.8
31.9
32.7
34.6
36.5
38.4
40.4
42.3
46.1
47.3
50.0
53.1
53.8
57.7
58.8
61.5
65.4
67.3
69.2
73.0
75
76.9
82.7
84.6
21.2
23.3
25.5
27.6
29.7
31.8
33.9
35.2
36.1
38.2
40.3
42.4
44.6
46.7
50.9
52.2
55.1
58.5
59.4
63.6
64.9
67.9
72.1
74.2
76.4
80.6
82.7
84.8
91.2
93.3
23.1
25.4
27.7
30.0
32.3
34.6
36.9
38.3
39.2
41.5
43.8
46.1
48.4
50.7
55.3
56.7
59.9
63.3
64.5
69.2
70.5
73.8
78.4
80.7
83.0
87.6
89.9
92.2
99.1
101.4
251.4
276.3
302.4
327.3
352.3
377.2
402.1
417.5
428.2
453.1
478.0
502.9
529.0
553.9
603.7
619.1
653.5
693.8
704.5
754.3
769.7
805.3
855.1
880.0
906.1
956.0
980.9
1005.8
1081.7
1106.6
D691 Fig. 8

20044168 12
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Installation
5.8 Combustion head setting
The setting of the combustion head depends exclusively on the
burner delivery in the 2nd stage - in other words, the combined
delivery of the two nozzles selected in table (Tab. A).
Turn screw 4) (Fig. 12) until the notch shown in diagram (Fig. 13)
is level with the front surface of flange 5) (Fig. 10, pag. 12).
Example:
The RL 190 Model with two 18 GPH nozzles and 12 bar pump
pressure.
Find the delivery of the two 18 GPH nozzles in (Tab. A, pag. 7):
76.4 + 76.4 = 152,8 kg/h.
Diagram (Fig. 13) indicates that for a delivery of 152,8 kg/h the
RL 190 Model requires the combustion head to be set to approx.
three notches, as shown in (Fig. 12).
Fig. 9
D692
Fig. 10
D1248
Fig. 11
D694
Fig. 12
D462
Fig. 13
Notches no.
Light oil delivery in 2nd stage kg/h
D1250

13 20044168
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Electrical system
6 Electrical system
Notes on safety for the electrical wiring
DANGER
The electrical wiring must be carried out with the electrical supply disconnected.
Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in
force in the country of destination. Refer to the wiring diagrams.
declines all responsibility for modifications or connections different from those shown in the electrical
layouts.
Do not invert the neutral with the phase in the electrical supply line. Any inversion would cause a lockout due to
firing failure.
The RL 190 burners have been type-approved for intermittent operation. This means they should compulsorily
be stopped at least once every 24 hours to enable the control box to perform checks of its own start-up effi-
ciency. Normally the boiler’s thermostat/pressure switch ensures the stopping of the burner.
If this is not the case, it is necessary to apply in series with IN a timer switch that turns off the burner at least once
every twenty-four hours. Refer to the wiring diagrams.
The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement. In the event
of doubt, have the electrical system checked by qualified personnel.
The electrical system must be suitable for the maximum input power of the device, as indicated on the label and
in the manual, checking in particular that the section of the cables is suitable for the input power of the device.
For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use an omnipolar switch with an opening of at least 3 mm (overvoltage category) between the contacts, as
indicated by the current safety standards.
Do not touch the device with wet or damp body parts and/or in bare feet.
Do not pull the electric cables.

20044168 14
GB
Electrical system
6.1 Electrical system (factory set)
Key to wiring diagram (Fig. 14)
CMV - Motor contactor
FR - Photoresistor
I1 - Switch: burner off - on
I2 - Switch: 1st - 2nd stage operation
MB - Terminal strip
MV - Fan motor
RMO88.53A2 - Control box
RT - Thermal cut-out
TA - Ignition transformer
TB - Burner ground (earth) connection
V1 - 1st stage solenoid valve
V2 - 2nd stage solenoid valve
VS - Safety solenoid valve
XP1 - Connector for STATUS
NOTE:
For remote-reset, connect a push-button switch (NO) be-
tween terminal 3 and neutral of the control box (terminals 15,
16, 17 and 18).
6.1.1 Electrical connections
Set up by the installer
Use flexible cables according to regulation EN 60 335-1:
if in PVC boot, use at least H05 VV-F
if in rubber boot, use at least H05 RR-F.
All the cables to be connected to the burner terminal strip
8)(Fig. 15) must be routed through the fairleads.
The fairleads and precut holes can be used in various ways. One
example is given below:
1 Pg 13,5 Three-phase power supply
2 Pg 11 Single-phase power supply
3 Pg 11 Control device TL
4 Pg 9 Control device TR
5 Pg 9 Set up for faird lead
6 Pg 11 Set up for faird lead
7 Pg 13,5 Set up for faird lead
Fig. 14
D3229
Fig. 15
D3312

15 20044168
GB
Electrical system
RL 190 Models electrical connection three-phase 230/400 V power supply with neutral phase wire.
Fuses and cables section layout, see table (Fig. 16).
Cable section not indicated: 1.5 mm2.
Key to wiring diagram (Fig. 16)
H1 - 1st stage hourcounter
H2 - 2nd stage hourcounter
IN - Manual burner stop switch
MB - Terminal strip
S - Remote lock-out signal
TB - Burner ground (earth) connection
TL - Limit control device system: this shuts down the burner
when the boiler temperature or pressure exceeds the set-
point value.
TR - High-low mode control device system: this controls oper-
ating stages 1 and 2 and is necessary only for two-stage
operation.
TS - Safety control device system: this operates when TL is
faulty.
Alternatively, if single stage operation is required, instead of con-
trol device TR install a jumper lead between terminal 5 and 6 of
the terminal strip.
NOTE:
The RL 190 burner has been type- approved for intermittent
operation. This means they should compulsorily be stopped
at least once every 24 hours to enable the control box to per-
form checks of its own efficiency at start-up. Burner halts
are normally provided for automatically by the boiler load
control system.
If this is not the case, it is necessary to apply in series with
IN a timer switch that turns off the burner at least once every
twenty-four hours.
Fig. 16
S8544
RL 190
400 V
FAT25
Lmm22.5
WARNING
The burner is factory set for two-stage operation
and the TR remote control device that commands
light oil valve V2 must therefore be connected.
Model Thermal relay adjustment
RL 190 - 400 V 9,5 A
WARNING
Do not invert the neutral with the phase in the
electrical supply line.

20044168 16
GB
Hydraulic system
7.1 Fuel supply
Double-pipe circuit (Fig. 17)
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
The distance "P" must not exceed 10 meters in order to avoid
subjecting the pump’s seal to excessive strain; the distance "V"
must not exceed 4 meters in order to permit pump self-priming
even when the tank is almost completely empty.
The tank lower than the burner B
Pump depression of 0.45 bar (35 cm 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 proba-
ble that the suction line fails to prime or stops priming.
The loop circuit
A loop circuit consists of a loop of piping departing from and re-
turning to the tank with an auxiliary pump that circulates the fuel
under pressure. A branch connection from the loop goes to feed
the burner. This circuit is extremely useful whenever the burner
pump does not succeed in self-priming because the tank dis-
tance and/or height difference are higher than the values listed in
the table.
Tab. C
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 = Rapid closing manual valve - remote controlled (only Italy)
8 = On/off solenoid valve (only Italy)
9 = Return line
10= Check valve (only Italy)
7 Hydraulic system
Fig. 17
D701
+ H
- H
(m)
L (m)
Ø (mm)
12 14 16
+ 4.0 71 138 150
+ 3.0 62 122 150
+ 2.0 53 106 150
+ 1.0 44 90 150
+ 0.5 40 82 150
0 36 74 137
- 0.5 32 66 123
- 1.0 28 58 109
- 2.0 19 42 81
- 3.0 10 26 53
- 4.0 - 10 25

17 20044168
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Hydraulic system
7.2 Hydraulic connections
The pumps are equipped with a by-pass that connects return line
with suction line. The pumps are installed on the burner with the
by-pass closed by screw 6) (Fig. 23 pag. 19).
It is therefore necessary to connect both hoses to the pump.
The pump will break down immediately if it is run with the return
line closed and the by-pass screw inserted.
Remove the plugs from the suction and return connections of the
pump.
Insert the hose connections with the supplied seals into the con-
nections and screw them down.
Take care that the hoses are not stretched or twisted during in-
stallation.
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 by using the supplied nipples.
7.3 Pump
1 - Suction G 1/2"
2 - Return G 1/2"
3 - Pressure gauge connection G 1/8"
4 - Vacuum meter connection G 1/8"
5 - Pressure adjustment screw
6 - Screw for by-pass
A - Min. delivery rate at 12 bar pressure
B - Delivery pressure range
C - Max. suction depression
D - Viscosity range
E - Light oil max. temperature
F - Max. suction and return pressure
G - Pressure calibration in the factory
H - Filter mesh width
7.3.1 Pump priming
– Before starting the burner, make sure that the tank return line
is not clogged. Obstructions in the line could cause the sealing
organ located on the pump shaft to break. (The pump leaves
the factory with the by-pass closed).
– In order for self-priming to take place, one of the screw 3)
(Fig. 19) of the pump must be loosened in order to bleed off
the air contained in the suction line.
– Start the burner by closing the control devices and with switch
1) (Fig. 20 pag. 18) in the "ON" position. The pump must rotate
in the direction of the arrow marked on the cover.
– The pump can be considered to be primed when the light oil
starts coming out of the screw 3). Stop the burner: switch 1)
(Fig. 20 pag. 18) set to "OFF" and tighten the screw 3).
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 oper-
ation as often as required. After 5 or 6 starting operations allow 2
or 3 minutes for the transformer to cool.
Do not illuminate the photocell or the burner will lock out; the
burner should lock out anyway about 10 seconds after it starts.
Whenever the length of the suction piping exceeds 20-30 meters,
the supply line must be filled using a separate pump.
D1244
Fig. 18
Fig. 19
PUMP
SUNTEC J7 C
D1251
WARNING
The a.m. 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 on the vacuum meter prior to starting;
otherwise, the pump will seize.

20044168 18
GB
Burner calibration
8.1 Firing
Notes on safety for the first start-up
Set switch 1) (Fig. 20) to "ON".
During the first firing, during the passage from the 1st to the 2nd
stage, there is a momentary lowering of the fuel pressure caused
by the filling of the 2nd stage nozzle tubing. This lowering of the
fuel pressure can cause the burner to lock-out and can some-
times give rise to pulsations.
Once the following adjustments have been made, the firing of the
burner must generate a noise similar to the noise generated dur-
ing operation. If one or more pulsations or a delay in firing in re-
spect to the opening of the light oil solenoid valve occur, see the
suggestions provided on pag. 24: causes 34 ÷ 42
8.2 Operation
The optimum calibration of the burner requires an analysis of the
flue gases at the boiler outlet and interventions on the following
points:
1st and 2nd stage nozzles
See the information listed on pag. 11.
Combustion head
The adjustment of the combustion head already carried out need
not be altered unless the 2nd stage delivery of the burner is
changed.
Pump pressure
12 bar: this is the pressure calibrated in the factory which is usu-
ally sufficient for most purposes. Sometimes, this pressure must
be adjusted to:
10 bar: in order to reduce fuel delivery. This adjustment is possi-
ble only if the surrounding temperature remains above 0°C. Nev-
er calibrate to pressures below 10 bar, at which pressures the
cylinders may have difficulty in opening;
14 bar: order to increase fuel delivery or to ensure firings even at
temperatures of less than 0°C.
In order to adjust pump pressure, use the relevant screw 5)
(Fig. 19 pag. 17)
1st stage fan air gate valve
Keep the burner operating at 1st stage by setting the switch 2)
(Fig. 20) to the 1st stage position. Opening of the air gate valves
6) (Fig. 21) must be adjusted in proportion to the selected nozzle:
the index 8) (Fig. 21) must be aligned with the notch indicated on
the graduated sector 7) (Fig. 21).This adjustment is achieved by
turning the hex element 2) (Fig. 21):
– in rh direction (- sign) the opening is reduced;
– in lh direction (+ sign) the opening increases.
Tab. D
2st stage fan air gate valve
Set switch 2) (Fig. 20 pag. 18) to the 2nd stage position and ad-
just the air gate valve 6) (Fig. 21) by turning the hex element
4)(Fig. 21), after having loosened the ring nut 3) (Fig. 21).
NOTE:
in order to facilitate adjustment of hex elements 2) and 4)
(Fig. 21), use a 3 mm Allen key 5) (Fig. 21).
8 Burner calibration
WARNING
The first start-up of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
Burner
Fig. 20
12
D469
Off
On
Stage
1st
2nd
WARNING
Check the correct working of the adjustment, com-
mand and safety devices.
Fig. 21
D1252
J7 C
A
B
C
D
E
F
G
H
kg/h
bar
bar
cSt
°C
bar
bar
mm
230
10 - 21
0,45
2,8 - 200
90
1.5
12
0,170