Riello RL 28 Quick start guide

Installation, use and maintenance instructions
Instrucciones de Instalación, Funcionamiento y Mantenimiento
Instruções de Instalação, Funcionamento e Manutenção
Light oil burners
Quemadores de gasóleo
Queimadores a gasóleo
Two stage operation
Funcionamiento a dos llamas
Funcionamento a duas chamas
2916064 (0)
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3473232 RL 28 652 T1
3473233 RL 28 652 T1
3474132 RL 38 653 T1
3474133 RL 38 653 T1
3474332 RL 38 653 T1
3474333 RL 38 653 T1
3474632 RL 50 654 T1
3474633 RL 50 654 T1
GB
E
P

1
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 5
Choice of nozzles per il 1° e 2° stadio . . . . . . . . . . . . . . . . . . . . . 5
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Burner calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . 14
Resetting the control box and using diagnostics. . . . . . . . . . . 14
Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 15
Status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
N.B.
Figures mentioned in the text are identified as follows:
1)(A) = part 1 of figure A, same page as text;
1)(A)p.3 = part 1 of figure A, page number 3.
NOTE
In conformity with Efficiency Directive 92/42/EEC the application
of the burner on the boiler, adjustment and testing must be car-
ried out observing the instruction manual of the boiler, including
verification of the CO and CO2concentration in the flue gases,
their temperatures and the average temperature of the water in
the boiler.
GB

2
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.
(2) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.
VARIANTS
ACCESSORIES (optional):
•STATUS (see page 16): code 3010321
• DEGASSING UNIT
It may occur that a certain amount of air is contained in the light oil sucked up by the pump. This air may originate from the light oil itself as a
consequence of depressurization or air leaking past imperfect seals.
In double-pipe systems, the air returns to the tank from the return pipe; in single-pipe systems, the air remains in circulation causing pressure var-
iations in the pump and burner malfunctions.
For this reason, we advise installing a degassing unit near the burner in single-pipe installations.
Degassing units are provided in two versions:
CODE 3010054 without filter
CODE 3010055 with filter
Degassing unit characteristics
• Burner delivery : 80 kg/h max
• Light oil pressure : 0,7 bar max
• Ambient temperature : 40 °C max
• Light oil temperature : 40 °C max
• Attachment connectors : 1/4 inch
MODEL RL 28 RL 38 RL 38 RL 50
TYPE 652 T1 653 T1 653 T1 654 T1
OUTPUT (1)
DELIVERY (1)
2nd stage kW 166 - 332
143 - 286
14 - 28
237 - 450
204 - 387
20 - 38
237 - 450
204 - 387
20 - 38
296 - 593
255 - 510
25 - 50
Mcal/h
kg/h
1st stage kW 95 - 166 118 - 237 118 - 237 148 - 296
127 - 255
12,5 - 25
Mcal/h 82 - 143 102 - 204 102 - 204
kg/h 8 - 14 10 - 20 10 - 20
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
ELECTRICAL SUPPLY V
Hz
230 ~ +/-10%
50 - single-phase
230 - 400 with neutral ~ +/-10%
50 - three-phase
ELECTRIC MOTOR rpm
W
V
A
2800
300
220 - 240
2,4
2800
420
220 - 240
2,8
2800
450
220/240 - 380/415
2,0 - 1,2
2800
650
220/240 - 380/415
3,0 - 1,7
MOTOR CAPACITOR µF/V 12,5/450 16/450
IGNITION TRASFORMER V1 - V2
I1 - I2
230 V - 2 x 5 kV
1,9 A - 30 mA
PUMP delivery (at 20 bar)
pressure range
fuel temperature
kg/h
bar
° C max
45
10 - 18
60
67
4 - 18
60
67
4 - 18
60
88
4 - 18
60
ELECTRICAL POWER CONSUMPTION W max 370 600 560 750
ELECTRICAL PROTECTION IP 44
IN CONFORMITY WITH EEC DIRECTIVES 89/336 - 73/23 - 92/42 - 98/37
NOISE LEVELS (2) dBA 68,0 70,0 70,0 75,0
Model Code Electrical
supply
Blast tube
lenght mm
RL 28 3473232
3473233
single-phase
single-phase
216
351
RL 38
3474132
3474133
3474332
3474333
single-phase
single-phase
three-phase
three-phase
216
351
216
351
RL 50 3474632
3474633
three-phase
three-phase
216
351

3
BURNER DESCRIPTION (A)
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Photocell for flame presence control
5 Screw for fixing fan to flange
6 Slide bars for opening the burner and
inspecting the combustion head
7 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
dispersion from the boiler due to the flue
draught which draws air from the fan suction
inlet.
8 Safety solenoid valve (RL 38 - RL 50)
9Pump
10 Plate prearranged to drill 4 holes for the pas-
sage of hoses and electrical cables.
11 Air inlet to fan
12 Fan pressure test point
13 Boiler mounting flange
14 Flame stability disk
15 Flame inspection window
16 Extensions for slide bars 6)
17 Motor contactor and thermal cut-out reset
button (RL 38 three-phase - RL 50)
18 Motor capacitor
(RL 28 - RL 38 single-phase)
19 Control box with lock-out pilot light and lock-
out reset button
20 Two switches:
- one ≈burner off - on∆
- one for ≈1st - 2nd stage operation∆
21 Plugs for electrical connections
22 Air gate valve
23 Pump pressure adjustment
24 1st and 2nd stage valve assembly
Two types of burner failure may occur:
Control box lock-out: if the control box 19)(A)
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 (RL 38 three-phase - RL 50): release
by pressing the pushbutton on thermal cutout
17)(A).
PACKAGING-WEIGHT (B)
Approximate measurements
• The burner is shipped in cardboard boxe with
the maximum dimensions shown in table (B).
• The weight of the burner complete with pack-
aging is indicated in table (B).
MAX. DIMENSIONS (C)
Approximate measurements.
The maximum dimensions of the burner are giv-
en in (C).
Bear in mind that 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, without
casing, when open is give by measurement H.
STANDARD EQUIPMENT
2 - Flexible hoses
2 - Gaskets for flexible hoses
2 - Nipples for flexible hoses
1 - Thermal insulation screen
2 - Extensions 16)(A) for slide bars 6)(A)
(for model with 351 mm blast tube)
4 - Screws to secure the burner flange to the
boiler: M 8 x 25
3 - Fairleads for electrical connections
(RL 28 and 38 single-phase)
4 - Fairleads for electrical connections
(RL 38 three-phase and RL 50)
1 - Instruction booklet
1 - Spare parts lis
(A)
(B)
(C)
18 17 15
24
23
22
19
20
21
1234567
141312
11
10
9
8
mm A B C kg
RL 28 1010 620 495 36
RL 38 1010 620 495 38
RL 50 1010 620 495 39
(1) Blast tube: short-lang
mm A B C D (1) EFG H (1)
RL 28 476 474 468 216 - 351 140 352 52 672 - 807
RL 38 476 474 468 216 - 351 140 352 52 672 - 807
RL 50 476 474 468 216 - 351 152 352 52 672 - 807
D3260
D3275
D450
D88
D452

4
FIRING RATES (A)
The RL 28 - 38 - 50 Model burners can work in
two ways: one-stage and two-stage.
1st stage DELIVERY must be selected within
area A of the adjacent diagrams.
2nd stage DELIVERY must be selected within
area B (and C for model RL 50). This area pro-
vides the maximum delivery of the burner in
relation to the pressure in the combustion cham-
ber.
The work point may be found by plotting a verti-
cal line from the desired delivery and a horizon-
tal line from the pressure in the combustion
chamber. The intersection of these two lines is
the work point which must lie within area B.
In order to utilize also area C (RL 50) it is neces-
sary to perform the calibration of the combustion
head as explained on page 5.
Important
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
6.
TEST BOILER (B)
The firing rate was set in relation to special test
boilers in accordance with the methods defined
in EN 267 standards.
Figure (B) indicates the diameter and length of
the test combustion chamber.
Example:
delivery 35 kg/hour:
diameter = 50 cm; length = 1,5 m.
Whenever the burner is operated in a much
smaller commercially-available combustion
chamber, a preliminary test should be per-
formed.
(A)
(B)
RL 28
RL 38
RL 50
D453
D454
pressure mbar
Combustion chamber
pressure mbar
Combustion chamber
pressure mbar
Combustion chamberCombustion chamber
length m

5
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A).
The position of the threaded holes can be
marked using the thermal screen supplied with
the burner.
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected ac-
cording to the indications provided by the manu-
facturer of the boiler, and in any case it must be
greater than the thickness of the boiler door com-
plete with its fettling. The range of lengths avail-
able, L, is as follows:
Blast tube 7): RL 28 RL 38 RL 50
• short 216 216 216
• long 351 351 351
For boilers with front flue passes 10) or flame in-
version chambers, protective fettling in refractory
material 8) must be inserted between the boiler's
fettling 9) and the blast tube 7).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the refrac-
tory fettling 8)-9)(B) is not required unless it is ex-
pressly requested by the boiler manufacturer.
SECURING THE BURNER TO THE BOILER (B)
Disassemble the blast tube 7) from the burner 4)
by proceeding as follows:
- Remove the screws 2) from the two slide bars 3).
- Remove the screw 1) fixing the burner 4) to
the flange 5).
- Withdraw the blast tube 7) complete with
flange 5) and slide bars 3).
COMBUSTION HEAD CALIBRATION
At this point check, for model RL 50, whether the
maximum delivery of the burner in 2nd stage op-
eration is contained in area B or in area C of the
firing rate. See page 4.
If it is in area B then no operation is required.
If, on the other hand, it is in area C:
- Unscrew the screws 1)(C) and disassemble
the blast tube 2).
- Move the fixing of the rod 3)(C) from position
A to position B, thereby causing the shutter 4)
to retract.
- Now refit the blast tube 2)(C) and the screws 1).
Once this operation has been carried out (if it
was required), secure flange 5)(B) to the boiler
plate interposing the supplied gasket 6). Use the
4 supplied screws provided after having pro-
tected the thread with antiscruffing products
(high-temperature grease, compounds, graph-
ite).
The burner-boiler seal must be airtight.
CHOICE OF NOZZLES FOR 1st AND 2nd
STAGE
Both nozzles must be chosen from among those
listed in Table (D).
The first nozzle determines the delivery of the
burner in the 1st stage.
The second nozzle works together with the 1st
nozzle to determine 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 2. Use nozzles with a 60° spray angle at
the recommended pressure of 12 bar
The two nozzles usually have equal deliveries,
but the 1st stage nozzle may have the following
specifications if required:
• a delivery less than 50% of the total delivery
whenever the back-pressure peak must be re-
duced at the moment of firing;
• a delivery higher than 50% of the total delivery
whenever the combustion during the 1st stage
must be improved.
P
V
456
10
L
7
8
9
3
10
21
(A)
(B)
(C)
mm A B C
RL 28 160 224 M 8
RL 38 160 224 M 8
RL 50 160 224 M 8
(D)
(1) light oil: density 0,84 kg/dm3
viscosity 4,2 cSt/20 °C
temperature 10 °C
GPH kg/h (1) kW
12 bar
10 bar 12 bar 14 bar
RL 28 2,00
2,25
2,50
3,00
3,50
7,7
8,6
9,6
11,5
13,5
8,5
9,5
10,6
12,7
14,8
9,2
10,4
11,5
13,8
16,1
100,8
112,7
125,7
150,6
175,5
RL 38 2,50
3,00
3,50
4,00
4,50
5,00
9,6
11,5
13,5
15,4
17,3
19,2
10,6
12,7
14,8
17,0
19,1
21,2
11,5
13,8
16,1
18,4
20,7
23,0
125,7
150,6
175,5
201,6
226,5
251,4
RL 50 3,00
3,50
4,00
4,50
5,00
5,50
6,00
11,5
13,5
15,4
17,3
19,2
21,1
23,1
12,7
14,8
17,0
19,1
21,2
23,3
25,5
13,8
16,1
18,4
20,7
23,0
25,3
27,7
150,6
175,5
201,6
226,5
251,4
276,3
302,4
60
D455
D457
D456
(D)

6
Example with RL 38
Boiler output = 270 kW - efficiency 90 %
Output required by the burner =
270 : 0,9 = 300 kW
300 : 2 = 150 kW per nozzle
therefore, two equal, 60°, 12 bar nozzles are
required:
1° = 3,00 GPH - 2° = 3,00 GPH,
or the following two different nozzles:
1° = 2,50 GPH - 2° = 3,50 GPH,
or:
1° = 3,50 GPH - 2° = 2,50 GPH.
NOZZLE ASSEMBLY
At this stage of installation the burner is still dis-
assembled from the blast tube; it is therefore
possible to fit two nozzles with the box spanner
1)(A) (16 mm), after having removed the plastic
plugs 2)(A), fitting the spanner through the cen-
tral hole in the flame stability disk. Do not use any
sealing products such as gaskets, sealing com-
pound, or tape. Be careful to avoid damaging the
nozzle sealing seat. The nozzles must be
screwed into place tightly but not to the maxi-
mum torque value provided by the wrench.
The nozzle for the 1st stage of operation is the
one lying beneath the firing electrodes fig. (B).
Make sure that the electrodes are positioned as
shown in fig. (B).
Finally remount the burner 4)(C) to the slide bars
3) 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 2) on the slide bars 3) and
screw 1) that attaches 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. (B)p.5.
- Remove the nuts 1)(D) and the disk 2).
- Use spanner 3)(D) to change the nozzles.
COMBUSTION HEAD SETTING
The setting of the combustion head depends
exclusively on the delivery of the burner in the
2nd stage - in other words, the combined deliv-
ery of the two nozzles selected on page 6.
Turn screw 4)(E) until the notch shown in dia-
gram (F) is level with the front surface of flange
5)(E).
Example:
The RL 38 Model with two 3.00 GPH nozzles
and 12 bar pump pressure.
Find the delivery of the two 3.00 GPH nozzles in
table (D), page 5:
12,7 + 12,7 = 25,4 kg/h.
Diagram (F) indicates that for a delivery of 25.4
kg/h the RL 38 model requires the combustion
head to be set to approx. three notches, as
shown in fig. (E).
(A)
(C)
COMBUSTION HEAD SETTING
(F)
(E)
Notches nr.
Light oil delivery kg/h
(D)
(B)
D458
D590
D460
D461
D462
D463

7
HYDRAULIC SYSTEM
FUEL SUPPLY
Double-pipe circuit (A)
The burner is equipped with a self-priming pump
which is capable of feeding itself within the limits
listed in the table at the side.
The tank higer than the burner A
The distance "P" must not exceed 10 meters in
order to avoid subjecting the pump's seal to ex-
cessive 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 values higher than 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 probable 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 returning 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 distance and/or height differ-
ence are higher than the values listed in the table.
Key (A)
H=
Pump/Foot valve height difference
L=Piping length
Æ=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 con-
trolled (only Italy)
8 = On/off solenoid valve (only Italy)
9=
Return line
10 = Check valve (only Italy)
HYDRAULIC CONNECTIONS (B)
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)(B)p.12.
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 bj-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 connections and screw them
down.
Take care that the hoses are not stretched or
twisted during installation.
Route the hoses through the holes in the plate,
preferably using those on the rh side, fig. (B):
unscrew the screws 1), now divide the insert
piece into its two parts 2) and 3) and remove the
thin diaphragm blocking the two passages 4).
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
supplied nipples, using two wrenches, one to
hold the nipple steady while using the other one
to turn the rotary union on the hose.
(A)
(B)
123
4
95
7
10
6
6
753
9
4
A
B
2
1
P
+H
8
10 cm
-H V
+ H
- H
(m)
L (m)
RL 28
Æ (mm)
RL 38
Æ (mm)
RL 50
Æ (mm)
8 10 12 8 10 12 10 12 14
+ 4,0 52 134 160 35 90 152 63 144 150
+ 3,0 46 119 160 30 80 152 55 127 150
+ 2,0 39 104 160 26 69 152 48 111 150
+ 1,0 33 89 160 21 59 130 40 94 150
+ 0,5 30 80 160 19 53 119 37 86 150
0 27 73 160 17 48 108 33 78 150
- 0,5 24 66 144 15 43 97 29 70 133
- 1,0 21 58 128 13 37 86 25 62 118
- 2,0 15 43 96 9 27 64 17 45 88
- 3,0 8 28 65 4 16 42 10 29 58
- 4,0 - 12 33 - 6 20 - 12 28
D3279
D3278

8
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM as set up by the manu-
facturer
LAYOUT (A)
Burner RL 28 (single-phase)
LAYOUT (B)
Burner RL 38 (single-phase)
LAYOUT (C)
Burners RL 38 - 50 (three-phase)
• Models RL 38 three-phase and RL 50 leave
the factory preset for 400 V power supply.
• If 230 V power supply is used, change the mo-
tor connection from star to delta and change
the setting of the thermal cut-out as well.
Key to Layouts (A) - (B) - (C)
C - Capacitor
CMV - Motor contactor
FR - Photocell
I1 - Switch:
burner off - on
I2 - Switch:
1st - 2nd stage operation
MV - Fan motor
RMO88.53A2 - Control box
RT - Thermal cut-out
TA - Ignition transformer
TB - Burner ground (earth) connec-
tion
V1 - 1st stage solenoid valve
V2 - 2nd stage solenoid valve
VS - Safety solenoid valve
XP1 - Connector for STATUS
XP4 - 4 pole socket
XP5 - 5 pole socket
XP7 - 7 pole socket
NOTE
For remote-reset, connect a push-button switch
(NO) between terminal 4 and neutral of the con-
trol box (terminals 15, 16, 17 and 18).
RL 28
(A)
ELECTRICAL EQUIPMENT FACTORY-SET
RL 38 single-phase
ELECTRICAL EQUIPMENT FACTORY-SET
(B)
RL 38 three-phase - RL 50
ELECTRICAL EQUIPMENT FACTORY-SET
(C)
D3231
D3227
D3230

9
ELECTRICAL CONNECTIONS (A)
set up by the installer
Use flexible cables according to regulation EN
60 335-1:
• if in PVC boot, use at least H05 VV-F
• if in rubber boot, use at least H05 RR-F.
All the cables to be connected to the burner
sockets 5)(A) must be routed through the fair-
leads, supplied by the manufacturer for insertion
into the holes in the plate, preferably those on
the left side, after having removed the thin dia-
phragm effectively closing the aperture, as al-
ready explained above.
1 - Pg 11 Three-phase power supply
2 - Pg 11 Single-phase power supply
3 - Pg 9 Control device TL
4 - Pg 9 Control device TR
LAYOUT (B)
The RL 28 - 38 Models electrical connection
single-phase 230V power supply
Cable section not indicated: 1,5 mm2
LAYOUT (C)
The RL 38 - 50 Models electrical connection
three-phase 230/400 V power supply with
neutral phase wire
Cable section not indicated: 1,5 mm2
Key to wiring layouts (B) - (C)
h1 - 1st stage hourcounter
h2 - 2nd stage hourcounter
IN - Manual burner stop switch
X4 - 4 pole plug
X5 - 5 pole plug
X7 - 7 pole plug
S - Remote lock-out signal
TL - Limit control device system:
This shuts down the burner when the boiler
temperature or pressure exceeds the set-
point value.
TR - High-low mode control device system:
This controls operating stages 1 and 2 and
is necessary only for two-stage operation.
TS - Safety control device system:
This operates when TL is faulty.
Important: the burner is factory set for two-
stage operation and it must therefore be con-
nected to the TR remove control device to com-
mand light oil valve V2.
Alternatively, if single stage operation is
required, instead of control device TR install a
jumper lead between terminals T6 and T8 of
connector X4.
LAYOUT (D)
Calibration of thermal cut-out 17)(A)p.3
This is required to avoid motor burn-out in the
event of a significant increase in power absorp-
tion caused by a missing phase.
• If the motor is star-powered, 400 V, the cursor
should be positioned to "MIN".
• If the motor is delta-powered, 230 V, the cur-
sor should be positioned to "MAX".
Even if the scale of the thermal cut-out does not
include rated motor absorption at 400 V, protec-
tion is still ensured in any case.
NOTES
• Burners RL 38 three-phase and RL 50 leave
the factory preset for 400 V power supply. If
230 V power supply is used, change the motor
connection from star to delta and change the
setting of the thermal cutout as well.
• The RL 28 - 38 - 50 burners have been type-ap-
proved for intermittent operation. This means
they should compulsorily be stopped at least
once every 24 houres to enable the control box
to perform checks of its own efficiency at start-
up. Burner halts are normally provided for auto-
matically by the boiler load control system.
WARNING:
Do not invert the neutral with the phase
wire in the electricity supply line.
(A)
(B)
(D)
ELECTRICAL CONNECTIONS
RL 38 - RL 50 three-phase CALIBRATION OF THEREMAL RELAY
RL 28 - RL 38 single-phase
(C)
ELECTRICAL CONNECTIONS
RL 38 three-phase - RL 50
D465
D3232
D3228
D867
ELECTRICAL CONNECTIONS

10
PUMP (A)
1 - Suction G 1/4"
2 - Return G 1/4"
3 - Pressure gauge attachment G 1/8"
4 - Vacuum meter attachment G 1/8"
5 - Pressure adjustment screw
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
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 screws 3)(A) of the pump must be loos-
ened in order to bleed off the air contained in
the suction line.
- Start the burner by closing the control devices
and with switch 1)(B)p.11 in the "ON" position.
The pump must rotate in the direction of the
arrow marked on the cover.
- The pump can be considered to be primed
when the light oil starts coming out of the
screw 3). Stop the burner: switch 1)(B)p.11 set
to "OFF" and tighten the screw 3).
The time required for this operation depends
upon the diameter and length of the suction tub-
ing. If the pump fails to prime at the first starting
of the burner and the burner locks out, wait ap-
prox. 15 seconds, reset the burner, and then re-
peat the starting operation as often as required.
After 5 or 6 starting operations allow 2 or 3 min-
utes 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.
Important: 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. Whenever the length of the
suction piping exceeds 20-30 meters, the supply
line must be filled using a separate pump.
(A)
PUMP AN 57 C AL 65 C AL 75 C
A
B
C
D
E
F
G
H
kg/h
bar
bar
cSt
°C
bar
bar
mm
45
10 - 18
0,45
2 - 75
60
2
12
0,150
67
4 - 18
0,45
2 - 12
60
2
12
0,150
88
4 - 18
0,45
2 - 12
60
2
12
0,150
SUNTEC AN 57 C
RL 28:
RL 50: SUNTEC AL 75 C
RL 38: SUNTEC AL 65 C
D481

11
BURNER CALIBRATION
FIRING
Set switch 1)(B) 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 sometimes 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 during oper-
ation. If one or more pulsations or a delay in firing
in respect to the opening of the light oil solenoid
valve occur, see the suggestions provided on p.
15: causes 34 to 42.
OPERATION
The optimum calibration of the burner requires
an analysis of the flue gases at the boiler outlet
and interventions on the following points:
• 1st and 2nd nozzles
See the information listed on page 5.
• 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 fac-
tory which is usually sufficient for most purposes.
Sometimes, this pressure must be adjusted to:
10 bar in order to reduce fuel delivery. This ad-
justment is possible only if the surrounding tem-
perature remains above 0°C. Never calibrate to
pressures below 10 bar, at which pressures the
cylinders may have difficulty in opening;
14 bar in order to increase fuel delivery or to en-
sure firings even at temperatures of less than
0°C.
In order to adjust pump pressure, use the screw
5)(A), p. 10.
• 1st stage fan air gate valve
Keep the burner operating at 1st stage by set-
ting the switch 2)(B) to the 1st stage position.
Opening of the air gate valve 1)(A) must be
adjusted in proportion to the selected nozzle:
the index 7)(A) must be aligned with the speci-
fied in table (C). This adjustment is achieved by
turning the hex element 4):
- in rh direction (- sign) the opening is reduced;
- in lh direction (+ sign) the opening increases.
Example RL 38 - 1st stage nozzle 3.00 GPH:
18° notch aligned with index 7(A).
When the adjustment is terminated lock the hex
element 4) with the ring nut 3).
• 2nd stage fan air gate valve
Set switch 2)(B) to the 2nd stage position and
adjust the air gate valve 1)(A) by turning the hex
element 6)(A), after having loosened the ring nut
5)(A).
Air pressure at attachment 1)(D) must be
approximately the same as the pressure speci-
fied in table (D) plus the combustion chamber
pressure measured at attachment 2). Refer to
the example in the adjacent figure.
NOTE: in order to facilitate adjustment of hex
elements 4) and 6)(A), use a 3 mmc Allen key
8)(A).
(A)
(B)
12
Burner Stage
Off
On 2nd
1st
RL 28 RL 38 RL 50
GPH αGPH αGPH α
2,00
2,25
2,50
3,00
3,50
14
17
20
22
24
2,50
3,00
3,50
4,00
4,50
5,00
12
18
20
22
23
26
3,00
3,50
4,00
4,50
5,00
5,50
6,00
12
15
18
21
23
27
28
(C)
1st STAGE
α= Notch Nr.
RL 28 RL 38 RL 50
kg/h mbar kg/h mbar kg/h mbar
14
16
18
20
22
24
26
28
6,0
6,3
6,6
6,8
7,1
7,6
8,4
8,8
20
22
24
26
29
32
35
38
7,0
7,0
7,0
7,0
7,0
7,0
8,0
9,4
25
29
33
37
41
45
50
50
6,1
6,2
6,4
6,5
6,6
8,0
10,1
9,1 (1)
2nd STAGE
mbar = air pressure in 1) with zero
(1) With shutter 4)(C)p.5 retracted
D468
D469
(D)
pressure in 2)

12
BURNER OPERATION
BURNER STARTING (A) - (B)
Starting phases with progressive time intervals
shown in seconds:
• Control device TL closes.
After about 3s:
•0 s : The control box starting cycle begins.
•2 s : The fan motor starts.
•3 s : The ignition transformer is connected.
The pump 3) sucks the fuel from the tank
through the piping 1) and the filter 2) and
pumps it under pressure to delivery. The pis-
ton 4) rises and the fuel returns to the tank
through the piping 5) - 7). The screw 6) closes
the by-pass heading towards suction and the
solenoid valves 8) - 11) - 16), de-energized,
close the passage to the nozzles.
The hydraulic cylinder 15), piston A, opens the
air gate valve: pre-purging begins with the 1st
stage air delivery.
•22 s : Solenoid valves 8) and 16) open and the
fuel passes through the piping 9) and filter 10)
and is then sprayed out through the nozzle,
igniting when it comes into contact with the
spark. This is the 1st stage flame.
•29 s: The ignition transformer switches off.
•36 s: If the control device TR is closed or has
been replaced by a jumper wire, the 2nd stage
solenoid valve 11) is opened and the fuel
enters the valve 12) and raises the piston
which opens two passages: one to piping 13),
filter 14), and the 2nd stage nozzle, and the
other to the cylinder 15), piston B, that opens
the fan air gate valve in the 2nd stage.
The starting cycle comes to an end.
STEADY STATE OPERATION
System equipped with one control device TR
Once the starting cycle has come to an end, the
command of the 2nd stage solenoid valve pass-
es on to the control device TR that controls boiler
temperature or pressure.
• When the temperature or the pressure increas-
es until the control device TR opens, solenoid
valve 11) closes, and the burner passes from
the 2nd to the 1st stage of operation.
• When the temperature or pressure decreases
until the control device TR closes, solenoid
valve 11) opens, and the burner passes from
the 1st to the 2nd stage of operation, and so on.
• The burner stops when the demand for heat is
less than the amount of heat delivered by the
burner in the 1st stage. In this case, the control
device TL opens, and solenoid valves 8)-16)
close, the flame immediately goes out. The
fan's air gate valve closes completely.
Systems not equipped with control device
TR (jumper wire installed)
The burner is fired as described in the case
above. If the temperature or pressure increase
until control device TL opens, the burner shuts
down (Section A-A in the diagram).
When the solenoid valve 11) de-energizes, the
piston 12) closes the passage to the 2nd stage
nozzle and the fuel contained in the cylinder 15),
piston B, is discharged into the return piping 7).
FIRING FAILURE
If the burner does not fire, it goes into lock-out with-
in 5 s of the opening of the 1st nozzle valve and 30
s after the closing of control device TL.
The control box red pilot light will light up.
UNDESIRED SHUTDOWN DURING OPERA-
TION
If the flame goes out during operation, the burner
shuts down automatically within 1 second and
automatically attempts to start again by repeat-
ing the starting cycle.
(B)
(A)
TL
TR
0
1°
2°
A
A
TL
Off Yellow Green Red
For further details see page 14.
*
D480
D3280
D3281
LED
RMO *
LED
RMO *

13
FINAL CHECKS
• Obscure the photocell and switch on the con-
trol devices: the burner should start and then
lock-out about 5 s after opening of the 1st noz-
zle operation valve.
• Illuminate the photocell and switch on the con-
trol devices: the burner should start and then
go into lock-out after about 10 s.
• Obscure the photocell while the burner is in
2nd stage operation, the following must occur
in sequence: flame extinguished within 1 s,
pre-purging for about 20 s, sparking for about
5 s, burner goes into lock-out.
• Switch off control device TL followed by con-
trol device TS while the burner is operating:
the burner should stop.
MAINTENANCE
Combustion
The optimum calibration of the burner requires
an analysis of the flue gases. Significant differ-
ences with respect to the previous measure-
ments indicate the points where more care
should be exercised during maintenance.
Pump
The delivery pressure must be stable at 12 bar.
The depression must be less than 0.45 bar.
Unusual noise must not be evident during pump
operation.
If the pressure is found to be unstable or if the
pump runs noisily, the flexible hose must be de-
tached from the line filter and the fuel must be
sucked from a tank located near the burner. This
measure permits the cause of the anomaly to be
traced to either the suction piping or the pump.
If the pump is found to be responsible, check to
make sure that the filter is not dirty. The vacuum
meter is installed upstream from the filter and
consequently will not indicate whether the filter is
clogged or not.
Contrarily, if the problem lies in the suction line,
check to make sure that the filter is clean and
that air is not entering the piping.
Filters (A)
Check the following filter boxes:
• on line 1) • in the pump 2) • at the nozzle 3), and
clean or replace as required.
If rust or other impurities are observed inside the
pump, use a separate pump to lift any water and
other impurities that may have deposited on the
bottom of the tank.
Then clean the insides of the pump and the cov-
er sealing surface.
Fan
Check to make sure that no dust has accumulat-
ed inside the fan or on its blades, as this condi-
tion will cause a reduction in the air flow rate and
provoke polluting combustion.
Combustion head
Check to make sure that all the parts of the com-
bustion head are in good condition, positioned
correctly, free of all impurities, and that no defor-
mation has been caused by operation at high
temperatures.
Nozzles
Do not clean the nozzle openings; do not even
open them. The nozzle filters however may be
cleaned or replaced as required.
Replace the nozzles every 2-3 years or whenev-
er necessary.
Photocell (B)
Clean the glass cover from any dust that may
have accumulated. Photocell 1) is held in posi-
tion by a pressure fit and can therefore be re-
moved by pulling it outward forcefully.
Flame inspection window (C)
Clean the glass whenever necessary.
Flexible hoses
Check to make sure that the flexible hoses are
still in good condition and that they are not
crushed or otherwise deformed.
Fuel tank
Approximately every 5 years, or whenever nec-
essary, suck any water or other impurities
present on the bottom of the tank using a sepa-
rate pump.
Boiler
Clean the boiler as indicated in its accompanying
instructions in order to maintain all the original
combustion characteristics intact, especially the
flue gas temperature and combustion chamber
pressure.
TO OPEN THE BURNER (D)
- Switch off the electrical power
- Remove screw 1 and withdraw the casing 2)
- Unscrew screw 3)
- Fit the two extensions 4) supplied with the
burner onto the slide bars 5) (model with 351
mm blast tube)
- Pull part A backward keeping it slightly raised
to avoid damaging the disk 6) on blast tube 7).
Fuel pump and/or couplings replacement (E)
In conformity with fig. (E).
(A)
(B)
(D)
(E)
(C)
D482
D484
D483
D486
D1108

14
BURNER START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the followin table:
RESETTING THE CONTROL BOX AND USING DIAGNOSTICS
The control box features a diagnostics function through which any causes of malfunctioning are easily identified (indicator: RED LED).
To use this function, you must wait at least 10 seconds once it has entered the safety condition (lock-out), and then press the reset button.
The control box generates a sequence of pulses (1 second apart), which is repeated at constant 3-second intervals.
Once you have seen how many times the light pulses and identified the possible cause, the system must be reset by holding the button
down for between 1 and 3 seconds.
The methods that can be used to reset the control box and use diagnostics are given below.
RESETTING THE CONTROL BOX
To reset the control box, proceed as follows:
-Hold the button down for between 1 and 3 seconds.
The burner restarts after a 2-second pause once the button is released.
If the burner does not restart, you must make sure the limit thermostat is closed.
VISUAL DIAGNOSTICS
Indicates the type of burner malfunction causing lock-out.
To view diagnostics, proceed as follows:
-Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.
A yellow light pulses to tell you the operation is done.
Release the button once the light pulses. The number of times it pulses tells you the cause of the malfunction, according to the coding
system indicated in the table on page 15.
SOFTWARE DIAGNOSTICS
Reports burner life by means of an optical link with the PC, indicating hours of operation, number and type of lock-outs, serial number of
control box etc ...
To view diagnostics, proceed as follows:
-Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.
A yellow light pulses to tell you the operation is done.
Release the button for 1 second and then press again for over 3 seconds until the yellow light pulses again.
Once the button is released, the red LED will flash intermittently with a higher frequency: only now can the optical link be activated.
Once the operations are done, the control box»s initial state must be restored using the resetting procedure described above.
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are listed in the table on page 15.
COLOUR CODE TABLE
Sequences Colour code
Pre-purging
Ignition phase
Operation, flame ok
Operating with weak flame signal
Electrical supply lower than ~170V
Lock-out
Extraneous light
Key: Off Yellow Green Red
BUTTON PRESSED FOR CONTROL BOX STATUS
Between 1 and 3 seconds Control box reset without viewing visual diagnostics.
More than 3 seconds Visual diagnostics of lock-out condition:
(LED pulses at 1-second intervals).
More than 3 seconds starting from the visual
diagnostics condition
Software diagnostics by means of optical interface and PC (hours of operation, malfunc-
tions etc. can be viewed)
Press reset
for > 3s 3sPulses Pulses
RED LED on
wait at least 10s
Interval
Lock-out

15
SIGNAL FAULT PROBABLE CAUSE SUGGESTED REMEDY
No blink The burner does not
start
1 - No electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . Close all switches - Check fuses
2 - A limit or safety control device is open . . . . . . . . . . . . . . . . . . . Adjust or replace
3 - Control box lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset control box (no sooner than 10 s
after the lock-out)
4 - Pump is jammed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
5 - Erroneous electrical connections . . . . . . . . . . . . . . . . . . . . . . . Check connections
6 - Defective control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
7 - Defective electrical motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
8 - Defective capacitor (RL 28 - RL 38 single-phase) . . . . . . . . . . . Replace
4 x blinks The burner starts and
then goes into lock-out
9 - Photocell short-circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace photocell
10 - Light is entering or flame is simulated . . . . . . . . . . . . . . . . . . . . Eliminate light or replace control box
2 x blinks After pre-purge and the
safety time, the burner
goes to lock-out at the
end of the safety time
11 - No fuel in tank; water on tank bottom . . . . . . . . . . . . . . . . . . . . Top up fuel level or suck up water
12 - Inappropriate head and air damper adjustments . . . . . . . . . . . Adjust, see page 6 and 11
13 - Light oil solenoid valves fail to open (1st stage or safety). . . . . Check connections; replace coil
14 - 1st nozzle clogged, dirty, or deformed . . . . . . . . . . . . . . . . . . . Replace
15 - Dirty or poorly adjusted firing electrodes. . . . . . . . . . . . . . . . . . Adjust or clean
16 - Grounded electrode due to broken insulation . . . . . . . . . . . . . . Replace
17 - High voltage cable defective or grounded. . . . . . . . . . . . . . . . . Replace
18 - High voltage cable deformed by high temperature . . . . . . . . . . Replace and protect
19 - Ignition transformer defective . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
20 - Erroneous valves or transformer electrical connections . . . . . . Check
21 - Control box defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
22 - Pump unprimed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prime pump and see ≈Pump unprimes∆
23 - Pump/motor coupling broken . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
24 - Pump suction line connected to return line . . . . . . . . . . . . . . . . Correct connection
25 - Valves up-line from pump closed . . . . . . . . . . . . . . . . . . . . . . . Open
26 - Filters dirty: line - pump - nozzle . . . . . . . . . . . . . . . . . . . . . . . . Clean
27 - Defective photocell or control box . . . . . . . . . . . . . . . . . . . . . . . Replace photocell or control box
28 - Dirty photocell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean
29 - 1st stage operation of cylinder is faulty . . . . . . . . . . . . . . . . . . . Change the cylinder
30 - Motor protection tripped (RL 38 three-phase - RL 50) . . . . . . . Reset thermal cut-out
31 - Defective motor command control device (RL 38 three-phase - RL 50) Replace
32 - Missing phase (RL 38 three-phase - RL 50) . . . . . . . . . . . . . . . Reset thermal cut-out
thermal cut-out trips when third phase is re-connected
33 - Incorrect motor rotation direction . . . . . . . . . . . . . . . . . . . . . . . Change motor electrical connections
7 x blinks Flame detachment 34 - Poorly adjusted head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust, see page 6, fig. (F)
35 - Poorly adjusted or dirty firing electrodes . . . . . . . . . . . . . . . . . . Adjust, see page 6, fig. (B)
36 - Poorly adjusted fan air gate: too much air . . . . . . . . . . . . . . . . Adjust
37 - 1st nozzle is too big (pulsation). . . . . . . . . . . . . . . . . . . . . . . . . Reduce 1st nozzle delivery
38 - 1st nozzle is too small (flame detachment) . . . . . . . . . . . . . . . . Increase 1st nozzle delivery
39 - 1st nozzle dirty, or deformed . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
40 - Inappropriate pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust to between 10 and 14 bar
41 - 1st stage nozzle unsuited to burner or boiler . . . . . . . . . . . . . . See Nozzle Table, page 5; reduce 1st stage
42 - Defective 1st stage nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
The burner does not
pass to 2nd stage
43 - Control device TR does not close . . . . . . . . . . . . . . . . . . . . . . . Adjust or replace
44 - Defective control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
45 - 2nd stage sol. valve coil defective. . . . . . . . . . . . . . . . . . . . . . . Replace
46 - Piston jammed in valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace entire unit
Fuel passes to 2nd
stage but air remains in
1st
47 - Low pump pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Increase
48 - 2nd stage operation of cylinder is faulty . . . . . . . . . . . . . . . . . . Change cylinder
Burner stops at transi-
tion between 1st and
2nd stage. Burner
repeats starting cycle.
49 - Nozzle dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renew nozzle
50 - Photocell dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean
51 - Excess air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reduce
Uneven fuel supply 52 - Check if cause is in pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed burner from tank
or fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . located near burner
Internally rusted pump 53 - Water in tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suck water from tank bottom with separate
pump
Noisy pump, unstable
pressure
54 - Air has entered the suction line . . . . . . . . . . . . . . . . . . . . . . . . Tighten connectors
- Depression value too high (higher than 35 cm Hg):
55 - Tank/burner height difference too great . . . . . . . . . . . . . . . . . . Feed burner with loop circuit
56 - Piping diameter too small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Increase
57 - Suction filters clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean
58 - Suction valves closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open
59 - Paraffin solidified due to low temperature . . . . . . . . . . . . . . . . . Add additive to light oil
Pump unprimes after
prolonged pause
60 - Return pipe not immersed in fuel . . . . . . . . . . . . . . . . . . . . . . . Bring to same height as suction pipe
61 - Air enters suction piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten connectors
Pump leaks light oil 62 - Leakage from sealing organ . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace pump
Smoke in flame
- dark Bacharach
- yellow Bacharach
63 - Not enough air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust head and fan gate, see page 6 and 11
64 - Nozzle worn or dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
65 - Nozzle filter clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean or replace
66 - Erroneous pump pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust to between 10 - 14 bar
67 - Flame stability spirat dirty, loose, or deformed . . . . . . . . . . . . . Clean, tighten in place, or replace
68 - Boiler room air vents insufficient . . . . . . . . . . . . . . . . . . . . . . . . Increase
69 - Too much air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust head and fan gate, see page 6 and 11
Dirty combustion head 70 - Nozzle or filter dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
71 - Unsuitable nozzle delivery or angle . . . . . . . . . . . . . . . . . . . . . See recommended nozzles, page 5
72 - Loose nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten
73 - Impurities on flame stability spiral . . . . . . . . . . . . . . . . . . . . . . . Clean
74 - Erroneous head adjustment or not enough air . . . . . . . . . . . . . Adjust, see page 11; open gate valve
75 - Blast tube length unsuited to boiler . . . . . . . . . . . . . . . . . . . . . . Contact boiler manufacturer
10 x blinks 76 - Connection or internal fault

16
STATUS
Accessory available on request.
See page 2.
ASSEMBLY
The burners are preset to accept the Status. To
assemble, proceed as follows:
- Connect Status 1) using connector 2) fitted on
the bracket 3).
- Fasten Status to the bracket using the screws
4) supplied with the kit.
The STATUS unit has three functions:
1 - BURNER OPERATING HOURS AND THE
NUMBER OF FIRINGS ARE SHOWN ON
DISPLAY V
Total operating hours
Press button "h1".
2nd stage operating hours
Press button "h2".
1st stage operating hours
Total hours - 2nd stage operating hours
Number of firings
Press button "count".
Resetting operating hours and number of fir-
ings
Press the three ≈reset∆buttons simultaneously.
Non-volatile memory
The operating hours and the number of firings
will remain in the memory even in the case of
electrical power failures.
2 - INDICATES THE TIMES RELATIVE TO THE
FIRING STAGE
The leds illuminate in the following sequence,
see fig. A:
WITH CONTROL DEVICE TR CLOSED:
1 - Burner off, TL open
2 - Control device TL closed
3 - Motor start:
seconds count starts on read-out V
4 - 1st stage valve energized
5 - 2nd stage valve energized:
seconds count stops on read-out V
6 - 10 seconds after stage 5 the code I I I I
will appear on the read-out: this indicates
that the starting phase is terminated.
WITH CONTROL DEVICE TR OPEN:
1 - Burner off, TL open
2 - Control device TL closed
3 - Motor start:
seconds count starts on read-out V
4 - 1st stage valve energized
7 - 30 seconds after stage 4:
seconds count stops on read-out V
8 - 10 seconds after stage 7 the code I I I I
will appear on the read-out: this indicates
that the starting phase is terminated.
The times, in seconds, shown on read-out V,
indicate the succession of the various starting
stages described on page 12.
3 - IN THE CASE OF BURNER MALFUNC-
TIONS, THE STATUS PANEL INDICATES
THE EXACT TIME AT WHICH THE FAULT
OCCURRED.
There are 3 possible combinations of illumi-
nated leds, see fig. (B).
For the causes of the malfunction refer to the
numbers shown between brackets; see the
legend on page 15 for interpretation of the
numbers.
1 . . . . . . . . . . . (9 … 10)
2 . . . . . . . . . . . (11 … 29)
3 . . . . . . . . . . . (32)
Key to symbols:
= Power present
= Fan motor blocked (red)
= Burner lock-out (red)
= Not used
= 1st stage operation
= Load level reached (Stand-by), led:
on
(A)
Led flashing
Led illuminated
Time in seconds
Burner start cycle terminated
STATUS (optional)
Assembly
2
1 Status
2 Connector
3 Bracket of the burner
4 Fixing screws
1
4
3
D3057
D478

1
ÍNDICE
CARACTERÍSTICAS TÉCNICAS . . . . . . . . . . . . . . . . . . pagina 2
Versiones constructivas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Accesorios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Descripción del quemador . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Embalaje - Peso. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimensiones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Forma de suministro. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gráficos Caudal, Potencia-Sobrepresión . . . . . . . . . . . . . . . . . . . 4
Caldera de prueba . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALACIÓN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Placa de caldera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Longitud tubo llama . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fijación del quemador a la caldera . . . . . . . . . . . . . . . . . . . . . . . 5
Selección boquillas 1≤y 2≤llama . . . . . . . . . . . . . . . . . . . . . . . . . 5
Montaje de las boquillas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Regulación del cabezal de combustión . . . . . . . . . . . . . . . . . . . . 6
Regulación registro ventilador . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instalación hidráulica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instalación eléctrica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bomba . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Regulación del quemador . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Funcionamiento del quemador. . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diagnóstico del programa de puesta en marcha . . . . . . . . . . 14
Desbloqueo de la caja de control y uso de la función
de diagnóstico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Anomalía - Causa Probable - Solución . . . . . . . . . . . . . . . . . . . 15
Status (suministro bajo demanda) . . . . . . . . . . . . . . . . . . . . . . . 16
Nota
Las figuras que se mencionan en el texto se identifican del modo siguiente:
1)(A) =Detalle 1 de la figura A, en la misma página que el texto;
1)(A)p.3 =Detalle 1 de la figura A, página N≥3.
NOTA
De conformidad con la Directiva sobre Rendimiento
92/42/CEE, la aplicación del quemador a la caldera, la regula-
ción y la prueba deben realizarse siguiendo las indicaciones con-
tenidas en el Manual de Instrucciones de la caldera, incluyendo
el control de la concentración de CO y CO2en los gases de com-
bustión, su temperatura y la temperatura media del agua de la
caldera.
E

2
CARACTERÍSTICAS TÉCNICAS
(1) Condiciones de referencia: Temperatura ambiente 20≥C - Presión barométrica 1000 mbar - Altitud sobre el nivel del mar 100 metros.
(2) Presión acústica medida en el laboratorio de combustión del constructor, con quemador funcionando en caldera de prueba a la máxima poten-
cia.
VERSIONES CONSTRUCTIVAS
ACCESORIOS (suministro bajo demanda):
•STATUS (ver página 16): cod. 3010321
•DESGASIFICADOR
Es posible que en el gasóleo aspirado por la bomba haya aire proveniente del mismo gasóleo bajo presión o desde algún cierre imperfecto.
En las instalaciones de dos tubos, el aire retorna en la cisterna desde el tubo de retorno; por el contrario, en las instalaciones de un tubo sigue
circulando causando variaciones de presión en la bomba y un funcionamiento defectuoso del quemador.
Para resolver este problema, aconsejamos, para las instalaciones de un tubo, instalar un desgasificador cerca del quemador. Está disponible en
dos versiones:
COD. 3010054 sin filtro
COD. 3010055 con filtro
Características desgasificador
• Caudal quemador : 80 kg/h max
• Presión gasóleo : 0,7 bar max
• Temperatura ambiente : 40 °C max
• Temperatura gasóleo : 40 °C max
• Racores de unión : 1/4 pulgada
MODELO RL 28 RL 38 RL 38 RL 50
TIPO 652 T1 653 T1 653 T1 654 T1
POTENCIA (1)
CAUDAL (1)
llama 2° kW 166 - 332
143 - 286
14 - 28
237 - 450
204 - 387
20 - 38
237 - 450
204 - 387
20 - 38
296 - 593
255 - 510
25 - 50
Mcal/h
kg/h
llama 1° kW 95 - 166 118 - 237 118 - 237 148 - 296
127 - 255
12,5 - 25
Mcal/h 82 - 143 102 - 204 102 - 204
kg/h 8 - 14 10 - 20 10 - 20
COMBUSTIBLE GAS‡LEO
- Poder Calorífico Inferior kWh/kg
Mcal/kg
11,8
10,2 (10.200 kcal/kg)
- Densidad kg/dm30,82 - 0,85
- Viscosidad a 20 °C mm2/s max 6 (1,5 °E - 6 cSt)
FUNCIONAMIENTO • Intermitente (mín. 1 paro en 24 horas).
•2llamas(2≤y 1≤) ó 1 llama (todo-nada).
BOQUILLAS numero 2
UTILIZACI‡N Calderas: de agua, a vapor y aceite térmico
TEMPERATURA AMBIENTE °C 0 - 40
TEMPERATURA AIRE COMBURENTE °C max 60
ALIMENTACI‡N ELÉCTRICA V
Hz
230 ~ +/-10%
50 - Monofásica
230 - 400 con Neutro ~ +/-10%
50 - Trifásica
MOTOR ELÉCTRICO rpm
W
V
A
2800
300
220 - 240
2,4
2800
420
220 - 240
2,8
2800
450
220/240 - 380/415
2,0 - 1,2
2800
650
220/240 - 380/415
3,0 - 1,7
CONDENSADOR MOTOR µF/V 12,5/450 16/450
TRANSFORMADOR DE ENCENDIDO V1 - V2
I1 - I2
230 V - 2 x 5 kV
1,9 A - 30 mA
BOMBA Caudal (a 12 bar)
Rango presiones
Temp. combustible
kg/h
bar
° C max
45
10 - 18
60
67
4 - 18
60
67
4 - 18
60
88
4 - 18
60
POTENCIA ELÉCTRICA ABSORBIDA W max 370 600 560 750
GRADO DE PROTECCI‡N IP 44
CONFORMIDAD DIRECTIVAS CEE 89/336 - 73/23 - 92/42 - 89/392
NIVEL SONORO (2) dBA 68,0 70,0 70,0 75,0
Modelo Código Alimentación
eléctrica
Longitud tubo
llama mm
RL 28 3473232
3473233
monofásica
monofásica
216
351
RL 38
3474132
3474133
3474332
3474333
monofásica
monofásica
trifásica
trifásica
216
351
216
351
RL 50 3474632
3474633
trifásica
trifásica
216
351

3
DESCRIPCIÓN DEL QUEMADOR (A)
1 Electrodos de encendido
2 Cabezal de combustión
3 Tornillo regulación cabezal de combustión
4 Seguridad contra fallo de llama mediante
fotorresistencia
5 Tornillo fijación del ventilador a la brida
6 Guías para abertura del quemador e inspec-
ción del cabezal de combustión
7 Cilindro hidráulico para regular el registro de
aire en la posición de 1≤y 2≤llama.
Cuando el quemador está parado, el registro
del aire está completamente cerrado para
reducir al mínimo la dispersión térmica de la
caldera debido al tiro que toma aire de la
boca de aspiración del ventilador.
8 Electroválvula de seguridad (RL 38 - RL 50)
9 Bomba
10 Soporte con 4 orificios para el paso tubos
flexibles y eléctricos.
11 Entrada de aire en el ventilador
12 Toma de presión ventilador
13 Brida para la fijación a la caldera
14 Disco estabilizador de llama
15 Visor llama
16 Prolongadores guías 6)
17 Contactor motor y relé térmico con pulsador
de desbloqueo (RL 38 trifásico - RL 50)
18 Condensador motor
(RL 28 - RL 38 monofásico)
19 Caja de control con piloto luminoso de blo-
queo y pulsador de desbloqueo
20 Dos interruptores eléctricos:
- uno de ≈marcha-paro∆quemador
- uno para ≈1≤llama - 2≤llama∆
21 Conectores para la conexión eléctrica
22 Registro de aire
23 Regulación pressión bomba
24 Grupo válvulas 1ay 2allama
Hay dos posibilidades de bloqueo del quema-
dor:
Bloqueo caja control: la iluminación del pulsador
(led rojo) de la caja 19)(A) indica que el quema-
dor está bloqueado.
Para desbloquear, oprimir el pulsador durante
un tiempo comprendido entre 1 y 3 segundos).
Bloqueo motor (RL 38 trifásico - RL 50): Para
desbloquear, oprimir el pulsador del relé térmico
17)(A).
EMBALAJE - PESO (B) - Medidas aproxima-
das
• Los quemadores se expiden en embalaje de
cartón, cuyas dimensiones se especifican en la
tabla (B).
• El peso del quemador completo con emba-
laje se indica en la tabla (B).
DIMENSIONES MÁXIMAS (C) - Medidas
aproximadas
Las dimensiones máximas del quemador se
indican en (C).
Tener en cuenta que para inspeccionar el cabe-
zal de combustión, el quemador debe abrirse
desplazando la parte posterior por las guías.
La longitud máxima del quemador abierto, sin
envolvente, está indicada por la cota H.
FORMA DE SUMINISTRO
2 - Tubos flexibles
2 - Juntas para tubos flexibles
2 - Rácores para tubos flexibles
1 - Junta aislante
2 - Prolongadores 25)(A) para guías 6)(A)
(solo en modelos con cabezal de 351 mm)
4 - Tornillos M8 x 25 fijación del quemador a la
caldera
3 - Pasacables conexionado eléctrico
(RL 28 y 38 monofásico)
4 - Pasacables conexionado eléctrico
(RL 38 trifásico y RL 50)
1 - Instrucciones
1 - Lista de recambios
(A)
(B)
(C)
18 17 15
24
23
22
19
20
21
1234567
141312
11
10
9
8
mm A B C kg
RL 28 1010 620 495 36
RL 38 1010 620 495 38
RL 50 1010 620 495 39
(1) Tubo llama: Normal - Alargado
mm A B C D (1) EFG H (1)
RL 28 476 474 468 216 - 351 140 352 52 672 - 807
RL 38 476 474 468 216 - 351 140 352 52 672 - 807
RL 50 476 474 468 216 - 351 152 352 52 672 - 807
D3260
D3275
D450
D88
D452