Riello RL 190 Quick start guide

2916080 (11) - 10/2013
Installation, use and maintenance instructions
Instrucciones de instalación, uso y mantenimiento
Instruções para a instalação, uso e manutenção
Light oil burners
Quemadores de gasóleo
Queimador de gasóleo
Two stage operation
Funcionamiento a dos llamas
Funcionamento a duas chamas
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3475614 RL 190 673 T1
20011018 RL 190 673 T1
GB
E
P

1 6080
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Contents
1 Declarations................................................................................................................................................................................ 2
2 Information and general instructions....................................................................................................................................... 3
2.1 Information about the instruction manual.......................................................................................................................... 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
4.2 Electrical data ................................................................................................................................................................... 6
4.3 Burner description............................................................................................................................................................. 7
4.4 Firing rates ........................................................................................................................................................................ 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 Notes on safety for the electrical wiring .......................................................................................................................... 13
6.2 Calibration of thermal relay ............................................................................................................................................. 15
7 Hydraulic system...................................................................................................................................................................... 16
7.1 Fuel supply...................................................................................................................................................................... 16
7.2 Hydraulic connections..................................................................................................................................................... 17
7.3 Pump............................................................................................................................................................................... 17
8 Burner calibration .................................................................................................................................................................... 18
8.1 Firing ............................................................................................................................................................................... 18
8.2 Burner operation ............................................................................................................................................................. 19
8.3 Burner start-up cycle diagnostics.................................................................................................................................... 20
8.4 Resetting the control box and using diagnostics............................................................................................................. 21
8.5 Resetting the control box ................................................................................................................................................ 21
8.6 Visual diagnostics ........................................................................................................................................................... 21
8.7 Software diagnostics....................................................................................................................................................... 21
9 Maintenance.............................................................................................................................................................................. 22
9.1 Notes on safety for the maintenance .............................................................................................................................. 22
9.2 Maintenance programme ................................................................................................................................................ 22
9.3 Opening the burner ......................................................................................................................................................... 23
9.4 Closing the burner........................................................................................................................................................... 23
10 Faults - Possible causes - Solutions...................................................................................................................................... 24

6080 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
Such products are marked as follows:
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, 10.10.2012 Executive Director
RIELLO S.p.A. - Burner Department
Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. I. Zinna Mr. R. Cattaneo
CE-0440/B

3 6080
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Information and general instructions
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance
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.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
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
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE HOOD AND
ALL THE SAFETY AND PROTECTION DEVIC-
ES
This symbol signals the obligation to reassemble
the hood and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

6080 4
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Information and general instructions
2.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in 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 must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to peo-
ple, 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 unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregularity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and tear;
the use of non-original components, including spare parts,
kits, accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installation
and carrying out of non authorised modifications
will result in the annulment by the manufacturer of
the guarantee that it supplies with the burner.

5 6080
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly named by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
Undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
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;
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem 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 every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
the user must take all the measures neces-
sary to prevent unauthorised people gaining
access to the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation.
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this manual.

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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.
4.2 Electrical data
4 Technical description of the burner
MODEL RL 190
CODE 3475614 20011018
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
PUMP J7C delivery (at 12 bar)
pressure range
fuel temperature
kg/h
bar
°C max
230
10 - 21
90
NOISE LEVELS (2) dBA 83,9
CODE 3475614 20011018
POWER SUPPLY V
Hz
400 with neutral ~ +/- 10%
50 - three-phase
230 with neutral ~ +/- 10%
50 - three-phase
ELECTRICAL MOTOR IE2 rpm
W
V
2900
4500
400
2900
4500
230
Operating current A8,7 15
Acceleration current A81 141
IGNITION TRASFORMER V1 - V2
I1 - I2
230 V - 2 x 5 kV
1,9 A - 35 mA
ELECTRICAL POWER CONSUMPTION W max 5500
ELECTRICAL PROTECTION IP 44

7 6080
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Technical description of the burner
4.2.1 Accessories (optional):
•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.
4.2.2 Variants
4.3 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
26 Sockets for electrical connections
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
4.3.1 Weight - approximate measurements
• The weight of the burner complete with its packaging is
shown in table (Tab. A)
BURNER RL 190
Code 3010386
Model Code Power supply
electrical
RL 190 3475614 400 V
RL 190 20011018 230 V
D3929
Fig. 1
kg
RL 190 75

6080 8
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Technical description of the burner
4.3.2 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.
4.3.3 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
2 - Plugs for electrical connections
1 - Instruction booklet
1 - Spare parts list
4.4 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.
4.4.1 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
combustion chamber pressure
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 page 12.
D688 Fig. 4
combustion chamber pressure mbar

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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 vari-
ous 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
RI ELL O 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.

6080 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 8Fig. 7). Use the 4 screws provided after having pro-
tected 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
D3329

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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 page 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
page 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
Fig. 9
D692

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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, page 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 (page 7, Tab. A):
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. 10
D3330
Fig. 11
D1249
Fig. 12
D462
Fig. 13
Notches no.
Light oil delivery in 2nd stage kg/h
D1250

13 6080
GB
Electrical system
6.1 Notes on safety for the electrical wiring
Before carrying out any maintenance, cleaning or checking oper-
ations:
If the cover is still present, remove it and proceed with the electri-
cal wiring according to the wiring diagrams.
6.1.1 Electrical connections
Use flexible cables according to EN 60 335-1.
– if in PVC sheath, use at least H05 VV-F;
– if in rubber sheath, use at least H05 RR-F.
All the wires to connect to the burner terminal strip 8)(Fig. 14)
must enter through the supplied fairleads. The fair leads and
precut holes can be used in various ways.
One example is given below:
1 - Pg 13,5 Three-phase power supply
2 - Pg 9 Fitting hole for fair lead, if required
3 - Pg 11 Fitting hole for fair lead, if required
4 - Pg 13,5 Fitting hole for fair lead, if required
6 Electrical system
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.
The manufacturer declines all responsibility for modifications or connections different from those shown in the
wiring diagrams.
Do not invert the neutral with the phase in the electrical supply line. Any inversion would cause a lockout due to
firing failure.
Check that the electrical supply of the burner corresponds to that shown on the identification label and in this
manual.
The burners have been set 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 efficiency. 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, 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.
DANGER
disconnect the electrical supply from the burner by
means of the main system switch;
DANGER
isolate the fuel supply.
Fig. 14
D3311

6080 14
GB
Electrical system
6.1.2 Electrical wiring factory-set
NOTE:
In case of remote-reset, connect a push-button with a nor-
mally open contact (NA) between the terminal 3 and the neu-
tral of the control box (for example, terminals 15, 16, 17 and
18).
Key to layout (Fig. 15)
CMV Motor contactor
FR Photocell
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
XP4 4 pole socket
XP7 7 pole socket
Fig. 15
20078333

15 6080
GB
Electrical system
6.1.3 Electrical wiring to be completed by the
installer
Fuses and cables cross-section (Fig. 16), see Tab. C.
Cross-section when not indicated: 1.5 mm2.
Tab. C
Key to layout (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 setpoint value.
TR High-low mode control device system:
This controls operating stages 1 and 2 and is necessary
only for two-stage operation.
TS Safety control device system:
This operates when TL is faulty.
X4 4 pole plug
X7 7 pole plug
6.2 Calibration of thermal relay
Tab. D
Fig. 16
D3238
RL 190
230 V 400 V
FAT25T25
Lmm22,5 2,5
WARNING
The burner is factory set for two-stage operation
and it must therefore be connected to the TR re-
move control device to command fuel valve V2.
Alternatively, if single stage operation is required,
instead of control device TR install a jumper lead
between terminal T8 and T6 (Fig. 16).
Model 230 V 400 V
RL 190 16 A 9,5 A

6080 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. E
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 6080
GB
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) (page 19 Fig. 23).
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) (page 18 Fig. 20) in the "ON" position. The pump must ro-
tate 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)
(page 18 Fig. 20) 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.
Fig. 18
D3331
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.

6080 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 page 24: causes 34 ÷ 42
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 page 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)
(page 17, Fig. 19)
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. F
2st stage fan air gate valve
Set switch 2) (Fig. 20 page 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.
WARNING
Check the correct working of the adjustment, com-
mand and safety devices.
Burner
Fig. 20
12
D469
Off
On
Stage
1st
2nd
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