Riello RL 190/M Quick start guide

20051197 (5) - 11/2014
Installation, use and maintenance instructions
Light oil burner
Low - high or modulating operation
CODE MODEL
20050171 RL 190/M
GB

1
20051197
GB
Contents
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Other symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Delivery of the system and the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Packaging - weight - Approximate measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Burner dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6.1 Procedure to refer burner operating condition in high altitude plants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Commercial boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.10 Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.11 Honeywell control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11.1 RM7840 ... sequence diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.12 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Operation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5 Burner raising. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Boiler plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.7 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.8 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9 Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9.1 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9.2 Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9.3 Adjusting the nozzle flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.10 Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.11 Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.11.1 Double-pipe circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.11.2 The loop circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.11.3 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.11.4 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.11.5 Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.12 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.12.1 Supply cables and external connections passage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.13 Thermal relay calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.13.1 Electro-mechanical thermal relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.13.2 Electronic thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.14 Motor connection at 208-230 or 460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

20051197
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Contents
4.15 Motor connection at 575V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.16 Reversible direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Adjustments before first firing (light oil operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.1 Combustion head setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.2 Pump adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.3 Air damper adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.4 Electrode position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.1 Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.2 Minimum output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.3 Intermediate output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4 Actuator regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Cams and trim potentiometers functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Flame signal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5.1 Preliminary inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5.2 Measuring flame signal with keyboard display module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5.3 Measuring flame signal with a volt ohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5.4 Flame signal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.5 Inadequate flame signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.6 Final calibration of the pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6.1 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6.2 High oil pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.7 Burner starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7.1 Steady state operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7.2 Firing failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.8 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Notes on safety for the maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
B Appendix - Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
C Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Information and general instructions
3
20051197
GB
1.1 Information about the instruction manual
1.1.1 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 sys-
tem. 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 youwill see triangular DANGER signs.
Pay great attention to these, as they indicate a situation of potential
danger.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 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 lethal
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 DEVICES
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 ma-
chine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
➤This symbol indicates a list.

20051197
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Information and general instructions
1.1.4 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 Assis-
tance 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 recommends
the drawing up of a Maintenance Contract.
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installation
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, incorrectly
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 pre-
vent the regular development of the structurally established
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 respon-
sibility 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.

Safety and prevention
5
20051197
GB
2.1 Introduction
The burners have been designed and built in compliance with cur-
rent 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, diathermic
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 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 destina-
tions is not allowed.
➤The burner must be used in exemplary technical safety condi-
tions. 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.
2.2 Personnel training
The user is the person, body or company that has acquired the ma-
chine and intends to use it for the specific purpose. He is responsi-
ble for the machine and for the training of the people working
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 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 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:
2 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 necessary
to prevent unauthorised people gaining access
to the machine;
➤the user 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 pro-
tective equipment envisaged by legislation and
follow the indications given in this manual.

20051197
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Technical description of the burner
3.1 Technical data
Tab. A
(*)
Firing rate for C - UL Canadian Listing (CNL).
(1)
Reference conditions: Ambient temperature 68 °F (20°C) - Barometric pressure 394” WC - Altitude 329 ft.
(2)
Pressure at test point with zero pressure in the combustion chamber and maximum burner output.
(3)
Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
(4)
Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.
3.2 Electrical data
Tab. B
3.3 Burner models designation
Tab. C
3 Technical description of the burner
Model RL 190/M
Output
(1)
Delivery
(1)
High MBtu/hr
(4)
GPH 5376 - 9184
38.4 - 65.6
Low MBtu/hr
(4)
GPH 1792 - 5376
12.8 - 38.4
Fuel #2 Fuel oil
Operation Low-high or modulating
Nozzle number 1 (return flow nozzle)
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Pump TA2 delivery (at 290 PSI)
pressure range
fuel temperature
GPH
PSI
° F max
146
101.5 - 580
284
Electrical protection NEMA 1
Noise levels
(3)
dB(A) 83.9
Model RL 190/M
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply V/Ph/Hz 208-220/3/60 460/3/60
Fan motor IE2/EPACT rpm
HP
V
A
3540
5.5
208-230
13.2
3540
5.5
460
6.6
Ignition transformer Oil V1 - V2
I1 - I2 120 V - 2 x 5 kV 2.7 A - 30 mA
Electrical power consumption W max 4600
Electrical control circuit consumption W 750
Total electrical consumption W 5350
Electrical protection NEMA 1
Model Code Code RBNA Voltage Flame safeguard
RL 190/M 20050171 tbd 208-220/3/60 Burner mounted
tbd 460/3/60 Burner mounted

Technical description of the burner
7
20051197
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3.4 Packaging - weight - Approximate measurements
The burners are skid mounted. Outer dimensions of packaging are
indicated in (Tab. D).
The weight of the burner complete with packaging is indicated in
(Tab. D).
Tab. D
3.5 Burner dimensions
The maximum dimensions of the burners are given in Fig. 2.
Inspection of the combustion head requires the burner to be
opened and the rear part withdrawn on the slide bars.
The maximum dimension of the burner when open, without casing,
is give in measurement I.
Tab. E
3.6 Firing rate
MAXIMUM OUTPUT must be selected in area A (Fig. 3).
MINIMUM OUTPUT must be selected in area B (Fig. 3).
Tab. F
NOTE:
the firing rate areas given in figure (A) have been reduced by
10% with respect to the maximum range that can be reached.
inch A B C lbs
RL 190/M 59
1
/
16“
30
51
/
64“
39
3
/
8“
273
Fig. 1
D36
Model A B C D E F G H I
RL 190/M 32” 14
13
/
32“
17
19
/
32“
23
9
/
16“
41
13
/
32“
14
9
/
16“
8
3
/
4“
16
15
/
16“
54“
Fig. 2
D1217
Model MBtu/hr GPH
RL 190/M 9/84 65.6
WARNING
The firing rate area values have been obtained con-
sidering an ambient temperature of 68 °F, and an
atmospheric pressure of 394” WC and with the
combustion head adjusted as shown on page 19.
Fig. 3
D2422
Firing rate for C - UL Canadian Listing (CNL)
comb. chamber “ WC
AB

20051197
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Technical description of the burner
3.6.1 Procedure to refer burner operating condition
in high altitude plants
Find the CORRECTED BURNER CAPACITY for the plant’s alti-
tude in chart 1 and the CORRECTED PRESSURE in chart 2.
Check in the firing rate graph of the burner (Fig. 3), if the working
point defined by the values above is within the range limits.
If not, higher burner size is needed.
Note
➤Charts are based only on altitude variation (reference temper-
ature = 68°F, 20°C)
➤To get the combined correction in case of different air temper-
ature, a compensation of 1000 ft each 20°F (305 m each
11°C) is applicable (100 ft = 2°F).
Example
Rated capacity = 3000 MBtu/hr - Rated air pressure = 1.5” WC
Real altitude = 5000 ft - Real temperature = 108°F
∆= 108°F - 68°F (reference temp.) = 40°F
(equivalent 2000 ft variation)
40 : 2 = 20 x 100 = 2000 ft
Proceeding as descripted above and considering a “virtual altitude”
of (5000 + 2000) ft:
– 3000 MBtu/hr at 7000 ft, the corrected capacity is 3847 MBtu/hr
– 1.5” WC at 7000 ft, the corrected burner air pressure is 1.92
Reference conditions:
– Ambient temperature 68 °F (20 °C)
– Barometric pressure 394” WC (1000 mbar)
– Altitude 328 ft a.s.l. (100 m a.s.l.).
CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE
Altitude
Rated Capacity m a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000
500 494 500 512 530 551 571 593 616 641 669
1000 987 1000 1023 1061 1101 1142 1186 1232 1282 1337
1500 1481 1500 1535 1591 1652 1713 1778 1848 1924 2006
2000 1974 2000 2046 2121 2202 2284 2371 2464 2565 2675
2500 2468 2500 2558 2652 2753 2855 2964 3079 3206 3343
3000 2962 3000 3069 3182 3303 3425 3557 3695 3847 4012
3500 3455 3500 3581 3712 3854 3996 4149 4311 4488 4680
4000 3949 4000 4092 4243 4404 4567 4742 4927 5130 5349
4500 4442 4500 4604 4773 4955 5138 5335 5543 5771 6018
5000 4936 5000 5116 5303 5505 5709 5928 6159 6412 6686
5500 5429 5500 5627 5834 6056 6280 6520 6775 7053 7355
6000 5923 6000 6139 6364 6606 6851 7113 7391 7694 8024
6500 6417 6500 6650 6894 7157 7422 7706 8006 8335 8692
7000 6910 7000 7162 7425 7708 7993 8299 8622 8977 9361
7500 7404 7500 7673 7955 8258 8564 8892 9238 9618 10029
8000 7897 8000 8185 8485 8809 9135 9484 9854 10259 10698
8500 8391 8500 8697 9016 9359 9705 10077 10470 10900 11367
9000 8885 9000 9208 9546 9910 10276 10670 11086 11541 12035
9500 9378 9500 9720 10076 10460 10847 11263 11702 12183 12704
10000 9872 10000 10231 10607 11011 11418 11855 12318 12824 13373
Average barometric
pressure (20°C) mbar 1013 1000 977.4 942.8 908.2 875.8 843.5 811.85 779.8 747.8
Average barometric
pressure (68°F) "w.c. 399 394 385 371 358 345 332 320 307 294
1

Technical description of the burner
9
20051197
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3.7 Minimum furnace dimensions
The firing rates were set in relation to certified test boilers.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example
Output 2579 MBtu/hr: diameter 24 inch - length 6.6 ft.
CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE
Altitude
Rated Pressure m a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000
0.50 0.49 0.50 0.51 0.53 0.55 0.57 0.59 0.62 0.64 0.67
1.00 0.99 1.00 1.02 1.06 1.10 1.14 1.19 1.23 1.28 1.34
1.50 1.48 1.50 1.53 1.59 1.65 1.71 1.78 1.85 1.92 2.01
2.00 1.97 2.00 2.05 2.12 2.20 2.28 2.37 2.46 2.56 2.67
2.50 2.47 2.50 2.56 2.65 2.75 2.85 2.96 3.08 3.21 3.34
3.00 2.96 3.00 3.07 3.18 3.30 3.43 3.56 3.70 3.85 4.01
3.50 3.46 3.50 3.58 3.71 3.85 4.00 4.15 4.31 4.49 4.68
4.00 3.95 4.00 4.09 4.24 4.40 4.57 4.74 4.93 5.13 5.35
4.50 4.44 4.50 4.60 4.77 4.95 5.14 5.33 5.54 5.77 6.02
5.00 4.94 5.00 5.12 5.30 5.51 5.71 5.93 6.16 6.41 6.69
5.50 5.43 5.50 5.63 5.83 6.06 6.28 6.52 6.77 7.05 7.35
6.00 5.92 6.00 6.14 6.36 6.61 6.85 7.11 7.39 7.69 8.02
6.50 6.42 6.50 6.65 6.89 7.16 7.42 7.71 8.01 8.34 8.69
7.00 6.91 7.00 7.16 7.42 7.71 7.99 8.30 8.62 8.98 9.36
7.50 7.40 7.50 7.67 7.96 8.26 8.56 8.89 9.24 9.62 10.03
8.00 7.90 8.00 8.18 8.49 8.81 9.13 9.48 9.85 10.26 10.70
8.50 8.39 8.50 8.70 9.02 9.36 9.71 10.08 10.47 10.90 11.37
9.00 8.88 9.00 9.21 9.55 9.91 10.28 10.67 11.09 11.54 12.04
9.50 9.38 9.50 9.72 10.08 10.46 10.85 11.26 11.70 12.18 12.70
10.00 9.87 10.00 10.23 10.61 11.01 11.42 11.86 12.32 12.82 13.37
Average barometric
pressure (20°C) mbar 1013 1000 977.4 942.8 908.2 875.8 843.5 811.85 779.8 747.8
Average barometric
pressure (68°F) "w.c. 399 394 385 371 358 345 332 320 307 294
2
Fig. 4
Diameter (inches)
Length (ft)
Furnace dimensions
D2919

20051197
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Technical description of the burner
3.8 Commercial boilers
The burner is suitable for operation on either flame-inversion boil-
ers* or boilers with combustion chambers featuring flow from the
base (three flue passes) on which the best results are obtained in
terms of low NOx emissions.
The maximum thickness of the boiler’s front door must not exceed
10” (Fig. 5).
(*) For flame inversion boilers, a kit is available to reduce CO emis-
sions if required.
The kit includes 5 gas pipes, identical to the other 5 already fit-
ted to the burner head. In standard conditions, the burner head
is fitted with a second group of pipes, with gas outlet in a differ-
ent direction with respect to the others.
With this Kit, the second group of pipes is replaced, so that all
the pipes are the same.
After fitting the kit, ensure they work correctly by measuring the
CO and flue gases emissions.
3.9 Burner description
Fig. 5
10” max
D1079
Fig. 6
20052606

Technical description of the burner
11
20051197
GB
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Screw for fixing fan to flange
5 Pressure gauge for pressure on nozzle return
6 Pressure gauge for pressure on nozzle delivery
7 Pump
8 Air inlet to fan
9 Air damper
10 Fan pressure test point
11 Boiler mounting flange
12 Flame stability disk
13 Slide bars for opening the burner and inspecting the combus-
tion head
14 Extensions for slide bars 13) (with kit)
15 High oil pressure switch
16 Ignition transformer
17 Fan motor contactor and thermal relay with reset button
18 "OFF - ON" switch
19 Burner terminal board "X1"
20 Terminal strip for oil valve "X2"
21 Flame safeguard with lock-out pilot light and lock-out reset
button
22 Flame inspection window
23 Low air pressure switch
24 Valve assembly with pressure regulator on nozzle return
25 UV scanner
26 Servomotor, provides adjustment of fuel delivery regulator
and of air damper. When the burner is not operating the air
damper is fully closed in order to reduce to a minimum heat
dispersion from the boiler.
27 Lifting rings
28 "AUTO-MAN" switch
29 "MANUAL +/-" switch
30 "ALARM SILENCE" button
31 Optional holes
32 RWF 40 modulator (with analog output 4-20 mA) (Available)
33 "POWER ON" signal
34 "CALL FOR HEAT" signal
35 "ALARM" signal
36 "IGNITION ON" signal
37 "FUEL ON" signal
38 Horn
39 Auxiliary fuse
40 Din bar for fuse holder, step-down transformer and OCI
412.10 (Available)
41 Ground terminals
42 Holes for cables grommets for electrical wirings, accessories
and power supply (to be carried out by the installer)
43 Terminal strip for UV scanner "X3"
44 Din bar available for accessories
45 Din bar for thermal relay, fan motor contactor and terminal
strip for UV "X3"
46 Fan motor
47 "K1" relay
48 "K3" relay
49 "KMIN" relay
50 "KMAX" relay
Two types of burner failure may occur:
–Flame safeguard lock-out: if the safeguard alarm 21)(Fig. 6,
page 10) lights up, it indicates that the burner is in lock-out. To
reset, press the pushbutton, no sooner than 10 s after the lock-
out.
–Motor trip: release by pressing the pushbutton on thermal
overload 17)(Fig. 6, page 10). See See “Thermal relay calibra-
tion” on page 23.
3.10 Standard equipment
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange fixing screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 4
Adaptor G 1/4” / 1/4” NPT . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Seal for adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Connector for adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Circular sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 4
Instruction booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
WARNING
For the installation and the adjustment of the high
fire switch, please refer to the specific manual of the
device.

20051197
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Technical description of the burner
3.11 Honeywell control box
APPLICATION
The Honeywell RM7840 ... Relay Modules are microprocessor-
based integrated burner controls for automatically fired gas, oil, or
combination fuel single burner applications.
The RM7840 ... Relay Modules are used for UL/CSA Modulating
and FM/IRI
Modulating burner applications. The RM7840 ... system consists of
a Relay Module. Keyboard Display Modules (standard with
RM7800), Dust Cover (standard with RM7840 ...), Subbase, Ampli-
fier, and Purge Card. Options include Personal Computer Inter-
face, DATA CONTROLBUS MODULE™, Remote Display
Mounting First-Out Expanded Annunciator and Combustion Sys-
tem Manager™ Software.
Functions provided by the RM7840 ... include automatic burner se-
quencing, flame supervision, system status indication, system or
self-diagnostics and troubleshooting.
SPECIFICATIONS
Electrical ratings
Environmental ratings
Fig. 7
S8158
Wiring subbase
Run/test switch
Configuration jumpers
Purge timer
Relay module
Sequence status led panel
Reset button
Keyboard display
Flame amplifier
Captive mounting
screw
module
MAINIGN00:10
FlameSignal3.5V
Voltage and Frequency: RM7840 ...—120 Vac (+10/-15%),
50 or 60 Hz (±10%)
Power Dissipation: RM7840 ...: 10W maximum in the
Run mode
Maximum Total
Connected Load: 2000 VA
Fusing: 15A maximum, Type SC or
equivalent Fast Blow
Ambient Temperature
Operating: -40°F to +140°F (-40°C to +60°C)
Storage: -40°F to +150°F (-40°C to +66°C)
Humidity: 85% relative humidity continuous,
noncondensing
Vibration: 0.5G environment

Technical description of the burner
13
20051197
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3.11.1 RM7840 ... sequence diagram
For further and specific information (setting and service work, etc.),
please refer to the specific instruction of the control box.
Warning notes
Fig. 8
S8160
WARNING
To avoid injury to persons, damage to property or
the environment, the following warning notes must
be observed!
The RM7840 ... is a safety device! Do not open, in-
terfere with or modify the unit.
The Manufacturer will not assume responsibility for
any damage resulting from unauthorized interfer-
ence!
WARNING
The installation of the device must be carried out by
qualified personnel, as indicated in this manual and
in compliance with the standards and regulations of
the laws in force.
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.

20051197
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Technical description of the burner
3.12 Actuator
Warning notes
➤All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
➤Before making any wiring changes in the connection area of
the actuator, completely isolate the burner control from the
mains supply (all-polar disconnection).
➤Ensure protection against electric shock hazard by providing
adequate protection for the connection terminals and by
securing the housing cover.
➤Check to ensure that wiring is in an orderly state.
➤Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not exhibit
any damage.
Use
The actuator (Fig. 9) is used to drive and position the air damper
and the oil pressure controller, without mechanical leverages
but via the interposition of an elastic coupling.
When used in connection with burner controls or electronic fuel / air
ratio control, the associated controlling elements are controlled de-
pending on burner output.
Installation notes
• Always run the high-voltage ignition cables separate from the
unit and other cables while observing the greatest possible dis-
tance.
• To ensure protection against electric shock hazard, make cer-
tain that the AC 120 V section of the actuator is strictly segregat-
ed from the functional low-voltage section.
• The holding torque is reduced when the actuator’s power supply
is switched off.
Technical data
Tab. G
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
should be observed!
Do not open, interfere with or modify the actua-
tors!
WARNING
The housing cover may only be removed for
short periods of time for wiring or when making
the addressing.
It must be made certain that dust or dirt will not
get inside the actuator while such work is car-
ried out.
WARNING
When servicing or replacing the actuators, take
care not to invert the connectors.
Model SQM50.481R1
Operating voltage and
frequency AC 110V - 15%/+10% 60 Hz
Power consumption 20 VA
Angular rotation Adjustable between 0° and max. 160°
(scale range)
Mounting rotation Optional
Degree of protection IP54 (provided knockout holes remain
closed for mounting or are closed off,
with adequate cable entries)
Cable entry 4 x Pg13.5 with thread
Direction of rotation Facing the gear train side. Counter-
clockwise or clockwise (selectable),
delivery: counterclockwise
Torque 10 Nm
Running time 90° - 25 sec; 130° - 36 sec
Weight Approx. 3.3 kg
Operation DIN EN 60721-3-3
Climatic conditions Class 3K3
Mechanical conditions Class 3M3
Temperature range with-
out integrated AGA56... -20...+60°C
Humidity <95% r.h.
Fig. 9
S8376

Installation
15
20051197
GB
4.1 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, pro-
ceed with the installation operations.
4.2 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.
4.3 Preliminary checks
Checking the consignment
4.4 Operation position
The burner is designed to operate only in the positions 1, 2, 3 and 4
(Fig. 10).
Installation 1is preferable, as it is the only one that allows the main-
tenance operations as described in this manual.
Installations 2, 3 and 4 permit operation but make maintenance
and inspection of the combustion head more difficult.
Any other position could compromise the correct operation of the
appliance.
Installation 5is prohibited for safety reasons.
4 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 regulations of
the laws in force.
WARNING
The handling operations for the burner can be high-
ly dangerous if not carried out with the greatest at-
tention: 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 eventof doubt, do not use the
burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of dan-
ger and pollution; they should be collected and dis-
posed of in the appropriate places.
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.
Fig. 10
2 3 4 51
D7739

20051197
16
GB
Installation
4.5 Burner raising
In order to lift the burner, proceed as follows:
➤screw the two extension bars 1) on the pins 2) (Fig. 11);
➤place the two plates 3) fix them on the relevant ring nuts 4);
➤the four burner lifting points are indicated in Fig. 11.
4.6 Boiler plate
Drill the combustion chamber mounting plate as shown in (Fig. 12).
The position of the threaded holes can be marked using the gasket
supplied with the burner.
Tab. H
4.7 Blast tube length
The length of the blast tube must be selected according to the indi-
cations provided by the manufacturer of the boiler, it must be great-
er than the thickness of the boiler door complete with its insulation.
The range of lengths available, L (inch), is as follows:
Tab. I
For boilers with front flue passes 12) or flame inversion chambers,
protective insulation 10) must be inserted between the boiler re-
fractory 11) and the blast tube 9).
This protective insulation must not compromise the extraction of
the blast tube.
For boilers having a water-cooled front the insulation 11)(Fig. 13) is
not required unless it is required by the boiler manufacturer.
WARNING
The manufacturer declines any and every
responsibility for any possible lifting movements,
different from those indicated in this manual.
1 2
3
4
Fig. 11
D10111
A B C
inch 9
1
/
16
“ 12
25
/
32
“ - 14
15
/
32
“
5
/
8
W
Fig. 12
D455
Model L
RL 190/M 14
9
/
16
“

Installation
17
20051197
GB
4.8 Securing the burner to the boiler
Disassemble the blast tube 9) from the burner 6) by proceeding as
follows (Fig. 13):
➤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) to the boiler plate inserting the supplied gas-
ket 8). Use the 4 screws provided after having protected the
thread with an anti-seizing product.
➤The burner-boiler seal must be airtight.
4.9 Nozzle
The burner complies with the emission requirements of the UL 296
standard.
In order to guarantee that emissions do not vary, recommended
and/or alternative nozzles specified by Riello in the Instruction and
warning booklet should be used.
4.9.1 Recommended nozzles
• BERGONZO A4 45° - return flow nozzle
4.9.2 Nozzle assembly
At this stage of installation the burner is still disassembled from the
blast tube.
At this point install the nozzle with the box wrench 1)(Fig. 14), fitting
the wrench through the central hole in the flame stability disk.
L
9
10
11
12
12
6
5
4
3
2
1
37 8
Fig. 13
20052607
WARNING
It is advisable to replace nozzles every year during
regular maintenance operations.
CAUTION
The use of nozzles other than those specified by the
Manufacturer and inadequate regular maintenance
may result into emission limits non-conforming to
the values set forth by the regulations in force, and
in extremely serious cases, into potential hazards to
people and objects.
The manufacturing company shall not be liable for
any such damage arising from nonobservance of
the requirements contained in this manual.
WARNING
Do not use any sealing products such as gaskets,
sealing compound, or tape.
Be careful to avoid damaging the nozzle sealing
seat.
Fig. 14
D1220

20051197
18
GB
Installation
Make sure that the electrodes are positioned as shown in Fig. 15.
Finally remount the burner 3)(Fig. 16) on the slide bars 2) and slide
it up to the flange 5), keeping it slightly raised to prevent the flame
stability disk from pressing against the blast tube.
Tighten the screws 1) on the slide bars 2) and screws 4) fixing the
burner to the flange.
If it proves necessary to change a nozzle with the burner already
fitted to the boiler, proceed as outlined below:
➤Pull back the burner on its slide bars as shown in Fig. 17;
➤Remove the nuts 1) and the disk 2);
➤Use wrench 3) to change the nozzles.
4.9.3 Adjusting the nozzle flow rate
The nozzle flow rate varies according to the fuel pressure on the
nozzle return.
Diagram (Fig. 19) indicates this relationship for type A4 return flow
nozzles with pump delivery pressure of 290 PSI. See Fig. 19:
Horizontal axis: PSI, nozzle return pressure
Vertical axis: GPH, nozzle flow rate
With a pump delivery pressure of 290 PSI, the pressure on the noz-
zle return must not exceed 246.5 PSI.
The pressure difference between pump delivery and nozzle return
must be at least 43.5 PSI. With smaller pressure differences, the
pressure on the nozzle return can be unstable.
The nozzle return pressure value is indicated by the pressure
gauge 1)(Fig. 18).
The nozzle return pressure value is indicated by the pressure
gauge 2)(Fig. 18).
The output and the pressure of the nozzle are at maximum when
the servomotor is positioned on maximum.
The fine adjustment of the pressure in the return line may be car-
ried out by changing the setting of the eccentric 7)(Fig. 18), of the
nut and lock-nut 5)(Fig. 18).
The eccentric setting should be carried out by loosening screws 8),
and turning the screw 6) to obtain the desired eccentricity. Turn
clockwise the screw 6) to increase the eccentricity, increasing the
difference between the min. and max. capacity of the nozzle; turn
counter-clockwise the screw 6) to decrease the eccentricity and,
consequently the difference between the min. and max. capacity of
the nozzle.
1 Gauge for pressure in return line
2 Gauge for pressure in delivery line
3 High oil pressure switch
4 Ring for piston stop
5 Nut and lock-nut for piston setting
6 Variable eccentric
7 Eccentric locking screws
8 Screws
WARNING
➤Do not use any sealing products such as gas-
kets, sealing compound, or tape.
➤Be careful to avoid damaging the nozzle seal-
ing seat.
➤The nozzles must be screwed into place tightly
but carefully.
➤The nozzle for low fire operation is the one
lying beneath the firing electrodes (Fig. 17).
➤Make sure that the electrodes are positioned
as shown in Fig. 17.
Fig. 15
D2528
12 3 4
5
Fig. 16
20052608
Fig. 17
D1222
Fig. 18
D1984